WO2021166497A1

WO2021166497A1 - Stator

Info

Publication number: WO2021166497A1
Application number: PCT/JP2021/000890
Authority: WO
Inventors: 康頌塩月; 尚登齋藤; 新一大竹; 哲平津田
Original assignee: アイシン・エィ・ダブリュ株式会社; アイシン精機株式会社
Priority date: 2020-02-20
Filing date: 2021-01-13
Publication date: 2021-08-26

Abstract

A stator core of this stator includes an annular radially inner portion, and an annular radially outer portion as a yoke part arranged radially outside of the radially inner portion. Also, the radially outer portion is configured by a linear magnetic member arranged to wind the radially inner portion from radially outside.

Description

Stator

The present invention relates to a stator.

Conventionally, a stator having a stator core is known. Such a stator is disclosed in, for example, Japanese Patent Application Laid-Open No. 2016-171652.

Japanese Patent Application Laid-Open No. 2016-171652 provides a stator provided with a mechanism (outer diameter punching punch, outer diameter punching die) for punching a strip-shaped electromagnetic steel sheet into an annular electromagnetic steel sheet having a shape corresponding to the shape of the stator core body. Manufacturing equipment is described. The punched electrical steel sheet includes the parts corresponding to the teeth, slots and back yoke of the stator core.

Japanese Unexamined Patent Publication No. 2016-171652

However, in the stator manufacturing apparatus described in JP-A-2016-171652, since the annular electromagnetic steel sheet is punched out from the strip-shaped electrical steel sheet by press working, the portion corresponding to the outside of the annular electrical steel sheet is formed. It is discarded without being used as an electromagnetic steel sheet that constitutes a stator. Further, in the stator described in Japanese Patent Application Laid-Open No. 2016-171652, the punched electrical steel sheet includes a portion corresponding to the teeth, the slot and the back yoke of the stator core, so that the diameter is relatively large. In this case, the size of the strip-shaped electrical steel sheet (length of the short side) is also relatively large. Therefore, the amount of the discarded portion of the electromagnetic steel sheet remaining after the annular electromagnetic steel sheet is punched by press working becomes excessively large. In particular, in the case of a large motor, when the stator becomes large, the amount of electrical steel sheets discarded during the manufacture of the annular electrical steel sheets becomes excessively large. That is, there is a problem that the yield of the electromagnetic steel sheet is lowered because the amount of the electromagnetic steel sheet used as a material in the manufacturing process of the stator is excessively large with respect to the amount of the electromagnetic steel sheet constituting the stator.

The present invention has been made to solve the above problems, and one object of the present invention is to reduce the amount of electrical steel sheets discarded in the stator manufacturing process to improve the yield of electrical steel sheets. It is to provide a stator that can be made to.

In order to achieve the above object, the stator in one aspect of the present invention has an annular radial inner portion provided with a plurality of teeth and a plurality of slots formed between adjacent teeth, and a radial inner portion. A stator core including an annular radial outer portion as a yoke portion provided separately from the portion and arranged radially outer of the radial inner portion, and a coil portion including a conductor portion arranged in the slot. The radial inner portion is composed of a plurality of electromagnetic steel plates laminated in the axial direction of the stator core, and the radial outer portion is arranged so as to wind the radial inner portion from the radial outer side. It is composed of a linear magnetic member. The linear shape means a shape that can be used as a back yoke (without cracks or the like) by bending the stator core so as to wind it, regardless of whether the cross-sectional shape is circular or rectangular.

In the stator in one aspect of the present invention, as described above, the radial outer portion is composed of a linear magnetic member arranged so as to wind the radial inner portion from the radial outer side. As a result, the portion corresponding to the yoke portion of the electromagnetic steel sheet constituting the stator core can be reduced, so that the length of the short side of the strip-shaped electromagnetic steel sheet used as a material in the manufacturing process of the stator can be reduced. .. As a result, it is possible to reduce the amount of discarded electromagnetic steel sheets remaining after the electromagnetic steel sheets forming the radial inner portion are punched by press working. Thereby, the amount of the electromagnetic steel sheet used as a material in the manufacturing process of the stator can be reduced with respect to the amount of the electromagnetic steel sheet constituting the stator, and the yield of the electromagnetic steel sheet can be improved. Since the radial outer portion is composed of a linear magnetic member arranged so as to wind the radial inner portion from the radial outer portion, the electromagnetic steel plate constituting the radial inner portion is reduced in size. However, the yoke portion is not insufficient due to the radial outer portion formed of the linear magnetic member.

According to the present invention, as described above, the amount of electrical steel sheets used as a material in the manufacturing process of the stator can be reduced with respect to the amount of electrical steel sheets constituting the stator to improve the yield of the electrical steel sheets. ..

