WO2023132183A1 - Stator of rotating electric machine, rotating electric machine, method for manufacturing stator of rotating electric machine, and method for manufacturing rotating electric machine - Google Patents

Abstract

The present invention comprises: a laminated core (50) that is formed by laminating a plurality of core pieces (40) in an axial direction (Y), each core piece having an annular core back part (41), and a plurality of tooth parts (42) at intervals in a circumferential direction (Z), the tooth parts protruding inward (X2) in a radial direction (X) from a core inner circumferential surface (44); an adhesion part (9) that fixes the core piece (40) in the axial direction (Y) in a continuous manner from one end to another end in the axial direction (Y) on each surface forming a slot region (30) surrounded by the core back part (41) and the tooth parts (42); an axial end insulator (34) that contacts one end and another end in the axial direction (Y) of the adhesion part (9) and is disposed at both ends in the axial direction (Y) of the laminated core (50); and a coil (33) that is wound around the tooth parts (42) and is formed in the slot region (30).

Description

Rotating electric machine stator, rotating electric machine, manufacturing method of rotating electric machine stator, and manufacturing method of rotating electric machine

This application relates to a stator for a rotating electrical machine, a rotating electrical machine, a method for manufacturing a stator for a rotating electrical machine, and a method for manufacturing a rotating electrical machine.

In recent years, there has been a demand for smaller and higher output rotating electric machines such as electric motors and generators. 2. Description of the Related Art It is widely known that eddy currents generated in an armature core are suppressed and efficiency is improved by configuring an armature core used in a rotating electric machine with a laminated core that is a laminated core of magnetic steel sheets. As a means of fixing the laminated magnetic steel sheets, there is a method of crimping or welding the magnetic steel sheets together, but since the magnetic steel sheets are electrically short-circuited in the stacking direction at the fixed part, eddy currents are generated and efficiency is reduced. had a problem of exacerbation. In addition, since residual stress is generated in the crimped portion or the welded portion, hysteresis loss increases and the efficiency of the rotary electric machine deteriorates.

As a method of solving these problems, a method of fixing electromagnetic steel sheets together by adhesion is known. Considering that the number of laminated magnetic steel sheets in a typical laminated core is several hundred, it is necessary to impregnate the adhesive between several hundred electromagnetic steel sheets, which reduces productivity. There was a problem.

As a method for solving these problems, a method is known in which an adhesive is applied to all core pieces continuously or intermittently on the side surface of the laminated core and cured to form a laminated core. (See Patent Document 1, for example). For example, in the laminated core described in Patent Document 1, all the core pieces are bonded to all the core pieces continuously or intermittently in the axial direction on at least one of the surfaces forming the slot regions of the laminated core. are formed to form a laminated core. Furthermore, a rotating electrical machine is presented in which an insulator is formed on the surface of a laminated core forming a slot region without being adhered to the adhesive portion, and a coil is formed in the slot region via the insulator.

Japanese Patent Application Laid-Open No. 2021-111977

In conventional rotating electric machine stators, rotating electric machines, methods of manufacturing stators of rotating electric machines, and methods of manufacturing rotating electric machines, the slot regions of the laminated core have adhesive portions and insulators, and thus the slot regions are pressed. , there is a problem that a sufficient coil space cannot be secured, which hinders the realization of a high-performance rotating electric machine.

In the manufacturing process, insulators are placed in slot regions as insulating sheets and sandwiched between coils. There is a problem that the contact between the coil and the laminated core results in a defective withstand voltage to the ground, which hinders the realization of a high-performance rotating electric machine.

On the other hand, in a stator of the type in which an insulator is integrally molded with a laminated core by injection molding of a resin material, the adhesive part in the slot area hinders the resin flow in the injection molding, causing molding defects and degrading the insulation performance. There was a problem.

The present application discloses a technique for solving the above-described problems, and provides a high-performance rotating electric machine stator, rotating electric machine, and rotating electric machine without reducing the performance of electrical insulation between the coil and the laminated core. and a method for manufacturing a rotating electric machine.

