WO2022107713A1 - Motor and stator manufacturing method - Google Patents

Motor and stator manufacturing method Download PDF

Info

Publication number
WO2022107713A1
WO2022107713A1 PCT/JP2021/041863 JP2021041863W WO2022107713A1 WO 2022107713 A1 WO2022107713 A1 WO 2022107713A1 JP 2021041863 W JP2021041863 W JP 2021041863W WO 2022107713 A1 WO2022107713 A1 WO 2022107713A1
Authority
WO
WIPO (PCT)
Prior art keywords
stator
flat plate
shaped member
teeth
stator sheet
Prior art date
Application number
PCT/JP2021/041863
Other languages
French (fr)
Japanese (ja)
Inventor
浩威 西野
光生 児玉
Original Assignee
ミネベアミツミ株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by ミネベアミツミ株式会社 filed Critical ミネベアミツミ株式会社
Priority to JP2022563736A priority Critical patent/JPWO2022107713A1/ja
Publication of WO2022107713A1 publication Critical patent/WO2022107713A1/en

Links

Images

Classifications

    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K1/00Details of the magnetic circuit
    • H02K1/06Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/12Stationary parts of the magnetic circuit
    • H02K1/14Stator cores with salient poles

Definitions

  • the present invention relates to a method for manufacturing a motor and a stator.
  • a technique in which a stator core constituting a stator is formed from a core back and a plurality of teeth portions separated in the circumferential direction.
  • One aspect is to provide a method of manufacturing a motor and a stator that can improve efficiency.
  • the motor comprises a rotor having a magnet and a stator facing the rotor.
  • the stator includes an annular core back portion and a teeth portion formed by laminating a plurality of plate materials.
  • the plurality of plate members include a first flat plate-shaped member and a second flat plate-shaped member.
  • the teeth portion is composed of the second flat plate-shaped member.
  • the first flat plate-shaped member is arranged at the end of the teeth portion.
  • efficiency can be improved.
  • FIG. 1 is a plan view showing an example of the first stator sheet in the embodiment.
  • FIG. 2 is a plan view showing an example of the second stator sheet in the embodiment.
  • FIG. 3 is a plan view showing an example of the first stator sheet to which the second stator sheet is joined in the embodiment.
  • FIG. 4 is a perspective view showing an example of the stack assembly in the embodiment.
  • FIG. 5 is a cross-sectional view showing an example of the stack assembly in the embodiment.
  • FIG. 6 is a perspective view showing an example of the assembly process of the stator coil assembly in the embodiment.
  • FIG. 7 is a perspective view showing an example of a stator coil assembly to which an inner insulator is attached according to the embodiment.
  • FIG. 1 is a plan view showing an example of the first stator sheet in the embodiment.
  • FIG. 2 is a plan view showing an example of the second stator sheet in the embodiment.
  • FIG. 3 is a plan view showing an example of the first stator sheet to which the second stator sheet
  • FIG. 8 is a perspective view showing an example of a stator coil assembly to which a coil is attached according to the embodiment.
  • FIG. 9 is a perspective view showing an example of a stator coil assembly to which an outer insulator is attached according to the embodiment.
  • FIG. 10 is a perspective view showing an example of the stator assembly process in the embodiment.
  • FIG. 11 is a perspective view showing an example of the stator in the embodiment.
  • FIG. 12 is a plan view showing an example of a punching process of the first stator sheet in the embodiment.
  • FIG. 13 is a cross-sectional view showing an example of the motor in the embodiment.
  • FIG. 14 is a cross-sectional view showing an example of the positional relationship between the stator sheet and the magnet in the embodiment.
  • FIG. 15 is an enlarged cross-sectional view showing an example of the positional relationship between the stator sheet and the magnet in the embodiment.
  • FIG. 16 is a perspective view showing an example of the first stator sheet in the modified example.
  • FIG. 17 is an exploded perspective view showing an example of the stack assembly in the modified example.
  • FIG. 18 is a perspective view showing an example of the stack assembly in the modified example.
  • FIG. 19 is a perspective view showing an example of the stator coil assembly in the modified example.
  • FIG. 20 is a perspective view showing an example of a stator coil assembly to which an outer peripheral ring is attached in a modified example.
  • the stack assembly SA constituting the stator ST is formed by laminating a plurality of second stator sheets 20 shown in FIG. 2 on the first stator sheet 10 shown in FIG. 1 in the axial direction.
  • the first stator sheet 10 is an example of a first flat plate-shaped member
  • the second stator sheet 20 is an example of a plurality of flat plate-shaped members and a second flat plate-shaped member.
  • FIG. 1 is a plan view showing an example of the first stator sheet in the embodiment.
  • FIG. 2 is a plan view showing an example of the second stator sheet in the embodiment.
  • the first stator sheet 10 in the embodiment is a flat plate-shaped member made of a non-magnetic material such as resin.
  • the thickness of the first stator sheet 10 is, for example, about 1.0 mm.
  • the first stator sheet 10 includes a substantially circular central portion 15 and a plurality of projecting portions 11 protruding in the radial direction from the outer periphery of the central portion 15.
  • FIG. 1 describes the first stator sheet 10 having six protrusions 11, the number of protrusions 11 is not limited to this.
  • a plurality of hole portions 16 and a plurality of notched portions 17 are formed between the central portion 15 and the protruding portion 11.
  • the plurality of holes 16 and the plurality of notches 17 are formed, for example, at equal intervals in the circumferential direction.
  • the plurality of protruding portions 11 are formed at equal intervals in the circumferential direction.
  • a plurality of caulking portions 12 and 13 and an arc-shaped portion 14 formed so as to face the central portion 15 are formed in each protruding portion 11.
  • the second stator sheet 20 in the embodiment is a flat plate-shaped member made of a magnetic material such as a magnetic steel plate.
  • the second stator sheet 20 is formed of, for example, a magnetic material having a thickness of about 0.5 mm. That is, in the embodiment, the thickness of the first stator sheet 10 made of resin or the like is formed to be slightly larger than the thickness of the second stator sheet 20 in order to secure the rigidity.
  • the first stator sheet 10 may be formed by using a magnetic material like the second stator sheet 20, but a non-magnetic material such as a resin is used in consideration of suppressing iron loss, which will be described later. Is preferable.
  • the second stator sheet 20 includes a protruding portion 21 and an arc-shaped portion 24.
  • the protruding portion 21 is formed with, for example, a plurality of caulking portions 22 and 23 which are boss portions protruding in the axial direction.
  • the plurality of caulking portions 22, 23 are formed at positions facing each other in the axial direction with the caulking portions 12, 13 of the first stator sheet 10, respectively.
  • a fitting portion 25 is further formed in the vicinity of the tip portion on the outer diameter side of the protruding portion 21 in the radial direction.
  • FIG. 3 is a plan view showing an example of the first stator sheet to which the second stator sheet is joined in the embodiment.
  • FIG. 3 shows a state in which one second stator sheet 20 is laminated on the first stator sheet 10 as viewed from above in the axial direction.
  • each second stator sheet 20 is laminated on any one of the protruding portions 11 of the first stator sheet 10.
  • the caulked portion 22 of the second stator sheet 20 is fixed to the caulked portion 12 of the first stator sheet 10 by caulking.
  • the caulked portion 23 of the second stator sheet 20 is fixed to the caulked portion 13 of the first stator sheet 10 by caulking.
  • the second stator sheet 20 and the first stator sheet 10 are fixed so that the projecting portion 11 and the projecting portion 21, and the arc-shaped portion 14 and the arc-shaped portion 24 are overlapped with each other in the top view.
  • the number and shape of the caulked portions are not limited to those shown in the figure, by providing a plurality of caulked portions, it is possible to suppress the positional deviation and rotation between the first stator sheet 10 and the second stator sheet 20.
  • the second stator sheet 20 is similarly fixed to the other protruding portion 11 of the first stator sheet 10. Further, the second stator sheet 20 is further laminated and fixed to another second stator sheet 20 which is directly or indirectly fixed to the first stator sheet 10. By repeating the stacking of the second stator sheets 20 in this way, the stack assembly SA as shown in FIGS. 4 and 5 is formed.
  • FIG. 4 is a perspective view showing an example of the stack assembly in the embodiment.
  • FIG. 5 is a cross-sectional view showing an example of the stack assembly in the embodiment.
  • FIG. 5 shows a cross section cut along the line AA of FIG.
  • the stack assembly SA in the embodiment is formed by laminating a plurality of second stator sheets 20 on the six protrusions 11 of the first stator sheet 10.
  • the second stator sheet 20 laminated on the six protrusions 11 constitutes the teeth Ta to Tf, respectively.
  • the teeth Ta to Tf are expressed without distinction, they may be referred to as the teeth portion TT.
  • the second stator sheet 20 constituting the teeth Ta is in contact with each of the laminated second stator sheets 20 constituting the other teeth Tb to Tf separated in the circumferential direction.
  • the teeth Ta is indirectly connected to other teeth Tb to Tf separated in the circumferential direction via the central portion 15 of the first stator sheet 10.
  • the stack assembly SA is composed of the teeth Ta to Tf and the first stator sheet 10.
  • FIG. 6 is a perspective view showing an example of the assembly process of the stator coil assembly in the embodiment.
  • FIG. 6 shows a configuration in which the inner insulator 31, the coil 40, and the outer insulator 32 are attached to the teeth Tb to Tf but not to the teeth Ta in the assembly process of the stator coil assembly CA.
  • FIG. 7 is a perspective view showing an example of a stator coil assembly to which an inner insulator is attached according to the embodiment.
  • the inner insulator 31 constitutes the insulator 30 together with the outer insulator 32.
  • the inner insulator 31 is attached to the stack assembly SA from the outside in the radial direction.
  • FIG. 8 is a perspective view showing an example of a stator coil assembly to which a coil is attached according to the embodiment.
  • the coil 40 is composed of, for example, a flat wire and is prewound before being mounted on the stack assembly SA. Further, both ends of the flat wire wound around the coil 40 are drawn out as lead wires 41.
  • the coil 40 is mounted on the stack assembly SA from the outside in the radial direction via the inner insulator 31.
  • FIG. 9 is a perspective view showing an example of a stator coil assembly to which an outer insulator is attached according to the embodiment.
  • the outer insulator 32 is attached to the stack assembly SA from the outside in the radial direction so as to be inserted between the stack assembly SA and the coil 40.
