WO2014057841A1 - 回転電機の絶縁構造及びその製造方法 - Google Patents

回転電機の絶縁構造及びその製造方法 Download PDF

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Publication number
WO2014057841A1
WO2014057841A1 PCT/JP2013/076689 JP2013076689W WO2014057841A1 WO 2014057841 A1 WO2014057841 A1 WO 2014057841A1 JP 2013076689 W JP2013076689 W JP 2013076689W WO 2014057841 A1 WO2014057841 A1 WO 2014057841A1
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Prior art keywords
iron core
insulator
rotating electrical
electrical machine
insulating structure
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Application number
PCT/JP2013/076689
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English (en)
French (fr)
Japanese (ja)
Inventor
大毅 梶田
中須　信昭
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株式会社日立製作所
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Application filed by 株式会社日立製作所 filed Critical 株式会社日立製作所
Priority to CN201380051714.9A priority Critical patent/CN104704716B/zh
Priority to DE112013004576.1T priority patent/DE112013004576T5/de
Publication of WO2014057841A1 publication Critical patent/WO2014057841A1/ja

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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/32—Windings characterised by the shape, form or construction of the insulation
    • H02K3/325—Windings characterised by the shape, form or construction of the insulation for windings on salient poles, such as claw-shaped poles
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/32—Windings characterised by the shape, form or construction of the insulation
    • H02K3/34—Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation
    • H02K3/345—Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation between conductor and core, e.g. slot insulation
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/10—Applying solid insulation to windings, stators or rotors

Definitions

  • the present invention relates to an insulating structure of a rotating electrical machine, and more particularly to an insulating structure of a stator and a manufacturing method thereof.
  • Rotating electrical machines such as motors and alternators are composed of a rotor, a stator, and a housing that covers them.
  • the stator is composed of a plurality of stator teeth that are composed of an iron core made of a soft magnetic material, an electric wire wound around the iron core, and an insulator that insulates between the iron core and the electric wire. It is arranged and configured. Since a large-capacity current is passed through the stator wires, the insulator is required to have insulation, and in order to maintain the performance of the rotating electrical machine, strength is also required to maintain the iron core shape.
  • an insulating paper or an insulating resin material formed by injection molding is used as the insulator.
  • An insulator obtained by injection molding is effective in terms of winding of an electric wire, fixing of a stator, and the like because a desired shape can be accurately obtained in accordance with the dimensions of an iron core.
  • a mold is indispensable for injection molding, it is necessary to change the shape of the mold for injection molding as the shape of the iron core changes, resulting in a low degree of freedom in changing the shape and increasing manufacturing costs. It was a problem.
  • Patent Document 1 discloses an example in which an insulating film is pressure-molded around an iron core.
  • a coil-wrapped part and a hook part are configured by a compression-molded film, and by combining these, insulation between the iron core and the electric wire is secured, and the iron core and the core are formed by the hook part arranged at the end of the iron core.
  • the present invention relates to an insulating structure of a rotating electrical machine that retains the shape of a film, and is a structure in which the shape of an insulator can be easily changed.
  • the insulation structure of the above-mentioned Patent Document 1 has an object to make the coil winding part as thin as possible on the premise of the presence of the collar part.
  • the coil winding part alone cannot maintain the iron core shape, and the stator teeth. Since the magnetic performance is greatly affected, a collar portion is required, and there is a problem in that the production cost is limited.
  • the iron core is constructed by laminating soft magnetic material plates, but each plate material is shaped like a leaf spring due to deformation during cutting, etc. It is necessary to reduce the gap and ensure the space factor, that is, the ratio between the apparent volume of the iron core and the actual volume of the soft magnetic material plate.
  • Patent Document 1 it is possible to press and hold the iron core in the stacking direction by using the flange portion by adjusting the flange portion to the size of the iron core, but the film constituting the coil winding portion Since the portion is low in strength, the state where the iron core is pressurized cannot be maintained by itself, and the central portion of the iron core is swollen. Since the stress generated in the soft magnetic material is increased in the swelled iron core in the central portion, the iron loss increases and the efficiency of the rotating electrical machine decreases as the space factor decreases. Furthermore, when a film is compression-molded, a pressurizing jig adapted to the shape of the iron core is required, and thus the manufacturing cost increases.
  • the present invention has been made in view of such circumstances, and has an insulating structure for a rotating electrical machine and a method for manufacturing the same that can manufacture stator teeth having a high space factor in an arbitrary shape without using a mold.