The stator of the rotary electric machine disclosed in the present application is
A core piece having an annular core-back portion and a plurality of tooth portions protruding radially inwardly from a core inner peripheral surface radially inward of the core-back portion at intervals in the axial direction. a laminated core in which a plurality of sheets are laminated;
Of the slot regions surrounded by the tooth portions and the core back portion of the laminated core, each of the surfaces forming at least one of the slot regions is provided with the an adhesive portion for axially fixing the core pieces;
axial end insulators that are in contact with one axial end and the other axial end of the bonding portion and are arranged at both axial ends of the laminated core;
and a coil formed in the slot region by winding an electric wire around the teeth.
Further, the rotating electric machine disclosed in the present application is
The rotating electric machine includes a stator of the rotating electric machine, and a rotor arranged to face the stator with a gap therebetween.
Further, a method for manufacturing a stator for a rotating electric machine disclosed in the present application includes:
A punching step of punching out a plurality of the core pieces from a plate;
an aligning step of axially laminating and aligning the punched core pieces;
a fixing step of axially arranging the adhesive portions continuously on each of the surfaces forming the slot regions to fix the core pieces in the axial direction;
a dividing step of cutting the core pieces laminated in the axial direction into a plurality of the laminated cores by cutting them in a predetermined length in the axial direction;
a disposing step of disposing the axial end insulators on both axial ends of the laminated core while being in contact with one axial end and the other axial end of the adhesive portion.
Further, a method for manufacturing a stator for a rotating electric machine disclosed in the present application includes:
A convex portion extending in the axial direction is provided on the surface of the bonding portion formed on the tooth portion,
The wires forming the first layer of the coil are placed in contact with the radially adjacent protrusions.
A punching step of punching out a plurality of the core pieces from a plate;
an aligning step of axially laminating and aligning the punched core pieces;
a fixing step of axially arranging the adhesive portions continuously on each of the surfaces forming the slot regions to fix the core pieces in the axial direction;
a dividing step of cutting the core pieces laminated in the axial direction into a plurality of the laminated cores by cutting them in a predetermined length in the axial direction;
an arranging step of arranging the axial end insulators on both axial ends of the laminated core while being in contact with one axial end and the other axial end of the adhesive portion;
The fixing step includes
an application step of applying an adhesive to the surface forming the slot region;
and a curing step of curing the adhesive,
The coating step includes
A coating jig having a predetermined distance secured on the surface forming the slot region and having a concave portion formed in a portion of the bonding portion facing the convex portion is arranged to form the slot region. The adhesive is spread in the gap of the distance between the surface and the application jig by capillary action to form a film thickness equal to or less than the gap, and the adhesive is applied to the concave portion of the application jig. The convex portion is formed.
Further, in a method for manufacturing a rotating electrical machine disclosed in the present application, the rotating electrical machine is manufactured using the stator manufactured using the method for manufacturing a stator for a rotating electrical machine.

According to a rotating electrical machine stator, a rotating electrical machine, a method for manufacturing a stator for a rotating electrical machine, and a method for manufacturing a rotating electrical machine disclosed in the present application,
A high-performance rotating electric machine can be obtained without deteriorating the performance of electrical insulation between the coil and the laminated core.

1 is a cross-sectional view showing a configuration of a rotating electric machine according to Embodiment 1; FIG. 2 is a cross-sectional view showing the configuration of the stator of the rotary electric machine shown in FIG. 1; FIG. FIG. 3 is a cross-sectional view of the stator shown in FIG. 2 taken along line MM; 4 is a diagram showing the configuration of one laminated core of the stator shown in FIG. 3; FIG. FIG. 5 is a diagram showing a configuration of the laminated core shown in FIG. 4 before coil installation; 5 is a diagram showing another configuration of the laminated core shown in FIG. 4 before coil installation; FIG. 2 is a flowchart showing a method of manufacturing the rotating electric machine shown in FIG. 1; FIG. 2 is a diagram showing the configuration of the rotating electric machine manufacturing apparatus shown in FIG. 1 ; FIG. 2 is a perspective view showing a configuration of the laminated core of the rotary electric machine shown in FIG. 1 before bonding; FIG. 9 is a cross-sectional view showing a state of the manufacturing apparatus shown in FIG. 8 at the time of applying an adhesive along line NN; FIG. 10 is a perspective view showing a state in which a shaft end insulator is attached to the laminated core shown in FIG. 9; FIG. 10 is a diagram showing the configuration of one laminated core of the stator of the rotary electric machine according to Embodiment 2; FIG. 13 is a diagram showing a configuration of the laminated core shown in FIG. 12 before coil installation; FIG. 14 is a perspective view showing the configuration of the laminated core shown in FIG. 13; FIG. 15 is a cross-sectional view taken along line NN of the manufacturing apparatus shown in FIG. 8 in a state where the laminated core shown in FIG. 14 is coated with an adhesive; FIG. 10 is a diagram showing the configuration of one laminated core of the stator of the rotary electric machine according to Embodiment 3; 17 is a flow chart showing a method of manufacturing a rotating electric machine using the laminated core shown in FIG. 16; FIG. 17 is a diagram showing the configuration of a sticking device that sticks an adhesive tape to the laminated core shown in FIG. 16; FIG. 19 is a diagram showing the configuration of the sticking device shown in FIG. 18 at a viewpoint P; FIG. 6 is an enlarged partial cross-sectional view of the laminated core shown in FIG. 5 taken along line PP; FIG. 12 is an enlarged cross-sectional view taken along the QQ line of a state in which the axial end insulator is attached to the laminated core shown in FIG. 11; FIG. 11 is a perspective view showing a state where a shaft end insulator is attached to a laminated core according to Embodiment 4; FIG. 23 is an enlarged cross-sectional view taken along line RR of a state in which a shaft end insulator is attached to the laminated core shown in FIG. 22; FIG. 9 is a cross-sectional view showing a state of the manufacturing apparatus shown in FIG. 8 in Embodiment 4 when adhesive is applied on both axial end sides of the laminated core along line NN. FIG. 11 is an enlarged cross-sectional view of a state in which a shaft end insulator is attached to a laminated core according to Embodiment 5;

In the following description, each direction in the rotating electric machine is indicated as a circumferential direction Z, an axial direction Y, a radial direction X, an outer side X1 in the radial direction X, and an inner side X2 in the radial direction X. Therefore, the directions of the stator 10 and the rotor 20, as well as other parts, are the same, and each direction will be described with reference to that direction. Moreover, in each embodiment, a configuration in which the stator is divided for each tooth portion in the circumferential direction Z is shown as an example. Therefore, the one in which the stator is divided in the circumferential direction Z is indicated as a laminated core.