It is sectional drawing of the rotary electric machine provided with the stator according to 1st Embodiment. It is sectional drawing along the line 900-900 of FIG. It is a perspective view which shows the structure of the coil part by 1st Embodiment. It is sectional drawing of the slot insertion part by 1st Embodiment. It is sectional drawing of the coil end part by 1st Embodiment. It is sectional drawing of the magnetic member by 1st Embodiment. It is a partially enlarged view near the end of the slot of FIG. It is a flow figure for demonstrating the manufacturing method of the stator according to 1st Embodiment. It is the schematic for demonstrating the method of forming the electromagnetic steel sheet by 1st Embodiment. It is sectional drawing of the rotary electric machine provided with the stator according to 2nd Embodiment. It is sectional drawing along the line 910-910 of FIG. It is sectional drawing along the line 920-920 of FIG. It is a flow chart for demonstrating the manufacturing method of the stator according to 2nd Embodiment. It is the schematic for demonstrating the method of forming the electromagnetic steel sheet by 2nd Embodiment. FIG. 5 is a cross-sectional view of a rotary electric machine provided with a stator according to the third embodiment (cross-sectional view taken along the line 950-950 in FIG. 16). It is a top view of the stator core according to 3rd Embodiment. FIG. 5 is a cross-sectional view taken along the line 930-930 of FIG. It is sectional drawing along the line 940-940 of FIG. It is a flow diagram for demonstrating the manufacturing method of the stator according to 3rd Embodiment. It is a figure for demonstrating the process of arranging a segment conductor in a slot in step S2 of FIG. (FIG. 20A is a cross-sectional view taken along the axial direction of the stator core. FIG. 20B is a cross-sectional view taken along the line 960-960 of FIG. 20A. FIG. 20C is a cross-sectional view taken along the line 961-961 of FIG. 20A. It is a cross-sectional view.) It is a figure for demonstrating the process of arranging the insulating member in a slot in step S2 of FIG. 21A is a cross-sectional view taken along the axial direction of the stator core. FIG. 21B is a cross-sectional view taken along line 962-962 of FIG. 21A. FIG. 21C is taken along line 963-963 of FIG. 21A. It is a cross-sectional view.) It is a figure for demonstrating the step of arranging the radial outer part in step S3 of FIG. (FIG. 22A is a cross-sectional view taken along the axial direction of the stator core. FIG. 22B is a cross-sectional view taken along line 964-964 of FIG. 22A. FIG. 22C is taken along line 965-965 of FIG. 22A. It is a cross-sectional view.) It is sectional drawing of the rotary electric machine provided with the stator according to the 1st modification of 1st Embodiment. It is a figure for demonstrating the method of forming the stator core (diameter inner part) by the 2nd modification of 1st to 3rd Embodiment. It is a top view which showed the structure of the strip-shaped electromagnetic steel plate of FIG. It is sectional drawing of the stator according to the 3rd modification of 3rd Embodiment.

Hereinafter, embodiments embodying the present invention will be described with reference to the drawings.

[First Embodiment]
(Structure of stator)
The structure of the stator 100 according to the first embodiment will be described with reference to FIGS. 1 to 9. In the following description, the axial direction, the radial direction, and the circumferential direction of the stator core 10 (see FIG. 1) included in the stator 100 are the Z direction, the R direction, and the C direction, respectively. Further, one side and the other side in the axial direction (Z direction) are defined as the Z1 side and the Z2 side, respectively. Further, the inner side (one side) and the outer side (the other side) in the radial direction (R direction) are the R1 side and the R2 side, respectively.

As shown in FIG. 1, the stator 100 and the rotor 101 form a part of the rotary electric machine 102. The rotary electric machine 102 is, for example, a motor, a generator, or a motor / generator. The rotor 101 is arranged on the R1 side of the stator 100 (see FIG. 2) so that the outer peripheral surface of the rotor 101 and the inner peripheral surface of the stator 100 face each other in the R direction. That is, the stator 100 is configured as a part of the inner rotor type rotary electric machine 102.

Further, the stator 100 includes a stator core 10. The stator core 10 has a cylindrical shape with the central axis A (rotational axis of the rotor 101) along the Z direction as the central axis.

The stator core 10 includes an annular radial inner portion 11. Further, the stator core 10 includes an annular radial outer portion 12 as a yoke portion (back yoke) arranged radially outer of the radial inner portion 11. The radial outer portion 12 is provided separately from the radial inner portion 11.

The radial inner portion 11 is provided with a plurality of teeth 11a (see FIG. 2) and a plurality of slots 11b (see FIG. 2) formed between adjacent teeth 11a. Note that FIG. 1 is a cross-sectional view of the position where the teeth 11a is provided in the circumferential direction.

Further, the stator 100 includes a coil portion 20.

As shown in FIG. 3, the coil portion 20 is configured as a wave winding coil. The coil portion 20 is provided in each of the U phase, the V phase, and the W phase. The coil portion 20 includes a plurality of segment conductors 30. The coil portion 20 is configured by electrically connecting a plurality of segment conductors 30. The segment conductor 30 is an example of the "conductor portion" in the claims. Further, in FIG. 3, for convenience of explanation, only the U-phase coil portion 20 of the U-phase, V-phase, and W-phase coil portions 20 is shown.

The segment conductor 30 is a coil end portion 32 formed continuously with the slot insertion portion 31 so as to connect the pair of slot insertion portions 31 arranged (inserted) in the slot 11b and the pair of slot insertion portions 31 to each other. And, including. The segment conductor 30 is formed by a pair of slot insertion portions 31 and a coil end portion 32 so as to have a substantially U shape when viewed in the R direction. A plurality of segment conductors 30 are arranged on the Z1 side and the Z2 side. The segment conductor 30 arranged on the Z1 side and the segment conductor 30 arranged on the Z2 side are electrically connected by contacting the tip portions 31a of the slot insertion portion 31 with each other.

As shown in FIGS. 4 and 5, the segment conductor 30 includes a conductor 30a made of copper or aluminum. The conductor 30a is a flat conductor having a substantially rectangular cross section. As shown in FIG. 4, in the slot insertion portion 31, the conductor surface 30b of the conductor 30a is exposed. Further, as shown in FIG. 5, in the coil end portion 32, the conductor surface 30b of the conductor 30a is covered with the insulating coating portion 30c so as to electrically insulate the coil end portion 32 of the adjacent different phase segment conductors 30. ing. The insulating coating portion 30c is covered by, for example, electrodeposition coating.