  • the purpose is to provide.
  • an insulating structure of a rotating electrical machine is an insulating structure of a rotating electrical machine having a stator and a rotor, and the stator teeth constituting the stator are made of a soft magnetic material plate. It comprises a laminated iron core, an electric wire arranged around the iron core, and an insulator arranged between the iron core and the electric wire, and the insulator is made of a stretchable member. It is mounted around the iron core in a stretched state, and has a tensile strength that presses a soft magnetic material plate constituting the iron core in the stacking direction.
  • another rotating electrical machine insulation structure is a rotating electrical machine insulation structure having a stator and a rotor, and the stator teeth constituting the stator are made of a soft magnetic material.
  • the iron core formed by laminating plate materials, the electric wires arranged around the iron core, and the insulator are made of an elastic body having a bending strength of 10 to 2000 MPa, and are expanded in the width direction of the plate material of the soft magnetic material. In this state, it is mounted around the iron core, and has a bending strength that pressurizes the soft magnetic material plate constituting the iron core in the stacking direction.
  • a method for manufacturing an insulating structure for a rotating electrical machine is a method for manufacturing an insulating structure for a rotating electrical machine having stator teeth, in which an iron core formed by laminating soft magnetic material plates is stacked.
  • a first step of pressing and gripping in the thickness direction a second step of disposing a stretchable insulator around the iron core, and a third step of fixing the insulator around the iron core.
  • the divided insulators are arranged in a plurality of times.
  • a stator tooth having a high space factor can be produced in an arbitrary shape without a mold, and the insulation structure of the rotating electrical machine can be reduced. Can be obtained at a cost.
  • FIG. 1 is a diagram showing a configuration of an axial gap type rotating electrical machine according to the first embodiment of the present invention.
  • FIG. 2 is a diagram illustrating the configuration of the stator teeth of the axial gap type rotating electrical machine according to the first embodiment of the present invention.
  • FIG. 3 is a diagram showing a form 1 of the iron core and the insulator according to the first embodiment of the present invention.
  • FIG. 4 is a diagram showing a form 2 of the iron core and insulator according to the first embodiment of the present invention.
  • FIG. 5 is a diagram showing a third form of the iron core and the insulator according to the first embodiment of the present invention.
  • FIG. 6 is a diagram showing a form 4 of the iron core and insulator according to the first embodiment of the present invention.
  • FIG. 1 is a diagram showing a configuration of an axial gap type rotating electrical machine according to the first embodiment of the present invention.
  • FIG. 2 is a diagram illustrating the configuration of the stator teeth of the axial gap type rotating
  • FIG. 7 is a diagram showing the compressive force of the insulator according to Example 1 of the present invention.
  • FIG. 8 is a diagram showing a form 5 of the iron core and insulator according to the first embodiment of the present invention.
  • FIG. 9A is a diagram showing a configuration of an iron core and an insulator related to Example 1 of the present invention.
  • FIG. 9B is a diagram showing a configuration of an iron core and an insulator related to Example 1 of the present invention.
  • FIG. 10 is a diagram illustrating a manufacturing method of the rotating electrical machine of mode 1 according to the first embodiment of the present invention.
  • FIG. 11 is a diagram showing a method of manufacturing the rotating electrical machine of mode 2 according to the first embodiment of the present invention.
  • FIG. 12 is a diagram illustrating a manufacturing method of the rotating electrical machine of mode 3 according to the first embodiment of the present invention.
  • FIG. 13 is a diagram showing a method of manufacturing the rotating electrical machine of form 4 according to the first embodiment of the present invention.
  • FIG. 14 is a diagram showing a method of manufacturing the rotating electrical machine of Form 5 according to Example 1 of the present invention.
  • FIG. 15 is a diagram showing a first form of an iron core and an insulator related to Example 2 of the present invention.
  • FIG. 16 is a diagram showing the compressive force of the insulator according to Example 2 of the present invention.
  • FIG. 17A is a diagram showing a form 2 of an iron core and an insulator related to Example 2 of the present invention.
  • FIG. 17B is a diagram showing a second form of the iron core and the insulator according to the second embodiment of the present invention.
  • FIG. 18 is a diagram showing a third form of the iron core and insulator according to the second embodiment of the present invention.
  • FIG. 1 is a diagram for explaining the structure of an axial gap type rotating electrical machine using an insulating structure according to the present embodiment.
