WO2011037087A1

WO2011037087A1 - Magnetic core for use in an armature, and method for manufacturing a magnetic core

Info

Publication number: WO2011037087A1
Application number: PCT/JP2010/066207
Authority: WO
Inventors: 能成浅野; 明宣石嵜
Original assignee: ダイキン工業株式会社
Priority date: 2009-09-25
Filing date: 2010-09-17
Publication date: 2011-03-31
Also published as: JP4730461B2; JP2011072127A

Abstract

Disclosed is a magnetic core that minimizes not only eddy currents due to circumferential components of magnetic flux, but also those due to radial components. Each magnetic core (1) is provided with a first section (1a) on one side in a circumferential direction (θ) and a second section (1b) on the other side. The first section (1a) and second section (1b) each contain a plurality of magnetic steel sheets (100) layered in a radial direction (R) that is perpendicular to both the circumferential direction (θ) and an axial direction (Z). The first section (1a) has a first winding section (11a) and a first boundary surface (110a), and the second section (1b) has a second winding section (11b) and a second boundary surface (110b). The first boundary surface (110a) and the second boundary surface (110b) are parallel to the axis direction (Z) and the radial direction (R) and are placed up against each other. An armature winding wire is wound around the first winding section (1a) and the second winding section (1b), centered on the axis direction (Z).

Description

Magnetic core for armature and method of manufacturing magnetic core

The present invention relates to an armature magnetic core and a method for manufacturing the magnetic core. The armature magnetic core is used particularly in an armature used in an axial gap type rotating electric machine.

An axial gap type rotating electrical machine includes a rotor provided to be rotatable about a rotation axis, and a stator that faces the rotor in a direction parallel to the rotation axis (hereinafter referred to as “axial direction”). . In most cases, the rotor and stator function as field elements and armatures, respectively.

In the armature, an armature magnetic core (hereinafter, also simply referred to as “magnetic core”) is annularly arranged in a circumferential direction perpendicular to the axial direction.

In the axial gap type rotating electrical machine, the magnetic flux flowing through the magnetic core has a circumferential component because it flows in and out between a plurality of magnetic cores arranged annularly in the circumferential direction. The circumferential component of the magnetic flux causes the generation of eddy currents in the plane perpendicular to the circumferential direction, and consequently increases the iron loss. In order to suppress the generation of the eddy current, it is proposed that the magnetic core is formed of electrical steel sheets laminated in a radial direction with respect to the rotation axis (which is perpendicular to the axial direction and the circumferential direction of the magnetic core). Has been.

The shape of the magnetic core as viewed from the opposing direction of the field element and the armature (hereinafter referred to as “the shape of the magnetic core in a plan view of the opposing direction” etc.) increases as the position in the radial direction increases (that is, It is desirable that the width be increased in the circumferential direction. Such a shape brings about the advantage that it is easy to increase the space factor of the armature winding while increasing the area of the magnetic core in the plan view in the opposite direction. For example, the technique disclosed in Patent Document 1 can be used to manufacture such a magnetic core.

Note that Patent Document 2 exemplifies a technique in which two laminated structures of electromagnetic steel sheets are provided in one magnetic core that is wider in the circumferential direction toward the outer periphery.

JP 2007-252064 A JP 2009-11086 A

However, the magnetic flux flowing through the magnetic core tends to have a radial component. This is because the magnitude of the magnetic flux tends to be non-uniform in the radial direction. In particular, as described above, this tendency becomes prominent when the circumferential dimension of the magnetic core depends on the radial position.

The magnetic core can flow more magnetic flux in the axial direction as its circumferential dimension is larger. On the other hand, the distribution in the radial direction of the magnetic flux amount of the field magnetic flux flowing between the field element and the magnetic core and the distribution in the radial direction of the circumferential dimension of the magnetic core are not necessarily proportional to each other. . Therefore, the radial distribution of the magnetic flux in the magnetic core becomes non-uniform as it gets closer to the field element, and becomes uniform as it gets away from the field element. Such a variation in the radial distribution of the magnetic flux in the axial direction indicates that the magnetic flux flowing through the magnetic core has a radial component.

Also, when the above two distributions are proportional, the magnetic flux flowing in the axial direction has a distribution in the radial direction, and the larger the circumferential dimension of the magnetic core, the more the magnetic flux flows. On the other hand, inflow and outflow of magnetic flux between the plurality of magnetic cores is guided by the yoke, but the magnetic flux distribution in the yoke is uniform. Therefore, the magnetic flux flowing in the magnetic core in the vicinity of the yoke tends to have a radial component. The radial component of the magnetic flux causes the generation of eddy currents in a plane perpendicular to the radial direction.

However, each of the electrical steel sheets laminated in the radial direction extends in parallel to the plane perpendicular to the radial direction, and thus it is difficult to suppress the generation of eddy currents caused by the radial component of the magnetic flux.

Therefore, an object of the present invention is to provide a magnetic core that suppresses not only the generation of eddy current due to the circumferential component of magnetic flux but also the generation of eddy current due to the radial component. Another object is to improve the yield in manufacturing the magnetic core.

The armature magnetic core according to the present invention includes a magnetic core (1) arranged in an annular shape in a circumferential direction (θ) perpendicular to the axial direction in an armature facing the field element (4) in the axial direction (Z). ).

In the first aspect, each of the magnetic cores includes a first portion (1a) on one side in the circumferential direction and a second portion (1b) on the other side in the circumferential direction. Each of the first part and the second part includes a plurality of electromagnetic steel sheets (100) stacked in a radial direction (R) perpendicular to both the axial direction and the circumferential direction. The first portion has a first winding portion (11a) and a first boundary surface (110a), and the second portion has a second winding portion (11b) and a second boundary surface (110b). The first boundary surface and the second boundary surface are parallel to the axial direction and the radial direction, and the first boundary surface and the second boundary surface are disposed adjacent to each other, and the first winding surface The part and the second winding part form a winding part (11) around which the armature winding (15) around the axial direction is wound.