Embodiment 1.
FIG. 1 is a cross-sectional view showing the configuration of a rotating electric machine according to Embodiment 1. FIG. FIG. 2 is a cross-sectional view showing the configuration of the stator of the rotating electric machine shown in FIG. FIG. 3 is a cross-sectional view of the stator shown in FIG. 2 taken along line MM. 4 is a diagram showing the configuration of one laminated core of the stator shown in FIG. 3. FIG. FIG. 5 is a diagram showing the configuration of the laminated core shown in FIG. 4 before coil installation. FIG. 6 is a diagram showing another configuration of the laminated core shown in FIG. 4 before coil installation. FIG. 7 is a flow chart showing a method of manufacturing the rotating electric machine shown in FIG.

FIG. 8 is a diagram showing the configuration of the manufacturing apparatus for the rotating electric machine shown in FIG. 1, which is a manufacturing apparatus that interlocks the punching process to the dividing process of the manufacturing method for the rotating electric machine shown in FIG. FIG. 9 is a perspective view showing the configuration of the laminated core of the rotary electric machine shown in FIG. 1 before bonding. FIG. 10 is a cross-sectional view showing a state of the manufacturing apparatus shown in FIG. 11 is a perspective view showing a state in which the axial end insulator is attached to the laminated core shown in FIG. 9. FIG. FIG. 20 is an enlarged partial cross-sectional view of the laminated core shown in FIG. 5 taken along line PP. 21 is an enlarged partial cross-sectional view taken along line QQ of a state in which the axial end insulator is attached to the laminated core shown in FIG. 11. FIG.

In FIG. 1, a rotating electrical machine 100 includes a cylindrical frame 1, an upper bracket 2 and a lower bracket 3 that close an opening in the frame 1, a stator 10 as an armature housed in a cylindrical portion of the frame 1, It is arranged in the axial direction Y through bearings 4 and 5 at the axial positions of the upper bracket 2 and the lower bracket 3 of the frame 1, and is fixed to a rotating shaft 6 that is rotatably supported. A rotor 20 that is rotatably disposed on the inner peripheral side of the inner side X2 and that generates a magnetic field is provided.

The rotor 20 includes a rotor core 7 fixed to a rotating shaft 6 inserted at the axial position, and a rotor core 7 attached to the outer peripheral surface side of the rotor core 7 and arranged at a pitch set in the circumferential direction Z to form magnetic poles. It is a permanent magnet type rotor provided with a plurality of permanent magnets 8 constituting the rotor. The rotor 20 is not limited to a permanent magnet type rotor, and may be a squirrel cage rotor in which non-insulated rotor conductors are accommodated in slots of the rotor iron core and both sides are short-circuited by short-circuit rings, or an insulated rotor. A wound rotor in which the conductor wires are mounted in the slot regions of the rotor core may also be used.

1 to 3, the stator 10 is annularly formed and fixed within the frame 1. As shown in FIG. The stator 10 includes a laminated core 50 formed by laminating a predetermined number of core pieces 40 in the axial direction Y, and a wire as a core material 601 such as copper or aluminum as shown in FIG. Electrical insulation is provided between the coil 33 formed from the magnet wire as the electric wire 60 having an insulating film as the surface film 602 on the surface and the axial end sides of both ends in the axial direction Y of the laminated core 50 and the coil 33. A shaft end insulator 34 having a function and a function of holding the coil 33 is provided.

The shaft end insulator 34 is made of a resin material such as nylon, polyphenylene sulfide (PPS), liquid crystal polymer (LCP), polybutylene terephthalate (PBT), or the like. On the other hand, the bonding portion 9 having the function of electrically insulating between the slot region 30 side of the laminated core 50 and the coil 33 is provided. In addition, in order to clarify the formation location of the adhesive portion 9 in each figure, the actual thickness is exaggerated and indicated by a thick black line. Moreover, since this also applies to the following embodiments, the description thereof will be omitted as appropriate.

In FIGS. 4 and 5, a laminated core 50 is obtained by laminating a large number of core pieces 40 punched in the same shape from a belt-like electromagnetic steel sheet in the axial direction Y and integrating them. The core piece 40 includes a core back portion 41 , tooth portions 42 and shoe portions 43 . The core back portion 41 is formed in an arc shape. The tooth portion 42 is formed extending from the center portion in the circumferential direction Z of the core inner peripheral surface 44 on the inner side X2 in the radial direction X of the core back portion 41 to the inner side X2 in the radial direction X. As shown in FIG. The shoe portion 43 is formed to extend toward both sides in the circumferential direction Z from the side surface in the circumferential direction Z at the inner X2 end portion in the radial direction X of the tooth portion 42 .

In the core piece 40 and the laminated core 50, the surface along the axial direction Y on the outer side X1 in the radial direction X of the core back portion 41 is defined as the core outer peripheral surface 47, and the inner side X2 in the radial direction X of the core back portion 41 in the axial direction Y. A core inner circumferential surface 44 is defined as a surface along the . Also, the surfaces along the axial direction Y at both ends in the circumferential direction Z of the core back portion 41 are defined as core side surfaces 401 . The surfaces of the core pieces 40 and the laminated core 50 along the axial direction Y at both ends in the circumferential direction Z of the tooth portions 42 are tooth side surfaces 45 .