  • the axial gap type rotating electrical machine 10 includes a rotor 50 in which a plurality of magnets 20 are arranged in a circumferential direction on a disk-shaped member 21, and an electric wire 33 wound around an iron core 31 via an insulator 32.
  • a stator 60 having a plurality of stator teeth 30 arranged in the circumferential direction, a rotary shaft 70 for arranging the rotor 50 and the stator 60 concentrically, and a housing 80 for storing them.
  • the magnet 20 can be replaced with an electromagnet.
  • stator teeth 30 are excited by energization to generate an attractive force between the magnet 20 and the stator teeth 30 and rotate between the rotor 50 and the stator 60 by exciting different stator teeth 30 continuously.
  • the stator 60 includes a plurality of stator teeth 30, each stator tooth 30 is individually provided with a block-shaped iron core 31, and an insulator 32 and an electric wire 33 are arranged around each iron core 31. Is done.
  • FIG. 2 is a diagram illustrating the structure of the stator teeth in the present embodiment.
  • the stator tooth 30 is composed of an iron core 31, an insulator 32, and an electric wire 33.
  • the insulator 32 is arranged around the iron core 31 in order to ensure insulation between the iron core 31 and the electric wire 33, and the electric wire 33 is wound around the insulator 32.
  • the iron core 31 is made of a plate-like soft magnetic material such as an electromagnetic steel plate, amorphous metal, or permendur, and in the example of FIG. 2, the soft magnetic is gradually widened so that a trapezoidal end face is formed when viewed from above. It is formed by laminating plate materials.
  • FIG. 1 is a diagram illustrating the structure of the stator teeth in the present embodiment.
  • the stator tooth 30 is composed of an iron core 31, an insulator 32, and an electric wire 33.
  • the insulator 32 is arranged around the iron core 31 in order to ensure insulation between the iron core 31 and the electric wire 33, and the electric wire
  • the upward arrow indicates the axial length direction of the rotating electrical machine, and the arrow orthogonal thereto indicates the stacking direction of the plate materials made of the soft magnetic material constituting the iron core 31. This also applies to FIGS. 3 to 6, 8, 9A, and 9B described later.
  • Each plate is in the form of a leaf spring due to the deformation of the cut edge and the residual stress generated when a thin plate made of a soft magnetic material is cut. When these are simply stacked, there is a gap in the axial length direction between each plate. Will occur.
  • a single wire or a stranded wire having a substantially circular cross section or a substantially rectangular cross section using copper or aluminum as a base material is used for the electric wire 33.
  • the electric wire 33 is wound around the iron core 31 via the insulator 32, the iron core It is necessary to obtain a space factor which is a design target by pressing the plate material of the soft magnetic material constituting the plate 31 in the stacking direction and keeping the gap generated between the plate materials compressed.
  • FIG. 3 shows Embodiment 1 of the first embodiment for realizing this, and is a diagram illustrating the structure of the iron core and the insulator constituting the stator teeth.
  • the insulator 32 is made of polyethylene, polyvinyl chloride, polyimide, synthetic rubber or the like, and is made of an insulating tape having stretchability and a tensile strength of 10 to 200 MPa.
  • An insulating structure using an insulating tape is formed by winding an insulator 32 around the iron core 31 held in a pressurized state in the stacking direction, and bonding, fusing or welding the insulators 32 to each other at the ends. It is obtained by fixing.
  • the winding start end is fixed to the iron core 31 pressed in the stacking direction by a tape winding device. Both ends are fixed after winding along the entire circumference while maintaining the tension. Thereby, the pressurizing force applied to the iron core 31 can be maintained, and the space factor of the soft magnetic material plate can be maintained at the designed target value.
  • the tensile strength of the insulating tape and the tension applied to the insulating tape during winding are selected from the viewpoint of maintaining the compressive stress necessary to obtain the design space factor. The optimum value is selected according to the size, thickness, stacking thickness, etc. of each sheet. For example, when the insulating tape is wound twice, the tensile strength of the insulating tape itself may be about half of the required compressive stress.
  • the insulator 32 is fixed by a method in which an insulator having an adhesive surface is adhered to the adhesive surface, a method in which an insulator having a self-bonding property is fused, or an end surface of the insulator is laser-bonded. Examples include a method of melting and welding.
  • the upper half that is less than half in the axial length direction of the iron core 31 is gripped by the gripping tool and pressed in the stacking thickness direction, so that even in the lower half that is not gripped, between the plate members
  • the insulating tape 32a is wound around the lower part that does not interfere with the gripping tool so that the gap of the gap satisfies the designed space factor.