A second aspect of the armature core according to the present invention is the first aspect, wherein the field element rotates from the other side in the circumferential direction to the one side in the circumferential direction, Regarding the cross section at an arbitrary position in the radial direction (R) perpendicular to both the axial direction (Z) and the circumferential direction (θ), the second portion (1b) is more than the first portion (1a). Is too narrow.

In the first aspect of the method for manufacturing a magnetic core according to the present invention, the raw material (8), which is an electromagnetic steel sheet, is conveyed every predetermined length (P) in the conveying direction (K). And (a) when the conveyance of the raw material is stopped, the step of punching out the raw material using the first punch (92), (b) left on the raw material in the step (a) Punching the electromagnetic steel sheet into a rectangle (Q) whose dimension in the transport direction is equal to or less than the predetermined length to obtain steel sheets for lamination (101 to 106, 201 to 206); (c) the step (b) Step of laminating the steel sheets for laminating obtained in step (101 to 106) obtained on one side with respect to the first punch in the width direction perpendicular to the conveying direction in the punched order. With. However, in the step (a), in the width direction, the first punch reciprocates between the first position (92a, 92f; 90g, 90l) and the second position (92c, 92d; 90i, 90j). The position of the first punch is updated and repeated, and in the step (c), the laminated steel plates (101, 106) punched at the first position and the second position The laminated steel plates are laminated with the punched laminated steel plates (103, 104) as a boundary to obtain a plurality of laminated bodies (10a, 10b). And (d) It further has the process of forming the magnetic core (1) by making the laminated bodies in the said process (c) adjoin, making the position punched out by the said 1st punch into the other side.

The 2nd aspect of the manufacturing method of the magnetic core concerning this invention is the 1st aspect, Comprising: Among the said steel plates for lamination obtained by the said process (b), it is perpendicular | vertical to the said conveyance direction. The laminated steel plates (201, 206) punched at the first position in the punched order (201-206) obtained on the other side with respect to the first punch in the width direction as a direction; A step of laminating the laminating steel plates with the laminating steel plates (203, 204) punched out at the second position as a boundary to obtain a plurality of laminates (20a, 20b), and (f) the step A step of forming the magnetic core (1) by adjoining the stacked bodies in (e) with the positions punched by the first punches opposite to each other.

A third aspect of the method for manufacturing a magnetic core according to the present invention is the second aspect or the third aspect, wherein (g) the step (a) is performed before the step (c) is performed. When the conveyance of the raw material (8) is stopped, the raw material is moved using the second punch (91) that maintains the position (91a to 91f) in the width direction. A punching process is further provided.

In the first aspect of the magnetic core according to the present invention, any cross section perpendicular to the radial direction is divided by the first boundary surface and the second boundary surface, so that the area where the eddy current can be generated is reduced. Thus, generation of eddy current is reduced. Further, since the surface perpendicular to the circumferential direction is divided by the boundaries between the plurality of electromagnetic steel plates laminated in the radial direction, the area where the eddy current can be generated is reduced, and the generation of eddy current is reduced. Furthermore, the magnetic resistance in the radial direction of the winding part is increased, which contributes to the reduction of the radial component itself of the magnetic flux flowing through the winding part. Moreover, manufacture becomes easy by aligning and laminating | stacking an electromagnetic steel plate in a 1st interface and a 2nd interface.

When the field element rotates from the other side in the circumferential direction to one side, the amount of magnetic flux flowing between the field element and the magnetic core is greater on the other side than on the one side. In the second aspect of the magnetic core according to the present invention, the cross-sectional area of the second portion located on the other side in the circumferential direction is smaller than the cross-sectional area of the first portion, and the reduction of eddy current becomes more remarkable.

The first aspect of the magnetic core manufacturing method according to the present invention can manufacture the magnetic core according to the present invention.

According to a second aspect of the method for manufacturing a magnetic core according to the present invention, the steel sheet for lamination used in the magnetic core is obtained from the raw material with less waste, and the use efficiency of the raw material is increased, and as a result, the magnetic core is manufactured. Improve the yield in

The third aspect of the method for manufacturing a magnetic core according to the present invention can form a magnetic flux guide portion and a buried portion of the magnetic core having dimensions in the width direction independent of the radial position.

The objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description and the accompanying drawings.

It is a perspective view which illustrates the structure of the armature core employ | adopted as an axial gap type rotary electric machine. It is a perspective view which shows the external appearance of a magnetic core. It is a perspective view which shows the external appearance of the 1st part of a magnetic core. It is a perspective view which shows the external appearance of the 2nd part of a magnetic core. It is a perspective view which shows the external appearance of a magnetic core. It is a top view which shows the external appearance of the magnetic core in opposing direction planar view. It is a top view which shows the position of the fixed punch with respect to a raw material. It is a top view which shows the position of the movable punch with respect to a raw material. It is a top view which shows the raw material after punching with the fixed punch and the movable punch. It is a schematic diagram which shows the planar shape of the steel plate for lamination punched out. It is a schematic diagram which shows lamination | stacking of the steel plate for lamination punched out. It is a schematic diagram which shows lamination | stacking of the steel plate for lamination punched out. It is a schematic diagram which shows the planar shape of the steel plate for lamination punched out. It is a schematic diagram which shows lamination | stacking of the steel plate for lamination punched out. It is a schematic diagram which shows lamination | stacking of the steel plate for lamination punched out. It is a top view which shows the raw material after punching with the movable punch. It is a perspective view which shows the external appearance of a magnetic core. It is a top view which shows the raw material after punching with the movable punch. It is a perspective view which shows the external appearance of a magnetic core. It is a perspective view which shows a magnetic core and an insulator. It is a disassembled perspective view which shows the assembly of a magnetic core and an insulator. It is a perspective view which shows a magnetic core and an insulator. It is a disassembled perspective view which shows the assembly of a magnetic core and an insulator. It is sectional drawing which shows the structure of an axial gap type rotary electric machine.