Here, in the first embodiment, as shown in FIG. 1, the radial outer portion 12 is composed of a linear magnetic member 12a arranged so as to wind the radial inner portion 11 from the radial outer side. ing. The magnetic member 12a is a thin magnetic wire. The magnetic member 12a is a round wire having a diameter r1. The diameter r1 is, for example, about 1 mm. The diameter r1 is larger than the thickness (not shown) of the electrical steel sheet 110 described later. Further, the magnetic member 12a wound around the radial inner portion 11 may be formed by one continuously provided wire member, or the annularly formed magnetic member 12a may be formed in the radial direction and the axial direction. It may be provided so as to overlap. Although the magnetic member 12a will be described as being formed of the same material as the radial inner portion 11 as an example in the first embodiment, it may be formed of another material. Considering the entire motor, it is desirable that the magnetic member 12a has the same magnetism as the electromagnetic steel sheet 110 described later, which is the inner portion 11 in the radial direction in terms of cost, physique, and efficiency. The magnetic member 12a does not have to be non-magnetic because it functions as a substitute for the back yoke if it has magnetism.

Further, the linear magnetic member 12a is covered with an insulating coating 12b (see FIG. 6). That is, the adjacent magnetic members 12a are insulated from each other by the insulating coating 12b. Further, the adjacent magnetic member 12a and the radial inner portion 11 are also insulated by the insulating coating 12b. The electromagnetic steel sheet 110, which will be described later, is also covered with an insulating film (not shown) like the magnetic member 12a.

Further, in the first embodiment, the linear magnetic members 12a are provided so as to be wound in a plurality of layers in the radial direction. As a result, assuming that the magnetic members 12a are provided with n layers stacked in the radial direction, the yoke portion (back yoke) of the stator core 10 is the product of the diameter r1 of the magnetic member 12a and the number of wound layers (n). It is expanded by minutes (r1 × n). Note that FIG. 1 illustrates, as an example, an example in which the magnetic members 12a are provided in six layers in the radial direction.

Further, since the magnetic members 12a overlapping in the radial direction are insulated from each other by the insulating coating 12b, the generated eddy current can be reduced as compared with the case where the yoke portion (back yoke) is formed of the electromagnetic steel plate. Is.

Further, in the first embodiment, the radial outer portion 12 is provided from one end 11c to the other end 11d of the radial inner portion 11 in the axial direction. Specifically, the number of turns of the magnetic member 12a in the radial direction is constant from one end 11c of the radial inner portion 11 to the other end 11d. That is, the radial width W1 of the radial outer portion 12 is constant from one end 11c of the radial inner portion 11 to the other end 11d.

Further, as shown in FIG. 2, in the radial outer portion 12, when viewed from the axial direction, the peripheral edge portion 12c on the radial inner side of the radial outer portion 12 is the end portion on the radial outer side of each of the plurality of slots 11b. It is provided so as to be arranged in the vicinity of 11e. Specifically, the peripheral edge portion 12c is provided on the outer side in the radial direction by the width W2 (see FIG. 7) in the radial direction of the outer connecting portion 110c of the electrical steel sheet 110, which will be described later, with respect to the end portion 11e of the slot 11b. ing.

Further, in the first embodiment, the radial inner portions 11 are laminated in the axial direction, and are composed of a plurality of electromagnetic steel sheets 110 having the same diameter r2 (see FIG. 1). That is, the diameter r3 of the stator core 10 (see FIG. 1) is the sum of twice the radial width W1 of the radial outer portion 12 and the diameter r3 of the radial inner portion 11 (r3 = W1 × 2 + r2). .. The diameter r3 is constant from one end 11c of the radial inner portion 11 to the other end 11d. The electrical steel sheet 110 is an example of the "first electrical steel sheet" in the claims.

Further, in the first embodiment, as shown in FIG. 7, each of the plurality of electromagnetic steel sheets 110 is provided with a plurality of tooth portions 110a constituting the plurality of teeth 11a. That is, one tooth 11a is formed by laminating a plurality of tooth portions 110a in the axial direction. The teeth portion 110a is an example of the "first teeth portion" in the claims.

Further, each of the plurality of electrical steel sheets 110 is provided with a plurality of slot portions 110b formed between adjacent tooth portions 110a and opened inward in the radial direction to form the plurality of slots 11b. That is, one slot 11b is formed by arranging the plurality of slot portions 110b so as to be stacked in the axial direction. The slot portion 110b is an example of the "first slot portion" in the claims.

Further, each of the plurality of electrical steel sheets 110 includes an annular outer connecting portion 110c that connects the plurality of tooth portions 110a on the outer side in the radial direction. The radial width W2 of the outer connecting portion 110c is smaller than the radial length L1 of the slot 11b. Further, the radial width W2 of the outer connecting portion 110c is smaller than the radial width W1 of the radial outer portion 12 (see FIG. 1). The outer connection portion 110c is an example of the "first outer connection portion" in the claims.

(Manufacturing method of stator)
Next, a method of manufacturing the stator 100 will be described with reference to FIGS. 8 and 9.

First, as shown in FIG. 8, in step S1, a step of forming the radial inner portion 11 is performed. Specifically, first, the electromagnetic steel sheet 110 (see FIG. 2) is formed. Specifically, as shown in FIG. 9, the electromagnetic steel sheet 110 is punched from the strip-shaped electrical steel sheet 112 by press working using the punch 111. The strip-shaped electrical steel sheet 112 is continuously pressed by the punch 111 while being fed out by a moving mechanism (not shown) (to the right in FIG. 9).

Further, the strip-shaped electromagnetic steel sheet 112 has a rectangular shape and has a short side 112a having a length L2. The length L2 needs to be as large as or larger than the diameter r2 (see FIG. 1) of the electrical steel sheet 110. Further, the length L2 of the short side 112a of the electromagnetic steel sheet 112 is smaller than the diameter r3 of the stator core 10 (see FIG. 1).