  • the insulating tapes 32 a and 32 b constituting the insulator 32 are divided into a plurality of parts in the axial length direction of the iron core 31.
  • FIG. 5 shows still another form of the present embodiment, and is a diagram for explaining the iron core of the stator teeth and the form 3 of the insulator.
  • the insulator 32 is made of an insulating tape having a tensile strength of 10 to 200 MPa based on polyethylene, polyvinyl chloride, polyimide, synthetic rubber, or the like.
  • the iron core 31 is pressed by holding in the stacking direction with a holding member or the like at a position where the insulating tape does not interfere.
  • the insulating tape as the insulator 32 is spirally wound around the iron core 31 so that the end faces in the width direction are in contact with each other, It is obtained by bonding, fusing or welding the insulators 32 at the end of winding.
  • the insulator 32 can be arranged around the iron core 31 without being divided as shown in FIG.
  • FIG. 6 shows Embodiment 4 of the present example, in which both ends in the width direction are partially overlapped when the insulating tape is wound spirally.
  • the insulator 32 is arranged without being overlapped in the axial length direction of the iron core 31 as shown in FIGS. 3 and 5, depending on the type of the rotating electric machine, when the electric wire 33 is arranged in the gap between the insulators 32.
  • the iron core 31 and the electric wire 33 are in contact with each other and insulation cannot be secured.
  • the thickness of the insulating tape can be secured by partially overlapping both ends in the width direction of the insulating tape, and contact between the iron core 31 and the electric wire 33 is prevented. Can do.
  • FIG. 7 is a diagram for explaining the compressive force of the iron core expressed by the insulator of the first embodiment. Since the insulator 32 using the above-described base material has desired stretchability and tensile strength, by winding the insulator 32 around the iron core 31, the iron core 31 can be contracted by a force that the insulator 32 tends to contract. Can be pressurized.
  • the insulating tape fixed by bonding, fusing, or welding is in a position where the balance between the force to expand the iron core 31 in the stacking direction and the force at which the insulator 32 attempts to contract against this.
  • the iron core shape can be maintained while pressing the plate material of the soft magnetic material constituting the iron core 31 in the stacking direction.
  • the ratio between the apparent volume and the actual volume of the iron core 31 in a stable state at the balanced position is the space factor, and the proportion of the actual volume with respect to the apparent volume increases as the iron core 31 is pressurized.
  • the space factor becomes 100%.
  • the position of this balance can be adjusted by changing the material of the insulator 32, the thickness, the number of windings, and the tension applied to the insulating tape during winding.
  • the compressive force that is developed increases as the tensile strength material increases and as the tension increases, and is proportional to the product of the thickness of the insulating tape and the number of windings, that is, the total thickness of the insulator 32.
  • FIG. 8 shows the fifth embodiment of the present embodiment, and is a diagram illustrating the structure of the stator teeth when a stretchable insulator having a hollow cross section is used. That is, the insulator 32 is not limited to an insulating tape, and any insulator can be used as long as it is a stretchable insulator.
  • a stretchable insulator having a hollow cross section is made of polyethylene, polyvinyl chloride, synthetic It is an insulator with a tensile strength of 10 to 100 MPa using rubber or the like as a base material.
  • This insulator 32 is made of, for example, a cylindrical insulator having a predetermined diameter, and is fitted around the iron core 31 to maintain the applied pressure in the stacking direction applied to the iron core 31.
  • the space factor of the soft magnetic material plate is maintained at the design target value.
  • stator teeth in the case where a hollow cylindrical insulator whose inner cross-sectional area is smaller than the cross-sectional area of the iron core is used is, for example, the upper side of the iron core 31 as in the first embodiment shown in FIG.
  • a lower cylindrical insulator 32c expanded to fit the outer shape of the iron core 31 by an extension tool is inserted from the lower side around the iron core 31 grasped in the stacking direction by grasping the portion using a grasping tool. Arrange and open the extension tool and attach to the lower part of the iron core 31.
  • the cylindrical upper insulator 32d is mounted in the same manner, so that the circumference of the iron core 31 is added in the stacking direction by the elastic force of the cylindrical insulators 32c and 32d itself. Can be pressed.
  • the cylindrical insulators 32c and 32d it is necessary to mount the cylindrical insulators 32c and 32d on the iron core 31 gripped by the gripper on the upper side or the lower side, so that it interferes with the gripper.