  • the stator coil assembly CA is configured by mounting the insulator 30 and the coil 40 on each of the teeth Ta to Tf and the first stator sheet 10 constituting the stack assembly SA.
  • the teeth Ta to Tf and the first stator sheet 10 constituting the stack assembly SA in the embodiment do not have a portion protruding in the circumferential direction on the outer side in the radial direction.
  • the inner insulator 31, the outer insulator 32, and the wound coil 40 can be mounted from the outside in the radial direction.
  • the configuration for attaching the insulator and the coil is not limited to this, for example, the insulator is attached from the upper side and the lower side in the axial direction of the stack assembly SA, and the coil is wound around the stack assembly SA via the insulator. You may.
  • FIGS. 10 and 11 the stator coil assembly CA constitutes the stator ST by being mounted on the stator ring 50 which is the core back portion.
  • FIG. 10 is a perspective view showing an example of the stator assembly process in the embodiment.
  • FIG. 11 is a perspective view showing an example of the stator in the embodiment.
  • the stator ring 50 shown in FIG. 10 is formed by laminating a plurality of rings manufactured by pressing a steel plate such as an electromagnetic steel plate in the axial direction.
  • a plurality of fitting grooves 51 are formed on the inner peripheral side of the stator ring 50 in the radial direction at positions facing each of the teeth Ta to Tf.
  • the stator ring 50 is mounted on the stator coil assembly CA. At that time, the fitting portion 25 of each tooth Ta to Tf is fitted into the fitting groove 51 formed in the stator ring 50, respectively. Further, the stator coil assembly CA and the stator ring 50 are fixed so as not to have a gap by, for example, an adhesive, but the present invention is not limited to this, and the stator coil assembly CA and the stator ring 50 may be fixed by other methods such as welding.
  • stator coil assembly CA is fixed to the stator ring 50 formed so as to guarantee the roundness while maintaining the roundness, so that the roundness of each teeth Ta to Tf can be maintained.
  • the teeth Ta to Tf are indirectly connected via the first stator sheet 10, so that the teeth Ta to Tf are connected to each other indirectly.
  • the roundness of is secured by the first stator sheet 10 to which the second stator sheet 20 is fixed. Therefore, it is possible to reduce the value of roundness and improve the performance, it is possible to bring the value of the torque generated with respect to the current close to the ideal value, and improve the efficiency of the motor. Can be done.
  • FIG. 12 is a plan view showing an example of a punching process of the first stator sheet in the embodiment.
  • the central portion 15 of the first stator sheet 10 is punched out to form an opening 19 in the first stator sheet 10.
  • the plurality of holes 16 and the plurality of notches 17 shown in FIG. 1 function as perforations when separating the central portion 15 and the protruding portion 11, so that the central portion 15 can be easily projected. It can be separated from the portion 11.
  • each of the teeth Ta to Tf becomes an independent component from each other, but since each of the teeth Ta to Tf is fixed to the stator ring 50, deterioration of the roundness of the stack assembly SA is suppressed.
  • the convex portion 18 may remain on each tooth Ta to Tf, that is, a part of the first stator sheet 10 may protrude inward in the radial direction from the second stator sheet 20. be.
  • the area of the first stator sheet 10 is larger than the area of the second stator sheet 20. At this time, it is possible to secure a clearance when punching out the first stator sheet 10, which facilitates manufacturing.
  • FIG. 13 is a cross-sectional view showing an example of the motor in the embodiment.
  • the rotor 70 is inserted into the opening 19 formed by punching out the central portion 15 of the first stator sheet 10.
  • the rotor 70 is rotatably supported by, for example, the shaft 80.
  • a plurality of magnets 71 are arranged on the outer peripheral surface of the rotor 70.
  • the magnet 71 is a permanent magnet such as neodymium sintered.
  • the stack assembly SA including the laminated teeth TT is formed so as to be longer than the magnet 71 in the axial direction as shown in FIGS. 14 and 15, but the magnet 71 shown in FIG. 15 is formed.
  • the end portion 7a in the axial direction of the tooth TT is arranged so as to face the second stator sheet 20 made of a magnetic material, not the first stator sheet 10 arranged at the end portion in the axial direction of the teeth TT.
  • FIG. 14 is a cross-sectional view showing an example of the positional relationship between the stator sheet and the magnet in the embodiment.
  • FIG. 15 is an enlarged cross-sectional view showing an example of the positional relationship between the stator sheet and the magnet in the embodiment.
  • FIG. 15 is an enlarged view of the portion shown in the frame F of FIG.
  • the axial length L1 of the tooth portion TT is larger than the axial length L2 of the magnet 71.
  • the end portion 7a of the magnet 71 in the axial direction faces the boundary portion B between the first stator sheet 10 and the second stator sheet 20 of the stack assembly SA. That is, the magnet 71 faces the second stator sheet 20 of the teeth portion TT in the radial direction, but does not face the first stator sheet 10.
  • the motor MT in the embodiment has a rotor 70 having a magnet 71 and a stator ST facing the rotor 70.
  • the stator ST includes an annular core back portion 50 and a teeth portion TT formed by laminating a plurality of flat plate-shaped members 10 and 20.
  • the plurality of plate members include a first flat plate-shaped member 10 and a second flat plate-shaped member 20.
  • the tooth portion TT is composed of a second flat plate-shaped member 20.
  • the first flat plate-shaped member 10 is arranged at the end of the teeth portion TT.
  • the first flat plate-shaped member 10 may be made of, for example, a non-magnetic material. This can improve efficiency.
  • the annular core back portion 50, the teeth portion TT which is formed by laminating a plurality of flat plate-shaped members and protrudes inward in the radial direction from the core back portion 50, and the teeth.
  • a stator having a coil 40 arranged in the portion TT is manufactured by combining the core back portion 50 and the teeth portion TT.
  • the plurality of flat plate-shaped members are composed of a first flat plate-shaped member 10 made of a non-magnetic material and a second flat plate-shaped member 20 made of a magnetic material.
  • the stator ST is manufactured by removing the central portion 15 of the first flat plate-shaped member 10 after the teeth portion TT is combined with the core back portion 50.
  • the teeth Ta to Tf before the central portion 15 of the first flat plate-shaped member 10 is removed are integrated by the end portion 10 of the stack assembly SA, and do not need to be aligned. Therefore, productivity is improved.
  • the central portion 15 of the first stator sheet 10 shown in FIG. 1 is not limited to a disk shape, and may be an annular shape having a hole portion formed in the central portion.
  • FIG. 16 is a perspective view showing an example of the first stator sheet in the modified example.
  • the first stator sheet A0 is a flat plate-shaped member made of a non-magnetic material such as resin.
  • a plurality of projecting portions A1 are formed so as to project outward in the radial direction from the annular portion AA. That is, in the modified example, the plurality of projecting portions A1 are connected by the annular portion AA so as to extend side by side in the circumferential direction.
  • the second stator sheet B0 is laminated on the protruding portion A1 of the first stator sheet A0 in the modified example in the axial direction.
  • the first stator sheet A0 and the second stator sheet B0 are fixed by overlapping the caulked portions, for example, as in the embodiment.
  • the first stator sheet A0 and the second stator sheet B0 may be fixed by, for example, in-mold caulking.
  • the first stator sheet A0 and the second stator sheet B0 may be formed with the same caulking portions as the caulking portions 12, 13, 22 and 23 in the embodiment.
  • FIGS. 17 and 18 show.
  • the indicated stack assembly SZ is formed.
  • the stack assembly SZ is composed of a pair of first stator sheets A0 and a second stator sheet B0.
  • FIG. 17 is an exploded perspective view showing an example of the stack assembly in the modified example.
  • FIG. 18 is a perspective view showing an example of the stack assembly in the modified example.
  • the first stator sheets A0 are fixed to both sides of the plurality of second stator sheets B0 in the axial direction.
  • the plurality of second stator sheets B0 stacked in the axial direction each form a teeth portion TZ.
  • the stator coil assembly CZ shown in FIG. 19 is formed by arranging the coil C0 in the stack assembly SZ.
  • the stack assembly SZ is coated with insulation, other insulating means such as mounting an insulator (not shown) between the stack assembly SZ and the coil C0 may be used.
  • FIG. 19 is a perspective view showing an example of the stator coil assembly in the modified example.
  • the coil C0 is wound around each tooth portion TZ of the stack assembly SZ via a pair of first stator sheets A0.
  • the coil C0 is wound by, for example, a winding machine.
  • the air core coil formed in advance may be arranged so as to be mounted on the teeth portion TZ and the first stator sheet A0.
  • FIG. 20 is a perspective view showing an example of a stator coil assembly to which an outer peripheral ring is attached in a modified example.
  • the outer peripheral ring D0 is formed of an electromagnetic steel sheet or the like, similarly to the stator ring 50 in the embodiment.
  • the outer peripheral ring D0 is connected to the stator coil assembly CZ by press fitting or caulking.
  • the outer peripheral ring D0 is an example of a cylindrical member.
  • the spacing in the circumferential direction of each tooth portion TZ becomes equal, and the roundness of the stator ST can be improved, so that the cogging component can be reduced.
  • the teeth portion TZ is connected by using the non-magnetic first stator sheet A0, iron loss and an increase in cogging torque are suppressed.
  • the punching process of the first stator sheet becomes unnecessary, the manufacturing process can be simplified.
  • the coil when winding the coil around the teeth portion TZ, the coil is wound from the outside to the inside in the radial direction by using the winding machine used for the outer rotor type motor. Can be done. As a result, even when the number of teeth portions TZ increases and the distance between the inner diameters between the teeth portions TZ becomes small, winding to the teeth portions TZ becomes easy.
  • the present invention is not limited to the above embodiments.
  • the present invention also includes those configured by appropriately combining the above-mentioned constituent elements. Further, further effects and modifications can be easily derived by those skilled in the art. Therefore, the broader aspect of the present invention is not limited to the above-described embodiment, and various modifications can be made.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Iron Core Of Rotating Electric Machines (AREA)