Then, the radial inner portion 11 is formed by laminating the plurality of punched electrical steel sheets 110.

Next, as shown in FIG. 8, in step S2, a step of forming the radial outer portion 12 is performed. Specifically, the radial outer portion 12 is formed by winding the linear magnetic member 12a from the radial outer side with respect to the radial inner portion 11 formed in step S1.

The linear magnetic member 12a is fixed to the radial inner portion 11 by being molded with, for example, a resin. Further, the linear magnetic member 12a may be fixed to the radial inner portion 11 by an adhesive.

Then, in step S3, a step of arranging the coil portion 20 in the slot 11b is performed. Specifically, by inserting (arranging) the slot insertion portion 31 of the segment conductor 30 into the slot 11b, the coil portion 20 (segment conductor 30) is arranged in the stator core 10 (diameter inner portion 11). The tip portion 31a of the segment conductor 30 (slot insertion portion 31) arranged on the Z1 side and the tip portion 31a of the segment conductor 30 (slot insertion portion 31) arranged on the Z2 side are joined in the slot 11b. Will be done. At this time, a pressing jig or the like is introduced into the slot 11b through the opening inside the slot portion 110b (see FIG. 2) in the radial direction, and the joint portion between the tip portions 31a is pressed from the inside in the radial direction. Joining is done.

[Second Embodiment]
Next, the structure of the stator 200 according to the second embodiment will be described with reference to FIGS. 10 to 14. In this second embodiment, unlike the first embodiment in which the radial outer portion 12 is provided from one end 11c of the radial inner portion 11 to the other end 11d, the radial outer portion 212 is radially outer. It is provided only at a position corresponding to both end portions 211b of the inner portion 211. In the figure, the same reference numerals are given to the parts having the same configuration as that of the first embodiment.

As shown in FIG. 10, the stator 200 includes a stator core 210. The stator core 210 includes a radial inner portion 211 and a radial outer portion 212. Note that FIG. 10 is a cross-sectional view of the position where the teeth 11a is provided in the circumferential direction.

In the second embodiment, the radial outer portion 212 is not provided at a position corresponding to the central portion 211a of the radial inner portion 211 in the axial direction, but is a position corresponding to both end portions 211b of the radial inner portion 211. It is provided in. Specifically, only the electrical steel sheet 220, which will be described later, is provided at a position corresponding to the central portion 211a of the radial inner portion 211.

Here, the position corresponding to both end portions 211b of the radial inner portion 211 is a position where the magnetic flux from the coil end portion 32 of the coil portion 20 can easily pass through. Therefore, at positions corresponding to both ends 211b of the radial inner portion 211, a plurality of magnetic members 12a coated with the insulating coating 12b are provided so as to overlap in the radial direction, so that the magnetic flux from the coil end portion 32 can be generated. It is possible to reduce the resulting eddy current. This makes it possible to effectively reduce the eddy current.

Specifically, as shown in FIG. 11, the stator core 210 is axially laminated at a position corresponding to a position where the radial outer portion 212 is not provided, and the diameter r4 is the maximum diameter r5 of the stator core 210 (see FIG. 10). Includes an electromagnetic steel sheet 220 equal to. The electrical steel sheet 220 is an example of the "second electrical steel sheet" in the claims.

Each of the plurality of electromagnetic steel sheets 220 is provided with a plurality of tooth portions 220a constituting the plurality of teeth 11a. Further, each of the plurality of electrical steel sheets 220 is provided with a plurality of slot portions 220b formed between adjacent tooth portions 220a and opened inward in the radial direction to form the plurality of slots 11b. Further, each of the plurality of electrical steel sheets 220 includes an annular outer connecting portion 220c that connects the plurality of tooth portions 220a to each other on the radial outer side.

The central portion 211a of the radial inner portion 211 is configured by arranging so that the radial inner portions including the teeth portion 220a of the electromagnetic steel plate 220 are laminated.

Further, the radial outer portion 220d (see FIG. 10) is configured by arranging the radial outer portions of the electromagnetic steel plate 220 including the outer connecting portion 220c so as to be laminated. The radial outer portion 220d is integrally provided with the central portion 211a of the radial inner portion 211. The radial outer portion 220d is arranged so as to be axially sandwiched by the radial outer portions 212 on the Z1 side and the Z2 side.

Further, in the second embodiment, as shown in FIG. 12, the stator core 210 is vertically laminated at a position corresponding to the position where the radial outer portion 212 is provided, and the maximum diameter r5 of the stator core 210 (see FIG. 10). Includes electrical steel sheet 230 with a smaller diameter r6. The configuration (shape and dimensions) of the electromagnetic steel sheet 230 is substantially the same as that of the electrical steel sheet 110 in the first embodiment. The electrical steel sheet 230 is an example of the "third electrical steel sheet" in the claims.

Specifically, each of the plurality of electrical steel sheets 230 is provided with a plurality of tooth portions 230a. The plurality of teeth portions 230a together with the teeth portions 220a (see FIG. 11) of the electromagnetic steel sheet 220 form a plurality of teeth 11a. Further, each of the plurality of electromagnetic steel sheets 230 is formed between adjacent tooth portions 230a and opens inward in the radial direction, and a plurality of slot portions 230b are provided. The plurality of slot portions 230b form a plurality of slots 11b together with the slot portions 220b of the electromagnetic steel plate 220. Further, each of the plurality of electrical steel sheets 230 includes an annular outer connecting portion 230c that connects the plurality of tooth portions 230a to each other on the radial outer side. That is, the magnetic member 12a is provided so as to be wound from the radial outside of the outer connecting portion 230c.