Also, the surface along the axial direction Y of the tip of the inner side X2 in the radial direction X of the tooth portion 42 is defined as the tip surface 48 . A shoe outer peripheral surface 46 is defined as a surface along the axial direction Y on the outer side X1 in the radial direction X of the shoe portion 43 in the core pieces 40 and the laminated core 50 . Further, a surface along the axial direction Y of the circumferential direction Z of the shoe portion 43 is defined as a shoe side surface 49 . A core outer peripheral groove 471 is provided in a part of the core outer peripheral surface 47 . However, it is conceivable that the core outer peripheral groove 471 is not formed.

A region surrounded by the core back portion 41, the teeth portion 42, and the shoe portion 43 of the core piece 40 becomes the slot region 30 in which the coil 33 is arranged. Accordingly, the surfaces of the core piece 40 forming the slot region 30 are the core inner peripheral surface 44 of the core back portion 41 , the tooth side surface 45 of the tooth portion 42 , and the shoe outer peripheral surface 46 of the shoe portion 43 . In addition, in Embodiment 1, a case where the core pieces 40 and the laminated core 50 are divided for each tooth portion 42 in the circumferential direction Z is shown.

The magnetic steel sheet that forms the core piece 40 is made of a material with high magnetic permeability and is coated with an insulating coating on its surface. Therefore, even if these are laminated in the axial direction Y, the core pieces 40 adjacent to each other in the axial direction Y are insulated and do not conduct. In order to fix each core piece 40 in this state, the three surfaces of the core inner peripheral surface 44, the tooth side surface 45, and the shoe outer peripheral surface 46, which are the surfaces forming the slot region 30 of the laminated core 50, are covered. Adhesive is continuously applied in the axial direction Y to form an adhesive portion 9, which will be described later, to fix the core pieces 40 in the axial direction Y between laminations.

The range in which the adhesive portion 9 is formed may extend not only to the core inner peripheral surface 44, tooth side surface 45, and shoe outer peripheral surface 46, but also to the shoe side surface 49 as shown in FIGS. In addition, although the bonding portion 9 is not formed on the tip surface 48 in the drawing, the bonding portion 9 may be extended to the tip surface 48 .

In the conventional fixing method in the axial direction Y, which is the fixing method by caulking or welding, since the laminations in the axial direction Y are electrically connected, eddy current is generated in that part and the iron loss increases. However, as in the first embodiment, the axial direction Y is extended so as to cover each of the three surfaces of the core inner peripheral surface 44, the tooth side surface 45, and the shoe outer peripheral surface 46, which are the surfaces forming the slot region 30 of the laminated core 50. Since the lamination of the core pieces 40 in the axial direction Y is fixed and the state of insulation is maintained by fixing the adhesive portion 9 continuously formed in the axial direction Y, the eddy current is suppressed and the efficiency of the rotating electric machine can be improved.

In addition, here, the bonding portion 9 is formed by all the core pieces 40 laminated in the axial direction Y, that is, the core inner peripheral surfaces 44 of all the slot regions 30 of the laminated core 50, the tooth side surfaces 45, and the shoe outer peripheral surfaces 46. It is formed by coating continuously from one end side to the other end side in the axial direction Y so as to cover all three surfaces. Therefore, the coil 33 can be formed by directly winding the electric wire 60 multiple times around the bonding portion 9 without interposing another insulator.

That is, the laminated core 50 is formed by fixing the core pieces 40 in the lamination direction Y (axial direction Y). By being formed continuously in the axial direction Y so as to cover all three surfaces of the outer peripheral surface 46 , it also has a function of electrical insulation between the wires 60 forming the coil 33 and the core pieces 40 . By controlling the thickness of the adhesive portion 9 and the type of adhesive, it is possible to easily satisfy the insulation performance required for the rotary electric machine.

As another example, as shown in FIG. 6, a chamfered portion 402 is formed at the corner of the core inner peripheral surface 44 of the core piece 40 and the core side surface 401, and a reservoir portion 901 is formed on the chamfered portion 402. An adhesive is applied and cured to form the adhesive portion 9 . If the pooled portion 901 is formed in the chamfered portion 402 in this way, the number of windings of the electric wire 60 is increased, and the distance between the coil 33 and the core side surface 401 cannot be secured, making it difficult to secure electrical insulation. 6, the insulation distance between the coil 33 and the core side surface 401 can be ensured, and the insulation performance can be ensured, as compared with the case shown in FIG.

It should be noted that instead of the chamfered portion 402, R-chamfering, or providing a step in the X1 direction on the core side surface 401 side of the core inner peripheral surface 44, and forming a reservoir portion 901 in the R-chamfering or the stepped portion are the same. expected to be effective.