  • the insulator 32 is divided into a plurality of pieces in the axial length direction of the iron core 31 so as not to be formed.
  • the cylindrical insulator may be divided into three as in the form 2 shown in FIG. 4 of the first embodiment.
  • the stretchable insulator 32 having a hollow cross section disposed around the iron core 31 is stable at a balance between the force to expand in the stacking direction of the iron core 31 and the force to shrink the insulator 32. While pressing the iron core 31 in the stacking direction of the soft magnetic material, the iron core shape is maintained.
  • the balance position can be adjusted by changing the material and thickness of the insulator 32.
  • the compressive force that develops is higher for a material with higher tensile strength, and is proportional to the thickness of the insulator 32. Therefore, selecting the material and the thickness of the insulator as in FIG. It can be a value obtained.
  • a compressive force of 100 MPa is generated by arranging a single layer of a stretchable insulator having a cross section of 0.3 mm with a synthetic rubber as a base material, and an iron core with a stack thickness of 50 mm. It is possible to obtain
  • a heat-shrinkable cylindrical insulator having a hollow cross section may be used.
  • the heat-shrinkable insulator having a hollow cross section is an insulator having a tensile strength of 10 to 100 MPa based on, for example, polyolefin.
  • the stator teeth in the case where a heat-shrinkable insulator having a hollow cross section inside that is larger than the cross-sectional area of the iron core is used, the insulator 32 around the iron core 31 gripped in the stacking direction.
  • the insulator 32 is heated and contracted together with the iron core 31 by a heating furnace, a hot plate, or the like, and the iron core 31 is pressurized.
  • a heat-shrinkable insulator generally shrinks to 1/2 to 1/8 when heated at 50 to 200 degrees. Since the insulating core 32 needs to be disposed in the gripped iron core 31 as in the case of using an insulating tape, the insulator 32 is divided into a plurality of parts in the axial length direction of the iron core 31.
  • the heat-shrinkable insulator having a hollow cross section disposed around the iron core 31 is a position where a balance between the force to expand in the stacking direction of the iron core 31 and the force to shrink by heating the insulator 32 is obtained.
  • the core shape is maintained while pressing the iron core 31 in the stacking direction of the soft magnetic material.
  • the balance position can be adjusted by changing the material and thickness of the insulator 32.
  • the compressive force that is developed is higher as the material has higher tensile strength, and is proportional to the thickness of the insulator 32. Therefore, the thickness of the material and the insulator can be selected as in FIG.
  • FIGS. 9A and 9B show that the pressing force in the stacking direction is held in the core 31 by the integrally formed insulator 32 using a stretchable insulating material having a thickness of 1/10 or more of the stacking thickness of the core. It is a figure explaining the structure of the stator teeth in the case of doing it.
  • the notch 34 in a part of the insulator 32, it is possible to pressurize and hold the iron core shape without dividing in the axial direction. That is, the notch 34 into which a claw-like jig that pressurizes and holds the iron core 31 can be inserted is provided in the insulator 32, and the iron core 31 is inserted into the insulator 32 while holding the iron core 31.
  • a claw-shaped jig is pulled out from the notch 34 of the insulator to obtain a stator tooth in which the insulator 32 is not divided. be able to.
  • the thickness of the claw-shaped jig used for gripping increases because the thicker the core 31 is, the more rigid it is.
  • the thickness of the claw-shaped jig needs to be 1/20 or more of the stacking thickness. Therefore, the thickness of the insulator 32 is such that the claw-shaped jig can be removed, and the iron core 31. 1/10 or more of the stack thickness of the iron core, which is at least twice the thickness of the claw-shaped jig, is necessary.
  • the positions of the notches 34 need to be arranged on both sides of the iron core 31 in the stacking direction as shown in FIG. 9A so that the iron core 31 can be pressed and held in the stacking direction. When the width of the iron core 31 in the direction perpendicular to the stacking thickness direction is large, the number of the notches 34 may be increased so that the iron core shape can be easily held as shown in FIG. 9B.
  • FIG. 10 is a flowchart showing the method for manufacturing the insulating structure according to the first embodiment described with reference to FIG. 1stly, using the holding tool, the iron core 31 formed by laminating the plate-like soft magnetic materials is grasped and pressed in the stacking direction by grasping less than half of the iron core 31 as viewed from the axial length direction of the iron core (S11). ). Second, the end of the stretchable insulator 32 is held on one side of the axial length direction not held by the iron core 31 and is wound while applying a predetermined tension (S12).