Abstract

A motor (MT) comprises a rotor (70) which has magnets (71), and a stator (ST) which faces the rotor. The stator comprises an annular core back (50) and teeth (TT) each formed by laminating a plurality of plate materials (10, 20). The plate materials include first flat-plate members (10) and second flat-plate members (20). The teeth are each formed by the second flat-plate members (20). The first flat-plate members are disposed at ends of the teeth.

Description

モータ及びステータの製造方法Manufacturing method of motor and stator
 本発明は、モータ及びステータの製造方法に関する。 The present invention relates to a method for manufacturing a motor and a stator.
 モータや発電機等の回転電機において、ステータを構成するステータコアを、コアバックと、周方向に離間した複数のティース部とから形成する技術が知られている。 In rotary electric machines such as motors and generators, a technique is known in which a stator core constituting a stator is formed from a core back and a plurality of teeth portions separated in the circumferential direction.
特開2004-173390号公報Japanese Unexamined Patent Publication No. 2004-173390 特開2004-242384号公報Japanese Unexamined Patent Publication No. 2004-242384 国際公開第2016/178368号International Publication No. 2016/178368
 しかしながら、複数のティース部を周方向に並べてステータを構成する場合においては、ステータの真円度を担保することが難しい。このような真円度の悪化は、モータに印加される電流に対して発生するトルクの効率低下の原因となる場合がある。 However, when a plurality of tooth portions are arranged in the circumferential direction to form a stator, it is difficult to guarantee the roundness of the stator. Such deterioration of roundness may cause a decrease in the efficiency of the torque generated with respect to the current applied to the motor.
 一つの側面では、効率を向上できるモータ及びステータの製造方法を提供することを目的とする。 One aspect is to provide a method of manufacturing a motor and a stator that can improve efficiency.
 一つの態様において、モータは、磁石を有するロータと、前記ロータと対向するステータとを備える。前記ステータは、環状のコアバック部と、複数の板材を積層されてなるティース部とを備える。前記複数の板材は、第一の平板状の部材と、第二の平板状の部材とを含む。前記ティース部は、前記第二の平板状の部材によって構成される。前記第一の平板状の部材は、前記ティース部の端部に配置される。 In one embodiment, the motor comprises a rotor having a magnet and a stator facing the rotor. The stator includes an annular core back portion and a teeth portion formed by laminating a plurality of plate materials. The plurality of plate members include a first flat plate-shaped member and a second flat plate-shaped member. The teeth portion is composed of the second flat plate-shaped member. The first flat plate-shaped member is arranged at the end of the teeth portion.
 一つの態様によれば、効率を向上できる。 According to one aspect, efficiency can be improved.
図1は、実施形態における第1ステータシートの一例を示す平面図である。FIG. 1 is a plan view showing an example of the first stator sheet in the embodiment. 図2は、実施形態における第2ステータシートの一例を示す平面図である。FIG. 2 is a plan view showing an example of the second stator sheet in the embodiment. 図3は、実施形態における第2ステータシートが接合された第1ステータシートの一例を示す平面図である。FIG. 3 is a plan view showing an example of the first stator sheet to which the second stator sheet is joined in the embodiment. 図4は、実施形態におけるスタックアッシーの一例を示す斜視図である。FIG. 4 is a perspective view showing an example of the stack assembly in the embodiment. 図5は、実施形態におけるスタックアッシーの一例を示す断面図である。FIG. 5 is a cross-sectional view showing an example of the stack assembly in the embodiment. 図6は、実施形態におけるステータコイルアッセンブリの組立工程の一例を示す斜視図である。FIG. 6 is a perspective view showing an example of the assembly process of the stator coil assembly in the embodiment. 図7は、実施形態における内側インシュレータが取り付けられたステータコイルアッセンブリの一例を示す斜視図である。FIG. 7 is a perspective view showing an example of a stator coil assembly to which an inner insulator is attached according to the embodiment. 図8は、実施形態におけるコイルが取り付けられたステータコイルアッセンブリの一例を示す斜視図である。FIG. 8 is a perspective view showing an example of a stator coil assembly to which a coil is attached according to the embodiment. 図9は、実施形態における外側インシュレータが取り付けられたステータコイルアッセンブリの一例を示す斜視図である。FIG. 9 is a perspective view showing an example of a stator coil assembly to which an outer insulator is attached according to the embodiment. 図10は、実施形態におけるにおけるステータの組立工程の一例を示す斜視図である。FIG. 10 is a perspective view showing an example of the stator assembly process in the embodiment. 図11は、実施形態におけるステータの一例を示す斜視図である。FIG. 11 is a perspective view showing an example of the stator in the embodiment. 図12は、実施形態における第1ステータシートの打ち抜き工程の一例を示す平面図である。FIG. 12 is a plan view showing an example of a punching process of the first stator sheet in the embodiment. 図13は、実施形態におけるモータの一例を示す断面図である。FIG. 13 is a cross-sectional view showing an example of the motor in the embodiment. 図14は、実施形態におけるステータシートと磁石との位置関係の一例を示す断面図である。FIG. 14 is a cross-sectional view showing an example of the positional relationship between the stator sheet and the magnet in the embodiment. 図15は、実施形態におけるステータシートと磁石との位置関係の一例を示す拡大断面図である。FIG. 15 is an enlarged cross-sectional view showing an example of the positional relationship between the stator sheet and the magnet in the embodiment. 図16は、変形例における第1ステータシートの一例を示す斜視図である。FIG. 16 is a perspective view showing an example of the first stator sheet in the modified example. 図17は、変形例におけるスタックアッシーの一例を示す分解斜視図である。FIG. 17 is an exploded perspective view showing an example of the stack assembly in the modified example. 図18は、変形例におけるスタックアッシーの一例を示す斜視図である。FIG. 18 is a perspective view showing an example of the stack assembly in the modified example. 図19は、変形例におけるステータコイルアッセンブリの一例を示す斜視図である。FIG. 19 is a perspective view showing an example of the stator coil assembly in the modified example. 図20は、変形例における外周リングが取り付けられたステータコイルアッセンブリの一例を示す斜視図である。FIG. 20 is a perspective view showing an example of a stator coil assembly to which an outer peripheral ring is attached in a modified example.
 以下に、本願の開示するモータ及びステータの製造方法の実施形態を図面に基づいて詳細に説明する。なお、図面における各要素の寸法の関係、各要素の比率などは、現実と異なる場合がある。図面の相互間においても、互いの寸法の関係や比率が異なる部分が含まれている場合がある。各図面において、説明を分かりやすくするために、後に説明するモータMTにおける軸方向(モータMTの回転軸方向)、径方向及び周方向のうち、少なくともいずれかを含む座標系を図示する場合がある。また、以下において、モータMTの回転軸方向を、単に「軸方向」と表記する場合がある。 Hereinafter, embodiments of the motor and stator manufacturing method disclosed in the present application will be described in detail with reference to the drawings. The relationship between the dimensions of each element in the drawing, the ratio of each element, etc. may differ from the reality. Even between the drawings, there may be parts where the relationship and ratio of the dimensions are different from each other. In each drawing, in order to make the explanation easy to understand, a coordinate system including at least one of the axial direction (rotational axis direction of the motor MT), the radial direction, and the circumferential direction in the motor MT described later may be illustrated. .. Further, in the following, the rotation axis direction of the motor MT may be simply referred to as "axial direction".
 実施形態において、ステータSTを構成するスタックアッシーSAは、図1に示す第1ステータシート10に、図2に示す第2ステータシート20を軸方向において複数積層することにより形成される。なお、第1ステータシート10は、第一の平板状の部材の一例であり、第2ステータシート20は、複数の平板状の部材及び第二の平板状の部材の一例である。図1は、実施形態における第1ステータシートの一例を示す平面図である。図2は、実施形態における第2ステータシートの一例を示す平面図である。 In the embodiment, the stack assembly SA constituting the stator ST is formed by laminating a plurality of second stator sheets 20 shown in FIG. 2 on the first stator sheet 10 shown in FIG. 1 in the axial direction. The first stator sheet 10 is an example of a first flat plate-shaped member, and the second stator sheet 20 is an example of a plurality of flat plate-shaped members and a second flat plate-shaped member. FIG. 1 is a plan view showing an example of the first stator sheet in the embodiment. FIG. 2 is a plan view showing an example of the second stator sheet in the embodiment.
 実施形態における第1ステータシート10は、例えば樹脂等の非磁性の材料からなる平板状の部材である。実施形態において、第1ステータシート10の厚さは、例えば1.0mm程度である。図1に示すように、第1ステータシート10は、略円形状の中央部15と、中央部15の外周から径方向に向けて突出する、複数の突出部11とを備える。なお、図1では突出部11を6つ備える第1ステータシート10について説明するが、突出部11の数はこれに限られない。 The first stator sheet 10 in the embodiment is a flat plate-shaped member made of a non-magnetic material such as resin. In the embodiment, the thickness of the first stator sheet 10 is, for example, about 1.0 mm. As shown in FIG. 1, the first stator sheet 10 includes a substantially circular central portion 15 and a plurality of projecting portions 11 protruding in the radial direction from the outer periphery of the central portion 15. Although FIG. 1 describes the first stator sheet 10 having six protrusions 11, the number of protrusions 11 is not limited to this.
 図1に示すように、中央部15と突出部11との間には、複数の孔部16と、複数の切り欠き部17とが形成される。複数の孔部16と、複数の切り欠き部17とは、例えば、それぞれ周方向に等間隔で形成される。 As shown in FIG. 1, a plurality of hole portions 16 and a plurality of notched portions 17 are formed between the central portion 15 and the protruding portion 11. The plurality of holes 16 and the plurality of notches 17 are formed, for example, at equal intervals in the circumferential direction.
 また、図1に示すように、複数の突出部11は、周方向に等間隔で形成される。各突出部11には、複数のカシメ部12、13と、中央部15と対向して形成される弧状部14とがそれぞれ形成される。 Further, as shown in FIG. 1, the plurality of protruding portions 11 are formed at equal intervals in the circumferential direction. A plurality of caulking portions 12 and 13 and an arc-shaped portion 14 formed so as to face the central portion 15 are formed in each protruding portion 11.
 次に、実施形態における第2ステータシート20は、例えば磁性鋼板等の磁性材料からなる平板状の部材である。第2ステータシート20は、例えば厚さ0.5mm程度の磁性材料により形成される。すなわち、実施形態において、樹脂等で形成された第1ステータシート10の厚みは、剛性を確保するため、第2ステータシート20の厚みに比べてやや大きく成るように形成される。また、第1ステータシート10も、第2ステータシート20と同様に磁性材料を用いて形成されてもよいが、後に説明する鉄損を抑制することを考慮すると、樹脂等の非磁性材料を用いることが好ましい。 Next, the second stator sheet 20 in the embodiment is a flat plate-shaped member made of a magnetic material such as a magnetic steel plate. The second stator sheet 20 is formed of, for example, a magnetic material having a thickness of about 0.5 mm. That is, in the embodiment, the thickness of the first stator sheet 10 made of resin or the like is formed to be slightly larger than the thickness of the second stator sheet 20 in order to secure the rigidity. Further, the first stator sheet 10 may be formed by using a magnetic material like the second stator sheet 20, but a non-magnetic material such as a resin is used in consideration of suppressing iron loss, which will be described later. Is preferable.