Further, as shown in FIG. 20, the core pieces 40 are brought into close contact with each other in the axial direction Y and an adhesive is applied to form the adhesion portion 9 . As a result, the adhesive does not enter between the lamination surfaces 411 of the core pieces 40 adjacent to each other in the Y-axis direction. Therefore, the core pieces 40 adjacent to each other in the axial direction Y have lamination surfaces 411 in contact with each other without the bonding portion 9 interposed therebetween. When the core piece 40 is punched, sagging 412 is generated on one side of the core piece 40 in the axial direction Y, and burrs 413 are generated on the other side of the core piece 40 in the axial direction Y. Therefore, in this case, the adhesive enters gaps 414 formed by sagging 412 and burrs 413 between core pieces 40 adjacent in the axial direction Y to form bonded portions 9 . As a result, the core pieces 40 adjacent to each other in the axial direction Y can be stacked and fixed in close contact with each other in the axial direction Y without wasting space, and the size of the stator 10 in the axial direction Y can be reduced. Further, the adhesive portion 9 in the gap 414 can strengthen the fixing force.

As the adhesive that forms the adhesive portion 9, for example, a two-liquid curing adhesive may be used. A two-liquid curing type adhesive consists of a main agent and a curing accelerator, and as the main agent, an epoxy adhesive, an acrylic adhesive, or the like is used. In such a configuration, since there is no heating process, the configuration of the manufacturing equipment can be made compact, and heat energy can be reduced, so that there is an effect of energy saving.

Also, as the adhesive for forming the adhesive portion 9, for example, a heat-curable adhesive represented by an epoxy-based adhesive may be used. In this case, even if the adhesive adheres to the manufacturing equipment, it will not harden until heat is applied. Therefore, the adhesive adhering to the manufacturing apparatus can be removed simply by wiping it off before thermal curing, thereby improving maintainability. In addition, since the heat-curable adhesive has a higher heat-resistant temperature than the room-temperature-curable adhesive, the heat resistance of the laminated core 50 is improved.

Also, as the adhesive that forms the adhesive portion 9, for example, an ultraviolet curable adhesive may be used. In this case, even if the adhesive adheres to the manufacturing equipment, it will not harden until it is irradiated with ultraviolet rays. Therefore, the adhesive adhering to the manufacturing apparatus can be removed simply by wiping it off before thermal curing, thereby improving maintainability.

Also, the bonding portion 9 may be configured by powder coating or electrodeposition coating. In this case, the type of coating can be selected according to the usage environment, expanding the range of choices. In addition, for example, equipment can be shared with a painting apparatus for painting other parts such as the frame 1 or the brackets 2 and 3, so equipment investment can be suppressed.

Next, a method of manufacturing the stator 10 and the rotating electric machine 100 of Embodiment 1 configured as described above will be described with reference to the flow chart of FIG. 7 and FIGS. 8 to 11 . First, in the punching step ST1 in FIG. 7, as shown in FIG. 8, a plate material 301 made of an electromagnetic steel sheet wound in a reel shape is pulled out by an uncoiler, and a hydraulic or electric press machine is driven by a feeding device. 21 from the first direction A. A predetermined shape of the core piece 40 is punched out by the die 22 in the press machine 21 .

Next, in the aligning step ST2 in FIG. 7, the punched core pieces 40 are aligned and stacked in the stacking direction Y to form the laminated core 50 as shown in FIG. Alignment can be performed below the pressing machine 21 or inside the mold 22, but as shown in FIG. You can bend it and then align it. Note that the stacking direction Y and the axial direction Y shown above are the same direction.

Next, the coating step ST3 and the curing step ST4 as the fixing step ST30 in FIG. 7 will be described. The inside of the bonding device 23 of FIG. 8 has a function of applying an adhesive and a function of curing the applied adhesive. FIG. 10 is a cross section taken along line NN inside the bonding device 23 shown in FIG. 8, showing an example of a state during application of the adhesive. A plurality of core pieces 40 are moved forward in FIG.

Further, the positioning jig 231 includes the core inner peripheral surface 44, the tooth side surface 45, the shoe outer peripheral surface 46, and the shoe side surface 49 of the core piece 40 where the adhesive is to be applied, and a gap with a preset distance. 234 is set and the application jig 232 is attached. Furthermore, a hole 233 communicating with the gap 234 is provided. Then, the adhesive 91 before hardening is supplied to the gap 234 through the hole 233 . The adhesive 91 supplied to the gap 234 spreads over the entire gap 234 due to capillary action.

The core piece 40 to which the adhesive 91 is applied then proceeds to a curing step ST4 in which heating or ultraviolet irradiation according to the adhesive 91 is performed, and the adhesive portion 9 is formed. Note that the relationship between the gap 234 and the thickness of the adhesive portion 9 is in the relationship of "the distance of the gap 234>the thickness of the adhesive portion 9" due to the influence of the adhesive 91 remaining on the application jig 232 side and the effect of curing shrinkage. The thickness of the adhesive part 9 can be controlled by adjusting the distance of the gap 234 in order to obtain the required insulation performance.

In addition, in the application process and the curing process, side pressure is applied to the core side surface 401, the core outer peripheral surface 47, and the tip end surface 48 (see FIG. 5) of the core piece 40 where the adhesive 91 is not applied, and in the axial direction Y in FIG. By applying and curing the adhesive 91 while the core pieces 40 are in close contact with each other, the adhesive 91 is applied and cured so that the adhesive 91 does not enter the laminated surface 411 of the core pieces 40 adjacent to each other in the axial direction Y, and the adhesive portion 9 is formed. Form. As a result, since the core pieces 40 adjacent to each other in the axial direction Y can be stacked and fixed in close contact with each other in the axial direction Y without wasting space, the size of the stator 10 in the axial direction Y can be reduced.