Further, the radial outer portion 212 is provided with a plurality of magnetic members 12a stacked in the axial direction on each of the Z1 side and the Z2 side. Specifically, each of the radial outer portions 212 on the Z1 side and the Z2 side has a length (axial thickness) of about several percent (for example, 20%) of the total length in the axial direction of the stator core 210. The magnetic members 12a are provided so as to overlap in the axial direction.

(Manufacturing method of stator)
Next, a method of manufacturing the stator 200 will be described with reference to FIGS. 13 and 14.

First, as shown in FIG. 13, in step S11, a step of forming the radial inner portion 211 is performed. Specifically, first, the electromagnetic steel sheet 220 and the electrical steel sheet 230 are formed. Specifically, as shown in FIG. 14, the electromagnetic steel sheet 220 is punched from the base strip-shaped electrical steel sheet 222 by press working with the punch 221. Further, the electromagnetic steel sheet 230 is punched from the base strip-shaped electrical steel sheet 232 by press working using the punch 231.

Further, the strip-shaped electromagnetic steel sheet 222 has a rectangular shape and has a short side 222a having a length L3. The length L3 needs to be as large as or larger than the diameter r4 (see FIG. 11) of the electromagnetic steel sheet 220. That is, the length L3 of the short side 222a of the electrical steel sheet 222 is equal to or greater than the maximum diameter r5 (see FIG. 10) of the stator core 210.

Further, the strip-shaped electromagnetic steel sheet 232 has a rectangular shape and has a short side 232a having a length L4. The length L4 needs to be as large as or larger than the diameter r6 (see FIG. 12) of the electromagnetic steel sheet 230. The length L4 of the short side 232a of the electrical steel sheet 232 is smaller than the maximum diameter r5 (see FIG. 10) of the stator core 210.

Then, the radial inner portion 211 (and the radial outer portion 220d: see FIG. 10) is formed by laminating the plurality of punched electrical steel sheets 220 and the plurality of electrical steel sheets 230.

Next, as shown in FIG. 13, in step S12, a step of forming the radial outer portion 212 is performed. Specifically, the radial outer portion is formed by winding the linear magnetic member 12a from the radial outer side with respect to both end portions 211b (see FIG. 10) of the radial inner portion 211 formed in step S11. 212 is formed.

The other configurations of the stator 200 according to the second embodiment are the same as those of the first embodiment.

[Third Embodiment]
Next, the structure of the stator 300 according to the third embodiment will be described with reference to FIGS. 15 to 22. In the third embodiment, unlike the first embodiment in which the radial outer portion 12 is provided from one end 11c of the radial inner portion 11 to the other end 11d, the radial outer portion 312 is the stator core 310. It is provided only at the position corresponding to the central part of. In the figure, the same reference numerals are given to the parts having the same configuration as that of the first embodiment.

As shown in FIGS. 15 and 16, the stator 300 includes a stator core 310. The stator core 310 includes a radial inner portion 311 (see FIG. 16) and a radial outer portion 312. Note that FIG. 15 is a cross-sectional view of a position in the circumferential direction in which the teeth 11a is not provided (a position in the circumferential direction in which the slot 11b is provided).

As shown in FIG. 17, the radial inner portion 311 includes a plurality of electromagnetic steel sheets 320 laminated in the axial direction. The plurality of electrical steel sheets 320 are vertically laminated at the central portion in the axial direction of the stator core 310.

Each of the plurality of electrical steel sheets 320 is provided with a plurality of tooth portions 320a constituting the plurality of teeth 11a (see FIG. 16). Further, each of the plurality of electrical steel sheets 320 is provided with a plurality of slot portions 320b formed between adjacent tooth portions 320a and opened radially outward. The plurality of slot portions 320b constitute a plurality of slots 11b (see FIG. 16).

Further, the electromagnetic steel sheet 320 is provided with an annular inner connecting portion 320c that connects a plurality of tooth portions 320a in the radial direction.

Further, the segment conductor 30 on one side (Z1 side) in the axial direction (see FIG. 3) and the segment conductor 30 on the other side (Z2 side) in the axial direction are joined at the slot portion 320b of the electromagnetic steel plate 320.

Here, in the third embodiment, the radial outer portion 312 (linear magnetic member 12a) is wound around the radial outer side of the electrical steel sheet 320. Specifically, the magnetic member 12a wound on the innermost peripheral side is wound along the outer peripheral surface 320d of each of the plurality of tooth portions 320a. As a result, each of the plurality of slot portions 320b that open radially outward is closed from the radial outside by the radial outer portion 312 (linear magnetic member 12a).

Further, as shown in FIG. 18, the stator core 310 includes a plurality of electromagnetic steel sheets 330 laminated on both sides of the electrical steel sheet 320 in the axial direction.

Each of the plurality of electrical steel sheets 330 is provided with a plurality of tooth portions 330a and a plurality of slot portions 330b.

The teeth portion 330a constitutes a plurality of teeth 11a together with the teeth portion 320a (see FIG. 17). That is, one tooth 11a is formed by laminating the plurality of tooth portions 320a and the plurality of tooth portions 330a in the axial direction.

The slot portion 330b constitutes a plurality of slots 11b together with the slot portion 320b (see FIG. 17). That is, one slot 11b is formed by arranging the plurality of slot portions 320b and the plurality of slot portions 330b so as to be stacked in the axial direction.

Further, each of the plurality of electromagnetic steel sheets 330 is provided with an outer connecting portion 330c for connecting the plurality of tooth portions 330a on the outer side in the radial direction. The outer connecting portion 330c constitutes a yoke portion together with the radial outer portion 312. That is, the yoke portion is formed by laminating the plurality of outer connecting portions 330c and the radial outer portion 312 in the axial direction.