 図2に示すように、第2ステータシート20は、突出部21と、弧状部24とを備える。また、突出部21には、例えば軸方向において突出したボス部である複数のカシメ部22、23が形成される。複数のカシメ部22、23は、それぞれ第1ステータシート10のカシメ部12、13と軸方向において対向する位置に形成される。また、突出部21の径方向における外径側の先端部付近には、嵌合部25がさらに形成される。 As shown in FIG. 2, the second stator sheet 20 includes a protruding portion 21 and an arc-shaped portion 24. Further, the protruding portion 21 is formed with, for example, a plurality of caulking portions 22 and 23 which are boss portions protruding in the axial direction. The plurality of caulking portions 22, 23 are formed at positions facing each other in the axial direction with the caulking portions 12, 13 of the first stator sheet 10, respectively. Further, a fitting portion 25 is further formed in the vicinity of the tip portion on the outer diameter side of the protruding portion 21 in the radial direction.
 次に、第1ステータシート10に第2ステータシート20を積層する構成について、図3を用いて説明する。図3は、実施形態における第2ステータシートが接合された第1ステータシートの一例を示す平面図である。図3は、第1ステータシート10に、第2ステータシート20が1枚積層された状態を、軸方向の上側から見た図を示す。 Next, a configuration in which the second stator sheet 20 is laminated on the first stator sheet 10 will be described with reference to FIG. FIG. 3 is a plan view showing an example of the first stator sheet to which the second stator sheet is joined in the embodiment. FIG. 3 shows a state in which one second stator sheet 20 is laminated on the first stator sheet 10 as viewed from above in the axial direction.
 図3に示されるように、各第2ステータシート20は、第1ステータシート10の突出部11のうち、いずれか1つに積層される。その際、第2ステータシート20のカシメ部22は、第1ステータシート10のカシメ部12にカシメにより固定される。同様に、第2ステータシート20のカシメ部23は、第1ステータシート10のカシメ部13にカシメにより固定される。これにより、第2ステータシート20と第1ステータシート10とは、突出部11と突出部21、及び弧状部14と弧状部24とが、上面視においてそれぞれ重なるように固定される。なお、カシメ部の数及び形状は図示されるものに限られないが、カシメ部を複数設けることにより、第1ステータシート10と第2ステータシート20との位置ずれや回転を抑制できる。 As shown in FIG. 3, each second stator sheet 20 is laminated on any one of the protruding portions 11 of the first stator sheet 10. At that time, the caulked portion 22 of the second stator sheet 20 is fixed to the caulked portion 12 of the first stator sheet 10 by caulking. Similarly, the caulked portion 23 of the second stator sheet 20 is fixed to the caulked portion 13 of the first stator sheet 10 by caulking. As a result, the second stator sheet 20 and the first stator sheet 10 are fixed so that the projecting portion 11 and the projecting portion 21, and the arc-shaped portion 14 and the arc-shaped portion 24 are overlapped with each other in the top view. Although the number and shape of the caulked portions are not limited to those shown in the figure, by providing a plurality of caulked portions, it is possible to suppress the positional deviation and rotation between the first stator sheet 10 and the second stator sheet 20.
 実施形態において、第2ステータシート20は、第1ステータシート10のその他の突出部11にも、同様に固定される。さらに、第2ステータシート20は、第1ステータシート10に直接又は間接に固定された他の第2ステータシート20に、さらに積層して固定される。このように第2ステータシート20の積層を繰り返すことにより、図4及び図5に示すようなスタックアッシーSAが形成される。 In the embodiment, the second stator sheet 20 is similarly fixed to the other protruding portion 11 of the first stator sheet 10. Further, the second stator sheet 20 is further laminated and fixed to another second stator sheet 20 which is directly or indirectly fixed to the first stator sheet 10. By repeating the stacking of the second stator sheets 20 in this way, the stack assembly SA as shown in FIGS. 4 and 5 is formed.
 図4は、実施形態におけるスタックアッシーの一例を示す斜視図である。図5は、実施形態におけるスタックアッシーの一例を示す断面図である。図5では、図4のA-A線で切断した断面を示す。図4及び図5に示すように、実施形態におけるスタックアッシーSAは、第1ステータシート10の6つの突出部11に、それぞれ複数の第2ステータシート20が積層されることにより形成される。6つの突出部11に積層された第2ステータシート20は、それぞれティースTa乃至Tfを構成する。なお、以下において、ティースTa乃至Tfを区別せずに表現する場合に、ティース部TTと表記する場合がある。 FIG. 4 is a perspective view showing an example of the stack assembly in the embodiment. FIG. 5 is a cross-sectional view showing an example of the stack assembly in the embodiment. FIG. 5 shows a cross section cut along the line AA of FIG. As shown in FIGS. 4 and 5, the stack assembly SA in the embodiment is formed by laminating a plurality of second stator sheets 20 on the six protrusions 11 of the first stator sheet 10. The second stator sheet 20 laminated on the six protrusions 11 constitutes the teeth Ta to Tf, respectively. In the following, when the teeth Ta to Tf are expressed without distinction, they may be referred to as the teeth portion TT.
 図5に示すように、スタックアッシーSAにおいて、ティースTaを構成する第2ステータシート20は、周方向に離間した他のティースTb乃至Tfを構成する積層された各第2ステータシート20とは接していない。しかし、ティースTaは、第1ステータシート10の中央部15を介して、周方向に離間した他のティースTb乃至Tfと間接的に連結している。このように、スタックアッシーSAは、ティースTa乃至Tfと第1ステータシート10とによって構成される。 As shown in FIG. 5, in the stack assembly SA, the second stator sheet 20 constituting the teeth Ta is in contact with each of the laminated second stator sheets 20 constituting the other teeth Tb to Tf separated in the circumferential direction. Not. However, the teeth Ta is indirectly connected to other teeth Tb to Tf separated in the circumferential direction via the central portion 15 of the first stator sheet 10. As described above, the stack assembly SA is composed of the teeth Ta to Tf and the first stator sheet 10.
 図6乃至図9に示すように、内側インシュレータ31、コイル40及び外側インシュレータ32がスタックアッシーSAに装着されることにより、スタックアッシーSAはステータコイルアッセンブリCAを形成する。図6は、実施形態におけるステータコイルアッセンブリの組立工程の一例を示す斜視図である。図6は、ステータコイルアッセンブリCAの組立工程において、内側インシュレータ31、コイル40及び外側インシュレータ32が、ティースTb乃至Tfには装着されているが、ティースTaには装着されていない構成を示す。 As shown in FIGS. 6 to 9, the inner insulator 31, the coil 40, and the outer insulator 32 are mounted on the stack assembly SA, so that the stack assembly SA forms the stator coil assembly CA. FIG. 6 is a perspective view showing an example of the assembly process of the stator coil assembly in the embodiment. FIG. 6 shows a configuration in which the inner insulator 31, the coil 40, and the outer insulator 32 are attached to the teeth Tb to Tf but not to the teeth Ta in the assembly process of the stator coil assembly CA.
 次に、図7に示すように、スタックアッシーSAには、内側インシュレータ31が装着される。図7は、実施形態における内側インシュレータが取り付けられたステータコイルアッセンブリの一例を示す斜視図である。内側インシュレータ31は、外側インシュレータ32とともに、インシュレータ30を構成する。内側インシュレータ31は、スタックアッシーSAに対して、径方向における外側から装着される。 Next, as shown in FIG. 7, the inner insulator 31 is attached to the stack assembly SA. FIG. 7 is a perspective view showing an example of a stator coil assembly to which an inner insulator is attached according to the embodiment. The inner insulator 31 constitutes the insulator 30 together with the outer insulator 32. The inner insulator 31 is attached to the stack assembly SA from the outside in the radial direction.
 次に、図8に示すように、スタックアッシーSAには、内側インシュレータ31を介して、コイル40が装着される。図8は、実施形態におけるコイルが取り付けられたステータコイルアッセンブリの一例を示す斜視図である。実施形態において、コイル40は、例えば平角線により構成され、スタックアッシーSAに装着される前に、予め巻き回されている。また、コイル40に巻き回された平角線の両端部は、引き出し線41として外部に引き出される。コイル40は、スタックアッシーSAに、内側インシュレータ31を介して、径方向における外側から装着される。 Next, as shown in FIG. 8, the coil 40 is mounted on the stack assembly SA via the inner insulator 31. FIG. 8 is a perspective view showing an example of a stator coil assembly to which a coil is attached according to the embodiment. In an embodiment, the coil 40 is composed of, for example, a flat wire and is prewound before being mounted on the stack assembly SA. Further, both ends of the flat wire wound around the coil 40 are drawn out as lead wires 41. The coil 40 is mounted on the stack assembly SA from the outside in the radial direction via the inner insulator 31.
 そして、図9に示すように、スタックアッシーSAには、外側インシュレータ32が装着される。図9は、実施形態における外側インシュレータが取り付けられたステータコイルアッセンブリの一例を示す斜視図である。実施形態において、外側インシュレータ32は、スタックアッシーSAとコイル40との間に挿入されるように、スタックアッシーSAに対して、径方向における外側から装着される。このように、スタックアッシーSAを構成する各ティースTa乃至Tf及び第1ステータシート10に、インシュレータ30及びコイル40が装着されることにより、ステータコイルアッセンブリCAが構成される。 Then, as shown in FIG. 9, the outer insulator 32 is attached to the stack assembly SA. FIG. 9 is a perspective view showing an example of a stator coil assembly to which an outer insulator is attached according to the embodiment. In the embodiment, the outer insulator 32 is attached to the stack assembly SA from the outside in the radial direction so as to be inserted between the stack assembly SA and the coil 40. In this way, the stator coil assembly CA is configured by mounting the insulator 30 and the coil 40 on each of the teeth Ta to Tf and the first stator sheet 10 constituting the stack assembly SA.
 以上説明したように、実施形態におけるスタックアッシーSAを構成する各ティースTa乃至Tf及び第1ステータシート10は、径方向における外側において、周方向に突出する部位を有さない。これにより、内側インシュレータ31、外側インシュレータ32及び巻き回し済みのコイル40を、径方向における外側から装着することができる。ただし、インシュレータ及びコイルを取り付ける構成はこれに限られず、例えばスタックアッシーSAの軸方向における上側と下側とからインシュレータを装着し、インシュレータを介してスタックアッシーSAにコイルを巻き回すような構成であってもよい。 As described above, the teeth Ta to Tf and the first stator sheet 10 constituting the stack assembly SA in the embodiment do not have a portion protruding in the circumferential direction on the outer side in the radial direction. As a result, the inner insulator 31, the outer insulator 32, and the wound coil 40 can be mounted from the outside in the radial direction. However, the configuration for attaching the insulator and the coil is not limited to this, for example, the insulator is attached from the upper side and the lower side in the axial direction of the stack assembly SA, and the coil is wound around the stack assembly SA via the insulator. You may.