First embodiment.
Referring to FIG. 1, the core of the armature is roughly composed of a magnetic core 1, a back yoke 2, and a support member 3. However, in order to show the fitting relationship between the magnetic core 1, the back yoke 2, and the fixed plate 3, one magnetic core 1 is shown separately from the back yoke 2 and the fixed plate 3. Of course, when the armature is configured, the separation is not performed.

FIG. 24 shows a cross section of the rotating electrical machine at position XX in FIG. 1 and 24, the armature is employed in an axial gap type rotating electrical machine together with a field element 4 that rotates about an axis J as a rotational axis. The axial direction Z is adopted parallel to the axis J. The armature faces the field element 4 in the axial direction Z.

The field element 4 includes a base body 41 and a field generator 42. The base body 41 is fixed to the rotatable shaft 40, and the field generating section 42 is fixed to the base body 41 and generates a field magnetic flux. In order to cause the field magnetic flux to efficiently flow through the armature, it is desirable that the base body 41 employs a magnetic material so as to function as a so-called back yoke.

The armature core is employed in the armature together with the armature winding 15 (not shown in FIG. 1) wound around the magnetic core 1 around the axial direction Z. Note that “winding” includes not only an aspect involving an operation of winding a conducting wire around the magnetic core 1 but also an aspect in which an armature winding having a shape formed in advance as a coil is fitted to the magnetic core 1. . The coil is a so-called concentrated winding method in which the coil is wound around each of the magnetic cores 1.

The magnetic core 1 is annularly arranged in the circumferential direction θ with the axis J as the central axis. In each of the magnetic cores 1, electromagnetic steel plates (not shown: described in detail later) are laminated in the radial direction R. That is, when the magnetic core 1 is employed as the core of the armature, the radial direction R for any of the magnetic cores 1 is annularly arranged so as to be perpendicular to the axial direction Z. Accordingly, as shown in FIG. 1, the radial directions R1 and R2 of different magnetic cores 1 are different from each other when viewed as a whole core.

Similarly, the circumferential directions θ1 and θ2 for different magnetic cores 1 are different from each other when viewed as a whole core. However, the circumferential directions θ1 and θ2 can be regarded as common directions when viewed as the annular direction θ (FIG. 24).

The back yoke 2 is provided with an opening 21 that opens in the axial direction Z according to the magnetic core 1, and each opening 21 also opens radially inward. The magnetic core 1 has a winding part 11 around which the armature winding 15 is wound, and a magnetic flux guide part 12 positioned on the back yoke 2 side with respect to the winding part 11. The magnetic flux guide 12 is magnetically coupled to the magnetic core 1 and the back yoke 2 by fitting with the opening 21. Specifically, the magnetic flux guide 12 guides the magnetic flux flowing through the magnetic core 1 to the back yoke 2 or guides the magnetic flux flowing through the back yoke 2 to the magnetic core 1.

When the opening 21 is also opened radially inward, an eddy current due to the axial component of the magnetic flux flowing in the magnetic core 1 having the magnetic flux guide 12 fitted to the opening 21 is generated in the back yoke 2. To suppress. A plurality of openings 21 are combined to form an opening 20.

The magnetic core 1 also has an embedded portion 13 located on the opposite side of the winding portion 11 with respect to the magnetic flux guide portion 12. Correspondingly, the fixing plate 3 is provided with a groove 31. The groove 31 may penetrate in the axial direction Z.

Here, an example in which an odd number (9) of magnetic cores 1 are provided is illustrated. In FIG. 24, the winding portion 11, the magnetic flux guide portion 12, the embedded portion 13, and the flange portion 14 of the magnetic core 1 appear on the left side in the drawing. However, the armature winding 15 appears instead on the right side in the figure.

The embedded portion 13 is fitted with the groove 31, and the fixing plate 3 mechanically holds the magnetic core 1. On the other hand, the back yoke 2 and the magnetic core 1 are magnetically coupled, and the back yoke 2 does not necessarily need to mechanically hold the magnetic core 1. Therefore, if both the back yoke 2 and the fixed plate 3 are fixed to each other, the back yoke 2 and the fixed plate 3 can be formed with materials in view of the functions to be secured by the magnetic coupling and the mechanical coupling. For example, the back yoke 2 is mainly formed of electromagnetic steel plates laminated along the axial direction Z, or is formed of a dust core. An example of the material of the fixing plate 3 is a metal lump.

Securing of the fixing plate 3 and the magnetic core 1 does not require the fitting between the groove 31 and the embedded portion 13. For example, both can be fixed by adhesion or welding.

It is desirable that a flange portion 14 is provided at a position closest to the field element 4 in the magnetic core 1. In order to increase the efficiency of the magnetic interaction between the armature and the field element, the flange portion 14 is set wider than the winding portion 11. Here, since the electromagnetic steel sheets are laminated along the radial direction R, in order to simplify the lamination, the flange portion 14 does not expand from the winding portion 11 in the radial direction R, and expands only along the circumferential direction θ. The structure is illustrated. Of course, you may employ | adopt the magnetic core 1 of the structure which does not provide the collar part 14. FIG.

2 to 4, the magnetic core 1 includes a first portion 1a on one side in the circumferential direction θ (arrowhead side in the drawing) and a second portion 1b on the other side in the circumferential direction θ (arrowhead side in the drawing). Prepare. 3 and 4, the electromagnetic steel sheets 100 laminated in the radial direction are partially drawn while exaggerating their thickness.

In the magnetic core 1 exemplified here, the shapes of the magnetic flux guide portion 12 and the embedded portion 13 do not depend on the radial direction R, and thus exhibit a rectangular parallelepiped. The circumferential dimensions W2 and W3 of the magnetic flux guide portion 12 and the embedded portion 13 do not depend on the position in the radial direction R. On the other hand, the winding part 11 becomes wide on the outer peripheral side (radial direction R side) for reasons such as increasing the space factor of the armature winding 15.