Here, in the third embodiment, the radial outer portion 312 is provided so as to be sandwiched from both sides in the axial direction by the outer connecting portion 330c of the electromagnetic steel plate 330. That is, when viewed from the axial direction, the radial outer portion 312 is provided so as to overlap the outer connecting portion 330c of the electromagnetic steel plate 330. In other words, when viewed from the axial direction, the radial outer portion 312 is provided so as to be covered by the outer connecting portion 330c of the electromagnetic steel sheet 330.

Further, an insulating member 340 is provided between the segment conductors 30 adjacent to each other in the radial direction at least at a position corresponding to the joint portion. As a result, the segment conductors 30 adjacent to each other in the radial direction are insulated from each other. Note that FIG. 15 illustrates an example in which the insulating member 340 is arranged only at a portion corresponding to the joint portion between the segment conductors 30, but this is an example and is not limited to this configuration. For example, when the tip portion 31a of the slot insertion portion 31 is covered with an insulating coating, the insulating member 340 may be arranged only at a portion corresponding to the joint portion. Further, when the conductor surface 30b is exposed in the entire slot insertion portion 31, it is necessary to arrange the insulating member 340 so as to correspond to the entire slot insertion portion 31. Although not shown in the first and second embodiments, in the first and second embodiments as well, the insulating member 340 is at least between segment conductors 30 adjacent to each other in the radial direction. It is provided at a position corresponding to the joint portion.

(Manufacturing method of stator)
Next, a method of manufacturing the stator 300 will be described with reference to FIGS. 19 to 22.

First, as shown in FIG. 19, in step S21, a step of forming the radial inner portion 311 is performed. Specifically, first, the electromagnetic steel sheet 320 and the electrical steel sheet 330 are formed. Since the method for forming the

electrical steel sheets

320 and 330 is the same as that in FIG. 14, detailed illustration is omitted. Then, the radial inner portion 311 is formed by laminating the plurality of electromagnetic steel sheets 320 and the plurality of electrical steel sheets 330.

Next, in step S22, the step of arranging the coil portion 20 is performed. First, as shown in FIGS. 20A to 20C, the segment conductor 30 (slot insertion portion 31) is arranged (inserted) in the slot 11b from one side (Z1 side) and the other side (Z2 side) in the axial direction. Then, the tip portions 31a of the slot insertion portions 31 are joined to each other. At this time, the segment conductor 30 is arranged so that the tip portions 31a of each other are arranged in the slot portion 320b of the electrical steel sheet 320. Since the slot portion 320b of the electromagnetic steel sheet 320 is open to the outside in the radial direction, a pressing jig or the like is brought close to the tip portion 31a from the outside in the radial direction through the opening portion to press the tip portion 31a. Join by doing.

Next, as shown in FIG. 21, the insulating member 340 is arranged on the radial outer side of the joint portion between the tip portions 31a of the slot insertion portion 31. The insulating member 340 may be something like an insulating sheet or an insulating coating material. The insulating member 340 may be introduced into the slot 11b from the outside in the radial direction through the opening of the slot portion 320b, for example.

Next, as shown in FIG. 19, in step S23, the step of forming the radial outer portion 312 is performed. Specifically, after the arrangement of the outermost segment conductor 30 in the radial direction is completed, the radial outer portion to the radial outer portion 312 (linear magnetic member) with respect to the radial inner portion 311 (plural electromagnetic steel plates 320). 12a) is wound. Although FIGS. 20 to 22 show an example in which two slot insertion portions 31 are arranged in the radial direction for convenience, the number of slot insertion portions 31 is not limited to this.

The other configurations of the stator 300 according to the third embodiment are the same as those of the first embodiment.

[Effect of Embodiment]
In the first to third embodiments, the following effects can be obtained.

In the first to third embodiments, as described above, the radial inner portions (11, 211, 311) are the plurality of electromagnetic steel plates (110,) laminated in the axial direction of the stator cores (10, 210, 310). 220, 230, 320, 330). Further, the radial outer portion (12, 212, 312) is composed of a linear magnetic member (12a) arranged so as to wind the radial inner portion (11, 211, 311) from the radial outer side. ing. As a result, the portion corresponding to the yoke portion of the electromagnetic steel sheet constituting the stator core (10, 210, 310) can be made smaller, so that the strip-shaped portion used as a material in the manufacturing process of the stator (100, 200, 300) can be made smaller. The lengths (L2, L4) of the short sides (112a, 232a) of the electrical steel sheets (112, 232) can be reduced. As a result, it is possible to reduce the amount of the discarded portion of the electromagnetic steel sheet remaining after the electromagnetic steel sheet (110, 230, 320) constituting the radial inner portion (11, 211, 311) is punched by press working. As a result, the amount of electrical steel sheets used as materials in the manufacturing process of the stators (100, 200, 300) is reduced with respect to the amount of electrical steel sheets constituting the stators (100, 200, 300), and the yield of the electrical steel sheets is reduced. Can be improved. The radial outer portion (12, 212, 312) is composed of a linear magnetic member (12a) arranged so as to wind the radial inner portion (11, 211, 311) from the radial outer side. Therefore, even if the electromagnetic steel plate constituting the radial inner portion (11, 211, 311) is made smaller, the radial outer portion (12, 212, 312) composed of the linear magnetic member (12a). There is no shortage of yoke part.

Further, in the first to third embodiments, as described above, the linear magnetic members (12a) are provided so as to be wound in a plurality of layers in the radial direction. With this configuration, the yoke portion of the stator core (10, 210, 310) can be easily expanded by the magnetic member (12a). Thereby, at least in the place where the magnetic member (12a) is wound, the diameter of the radial inner portion (11, 211, 311) can be easily reduced.