 そして、ステータコイルアッセンブリCAは、図10及び図11に示すように、コアバック部となるステータリング50に装着されることにより、ステータSTを構成する。図10は、実施形態におけるにおけるステータの組立工程の一例を示す斜視図である。図11は、実施形態におけるステータの一例を示す斜視図である。図10に示すステータリング50は、例えば電磁鋼板などの鋼板をプレス加工して製作されたリングが、軸方向に複数積層されて形成される。ステータリング50の径方向における内周側には、図10に示すように、複数の嵌合溝51が、各ティースTa乃至Tfと対向する位置に形成される。 Then, as shown in FIGS. 10 and 11, the stator coil assembly CA constitutes the stator ST by being mounted on the stator ring 50 which is the core back portion. FIG. 10 is a perspective view showing an example of the stator assembly process in the embodiment. FIG. 11 is a perspective view showing an example of the stator in the embodiment. The stator ring 50 shown in FIG. 10 is formed by laminating a plurality of rings manufactured by pressing a steel plate such as an electromagnetic steel plate in the axial direction. As shown in FIG. 10, a plurality of fitting grooves 51 are formed on the inner peripheral side of the stator ring 50 in the radial direction at positions facing each of the teeth Ta to Tf.
 図10及び図11に示すように、ステータコイルアッセンブリCAには、ステータリング50が装着される。その際、各ティースTa乃至Tfの嵌合部25は、ステータリング50に形成された嵌合溝51に、それぞれ嵌合する。また、ステータコイルアッセンブリCAとステータリング50とは、例えば接着剤により隙間がないように固着されるが、これに限られず、溶接等のその他の方法により固着されてもよい。 As shown in FIGS. 10 and 11, the stator ring 50 is mounted on the stator coil assembly CA. At that time, the fitting portion 25 of each tooth Ta to Tf is fitted into the fitting groove 51 formed in the stator ring 50, respectively. Further, the stator coil assembly CA and the stator ring 50 are fixed so as not to have a gap by, for example, an adhesive, but the present invention is not limited to this, and the stator coil assembly CA and the stator ring 50 may be fixed by other methods such as welding.
 これにより、ステータコイルアッセンブリCAは、真円度を担保したまま、真円度を担保するように形成されたステータリング50に固着されるので、各ティースTa乃至Tfの真円度を維持できる。 As a result, the stator coil assembly CA is fixed to the stator ring 50 formed so as to guarantee the roundness while maintaining the roundness, so that the roundness of each teeth Ta to Tf can be maintained.
 実施形態において、ステータコイルアッセンブリCAがステータリング50に装着された段階においても、各ティースTa乃至Tfは、第1ステータシート10を介して、間接的に連結しているので、各ティースTa乃至Tfの真円度は、第2ステータシート20が固定される第1ステータシート10により担保される。そのため、真円度の値を低下させ、性能を向上させることが可能であり、電流に対して発生するトルクの値を理想的な値に近づけることが可能であり、モータの効率を向上させることができる。 In the embodiment, even when the stator coil assembly CA is mounted on the stator ring 50, the teeth Ta to Tf are indirectly connected via the first stator sheet 10, so that the teeth Ta to Tf are connected to each other indirectly. The roundness of is secured by the first stator sheet 10 to which the second stator sheet 20 is fixed. Therefore, it is possible to reduce the value of roundness and improve the performance, it is possible to bring the value of the torque generated with respect to the current close to the ideal value, and improve the efficiency of the motor. Can be done.
 そして、各ティースTa乃至Tfは、図12に示すように、第1ステータシート10の中央部15が切り離されることにより、相互に独立した部材となる。図12は、実施形態における第1ステータシートの打ち抜き工程の一例を示す平面図である。図12に示すように、第1ステータシート10の中央部15が打ち抜かれることで、第1ステータシート10に開口部19が形成される。その際、図1に示す複数の孔部16と、複数の切り欠き部17とが、中央部15と突出部11とを切り離す際のミシン目として機能することにより、中央部15を容易に突出部11から離脱させることができる。 Then, as shown in FIG. 12, each tooth Ta to Tf becomes a mutually independent member by separating the central portion 15 of the first stator sheet 10. FIG. 12 is a plan view showing an example of a punching process of the first stator sheet in the embodiment. As shown in FIG. 12, the central portion 15 of the first stator sheet 10 is punched out to form an opening 19 in the first stator sheet 10. At that time, the plurality of holes 16 and the plurality of notches 17 shown in FIG. 1 function as perforations when separating the central portion 15 and the protruding portion 11, so that the central portion 15 can be easily projected. It can be separated from the portion 11.
 この段階において、各ティースTa乃至Tfは、相互に独立した部品となるが、各ティースTa乃至Tfはステータリング50に固定されているため、スタックアッシーSAの真円度が悪化することが抑制される。また、中央部15を打ち抜く際に、凸部18が各ティースTa乃至Tfに残る場合、すなわち第1ステータシート10の一部が、第2ステータシート20よりも径方向において内側に突出する場合がある。言い換えると、第1ステータシート10の面積が、第2ステータシート20の面積よりも大きくなる。この時、第1ステータシート10を打ち抜く際のクリアランスを確保することができ、製造が容易となる。 At this stage, each of the teeth Ta to Tf becomes an independent component from each other, but since each of the teeth Ta to Tf is fixed to the stator ring 50, deterioration of the roundness of the stack assembly SA is suppressed. To. Further, when the central portion 15 is punched out, the convex portion 18 may remain on each tooth Ta to Tf, that is, a part of the first stator sheet 10 may protrude inward in the radial direction from the second stator sheet 20. be. In other words, the area of the first stator sheet 10 is larger than the area of the second stator sheet 20. At this time, it is possible to secure a clearance when punching out the first stator sheet 10, which facilitates manufacturing.
 そして、ステータSTがフレーム60に装着され、また、ロータ70が挿通されることにより、モータMTが形成される。図13は、実施形態におけるモータの一例を示す断面図である。図13に示すように、ロータ70は、第1ステータシート10の中央部15を打ち抜くことにより形成された開口部19に挿通される。ロータ70は、例えば、シャフト80に回転可能に支持される。また、ロータ70の外周面には、複数の磁石71が配置される。磁石71は、例えばネオジム焼結等の永久磁石である。 Then, the stator ST is mounted on the frame 60, and the rotor 70 is inserted to form the motor MT. FIG. 13 is a cross-sectional view showing an example of the motor in the embodiment. As shown in FIG. 13, the rotor 70 is inserted into the opening 19 formed by punching out the central portion 15 of the first stator sheet 10. The rotor 70 is rotatably supported by, for example, the shaft 80. Further, a plurality of magnets 71 are arranged on the outer peripheral surface of the rotor 70. The magnet 71 is a permanent magnet such as neodymium sintered.
 ところで、ロータ70の外周面に配置された磁石71の軸方向における端部では、マグネットと対向しない磁性体を設けた場合、ヒステリシス損によって鉄損が大きくなりやすい。そこで、実施形態において、積層されたティースTTを含むスタックアッシーSAは、図14及び図15に示すように、軸方向において磁石71よりも長くなるように形成されるが、図15に示す磁石71の軸方向における端部7aが、ティースTTの軸方向における端部に配置された第1ステータシート10ではなく、磁性材料で形成された第2ステータシート20と対向するように配置される。 By the way, at the axial end of the magnet 71 arranged on the outer peripheral surface of the rotor 70, when a magnetic material that does not face the magnet is provided, iron loss tends to increase due to hysteresis loss. Therefore, in the embodiment, the stack assembly SA including the laminated teeth TT is formed so as to be longer than the magnet 71 in the axial direction as shown in FIGS. 14 and 15, but the magnet 71 shown in FIG. 15 is formed. The end portion 7a in the axial direction of the tooth TT is arranged so as to face the second stator sheet 20 made of a magnetic material, not the first stator sheet 10 arranged at the end portion in the axial direction of the teeth TT.
 図14は、実施形態におけるステータシートと磁石との位置関係の一例を示す断面図である。図15は、実施形態におけるステータシートと磁石との位置関係の一例を示す拡大断面図である。図15は、図14の枠Fに示す部分を拡大した図である。図15に示すように、ティース部TTの軸方向における長さL1は、磁石71の軸方向における長さL2よりも大きい。より具体的には、実施形態において、磁石71の軸方向における端部7aは、スタックアッシーSAの第1ステータシート10と第2ステータシート20との境界部分Bと対向する。すなわち、磁石71は、径方向において、ティース部TTの第2ステータシート20と対向するが、第1ステータシート10とは対向しない。 FIG. 14 is a cross-sectional view showing an example of the positional relationship between the stator sheet and the magnet in the embodiment. FIG. 15 is an enlarged cross-sectional view showing an example of the positional relationship between the stator sheet and the magnet in the embodiment. FIG. 15 is an enlarged view of the portion shown in the frame F of FIG. As shown in FIG. 15, the axial length L1 of the tooth portion TT is larger than the axial length L2 of the magnet 71. More specifically, in the embodiment, the end portion 7a of the magnet 71 in the axial direction faces the boundary portion B between the first stator sheet 10 and the second stator sheet 20 of the stack assembly SA. That is, the magnet 71 faces the second stator sheet 20 of the teeth portion TT in the radial direction, but does not face the first stator sheet 10.
 図14及び図15に示す例において、磁石71の端部7aから径方向(図面における上側)に向かう磁束は、磁性鋼板で形成された第2ステータシート20に流れるので、磁石71の磁束を最大限活用でき、アルミや樹脂等の非磁性材料で形成された第1ステータシート10がマグネットと対向しない端部に設けられることによって鉄損の上昇を抑えることが可能になる。 In the examples shown in FIGS. 14 and 15, the magnetic flux directed in the radial direction (upper side in the drawing) from the end portion 7a of the magnet 71 flows to the second stator sheet 20 formed of the magnetic steel plate, so that the magnetic flux of the magnet 71 is maximized. It can be used to a limited extent, and the increase in iron loss can be suppressed by providing the first stator sheet 10 made of a non-magnetic material such as aluminum or resin at the end portion not facing the magnet.
 以上説明したように、実施形態におけるモータMTは、磁石71を有するロータ70と、ロータ70と対向するステータSTとを有する。ステータSTは、環状のコアバック部50と、複数の平板状の部材10、20を積層されてなるティース部TTと、を備える。複数の板材は、第一の平板状の部材10と、第二の平板状の部材20とを含む。ティース部TTは、第二の平板状の部材20によって構成される。また、第一の平板状の部材10は、ティース部TTの端部に配置される。また、第一の平板状の部材10は、例えば、非磁性の材料で構成されてもよい。これにより、効率を向上できる。 As described above, the motor MT in the embodiment has a rotor 70 having a magnet 71 and a stator ST facing the rotor 70. The stator ST includes an annular core back portion 50 and a teeth portion TT formed by laminating a plurality of flat plate-shaped members 10 and 20. The plurality of plate members include a first flat plate-shaped member 10 and a second flat plate-shaped member 20. The tooth portion TT is composed of a second flat plate-shaped member 20. Further, the first flat plate-shaped member 10 is arranged at the end of the teeth portion TT. Further, the first flat plate-shaped member 10 may be made of, for example, a non-magnetic material. This can improve efficiency.