An example of a technique for ensuring the bonding between laminated electromagnetic steel sheets 100 will be given. The electromagnetic steel sheet 100 is locally deformed in the thickness direction to form a coupling portion, and the coupling portions are fitted to each other between the adjacent electromagnetic steel plates 100. The coupling portion may be simple irregularities, or the electromagnetic steel sheet 100 may be partially broken and deformed in the thickness direction. A technique for obtaining a bond between laminated electromagnetic steel sheets 100 using the latter modification is a well-known technique commonly referred to as “Karamase”.

It is desirable that the coupling between the laminated electrical steel sheets 100 is applied individually to the first part 1a and the second part 1b. Usually, since the magnetic core 1 is elongated in the axial direction Z, a plurality of coupling portions are provided along the axial direction Z for each electromagnetic steel sheet 100. However, since the coupling portion deteriorates the magnetic properties of the electrical steel sheet, it is also desirable to provide the coupling portion in a place where the magnetic properties are less likely to be a problem, for example, the flange portion 14.

The first portion 1a and the second portion 1b are adjacent to each other through the boundary surface 110. The first portion 1a includes a first winding portion 11a, a first magnetic flux guide portion 12a, a first embedded portion 13a, and a first flange portion 14a. The second portion 1b includes a second winding portion 11b, a second magnetic flux guide portion 12b, a second embedded portion 13b, and a second flange portion 14b. The first winding part 11a and the second winding part 11b together with the winding part 11, the first magnetic flux guiding part 12a together with the second magnetic flux guiding part 12b, and the first embedded part 13a as the second embedded part. The embedded portion 13 is formed together with 13b, and the first flange portion 14a and the second flange portion 14b constitute the flange portion 14 (see also FIG. 1).

The first portion 1a has a first boundary surface 110a on the other side in the circumferential direction θ, and the second portion 1b has a second boundary surface 110b on one side in the circumferential direction θ. The first boundary surface 110a and the second boundary surface 110b are adjacent to each other. The boundary surface 110 can be grasped as an adjacent position between the first boundary surface 110a and the second boundary surface 110b. However, as will be described later, the first boundary surface 110a and the second boundary surface 110b are not necessarily in direct contact with each other, and an insulating material having a sufficiently small thickness in the circumferential direction may be interposed therebetween. .

Thus, the magnetic core 1 is formed by connecting the first portion 1a and the second portion 1b adjacent to each other via the boundary surface 110 (or the first boundary surface 110a and the second boundary surface 110b). Such coupling can be realized by employing, for example, a resin mold.

As described above, in the magnetic core 1, any cross section perpendicular to the radial direction R is divided by the first boundary surface 110 a and the second boundary surface 110 b, so that an area in which the eddy current can be generated in the cross section. And the generation of eddy currents is reduced. That is, the generation of eddy current due to the radial component of the magnetic flux flowing through the magnetic core 1 can be suppressed.

The plane perpendicular to the circumferential direction θ is divided by the boundaries between the plurality of electromagnetic steel plates 100 stacked in the radial direction R. Therefore, the area where eddy currents can be generated due to the circumferential component of the magnetic flux flowing in the magnetic core 1 is reduced, thereby reducing the generation of eddy currents. Moreover, since the boundary of the electromagnetic steel sheet 100 has a magnetic resistance and becomes a barrier, the magnetic flux flowing through the magnetic core is less likely to flow in the radial direction R, thereby contributing to the reduction of the radial component itself of the magnetic flux flowing through the magnetic core.

It is also desirable to sandwich an insulating material between the first boundary surface 110a and the second boundary surface 110b. This is because the insulating material improves the insulation between the first portion 1a and the second portion 1b, thereby ensuring the division in the plane perpendicular to the circumferential direction θ of the magnetic core 1. As an example, an insulating sheet is sandwiched between the first portion 1a and the second portion 1b. As another example, after the first portion 1a and the second portion 1b are individually coated with an insulating material, the first boundary surface 110a and the second boundary surface 110b are adjacent to each other, and both are coupled. Forming the core 1. This cuts off the current between the first part 1a and the second part 1b, and it is desirable to pass the magnetic flux. Therefore, it is sufficient if the thickness is enough to cut off the eddy current.

As a method of joining the first part 1a and the second part 1b, laser welding can be used in addition to the mold. However, it is desirable that the welds do not contact each other. This is because, when the welded portions are in contact with each other, the possibility that the extending directions of the electromagnetic steel sheets 100 of the first portion 1a and the second portion 1b are not perpendicular to the radial direction R increases. Specifically, it is desirable that the welded portion is within the thickness range of the electromagnetic steel sheet 100 and is provided for each electromagnetic steel sheet 100.

Also, instead of a mold, the periphery of the magnetic core 1 with the axial direction Z as an axis may be surrounded by a cylindrical insulator. As illustrated in FIGS. 20 and 21, the insulator 6 includes, for example, a pair of

components

6 a and 6 b. The

parts

6a and 6b are combined with each other along the circumferential direction θ to couple the first part 1a and the second part 1b. Alternatively, as illustrated in FIGS. 22 and 23, the insulator 6 includes, for example, a pair of

components

6c and 6d. Then, the

parts

6c and 6d are combined with each other along the radial direction R to couple the first part 1a and the second part 1b. In either case, the armature winding 15 (see FIG. 24) is wound around the magnetic core 1 via the insulator 6.

The magnetic core 1 may not be symmetric with respect to the boundary surface 110. FIG. 5 shows a case where the boundary surface 110 is shifted from the center of the magnetic core 1 in the circumferential direction θ to the other side in the circumferential direction θ. Thereby, the cross section in the arbitrary positions of radial direction R can make the 2nd part 1b narrower than the 1st part 1a. The magnetic core 1 having such a configuration brings about a unique effect particularly in the following situation.