Further, in the first embodiment, as described above, the electromagnetic steel sheet (110) has a plurality of first tooth portions (110a) constituting the plurality of teeth (11a) and an adjacent first tooth portion (110a). A plurality of first slot portions (110b) formed between them and opened inward in the radial direction to form a plurality of slots (11b) and a plurality of first tooth portions (110a) are connected to each other in the radial direction. Includes an annular first outer connecting portion (110c) and a first electrical steel sheet (110) provided with. With this configuration, the first tooth portions (110a) are connected to each other on the radial outer side by the first outer connecting portion (110c), so that the linear magnetic member (12a) is connected to the first outer connecting portion (110a). It can be wound along 110c). As a result, the magnetic member (12a) can be easily wound.

Further, in the second embodiment, as described above, the radial outer portion (212) is located at a position corresponding to the central portion (211a) of the radial inner portion (211) in the axial direction of the stator core (210). Is not provided, but is provided at a position corresponding to both ends (211b) of the radial inner portion (211). Further, the electromagnetic steel sheets (220) are laminated in the axial direction at a position corresponding to a position where the radial outer portion (212) is not provided, and the diameter (r4) is equal to the maximum diameter (r5) of the stator core (210). 2 Includes electrical steel sheet (220). Further, in the electromagnetic steel plate (230), the stator core (210) is vertically laminated at a position corresponding to the position where the radial outer portion (212) is provided, and is smaller than the maximum diameter (r5) of the stator core (210). Includes a third electrical steel sheet (230) having a diameter (r6). With this configuration, the radial outer portion (212) can be made smaller than the case where the radial outer portion (212) is also provided at the central portion (211a) of the radial inner portion (211). Therefore, the work of winding the linear magnetic member (12a) can be shortened. Further, since the diameter (r6) of the third electrical steel sheet (230) is smaller than the maximum diameter (r5) of the stator core (210), when the third electrical steel sheet (230) is punched by press working, the third electrical steel sheet (r6) is punched. The length (L4) of the short side (232a) of the strip-shaped electrical steel sheet (232) on which the 230) is based can be made relatively small. As a result, the amount of the discarded portion of the electromagnetic steel sheet remaining after the third electromagnetic steel sheet (230) is punched by press working can be relatively reduced.

[Modification example]
It should be noted that the embodiments disclosed this time are exemplary in all respects and are not considered to be restrictive. The scope of the present invention is shown by the claims rather than the description of the above-described embodiment, and further includes all modifications (modifications) within the meaning and scope equivalent to the claims.

For example, in the first to third embodiments described above, an example in which the linear magnetic member 12a is a round wire is shown, but the present invention is not limited to this. The linear magnetic member may be other than a round wire.

Specifically, as shown in FIG. 23, the linear magnetic member 120a is composed of a flat conductor. As a result, it is possible to prevent the formation of voids between the magnetic members 120a adjacent to each other, as compared with the case where the magnetic members are round wires. As a result, it is possible to prevent the flow of magnetic flux from being obstructed by the voids formed between the magnetic members 120a.

Further, in the first to third embodiments, the radial inner portions (11, 211, 311) are formed by laminating a plurality of electromagnetic steel sheets, but the present invention is limited to this. I can't. The radial inner portion may be formed of a material other than an electromagnetic steel plate.

For example, as shown in FIG. 24, the radial inner portion 411 is formed by winding a strip-shaped electromagnetic steel plate 411a having a strip-shaped shape so as to overlap a plurality of the strip-shaped electromagnetic steel sheets 411a in the axial direction (Z direction) in a circumferential direction. The strip-shaped electromagnetic steel sheet 411a is an example of the "electrical steel sheet" in the claims.

As shown in FIG. 25, the strip-shaped electromagnetic steel sheet 411a is formed by punching from the base strip-shaped electromagnetic steel sheet 411b by press working. The strip-shaped electromagnetic steel sheet 411a is provided so as to extend along the long side 411c of the electrical steel sheet 411b.

As a result, unlike the case where the electromagnetic steel sheet constituting the stator core has a circular (annular) shape, the electromagnetic steel sheet (belt-shaped electromagnetic steel sheet 411a) to be punched is along the direction in which the underlying electromagnetic steel sheet (electrical steel sheet 411b) extends. Since it extends, the area of the portion of the underlying electrical steel sheet that remains without being punched can be easily reduced. As a result, the amount of unnecessary electrical steel sheet remaining after punching by press working can be further reduced.

Further, as shown in FIG. 25, the strip-shaped electromagnetic steel sheets 411a are arranged side by side along the long side direction (X direction in FIG. 25) of the strip-shaped electromagnetic steel sheets 411a, and are arranged in the short side direction of the strip-shaped electromagnetic steel sheets 411a (FIG. 25). A plurality of projecting portions 411d projecting to one side (in the Y direction) are included. Then, in each of the plurality of teeth 11a (see FIG. 2), the protruding portions 411d are arranged so as to overlap each other in the axial direction by winding the strip-shaped electromagnetic steel sheets 411a in a circumferential shape so as to overlap in the axial direction. Is formed by. As a result, the teeth 11a can be easily formed by winding the strip-shaped electromagnetic steel sheet 411a provided with the protruding portion 411d without laminating the electromagnetic steel sheets.

Further, a gap portion 411e is provided between the adjacent protrusions 411d. Each of the plurality of slots 11b (see FIG. 2) is formed by winding the strip-shaped electromagnetic steel sheets 411a in a circumferential shape so as to overlap in the axial direction so that the gaps 411e overlap each other in the axial direction. Has been done.