 また、実施形態におけるステータSTの製造方法は、環状のコアバック部50と、複数の平板状の部材を積層されてなり、コアバック部50より半径方向内方に突出するティース部TTと、ティース部TTに配設されるコイル40と、を有するステータを、コアバック部50とティース部TTとを組み合わせて製造する。複数の平板状の部材は、非磁性の材料からなる第一の平板状の部材10と、磁性材料からなる第二の平板状の部材20とで構成される。ステータSTは、ティース部TTがコアバック部50に組み合わされた後、第一の平板状の部材10の中央部15を除去することで製造される。かかる製造方法において、第一の平板状の部材10の中央部15が除去される前の各ティースTa乃至Tfは、スタックアッシーSAの端部10により一体となっており、位置合わせの必要がないため、生産性が向上する。 Further, in the method of manufacturing the stator ST in the embodiment, the annular core back portion 50, the teeth portion TT which is formed by laminating a plurality of flat plate-shaped members and protrudes inward in the radial direction from the core back portion 50, and the teeth. A stator having a coil 40 arranged in the portion TT is manufactured by combining the core back portion 50 and the teeth portion TT. The plurality of flat plate-shaped members are composed of a first flat plate-shaped member 10 made of a non-magnetic material and a second flat plate-shaped member 20 made of a magnetic material. The stator ST is manufactured by removing the central portion 15 of the first flat plate-shaped member 10 after the teeth portion TT is combined with the core back portion 50. In such a manufacturing method, the teeth Ta to Tf before the central portion 15 of the first flat plate-shaped member 10 is removed are integrated by the end portion 10 of the stack assembly SA, and do not need to be aligned. Therefore, productivity is improved.
 さて、これまで本発明の実施形態について説明したが、本発明は上述した実施形態以外にも、種々の異なる形態にて実施されてよいものである。例えば、図1に示す第1ステータシート10の中央部15は円板状であるがこれに限られず、中央部に孔部が形成された環状であってもよい。 By the way, although the embodiment of the present invention has been described so far, the present invention may be implemented in various different forms other than the above-described embodiment. For example, the central portion 15 of the first stator sheet 10 shown in FIG. 1 is not limited to a disk shape, and may be an annular shape having a hole portion formed in the central portion.
 また、図16に示すように、第1ステータシートが、中央部15を備えないような構成であってもよい。図16は、変形例における第1ステータシートの一例を示す斜視図である。変形例においても、第1ステータシートA0は、例えば樹脂等の非磁性の材料からなる平板状の部材である。図16に示すように、変形例における第1ステータシートA0においては、複数の突出部A1が、環状部AAから、径方向における外側に突出するように形成される。すなわち、変形例においては、複数の突出部A1は、環状部AAにより連結されることにより、周方向に並んで延在する。 Further, as shown in FIG. 16, the first stator sheet may be configured not to include the central portion 15. FIG. 16 is a perspective view showing an example of the first stator sheet in the modified example. Also in the modified example, the first stator sheet A0 is a flat plate-shaped member made of a non-magnetic material such as resin. As shown in FIG. 16, in the first stator sheet A0 in the modified example, a plurality of projecting portions A1 are formed so as to project outward in the radial direction from the annular portion AA. That is, in the modified example, the plurality of projecting portions A1 are connected by the annular portion AA so as to extend side by side in the circumferential direction.
 図16に示すように、変形例における第1ステータシートA0の突出部A1には、軸方向において、第2ステータシートB0が積層される。第1ステータシートA0と第2ステータシートB0とは、例えば、実施形態と同様に、カシメ部を重ねることにより固定される。その際、第1ステータシートA0と第2ステータシートB0とを、例えば型内カシメにより固定してもよい。また、第1ステータシートA0及び第2ステータシートB0に、実施形態におけるカシメ部12,13,22及び23と同様のカシメ部が形成されていてもよい。 As shown in FIG. 16, the second stator sheet B0 is laminated on the protruding portion A1 of the first stator sheet A0 in the modified example in the axial direction. The first stator sheet A0 and the second stator sheet B0 are fixed by overlapping the caulked portions, for example, as in the embodiment. At that time, the first stator sheet A0 and the second stator sheet B0 may be fixed by, for example, in-mold caulking. Further, the first stator sheet A0 and the second stator sheet B0 may be formed with the same caulking portions as the caulking portions 12, 13, 22 and 23 in the embodiment.
 そして、第1ステータシートA0の全ての突出部A1のそれぞれに、複数の第2ステータシートB0が積層され、軸方向において第1ステータシートA0がさらに積層されることにより、図17及び図18に示すスタックアッシーSZが形成される。言い換えると、スタックアッシーSZは、一対の第1ステータシートA0と、第2ステータシートB0とによって構成される。図17は、変形例におけるスタックアッシーの一例を示す分解斜視図である。図18は、変形例におけるスタックアッシーの一例を示す斜視図である。変形例において、図17及び図18に示すように、複数の第2ステータシートB0には、軸方向における両側に、第1ステータシートA0がそれぞれ固定される。変形例におけるスタックアッシーSZにおいて、軸方向に積層された複数の第2ステータシートB0は、それぞれティース部TZを形成する。 Then, a plurality of second stator sheets B0 are laminated on each of all the protruding portions A1 of the first stator sheet A0, and the first stator sheet A0 is further laminated in the axial direction, so that FIGS. 17 and 18 show. The indicated stack assembly SZ is formed. In other words, the stack assembly SZ is composed of a pair of first stator sheets A0 and a second stator sheet B0. FIG. 17 is an exploded perspective view showing an example of the stack assembly in the modified example. FIG. 18 is a perspective view showing an example of the stack assembly in the modified example. In the modified example, as shown in FIGS. 17 and 18, the first stator sheets A0 are fixed to both sides of the plurality of second stator sheets B0 in the axial direction. In the stack assembly SZ in the modified example, the plurality of second stator sheets B0 stacked in the axial direction each form a teeth portion TZ.
 図18に示すように、変形例において、スタックアッシーSZに、コイルC0が配置されることにより、図19に示すステータコイルアッセンブリCZが形成される。なお、スタックアッシーSZには絶縁塗装が施されているが、コイルC0との間に不図示のインシュレータを装着する等、その他の絶縁手段を用いてもよい。図19は、変形例におけるステータコイルアッセンブリの一例を示す斜視図である。図19に示すように、コイルC0は、スタックアッシーSZの各ティース部TZに、一対の第1ステータシートA0を介して巻き回される。コイルC0は、例えば巻線機により巻き回される。なお、巻線機による巻き回しの他、事前に形成した空芯コイルをティース部TZおよび第1ステータシートA0に装着するように配置してもよい。 As shown in FIG. 18, in the modified example, the stator coil assembly CZ shown in FIG. 19 is formed by arranging the coil C0 in the stack assembly SZ. Although the stack assembly SZ is coated with insulation, other insulating means such as mounting an insulator (not shown) between the stack assembly SZ and the coil C0 may be used. FIG. 19 is a perspective view showing an example of the stator coil assembly in the modified example. As shown in FIG. 19, the coil C0 is wound around each tooth portion TZ of the stack assembly SZ via a pair of first stator sheets A0. The coil C0 is wound by, for example, a winding machine. In addition to the winding by the winding machine, the air core coil formed in advance may be arranged so as to be mounted on the teeth portion TZ and the first stator sheet A0.
 変形例において、ステータコイルアッセンブリCZの外周部には、図19及び図20に示すように、外周リングが固定される。図20は、変形例における外周リングが取り付けられたステータコイルアッセンブリの一例を示す斜視図である。外周リングD0は、実施形態におけるステータリング50と同様に、電磁鋼板等により形成される。外周リングD0は、圧入され、又はカシメ処理により、ステータコイルアッセンブリCZに連結される。なお、外周リングD0は、筒状部材の一例である。 In the modified example, the outer peripheral ring is fixed to the outer peripheral portion of the stator coil assembly CZ as shown in FIGS. 19 and 20. FIG. 20 is a perspective view showing an example of a stator coil assembly to which an outer peripheral ring is attached in a modified example. The outer peripheral ring D0 is formed of an electromagnetic steel sheet or the like, similarly to the stator ring 50 in the embodiment. The outer peripheral ring D0 is connected to the stator coil assembly CZ by press fitting or caulking. The outer peripheral ring D0 is an example of a cylindrical member.
 かかる変形例においても、実施形態と同様に、各ティース部TZの周方向の間隔が均等となり、ステータSTの真円度を改善できるので、コギング成分を小さくできる。また、実施形態と同様に、非磁性の第1ステータシートA0を用いてティース部TZが連結されるため、鉄損やコギングトルクの上昇が抑制される。また、第1ステータシートの打ち抜き工程が不要となるので、製造工程を簡略化できる。さらに、変形例においては、ティース部TZに対してコイルを巻き回す際に、アウターロータ型のモータに用いられる巻線機を用いて、径方向における外側から内側に向かって、コイルを巻き回すことができる。これにより、ティース部TZの本数が多くなり、ティース部TZ間の内径間の間隔が小さくなる場合においても、ティース部TZへの巻線が容易となる。 Also in such a modified example, as in the embodiment, the spacing in the circumferential direction of each tooth portion TZ becomes equal, and the roundness of the stator ST can be improved, so that the cogging component can be reduced. Further, as in the embodiment, since the teeth portion TZ is connected by using the non-magnetic first stator sheet A0, iron loss and an increase in cogging torque are suppressed. Further, since the punching process of the first stator sheet becomes unnecessary, the manufacturing process can be simplified. Further, in the modified example, when winding the coil around the teeth portion TZ, the coil is wound from the outside to the inside in the radial direction by using the winding machine used for the outer rotor type motor. Can be done. As a result, even when the number of teeth portions TZ increases and the distance between the inner diameters between the teeth portions TZ becomes small, winding to the teeth portions TZ becomes easy.
 また、上記実施の形態により本発明が限定されるものではない。上述した各構成素を適宜組み合わせて構成したものも本発明に含まれる。また、さらなる効果や変形例は、当業者によって容易に導き出すことができる。よって、本発明のより広範な態様は、上記の実施の形態に限定されるものではなく、様々な変更が可能である。 Further, the present invention is not limited to the above embodiments. The present invention also includes those configured by appropriately combining the above-mentioned constituent elements. Further, further effects and modifications can be easily derived by those skilled in the art. Therefore, the broader aspect of the present invention is not limited to the above-described embodiment, and various modifications can be made.
 10,A0 第1ステータシート、11,A1 突出部、12,13 カシメ部、14 弧状部、15 中央部、16 孔部、17 切り欠き部、19 開口部、AA 環状部、20,B0 第2ステータシート、21 突出部、22,23 カシメ部、24 弧状部、25 嵌合部、30 インシュレータ、31 内側インシュレータ、32 外側インシュレータ、40,C0 コイル、41 引き出し線、50 コアバック部(ステータリング)、51 嵌合溝、60 フレーム、70 ロータ、71 磁石、80 シャフト、D0 外周リング、SA,SZ スタックアッシー、CA,CZ ステータコイルアッセンブリ、ST ステータ、MT モータ、TT,TZ ティース部 10, A0 1st stator sheet, 11, A1 protruding part, 12, 13 caulking part, 14 arc-shaped part, 15 central part, 16 hole part, 17 notch part, 19 opening part, AA annular part, 20, B0 second Stator sheet, 21 projecting part, 22, 23 caulking part, 24 arc-shaped part, 25 fitting part, 30 insulator, 31 inner insulator, 32 outer insulator, 40, C0 coil, 41 lead wire, 50 core back part (stator ring) , 51 Fitting groove, 60 frame, 70 rotor, 71 magnet, 80 shaft, D0 outer ring, SA, SZ stack assembly, CA, CZ stator coil assembly, ST stator, MT motor, TT, TZ teeth part