When the field element 4 rotates from the other side in the circumferential direction θ to one side, that is, when the field element 4 rotates in accordance with the direction of the arrow in the circumferential direction θ, the field element 4 is interposed between the field element 4 and the magnetic core 1. The amount of magnetic flux that flows is greater on the other side than on one side. This is because, in the field element, when the field generating portion 42 approaches the magnetic core 1, a magnetic attractive force acts between them, and when it moves away, a magnetic repulsive force acts. Therefore, the amount of magnetic flux contributing to eddy current is greater on the other side in the circumferential direction than on one side in the circumferential direction of the magnetic core 1. Therefore, the eddy current is more effectively reduced by making the cross-sectional area of the cross section perpendicular to the radial direction R of the second portion 1b smaller than that of the first portion 1a.

Here, the case where both the first boundary surface 110a and the second boundary surface 110b extend parallel to the radial direction R and the axial direction Z (that is, perpendicular to the circumferential direction θ) is illustrated. However, if the laminated steel sheets extend perpendicular to the radial direction R when the first boundary surface 110a and the second boundary surface 110b are adjacent to form the magnetic core 1, the first boundary surface 110a. The second boundary surface 110b may be inclined with respect to the axial direction Z or the radial direction R.

For example, the angle formed by the first boundary surface 110a with the radial direction R at the outer peripheral end of the first portion 1a is different from the angle formed by the second boundary surface 110b with the radial direction R at the outer peripheral end within the second portion 1b. A complementary angle relationship (the sum of the two is a flat angle) may be used. Or the angle which the 1st boundary surface 110a makes with the axial direction Z in the axial direction Z side (side near the field element 4) of the 1st part 1a, and the 2nd boundary surface 110b in the axial direction Z side of the 2nd part 1b. The angle formed with the radial direction R may be a complementary angle.

Furthermore, the first boundary surface 110a and the second boundary surface 110b may be curved surfaces, and in this case, they are fitted together to form the boundary surface 110.

In addition, when providing the groove | channel 31 as mentioned above, the opening part 21 penetrates in the axial direction Z. However, there may be a case where the fixing plate 3 is not provided. In this case, the opening portion 21 does not need to penetrate in the axial direction Z, and in the axial direction Z, an opening for simply fitting with the magnetic flux guide portion 12 is provided. It's enough. In the case where the fixing plate 3 is not provided, the groove 31 is naturally not provided, and therefore, it is not necessary to provide the embedded portion 13 in the magnetic core 1.

Alternatively, the opening 21 and the groove 31 may have the same shape as viewed from the axial direction Z. In this case, the magnetic flux guide portion 12 and the embedded portion 13 have the same shape as viewed from the axial direction Z. Further, the magnetic flux guide portion 12, the embedded portion 13, and the winding portion 11 may have the same shape as viewed from the axial direction Z. The magnetic core 1 in such a case is shown in FIG.

Alternatively, the magnetic core 1 may be employed in an armature that is sandwiched between a pair of rotors in the axial direction Z. In the magnetic core 1 employed in this case, a pair of winding portions 11 are provided and have a configuration in which the magnetic flux guide portion 12 is sandwiched in the axial direction Z. Of course, the collar part 14 can be provided in any winding part 11. FIG. 19 shows the magnetic core 1 in such a case. However, a mode in which the back yoke 2 and the fixed plate 3 are not provided may be employed. In this case, the magnetic core 1 does not require not only the embedded portion 13 but also the magnetic flux guide portion 12, for example, only the winding portion 11 extends between the pair of flange portions 14.

Alternatively, even when the armature faces the field element only on one side in the axial direction Z, there are cases where advantages can be obtained by adopting the magnetic core 1 shown in FIG. For example, when the groove 31 penetrates in the axial direction Z in the fixing plate 3, the collar portion 14 located on the other side in the axial direction Z may be provided with a function of locking the groove 31 in the axial direction Z. In such a case, the groove 31 also opens in the radial direction R in the same manner as the opening 21, and the magnetic core 1 is arranged from the inner peripheral side of the groove 31 and the opening 21.

Second embodiment.
Although the structure of the magnetic core 1 can be variously modified as described above, the first boundary surface 110a and the second boundary surface 110b are parallel to the axial direction Z and the radial direction R from the viewpoint of easy manufacture. Is desirable. This is because the electromagnetic steel sheets forming the first portion 1a and the second portion 1b can be stacked with the first boundary surface 110a and the second boundary surface 110b parallel to the stacking direction aligned. In this respect, the structure is more advantageous than the structure of Patent Document 2 in which the electromagnetic steel sheets are stacked while being shifted with respect to the stacking direction.

Furthermore, if the magnetic core 1 is symmetrical with respect to the boundary surface 110, the magnetic core 1 has two advantages in the process of punching out the electromagnetic steel sheet constituting the magnetic core 1 from the raw material. One is reduction of waste materials, and one is reduction of the number of movable punches. Hereinafter, it will be described that these advantages can be obtained by explaining a specific punching process.

Such a magnetic core 1 is shown in FIG. FIG. 6 is a plan view showing the appearance of the magnetic core 1 in plan view in the opposite direction. However, a part on the radial direction R side of the first magnetic flux guiding portion 12a, the first embedded portion 13a, and the first winding portion 11a are all hidden behind the first flange portion 14a, and the diameter of the first magnetic flux guiding portion 12a Part of the direction R side, the second embedded portion 13b, and the second winding portion 11b are all hidden behind the second flange portion 14b.

7 to 9, the raw material 8 that is an electromagnetic steel plate is transported in the transport direction K. In general, the raw material 8 is long, and the longitudinal direction thereof is selected as the transport direction K. The raw material 8 is conveyed every predetermined length P, and when the conveyance of the raw material 8 is stopped, punching by a fixed punch or a movable punch, which will be described later, is executed.

However, FIGS. 7 and 8 are drawn from the viewpoint of moving in accordance with the conveyance direction K of the raw material 8 for the sake of simplicity of explanation. Therefore, although the punching does not actually move in the transport direction K, the punching is illustrated as being performed at a plurality of positions.