  • the end portion of the stretchable insulator 32 is fixed by adhesion, fusion or welding (S13). If the insulator 32 has not been arranged around the iron core 31 in the third step, the iron core 31 is once removed from the grip, and the portion of the iron core 31 where the insulator 32 has been arranged is held. The process of winding the insulator 32 around the part that is not gripped is repeated (S15). Through the above steps, an insulating structure using the stretchable insulator 32 can be obtained.
  • FIG. 11 is a flowchart showing the method for manufacturing the insulating structure of form 2 described with reference to FIG.
  • the iron core 31 formed by laminating plate-like soft magnetic materials is gripped by pressing the end portion in the axial length direction of the iron core in the stacking direction (S21).
  • the elastic insulator 32 is wound around the central portion of the axial length direction not held by the iron core 31 while applying a predetermined tension while holding the end of the stretchable insulator 32 (S22).
  • the end portion of the stretchable insulator 32 is fixed by adhesion, fusion or welding (S23).
  • the iron core 31 is once removed from the grip, and the portion of the iron core 31 where the insulator 32 has been arranged is held.
  • the process of winding the insulator 32 around the part that is not gripped is repeated (S25). Through the above steps, an insulating structure using the stretchable insulator 32 can be obtained.
  • FIG. 12 is a flowchart showing the method for manufacturing the insulating structure according to the third embodiment described with reference to FIG.
  • the iron core 31 formed by laminating plate-like soft magnetic materials is gripped by pressing the axially longitudinal upper portion of the iron core in the stacking direction (S31).
  • the end of the stretchable insulator 32 is held around the central portion of the axial length direction that is not gripped by the iron core 31, and is wound while applying a predetermined tension (S32).
  • the position where the iron core 31 is gripped is shifted in the opposite direction to the side where the insulator 32 is started to be wound, and the insulator 32 is wound around the empty portion by shifting the grip.
  • the iron core 31 is once removed, the portion of the iron core 31 where the insulator 32 has been arranged is grasped, and the iron core 31 is grasped.
  • the process of winding the insulator 32 around the unfinished portion is repeated (S35).
  • the end portion of the stretchable insulator 32 is fixed by adhesion, fusion or welding (S36).
  • FIG. 13 is a flowchart showing a method of manufacturing the insulating structure of form 4 using a stretchable insulator having a hollow cross section, which is described with reference to FIG.
  • the iron core 31 formed by laminating plate-like soft magnetic materials is pressed and gripped in the stacking thickness direction at a half or less of the axial length direction of the iron core (S41).
  • the stretchable insulator 32 having a hollow cross section is extended to one side of the axial length direction that is not gripped by the iron core 31, and is arranged so as to cover one side of the iron core 31 in the axial length direction (S42).
  • the expansion of the stretchable insulator 32 having a hollow cross section is released, and the iron core 31 in a portion not gripped is pressurized with the insulator 32 (S43). If the insulator 32 has not been arranged around the iron core 31 in the third step, the iron core 31 is once removed from the grip, and the portion of the iron core 31 where the insulator 32 has been arranged is held. The process of disposing the insulator 32 on the part that is not gripped is repeated (S45). Through the above steps, an insulating structure using the stretchable insulator 32 having a hollow cross section can be obtained.
  • FIG. 14 is a flow chart showing a method for manufacturing the insulating structure of form 5 using the heat-shrinkable insulator having a hollow cross section described in FIG.
  • the iron core 31 formed by laminating plate-like soft magnetic materials is pressed by pressing the upper half of the iron core in the axial length direction in the stacking direction (S51).
  • the heat-shrinkable insulator 32 having a hollow cross section is disposed in the lower half of the axial length direction that is not gripped by the iron core 31 (S52).
  • the heat-shrinkable insulator 32 having a hollow cross section is heated together with the iron core 31, and the portion of the iron core 31 that is not shrunk is pressed with the insulator 32 (S53).
  • the iron core 31 is once removed from the grip, and the portion of the iron core 31 where the insulator 32 has been arranged is held.
  • the process of disposing the insulator 32 on the part that is not gripped is repeated (S55).
  • an insulating structure using the heat-shrinkable insulator 32 having a hollow cross section can be obtained.
  • the insulation between the iron core 31 and the electric wire 33 is ensured by disposing the stretchable insulator 32 having a predetermined tensile strength between the iron core 31 and the electric wire 33. Further, by holding the iron core 31 under pressure, the space factor in design can be maintained over a long period of time, and an insulating structure that can be easily changed in shape can be obtained at low cost.