Next, in the dividing step ST5 of FIG. 7, the bonding portion 9 is cut by the dividing device 24 of FIG. 8 so as to have a predetermined length in the axial direction Y, discharged in the third direction C, and laminated. A plurality of cores 50 are formed. As a method for cutting the bonding portion 9, the bonding portion 9 may be cut by mechanically applying a shearing force, or may be burned off by laser irradiation or the like. Next, in the placement step ST6 of FIG. 7, the axial end insulator 34 is attached to the laminated core 50 as shown in FIG. 11 by way of example. However, portions of the bonding portion 9 shown in FIG. 11 that are continuously formed along the axial direction Y are not indicated by thick black lines.

In FIG. 21, as shown in the width in the circumferential direction Z at each location, the width in the circumferential direction Z of the portion of the axial end insulator 34 facing the laminated core 50 is H1, and the width in the circumferential direction Z of the tooth portion 42 is is the width H2, and the total value of the widths in the circumferential direction Z of the bonding portions 9 formed on both sides of the tooth portion 42 in the circumferential direction Z is H3, (Equation 1) shown below is established.
H1≧H2+H3 (Formula 1)

With this configuration, the axial end insulator 34 and the adhesive portion 9 are reliably brought into contact with each other, and the insulating performance between the laminated core 50 and the coil 33 can be ensured. Further, when the above (Equation 1) holds, the width H1 can be made as small as possible, that is, the width H1 can be brought closer to the width H2+H3, so that the slot region 30 in which the coil 33 is formed can be widened. 100 power can be improved.

The shaft end insulator 34 is fixed to the laminated core 50 by inserting the projection 341 of the shaft end insulator 34 into the core outer peripheral groove 471 of the laminated core 50 . Here, a method of inserting the shaft-end insulator 34 resin-molded in advance into the laminated core 50 is shown, but the present invention is not limited to this, and the laminated core 50 and the shaft-end insulator 34 are integrally molded by injection molding. may In that case, the resin flows in the core outer peripheral groove 471 or the like so as not to cover the bonding portion 9, and the pair of shaft end insulators 34 on both ends in the axial direction Y are connected to be integrally formed with the laminated core 50. can be considered.

Next, in the coil forming step ST7 in FIG. 7, the electric wire 60 is wound around the tooth portions 42 of the divided laminated core 50 to form the coil 33 . Next, in the stator forming step ST8 of FIG. 7, as shown in FIG. The core outer peripheral surface 47 of the back portion 41 is fixed. Next, in the rotating electric machine forming step ST9 in FIG. 7, the rotating shaft 6 of the rotor 20 is rotatably supported by the upper bracket 2 and the lower bracket 3 by the bearings 4 and 5 as shown in FIG. , a rotating electric machine 100 is formed by arranging a rotor 20 to face a stator 10 with a gap therebetween.

In the above first embodiment, the method of performing the dividing step ST5 after the coating step ST3 and the curing step ST4 (fixing step ST30) is shown, but the method is not limited to this, and the coating is performed after the dividing step ST5. Step ST3 and curing step ST4 (fixing step ST30) may be performed. In this case, it is possible to continuously extend the adhesive portion 9 not only to the side surfaces of the laminated core 50 but also to both axial end surfaces of the laminated core 50, thereby improving the insulation performance.

According to the stator of the rotary electric machine of Embodiment 1 configured as described above,
A core piece having an annular core-back portion and a plurality of tooth portions protruding radially inwardly from a core inner peripheral surface radially inward of the core-back portion at intervals in the axial direction. a laminated core in which a plurality of sheets are laminated;
Of the slot regions surrounded by the tooth portions and the core back portion of the laminated core, each of the surfaces forming at least one of the slot regions is provided with the an adhesive portion for axially fixing the core pieces;
axial end insulators that are in contact with one axial end and the other axial end of the bonding portion and are arranged at both axial ends of the laminated core;
a coil formed in the slot region by winding an electric wire around the teeth,
Also, according to the rotary electric machine,
A stator of the rotating electric machine, and a rotor arranged opposite to the stator with a gap therebetween,
According to the manufacturing method of the stator of the rotary electric machine,
A punching step of punching out a plurality of the core pieces from a plate;
an aligning step of axially laminating and aligning the punched core pieces;
a fixing step of axially arranging the adhesive portions continuously on each of the surfaces forming the slot regions to fix the core pieces in the axial direction;
a dividing step of cutting the core pieces laminated in the axial direction into a plurality of the laminated cores by cutting them in a predetermined length in the axial direction;
and an arranging step of arranging the axial end insulators on both axial ends of the laminated core while being in contact with one axial end and the other axial end of the adhesive portion,
Further, according to the manufacturing method of the rotary electric machine,
Since the rotating electrical machine is manufactured using the stator manufactured using the method for manufacturing a stator for a rotating electrical machine described above,
By forming the adhesive portion on the surface forming the slot region of the laminated core, electrical insulation between the coil and the laminated core can be maintained without interposing an insulator in the slot region of the laminated core. As a result, the slot area can be expanded, the number of coil turns and wire diameter can be increased, and the performance of the rotating electric machine can be improved. In addition, the material cost and labor for assembling the insulator can be saved, and the cost can be suppressed. In addition, since the core pieces are laminated and fixed by forming an adhesive portion, there is no need to fix the core pieces by caulking or welding as in the conventional art, so it is possible to prevent deterioration in efficiency due to eddy currents and hysteresis loss. In addition, since the core pieces are laminated and fixed by forming the adhesive portion, the space factor of the core pieces can be increased and the efficiency can be improved compared to the case where the adhesive is impregnated between all the plate materials (electromagnetic steel sheets). Moreover, productivity can also be improved.