Claims (10)

  1.  磁石を有するロータと、
     前記ロータと対向するステータと、を備え、
     前記ステータは、
     環状のコアバック部と、
     複数の板材を積層されてなるティース部と、を備え、
     前記複数の板材は、第一の平板状の部材と、第二の平板状の部材とを含み、
     前記ティース部は、前記第二の平板状の部材によって構成され、
     前記第一の平板状の部材は、前記ティース部の端部に配置される、モータ。
    With a rotor with a magnet,
    With a stator facing the rotor,
    The stator is
    The annular core back and
    It is equipped with a teeth part made by laminating multiple plates.
    The plurality of plate members include a first flat plate-shaped member and a second flat plate-shaped member.
    The tooth portion is composed of the second flat plate-shaped member.
    The first flat plate-shaped member is a motor arranged at the end of the teeth portion.
  2.  前記ティース部の軸方向長さは、前記磁石の軸方向長さよりも長い、請求項1に記載のモータ。 The motor according to claim 1, wherein the axial length of the teeth portion is longer than the axial length of the magnet.
  3.  前記磁石は、径方向において、前記第二の平板状の部材と対向する、請求項1又は2に記載のモータ。 The motor according to claim 1 or 2, wherein the magnet faces the second flat plate-shaped member in the radial direction.
  4.  前記第一の平板状の部材のうち少なくとも一部が、前記第二の平板状の部材よりも径方向における内側に突出する凸部を有する、請求項1から3のいずれか1項に記載のモータ。 The invention according to any one of claims 1 to 3, wherein at least a part of the first flat plate-shaped member has a convex portion that protrudes inward in the radial direction from the second flat plate-shaped member. motor.
  5.  前記第一の平板状の部材が、非磁性の材料で構成される、請求項1から4のいずれか1項に記載のモータ。 The motor according to any one of claims 1 to 4, wherein the first flat plate-shaped member is made of a non-magnetic material.
  6.  複数の前記ティース部を有し、
     複数の前記ティース部は、前記第一の平板状の部材に軸方向において連結されることにより、周方向に隣接して配置される、
     請求項1から5のいずれか1項に記載のモータ。
    It has a plurality of the teeth portions and has a plurality of the teeth portions.
    The plurality of teeth portions are arranged adjacent to each other in the circumferential direction by being connected to the first flat plate-shaped member in the axial direction.
    The motor according to any one of claims 1 to 5.
  7.  複数の前記ティース部は、外周側を筒状部材で連結される、請求項6に記載のモータ。 The motor according to claim 6, wherein the plurality of the teeth portions are connected to each other by a tubular member on the outer peripheral side.
  8.  前記第一の平板状の部材は、環状部と、前記環状部から径方向外側に延在する複数の突出部とを備え、軸方向において、前記第二の平板状の部材の両端部に配置される、請求項6又は7に記載のモータ。 The first flat plate-shaped member includes an annular portion and a plurality of protrusions extending radially outward from the annular portion, and is arranged at both ends of the second flat plate-shaped member in the axial direction. The motor according to claim 6 or 7.
  9.  環状のコアバック部と、
     複数の板材を積層されてなり、前記コアバック部より半径方向内方に突出するティース部と、
     前記ティース部に配設されるコイルと、
     を有し、
     前記コアバック部と前記ティース部とを組み合わせて製造されるステータの製造方法であって、
     前記複数の板材は、第一の平板状の部材と、第二の平板状の部材とで構成され、
     前記ティース部が前記コアバック部に組み合わされた後、前記第一の平板状の部材の中央部を除去することで製造される、ステータの製造方法。
    The annular core back and
    A teeth portion that is made by laminating a plurality of plate materials and protrudes inward in the radial direction from the core back portion.
    The coil arranged in the teeth portion and
    Have,
    A method for manufacturing a stator manufactured by combining the core back portion and the teeth portion.
    The plurality of plate members are composed of a first flat plate-shaped member and a second flat plate-shaped member.
    A method for manufacturing a stator, which is manufactured by removing the central portion of the first flat plate-shaped member after the teeth portion is combined with the core back portion.
  10.  前記第一の平板状の部材は、非磁性の材料から構成され、前記第二の平板状の部材は、磁性を有する材料から構成される、請求項9に記載のステータの製造方法。 The method for manufacturing a stator according to claim 9, wherein the first flat plate-shaped member is made of a non-magnetic material, and the second flat plate-shaped member is made of a magnetic material.
PCT/JP2021/041863 2020-11-19 2021-11-15 Motor and stator manufacturing method WO2022107713A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
JP2022563736A JPWO2022107713A1 (en) 2020-11-19 2021-11-15