  • FIG. 15 is a diagram illustrating a stator tooth iron core and an insulation structure according to the second embodiment.
  • the iron core 31 is made of a soft magnetic material such as an electromagnetic steel plate, amorphous metal, or permendur, and is obtained by laminating plate materials of soft magnetic material, and thus has a leaf spring shape.
  • the insulator 36 is made of a resin material such as polyethylene, polyvinyl chloride, polybutylene, polycarbonate, epoxy, urethane, phenol, polyimide, liquid crystal polymer, or a bending strength of 10 to 2000 MPa composed of a member in which insulating paper and a leaf spring are stacked.
  • a leaf spring it is made of a metal material such as spring steel, stainless steel, brass, phosphor bronze, beryllium copper, or a fiber reinforced plastic material.
  • the insulator 36 is formed, for example, by heat-molding the above-described resin material plate, so that the inner side thereof is shaped to match the outer shape of the iron core 31, and the dividing portion 91 is provided along the stacking direction of the iron core 31. It has been. As a result, the insulator 36 is disposed on the outer periphery of the iron core 31 so as to spread the dividing portion 91, and then the insulator 36 is opened so that both sides of the dividing portion 91 are caused to be in the iron core 31 by the bending stress of the insulator 36. Is pressed in the stacking thickness direction, and the space factor is maintained at a design target value.
  • FIG. 16 is a diagram for explaining the compressive force of the iron core expressed by the insulator.
  • the iron core 31 has a large force to expand in the stacking direction when it is pressed because the gap in the stacking direction increases as the thickness of the laminated magnetic material plate decreases or the stacking thickness increases.
  • the insulator 36 formed by laminating the plate materials made of the above-described materials has elasticity and tends to swell in the stacking direction. Therefore, the dividing portion 91 is bent inward so as to be smaller than the outer shape of the iron core 31.
  • the periphery of the dividing portion 91 is elastically deformed in the stacking direction of the iron core 31.
  • the insulator 36 is stabilized at a balance position between the force to expand in the stacking direction of the iron core 31 and the force to return to the vicinity of the dividing portion 91 of the insulator, and the iron core 31 is soft magnetic material. It becomes possible to hold
  • the space factor is 100%.
  • the balance position can be adjusted by changing the material and thickness of the insulator 36 and the amount of deformation when the dividing portion 91 is bent in the stacking direction.
  • Compressive force expressed is higher for materials with higher bending strength, and is proportional to the product of the amount of deformation and the cube of the thickness of the split part.
  • Compressive force expressed is higher for materials with higher bending strength, and is proportional to the product of the amount of deformation and the cube of the thickness of the split part.
  • a pressure of 50 MPa is generated on one side of the dividing portion of the insulator.
  • FIG. 17A and FIG. 17B are diagrams for explaining the second embodiment of the iron core and the insulating structure of the stator teeth according to the second embodiment.
  • the insulator 36 is made of a resin material such as polyethylene, polyvinyl chloride, polybutylene, polycarbonate, epoxy, urethane, phenol, polyimide, liquid crystal polymer, or a bending strength of 10 to 2000 MPa composed of a member in which insulating paper and a leaf spring are stacked.
  • the leaf spring is made of a metal material such as spring steel, stainless steel, brass, phosphor bronze, beryllium copper, or a fiber reinforced plastic material. As shown in FIG.
  • the insulator 36 has a non-movable part 36a, a movable part 36b provided with a partially convex shape, and a movable part 36c provided with a partially concave shape.
  • the movable parts 36b and 36c are provided in the stacking direction of the iron core 31, and are provided with a hemispherical convex fitting part 92a and a hemispherical concave fitting part 92b.
  • the movable part 36b and the movable part 36c are closed so as to be pushed together and fixed by the fitting part.
  • the inner shape of the insulator 36 in this state is formed in a shape that matches the outer shape of the iron core 31. Since the iron core 31 is disposed on the non-movable portion 36a inside the insulator 36, the iron core 31 is pressurized by fixing the movable portion 36b and the movable portion 36c of the insulator.
  • the iron core 31 in which the movable portion 36b and the movable portion 36c of the insulator are fixed by the fitting portions 92a and 92b and the swelling in the stacking direction is suppressed is pressed in the stacking direction of the soft magnetic material, and the core shape is maintained. Is done.