Furthermore, according to the stator of the rotary electric machine of Embodiment 1,
Since the adhesive portion is formed on the surface forming all of the slot regions,
Electrical insulation can be maintained in all regions between the coil and the laminated core, and the performance of the rotating electric machine can be further improved.

Furthermore, according to the stator of the rotary electric machine of Embodiment 1,
The tooth portion has a shoe portion extending in a circumferential direction from a radially inner end,
Since the slot region is formed surrounded by the tooth portion, the core-back portion, and the shoe portion,
Even when the shoe portion is provided, electrical insulation can be maintained in the entire region between the coil and the laminated core, and the performance of the rotating electric machine can be further improved.

Furthermore, according to the stator of the rotary electric machine of Embodiment 1,
Since the laminated core is formed by dividing each tooth portion in the circumferential direction,
Since the laminated core is divided, the bonding portion can be easily formed.

Furthermore, according to the stator of the rotary electric machine of Embodiment 1,
Since the adhesive portion is composed of any one of an ultraviolet curable adhesive that is cured by irradiation with ultraviolet rays, an anaerobic adhesive, and a thermosetting adhesive, the adhesive portion can be reliably formed.

Furthermore, according to the manufacturing method of the stator for the rotary electric machine of the first embodiment,
The fixing step includes
an application step of applying an adhesive to the surface forming the slot region;
and a curing step of curing the adhesive,
A bonding portion can be reliably formed.

Furthermore, according to the manufacturing method of the stator for the rotary electric machine of the first embodiment,
The coating step includes
An application jig is placed on the surface forming the slot region so as to face each other with a predetermined distance therebetween, and the adhesive is filled in a gap of the distance between the surface forming the slot region and the application jig. However, since it is spread by capillary action and formed with a film thickness equal to or less than the gap,
The adhesive portion can be reliably formed with the minimum required thickness.

Furthermore, according to the stator of the rotary electric machine of Embodiment 1,
Since the axially adjacent core pieces have lamination surfaces in contact with each other without an adhesive,
Further, according to the manufacturing method of the stator for the rotary electric machine of the first embodiment,
The fixing step includes
The core pieces are fixed in close contact with each other in the axial direction so that the core pieces adjacent to each other in the axial direction have lamination surfaces in contact with each other without an adhesive intervening therebetween.
The core pieces adjacent to each other in the axial direction can be stacked and fixed in close contact with each other in the axial direction without wasting space, and the size of the stator in the axial direction can be reduced.

Furthermore, according to the stator of the rotary electric machine of Embodiment 1,
A width H1 is the width in the circumferential direction of the portion of the shaft-end insulator facing the laminated core,
The width of the tooth portion in the circumferential direction is the width H2,
Assuming that the total value of the circumferential widths of the bonding portions formed on both sides of the tooth portion in the circumferential direction is H3,
H1≧H2+H3 (Formula 1)
(Equation 1) is established so that
The slot area can be widened, and the output of the rotating electric machine can be improved.

Embodiment 2.
FIG. 12 is a diagram showing the configuration of the stator of the rotary electric machine according to the second embodiment. 13 is a plan view showing the structure of the laminated core of FIG. 12. FIG. 14 is a perspective view showing the configuration of the laminated core shown in FIG. 13. FIG. In the following, the description of the points that are the same as in the first embodiment will be omitted as appropriate, and the description will focus on the points of difference. Further, the same reference numerals are given to the same parts as in the first embodiment, and the description thereof is omitted.

First, a description will be given using FIGS. 13 and 14. FIG. One or a plurality (here, a plurality of examples are shown) of protrusions 902 extending in the axial direction Y are formed on the surface of the bonding portion 9 formed on the tooth side surface 45 . The convex portion 902 is formed in a direction projecting from the tooth side surface 45 toward the slot region 30 . Moreover, as shown in FIG. 14, the convex portion 902 is formed continuously from one end to the other end in the axial direction Y. As shown in FIG. However, portions of the bonding portion 9 shown in FIG. 14 that are continuously formed along the axial direction Y are not indicated by thick black lines.

Next, the function of the convex portion 902 will be described using FIG. The electric wire 60 extends around the teeth portion 42 of the laminated core 50 made of the core pieces 40 from the side near the teeth portion 42 to the first layer 331, the second layer 332, the third layer 333, the fourth layer 334, and the fifth layer. The coil 33 is formed by winding 335 in order. At this time, the convex portion 902 functions as positioning of the electric wire 60 of the first layer 331 . That is, the convex portion 902 enters the concave space formed by the wires 60 adjacent to each other in the radial direction X on the tooth side surface 45 side, thereby preventing the positional displacement of the wires 60 of the first layer 331 .