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP2020192742 2020-11-19
JP2020-192742 2020-11-19

Publications (1)

Publication Number Publication Date
WO2022107713A1 true WO2022107713A1 (en) 2022-05-27

Family

ID=81708856

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/JP2021/041863 WO2022107713A1 (en) 2020-11-19 2021-11-15 Motor and stator manufacturing method

Country Status (2)

Country Link
JP (1) JPWO2022107713A1 (en)
WO (1) WO2022107713A1 (en)

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH01138953A (en) * 1987-11-26 1989-05-31 Toshiba Corp Manufacture of stator for rotary electric machine
JPH03284144A (en) * 1990-03-29 1991-12-13 Matsushita Seiko Co Ltd Manufacture of motor stator
JPH06133501A (en) * 1991-12-03 1994-05-13 Mitsui High Tec Inc Laminated stator core for motor and manufacture thereof
JP2006050743A (en) * 2004-08-03 2006-02-16 Nippon Densan Corp Core member for motor, motor, and manufacturing method for armature
JP2012120353A (en) * 2010-12-02 2012-06-21 Toyota Motor Corp Rotor for rotary electric machine
JP2015070721A (en) * 2013-09-30 2015-04-13 国産電機株式会社 Permanent magnet rotary electric machine

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH01138953A (en) * 1987-11-26 1989-05-31 Toshiba Corp Manufacture of stator for rotary electric machine
JPH03284144A (en) * 1990-03-29 1991-12-13 Matsushita Seiko Co Ltd Manufacture of motor stator
JPH06133501A (en) * 1991-12-03 1994-05-13 Mitsui High Tec Inc Laminated stator core for motor and manufacture thereof
JP2006050743A (en) * 2004-08-03 2006-02-16 Nippon Densan Corp Core member for motor, motor, and manufacturing method for armature
JP2012120353A (en) * 2010-12-02 2012-06-21 Toyota Motor Corp Rotor for rotary electric machine
JP2015070721A (en) * 2013-09-30 2015-04-13 国産電機株式会社 Permanent magnet rotary electric machine

Also Published As

Publication number Publication date
JPWO2022107713A1 (en) 2022-05-27

Similar Documents

Publication Publication Date Title
JP6640621B2 (en) Motor rotor and brushless motor
WO2018043026A1 (en) Surface magnet type motor
WO2007049411A1 (en) Capacitor motor and process for producing the same
WO2016136384A1 (en) Armature and rotating electric machine
WO2001043259A1 (en) Permanent magnet type motor and method of producing permanent magnet type motor
US20140009023A1 (en) Permanent magnet motor
JP3137510B2 (en) Stator for synchronous machine, method of manufacturing the same, teeth piece and yoke piece
JP6461381B2 (en) Rotating electric machine stator, rotating electric machine, and method of manufacturing rotating electric machine stator
WO2014192076A1 (en) Rotating electric machine iron core
WO2009093380A1 (en) Laminated wound core and rotor equipped with the core, dynamo-electric machine
WO2017195498A1 (en) Rotor and rotary electric machine
US11411447B2 (en) Axial gap motor
JP5258801B2 (en) Motor armature
JP2005080474A (en) Brushless motor
JP6110062B2 (en) Rotating electric machine
WO2007123057A1 (en) Motor
EP1341288B1 (en) Electric rotary machine
JP4543415B2 (en) Core structure of smooth armature winding AC servo motor and smooth armature winding AC servo motor using this core structure
WO2022107713A1 (en) Motor and stator manufacturing method
JPH1042497A (en) Stator for electric motor
JP2017225208A (en) Armature, rotary electric machine, and manufacturing method of armature
JP2012125111A (en) Rotor of outer rotor type rotary machine
CN108886304B (en) Stator for electric motor and method for manufacturing the same, electric motor and method for manufacturing the same
JPH07231587A (en) Magnetic member for electric rotating machine
JP4771278B2 (en) Permanent magnet type motor and method for manufacturing the same

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 21894587

Country of ref document: EP

Kind code of ref document: A1

ENP Entry into the national phase

Ref document number: 2022563736

Country of ref document: JP

Kind code of ref document: A

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 21894587

Country of ref document: EP

Kind code of ref document: A1