In addition, here, for simplicity of explanation, the number of stacked sheets is described as three, but the actual number of stacked sheets is much larger.

7 positions 91a to 91f indicate the positions of the fixed punches. Hereinafter, the positions 91a to 91f may be collectively referred to as the position 91, or the fixed punch itself may be described as the position 91.

The position of the fixed punch (and its position) 91 in the width direction perpendicular to the conveying direction K of the raw material 8 is maintained. In the sense that the position 91 in the width direction is fixed, it is “fixed”. Of course, from the necessity of punching the raw material 8, in the punching direction (in the direction perpendicular to the paper surface in accordance with FIGS. 7 to 9) It becomes movable. Therefore, the positions in the width direction of the positions 91a to 91f are equal.

8 positions 92a to 92f indicate the positions of the movable punches. Hereinafter, the positions 92a to 92f may be collectively referred to as the position 92, or the movable punch itself may be described as the position 92.

The movable punch (and its position) 92 is movable in the width direction. Of course, it is also movable in the punching direction. The movable punch (and its position) 92 includes

positions

92a and 92f (hereinafter also referred to as “

first positions

92a and 92f”) existing at the leftmost position in the drawing, and positions 92c and 92d (hereinafter referred to as “second position” positioned at the rightmost position). 92c, 92d ") in the width direction.

As described above, since the punching does not actually move with respect to the transport direction K, the positions 91a to 91f and the positions 92a to 92f are illustrated in the order opposite to the transport direction K in this order. Since the raw material 8 is conveyed every predetermined length P and punching is performed when the conveyance of the raw material 8 is stopped, the positions 91a to 91f and the positions 92a to 92f are respectively predetermined along the conveying direction K. It will be illustrated at intervals of length P.

The punching with the fixed punch and the punching with the movable punch are executed as a pair (however, the prior relationship between the two is not important), and the punching holes 90a to 90f shown in FIG. 9 are formed.

The rectangular area Q is a position where the raw material 8 is further punched after the punching holes 90a to 90f are formed. The dimension in the transport direction K is equal to or less than the predetermined length P, and is set at an interval of the predetermined length P. The It is desirable that the punching holes 90a to 90f protrude from the rectangular region Q in the direction along the transport direction K.

The punching hole 90a is obtained as a result of punching at the fixed punch position 91a and punching at the movable punch position 92a. The same applies to the other punched holes 90b to 90f. Positioning in the conveying direction K between the punching with the fixed punch and the punching with the movable punch is a well-known technique, and therefore details are not described here.

However, in the present embodiment, it is desirable that the punched portion at the fixed punch position 91a and the punched portion at the movable punch position 92a slightly overlap. The same applies to the positions 91b to 91f of the other fixed punches and the positions 92b to 92f of the movable punches. As a result, the punching holes 90a to 90f protrude from the rectangular region Q in the direction along the conveying direction K, so that the punching holes 90a to 90f allow the raw material 8 to be moved to the left and right sides in the rectangular region Q to which the punching holes 90a to 90f belong. And to separate.

Then, by punching the rectangular region Q, the steel plates 101 to 106 and the lamination steel plates 101 to 106 and the lamination are respectively formed from the raw material 8 on one side (here, the left side in the drawing) and the other side (here, the right side in the drawing) of the punching holes 90a to 90f. Steel plates 201 to 206 are obtained. Since the positioning in the transport direction K between the punching of the rectangular area Q and the punching by the fixed punch or the movable punch is also a well-known technique, the details thereof are omitted. If the width dimension of the raw material 8 is exactly constant, the punching in the rectangular region Q may be replaced by a process of simply cutting the raw material 8 in the transport direction K.

Taking the

laminated steel plates

101 and 201 as an example, the positional relationship in the rectangular region Q will be roughly described. The narrow portion of the fixed punch (and its position) 91 is the magnetic flux guide portion 12, and the wide portion is the buried portion 13. Are complementary to each other. Further, the narrow portion of the movable punch (and its position) 92 has a complementary relationship with the flange portion 14 and the wide portion with the winding portion 11. In the pair of laminated steel plates that are simultaneously punched, if the total width dimension of the flange portion 14 and the total width dimension of the magnetic flux guide portion 12 are substantially the same, the use efficiency of the electromagnetic steel sheet is further increased.

FIG. 10 shows the laminated steel plates 101 to 106 arranged in the order of punching. The arrowhead side of the white arrow is ahead in time, and the arrowhead side of the arrow is behind in time (the same applies to FIGS. 11, 13, and 14 described later). In order to make the shape easy to see, these are shown in an oblique arrangement in the punching order, but in practice it is not necessary to arrange them obliquely. Since the raw material 8 does not move in the direction (width direction) perpendicular to the conveyance direction K, the opposite side of the punched holes 90b to 90f (the width direction end side of the raw material 8) is aligned by punching out the rectangular region Q. In practice, it is desirable to be laminated in that way.

The laminated steel plates 101 to 106 are obtained on the left side of the punched holes 90b to 90f. The

first positions

92a and 92f are located on the leftmost side in the drawing. Therefore, the laminating

steel plates

101 and 106 obtained from the left side of the punched

holes

90a and 90f corresponding to the

first positions

92a and 92f have a width dimension at a position corresponding to the winding portion 11 and the flange portion 14 so that the laminating steel plates. The smallest of 101-106. On the contrary, since the

second positions

92c and 92d are located on the rightmost side in the drawing, the

steel plates

103 and 104 for lamination obtained from the left side of the punching holes 90c and 90d correspond to the winding part 11 and the flange part 14, respectively. The width dimension at the position is the largest among the steel plates 101 to 106 for lamination. The width dimension of the

steel plates

102 and 105 for lamination is smaller than that of the

steel plates

103 and 104 for lamination and larger than that of the

steel plates

101 and 106 for lamination.