Further, the strip-shaped electromagnetic steel sheet 411a includes a connecting portion 411f that connects a plurality of protruding portions 411d to each other on one side in the Y direction. The connecting portion 411f has a width W3 in the Y direction.

Further, since the yoke portion (back yoke) can be expanded by the magnetic member 12a (see FIG. 1) after the radial inner portion 411 is formed, the width W3 of the connecting portion 411f of the strip-shaped electromagnetic steel plate 411a is reduced. be able to. As a result, the band-shaped electromagnetic steel sheet 411a can be easily wound, so that the winding operation of the band-shaped electromagnetic steel sheet 411a can be facilitated.

Further, as the strip-shaped electromagnetic steel sheet 411a, it is preferable to use a grain-oriented electrical steel sheet (an electromagnetic steel sheet in which magnetic flux flows in one direction). Specifically, it is preferable to use a band-shaped electromagnetic steel sheet 411a in which magnetic flux flows in a direction (Y direction) along the direction in which the protruding portion 411d extends. The grain-oriented electrical steel sheet is characterized in that the loss is small and the saturation magnetic flux density is high in one direction in which the magnetic flux flows (easy magnetization axis).

Further, the linear magnetic member 12a has a feature that the loss is small and the saturation magnetic flux density is high in the direction in which the magnetic member 12a extends. Therefore, in the stator core formed by winding the magnetic member 12a from the radial outer side of the radial inner portion 411 formed by winding the strip-shaped electromagnetic steel plate 411a in a circumferential shape, the magnetic flux is generated in the protruding portion. In 411d, since the flow flows from the inner side in the radial direction to the outer side in the radial direction and then flows in a circumferential shape along the magnetic member 12a, the flow always flows in a path having a small loss and a high saturation magnetic flux density. As a result, it is possible to further improve the efficiency of the motor.

Further, in the first to third embodiments described above, a plurality of magnetic members 12a are wound in layers in the radial direction, but the present invention is not limited to this. The magnetic member 12a may be wound by only one layer in the radial direction.

Further, in the second embodiment, the example in which the radial outer portion 212 is provided only at the position corresponding to both end portions 211b of the radial inner portion 211 is shown, but the present invention is not limited to this. The radial outer portion 212 may be provided only at a position corresponding to the central portion 211a of the radial inner portion 211.

Further, in the above-mentioned third embodiment, an example in which only one radial outer portion 312 is provided is shown, but the present invention is not limited to this. As shown in FIG. 26, a plurality of radial outer portions 312 (electrical steel sheets 320) are provided so as to correspond to a plurality of joint portions of segment conductors 30 arranged at different positions in the axial direction (Z direction). You may be.

In this case, if the portion of the segment conductor 30 other than the joint portion (tip portion 31a) is covered with the insulating coating, the segment conductors 30 adjacent in the radial direction are insulated from each other by the insulating coating, and thus the insulating member 340. (See FIG. 15) is unnecessary.

10, 210, 310 ... Stator core, 11, 211, 311, 411 ... Radial inner part, 11a ... Teeth, 11b ... Slot, 12, 212, 312 ... Radial outer part, 12a, 120a ... Magnetic member, 20 ... Coil Part, 30 ... segment conductor (conductor part), 100, 200, 300 ... stator, 110 ... electromagnetic steel plate (first electromagnetic steel plate), 110a ... teeth part (first teeth part), 110b ... slot part (first slot part) ), 110c ... Outer connection portion (first outer connection portion), 211a ... Central portion (central portion of the radial inner portion), 211b ... Both ends (both ends of the radial inner portion), 220 ... Electromagnetic steel plate (second) Electromagnetic steel plate), 230 ... Electromagnetic steel plate (third electromagnetic steel plate), 411a ... Strip-shaped electromagnetic steel plate, r4 ... Diameter (diameter of second electromagnetic steel plate), r5 ... Maximum diameter, r6 ... Diameter (diameter of third electromagnetic steel plate)

Claims

An annular radial inner portion provided with a plurality of teeth and a plurality of slots formed between the adjacent teeth and a radial inner portion provided separately from the radial inner portion in the radial direction of the radial inner portion. A stator core including an annular radial outer portion as a yoke portion arranged on the outer side,
A coil portion including a conductor portion arranged in the slot is provided.
The radial inner portion is composed of a plurality of electromagnetic steel sheets laminated in the axial direction of the stator core.
The radial outer portion is a stator composed of a linear magnetic member arranged so as to wind the radial inner portion from the radial outer side.
The stator according to claim 1, wherein the linear magnetic member is provided so as to be wound in a plurality of layers in the radial direction.
The electromagnetic steel sheet is formed between a plurality of first tooth portions constituting the plurality of teeth and adjacent first tooth portions and is opened inward in the radial direction to form the plurality of slots. The stator according to claim 1 or 2, further comprising a first electrical steel sheet provided with a one-slot portion and an annular first outer connecting portion that connects the plurality of first tooth portions on the outer side in the radial direction.
The radial outer portion is not provided at a position corresponding to the central portion of the radial inner portion in the axial direction of the stator core, but is provided at a position corresponding to both ends of the radial inner portion. ,
The electromagnetic steel plate is laminated in the axial direction at a position corresponding to a position where the radial outer portion is not provided, and a second electromagnetic steel plate having a diameter equal to the maximum diameter of the stator core and the radial outer portion are provided. The stator according to claim 1 or 2, comprising a third electromagnetic steel plate laminated in the axial direction at a position corresponding to the position and having a diameter smaller than the maximum diameter of the stator core.
The stator according to any one of claims 1 to 4, wherein the electrical steel sheet has a strip-shaped shape and includes a strip-shaped electrical steel sheet that is wound in a circumferential shape so as to overlap a plurality in the axial direction.