  • the iron core 31 Since the gap in the stacking direction increases as the thickness of the soft magnetic material constituting the core 31 decreases and the stacking thickness increases, the iron core 31 also has a large force to expand in the stacking direction when pressed. Become. Therefore, by increasing the diameters of the fitting portions 92a and 92b, it is possible to strengthen the fixing of the movable portion 36b and the movable portion 36c. In addition, as shown in FIG. 17B, by increasing the number of convex shapes provided on the movable portion 36b and concave shapes provided on the movable portion 36c, the fixing of the movable portion 36b and the movable portion 36c may be strengthened. Is possible.
  • FIG. 18 is a diagram for explaining the core 3 of the stator teeth and the configuration 3 of the insulating structure according to the second embodiment.
  • the fitting portion can be replaced with a through hole and a bar.
  • the iron core 31 is disposed on the non-movable portion 36a inside the insulator 36, and is pressurized by fixing the movable portion 36b and the movable portion 36c of the insulator.
  • the iron core 31 in which the bar 94 is inserted and fixed in the through hole 93 provided in the movable portion 36b and the movable portion 36c of the insulator and the swelling in the stacking direction is suppressed is pressed in the stacking direction of the soft magnetic material. And the iron core shape is maintained.
  • the elastic insulator 36 between the iron core 31 and the electric wire 33, the insulation between the iron core 31 and the electric wire 33 can be secured and the iron core 31 can be held while being pressed. This makes it possible to obtain an insulating structure that can be easily changed in shape at a low cost.
  • the present invention has been specifically described based on the embodiment, but several kinds of individually described inventions can be used in combination.
  • the example in the case of the axial gap type rotating electrical machine has been described, since the shape of the insulator can be freely changed if it is a columnar iron core shape, the same effect can be obtained also in a radial gap type rotating electrical machine. be able to. That is, in the radial gap type rotating electrical machine, since the soft magnetic material plates constituting the iron core are laminated in the axial length direction, the insulator is configured to press the iron core to be expanded in the axial length direction. By adopting, the space factor can be maintained at the design target value.
  • the present invention is not limited to the embodiments of the invention, and in a rotating electrical machine having a stator tooth configured by arranging an insulator between an iron core and an electric wire, the scope of the present invention is not deviated. Needless to say, it can be changed.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Insulation, Fastening Of Motor, Generator Windings (AREA)
  • Iron Core Of Rotating Electric Machines (AREA)
  • Manufacture Of Motors, Generators (AREA)
PCT/JP2013/076689 2012-10-11 2013-10-01 回転電機の絶縁構造及びその製造方法 WO2014057841A1 (ja)

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CN201380051714.9A CN104704716B (zh) 2012-10-11 2013-10-01 旋转电机的绝缘构造及其制造方法
DE112013004576.1T DE112013004576T5 (de) 2012-10-11 2013-10-01 Isolationsaufbau für eine rotierende elektrische Maschine und Verfahren zu dessen Herstellung

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JP2012225651A JP5870003B2 (ja) 2012-10-11 2012-10-11 回転電機の絶縁構造及びその製造方法
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DE102017215248A1 (de) * 2017-08-31 2019-02-28 Robert Bosch Gmbh Isoliervorrichtung
JP6802202B2 (ja) 2018-02-22 2020-12-16 トヨタ自動車株式会社 軟磁性薄帯の積層体
JP7020180B2 (ja) 2018-02-27 2022-02-16 トヨタ自動車株式会社 回転電機用ステータ
CN108448770B (zh) * 2018-04-08 2020-05-15 新誉轨道交通科技有限公司 定子线圈绝缘一体化方法
JP7036223B2 (ja) * 2018-10-02 2022-03-15 日本製鉄株式会社 巻鉄心
DE102020107362A1 (de) 2020-03-18 2021-09-23 Schaeffler Technologies AG & Co. KG Verfahren zur Herstellung und/oder elektrischen Isolierung eines Einzelzahns oder einer Polkette von Einzelzähnen für eine elektrische Maschine, insbesondere einen Motor oder Generator, Einzelzahn, elektrische Maschine
CN111790771B (zh) * 2020-06-08 2022-06-03 日立电梯电机（广州）有限公司 成型整形装置及成型整形方法
WO2023177462A1 (en) * 2022-03-15 2023-09-21 Iowa State University Research Foundation, Inc. Soft magnetic wire/strip array for motor stator and rotor

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JP2014079101A (ja) 2014-05-01
CN104704716B (zh) 2017-10-03

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