As shown in FIG. 11, the steel plates for laminating 101 to 106 are stacked in the order of punching, specifically, the one punched first is stacked below. At this time, as described above, the opposite side of the punched holes 90b to 90f is aligned and the steel plates 101 to 106 for lamination are laminated. In addition, although the

steel plates

103 and 104 for lamination | stacking are shown laminated | stacked in the figure, they may not actually be laminated | stacked. The method for determining the unit of lamination can be realized by a known method.

Laminating steel plates 101 to 106 are laminated with the laminating

steel plates

101 and 106 punched at the

first positions

92a and 92f and the

laminating steel plates

103 and 104 punched at the

second positions

92c and 92d as a boundary.

Laminates

10a and 10b are obtained. Specifically, the laminated body 10a is composed of laminating steel plates 101 to 103, and the laminated body 10b is composed of laminating steel plates 104 to 106. In FIG. 10, for the sake of easy explanation, the laminated steel plates 101 to 106 constituting the

laminated bodies

10a and 10b are shown separately.

Then, the

stacked bodies

10a and 10b are adjacent to each other with the positions punched by the movable punch 92 opposite to the punched holes 90b to 90f, that is, the

stacked bodies

10a and 10b are adjacent to each other. It will function as the second portion 1b.

Referring to FIG. 13 to FIG. 15, the laminated steel plates 201 to 206 are laminated downward as they are punched out in the same manner as the laminated steel plates 101 to 106. A plurality of lamination steel plates 201 to 206 are laminated on the boundary between the

lamination steel plates

201 and 206 punched at the

first positions

92a and 92f and the

lamination steel plates

203 and 204 punched at the

second positions

92c and 92d. The

laminates

20a and 20b are obtained. Specifically, the laminate 20a is composed of lamination steel plates 204 to 206, and the laminate 20b is composed of lamination steel plates 201 to 203. In FIG. 13, the laminated steel plates 201 to 206 constituting the

laminated bodies

20a and 20b are shown separately.

And the

laminated bodies

20a and 20b function as the first part 1a and the second part 1b, respectively, by making the positions punched by the movable punch 92 opposite to each other and adjoining each other. .

As described above, when the movable punch positions 92a to 92f reciprocate in the width direction, the laminated steel plates 101 to 106 and 201 to 206 are obtained from the raw material 8 on both sides in the width direction. Therefore, one movable punch is enough. Since the conventional technique required a pair of movable punches that move symmetrically according to the width of the laminated steel sheet to be punched, this embodiment reduced the number of movable punches compared to the conventional technique. become.

Further, in the raw material 8, the portions not corresponding to the laminated steel plates 101 to 106 and 201 to 206 are the outside of the rectangular region Q and the portions corresponding to the punched holes 90 a to 90 f. As described above, in the present embodiment, considering the fact that the area of the punched holes 90a to 90f can be reduced by reducing the number of movable punches and that the outside of the rectangular region Q has been waste material in the past, In the embodiment, waste materials are reduced as compared with the conventional technique.

Of course, only one of the laminated steel plates 101 to 106 and the laminated steel plates 201 to 206 can be used for forming the magnetic core 1. If it considers except a viewpoint of waste material reduction, even if it is such a manufacturing process, there exists an effect that the magnetic core demonstrated in 1st Embodiment can be obtained.

In the present embodiment, since the width dimension of the magnetic flux guide portion 12 and the embedded portion 13 of the magnetic core 1 is constant regardless of the radial position, punching with the fixed punch 91 is necessary. However, this embodiment can also be applied to punching using only a movable punch.

When the winding part 11, the magnetic flux guide part 12, and the embedded part 13 are also formed in the same shape as seen from the axial direction Z as shown in FIG. 17, punched holes 90g to 90l shown in FIG. These holes are obtained only by a movable punch. The punching holes 90g to 90l are all the same shape, and only the positions in the width direction in the rectangular region Q are different.

A punching hole is formed at a position in the width direction of the movable punch that is updated by reciprocating the movable punch in the width direction each time the raw material 8 is conveyed in the conveyance direction K by a predetermined length P and the conveyance is stopped. 90g-90l is punched out. The laminated steel plates obtained from both sides of the punched holes 90g to 90l in this way are the same as the laminated steel plates 101 to 106 and 201 to 206, and the laminated steel plates and punched holes punched by the punched holes 90g and 90l. A plurality of laminates can be obtained by laminating the laminate steel plates punched at 90i and 90j as boundaries. Then, the magnetic core 1 can be formed by adjoining these laminated bodies with the positions punched by the movable punches opposite to each other. Here, since the shape of the punched holes 90g to 90l is constant in width except for the positions corresponding to the first flange portion 14a and the second flange portion 14b, the magnetic core shown in FIG. 17 can be formed. it can.

Further, the punching holes 90g to 90l shown in FIG. 18 can be employed for the magnetic core 1 in which the pair of flange portions 14 are provided without providing the embedded portion 13 as shown in FIG. These holes are also obtained only by a movable punch. The punched holes 90g to 90l are all the same shape, differ only in the position in the width direction in the rectangular region Q, and the width dimension is constant except for the positions corresponding to the pair of flange portions 14. Therefore, the magnetic core shown in FIG. 19 can be formed by laminating in the same manner as the laminating steel plates 101 to 106 and 201 to 206 to obtain a laminated body and adjoining them. Note that the shape of the steel plates 101 to 106 and 201 to 206 for lamination is plane symmetric with respect to a plane orthogonal to the axial direction Z. Therefore, all the laminates have the same shape, and any two laminates are formed. The magnetic core 1 can be configured by using it.

When obtaining the magnetic core 1 without the collar 14, a rectangular shape can be adopted as the shape of the punched holes 90 g to 90 l.

Third embodiment.
The magnetic core 1 obtained by implementing only the second embodiment has a trapezoidal shape in the plan view in the opposite direction. However, it is preferable that the corners of the trapezoid be chamfered or rounded so that the armature winding 15 can be in close contact with the winding part 11. Therefore, the difference in the width dimension in the circumferential direction θ between the electromagnetic steel sheet disposed at the outer end in the radial direction R or the inner end and the electromagnetic steel sheet adjacent thereto is adjacent to the central portion in the radial direction R. It is desirable that it is larger than the difference in the width dimension between the pair of electrical steel sheets.

Therefore, once the

laminated bodies

10a and 10b or the

laminated bodies

20a and 20b obtained by the second embodiment are additionally laminated with electromagnetic steel plates from the inside and outside in the radial direction R, respectively, You may obtain 1 part 1a and 2nd part 1b. Alternatively, it is possible to prepare another punching die (punch) in the same progressive die and further punch out the chamfered or rounded portion.

Variation of shape.
The angle formed by the two hypotenuses of the trapezoid can be set to a value obtained by dividing the peripheral angle (360 degrees) by the number of magnetic cores arranged in an annular shape in the armature.

Also, as shown in the above embodiment, a magnetic core that is divided in the circumferential direction θ and a magnetic core that is not divided as in the conventional case may be mixed. For example, the magnetic cores that are not divided have a rectangular shape in plan view in the facing direction, and are alternately arranged in the annular direction with the magnetic core into which the magnetic cores are divided. In this case, the angle formed by the two hypotenuses of the trapezoid in the plan view in the opposite direction of the divided magnetic core is a value obtained by dividing the peripheral angle (360 degrees) by the number of the divided magnetic cores arranged in the armature. Can be set to Note that the angle between the two hypotenuses of the trapezoid and the base must be the same isosceles trapezoid.

It is desirable that the area of the magnetic core in the opposing direction plan view is the same for all the magnetic cores. This is because the number of turns of the armature winding is usually selected equally for all the magnetic cores, so that the symmetry of the magnetic field generated by the armature is improved.

Of course, varying the number of turns of the armature winding for each magnetic core does not impair the success of the above-described embodiment, and can be appropriately designed and selected according to other requirements. Regarding the punching pattern, the two portions are a pair of electrical steel sheets, but a plurality of units may be simultaneously punched in the width direction of the electrical steel sheet with this as one unit.

Although the present invention has been described in detail, the above description is illustrative in all aspects, and the present invention is not limited thereto. It is understood that countless variations that are not illustrated can be envisaged without departing from the scope of the present invention.

DESCRIPTION OF SYMBOLS 1 Magnetic core 1a 1st part 1b 2nd part 100 Magnetic steel plate 101-106, 201-206 Steel plate for lamination | stacking 11 Winding part 11a 1st winding part 11b 2nd winding part 110a 1st interface 110b 2nd interface 15 Armature winding 4 Field element 8 Raw material 90a to 90l Punching hole 91, 91a to 91f Position of fixed punch 92, 92a to 92f Position of movable punch K Transport direction P Predetermined length R Radial direction Z Axis direction θ Circumference direction

Claims

A magnetic core (1) arranged annularly in a circumferential direction (θ) perpendicular to the axial direction in an armature facing the field element (4) in the axial direction (Z),
Each includes a first portion (1a) on one side in the circumferential direction and a second portion (1b) on the other side in the circumferential direction,
Each of the first part and the second part includes a plurality of electrical steel sheets (100) stacked in a radial direction (R) perpendicular to both the axial direction and the circumferential direction,
The first portion has a first winding portion (11a) and a first boundary surface (110a),
The second part has a second winding part (11b) and a second boundary surface (110b),
The first boundary surface and the second boundary surface are parallel to the axial direction and the radial direction,
The first boundary surface and the second boundary surface are disposed adjacent to each other;
The first winding portion and the second winding portion are armature cores that form a winding portion (11) around which the armature winding (15) around the axial direction is wound.
The field element rotates from the other side in the circumferential direction to the one side in the circumferential direction,
Regarding the cross section at an arbitrary position in the radial direction (R) perpendicular to both the axial direction (Z) and the circumferential direction (θ), the second portion (1b) is more than the first portion (1a). The armature core (1) according to claim 1, which is also narrow.
The raw material (8), which is an electromagnetic steel plate, is conveyed every predetermined length (P) in the conveying direction (K),
(A) when the conveyance of the raw material is stopped, the step of punching the raw material using the first punch (92);
(B) The electromagnetic steel sheet left on the raw material in the step (a) is punched into a rectangular shape (Q) whose dimension in the transport direction is equal to or less than the predetermined length, and the laminated steel sheets (101 to 106, 201) To 206), and
(C) Of the steel sheets for lamination obtained in the step (b), those obtained on one side with respect to the first punch in the width direction perpendicular to the conveying direction (101 to 106), And laminating in the punched order,
The step (a) reciprocates the first punch between the first position (92a, 92f; 90g, 90l) and the second position (92c, 92d; 90i, 90j) in the width direction. By repeatedly updating the position of the first punch,
In the step (c), the laminate steel plates (101, 106) punched at the first position and the laminate steel plates (103, 104) punched at the second position are used as boundaries. A plurality of laminated bodies (10a, 10b) are obtained by laminating laminated steel sheets,
(D) forming the magnetic core (1) by adjoining the stacked bodies in the step (c) with the positions punched by the first punches opposite to each other;
A method for manufacturing a magnetic core, further comprising:
(E) Of the steel sheets for lamination obtained in the step (b), those obtained on the other side with respect to the first punch in the width direction perpendicular to the transport direction (201 to 206), In the punched order, the laminated steel plates (201, 206) punched at the first position and the laminated steel plates (203, 204) punched at the second position as a boundary. A steel plate is laminated to obtain a plurality of laminates (20a, 20b);
(F) forming the magnetic core (1) by adjoining the stacked bodies in the step (e) with the positions punched by the first punches opposite to each other;
The method of manufacturing a magnetic core according to claim 3, further comprising:
(G) Prior to the execution of the step (c), when the conveyance of the raw material (8) is stopped in a pair with the step (a), the position in the width direction (91a The method of manufacturing a magnetic core according to claim 3 or 4, further comprising a step of punching out the raw material using a second punch (91) in which ... 91f) is maintained.