The convex portion 902 may be formed corresponding to all of the concave spaces formed by the wires 60 adjacent in the radial direction X, or may be formed corresponding to a part of the concave spaces. If the positional deviation of the electric wire 60 of the first layer 331 can be prevented by the above method, the electric wire 60 of the second layer 332 wound thereon can be arranged in the first layer 331 adjacent in the radial direction X on the side opposite to the tooth side surface 45. It is stable because it is wound so as to drop into the concave portion formed by the electric wire 60 of . Similarly, the third layer 333, the fourth layer 334, and the fifth layer 335, which are wound from above the second layer 332, can be stably wound so as to fall into the recess one layer below, without winding disturbance. This facilitates the realization of aligned winding in which the wires 60 are stacked in bales.

Next, a method for manufacturing the rotating electrical machine 100 according to the second embodiment configured as described above will be described, focusing on the adhesive application step ST3, which is different from the first embodiment. FIG. 15 is a cross section taken along the line NN inside the bonding device 23 shown in FIG. 8, and is an example of the second embodiment showing a state during adhesive application. As shown in FIG. 15, in the adhesive application step ST3, the adhesive is applied to the core inner peripheral surface 44, the tooth side surface 45, the shoe outer peripheral surface 46, and the shoe side surface 49 of the core piece 40 on the positioning jig 231. A gap 234 pre-opened with the part is set, and an application jig 232 is attached. A concave portion 235 is formed in the depth direction of the paper surface, that is, in the axial direction Y in a portion of the application jig 232 that faces the convex portion 902 of the bonding portion 9 .

Furthermore, a hole 233 that connects to the gap 234 and the recess 235 is provided. Then, the adhesive 91 before hardening is supplied to the gap 234 through the hole 233 . The adhesive 91 supplied to the gap 234 spreads over the entire gap 234 and the recess 235 due to capillary action. The core piece 40 to which the adhesive 91 is applied then proceeds to a curing step ST4 in which heating or ultraviolet irradiation is performed according to the adhesive 91, and the adhesive portion 9 having the convex portions 902 is formed.

According to the stator of the rotating electrical machine, the rotating electrical machine, the method of manufacturing the stator of the rotating electrical machine, and the method of manufacturing the rotating electrical machine of the second embodiment configured as described above, the same effects as those of the first embodiment can be obtained. Along with playing
A convex portion extending in the axial direction is provided on the surface of the adhesive portion formed on the tooth portion,
the wires forming the first layer of the coil are placed in contact with the convex portions adjacent in the radial direction;
again,
A punching step of punching out a plurality of the core pieces from a plate;
an aligning step of axially laminating and aligning the punched core pieces;
a fixing step of axially arranging the adhesive portions continuously on each of the surfaces forming the slot regions to fix the core pieces in the axial direction;
a dividing step of cutting the core pieces laminated in the axial direction into a plurality of the laminated cores by cutting them in a predetermined length in the axial direction;
an arranging step of arranging the axial end insulators on both axial ends of the laminated core while being in contact with one axial end and the other axial end of the adhesive portion;
The fixing step includes
an application step of applying an adhesive to the surface forming the slot region;
and a curing step of curing the adhesive,
The coating step includes
A coating jig having a predetermined distance secured on the surface forming the slot region and having a concave portion formed in a portion of the bonding portion facing the convex portion is arranged to form the slot region. The adhesive is spread in the gap of the distance between the surface and the application jig by capillary action to form a film thickness equal to or less than the gap, and the adhesive is applied to the concave portion of the application jig. Since the convex portion is formed,
The convex portion facilitates alignment winding of the coil, and productivity is improved by increasing the winding speed. In addition, since the coils can be wound in an aligned manner, even in the same slot area, the space factor of the coils can be increased, the number of turns can be increased, and the torque of the rotating electrical machine can be increased.

Embodiment 3.
16 is an enlarged view of one stator shown in FIG. 3 in Embodiment 3. FIG. FIG. 17 is a flow chart showing a method for manufacturing a rotating electric machine according to the third embodiment. FIG. 18 is a schematic diagram showing a sticking device for sticking an adhesive tape to a laminated core. FIG. 19 is a schematic view of the sticking device shown in FIG. 18 at a viewpoint P. FIG. In the following, the description of the points that are the same as those of the above-described embodiments will be omitted as appropriate, and the description will focus on the points of difference. Also, the same reference numerals are given to the same parts as in the above embodiments, and the description thereof is omitted.

First, a description will be given using FIG. Instead of using the adhesive 91 forming the adhesion portion 9, an insulating adhesive tape 92 forming the adhesion portion 9 is used. In order to fix each core piece 40 , the axial direction Y is extended so as to cover all three surfaces of the core inner peripheral surface 44 , the tooth side surface 45 , and the shoe outer peripheral surface 46 , which are the surfaces forming the slot region 30 of the laminated core 50 . An adhesive tape 92 is continuously attached to the . By attaching the adhesive tape 92, the space between the core pieces 40 in the axial direction Y in the axial direction Y (between laminations) is fixed.

The range of attachment of the adhesive tape 92 may extend not only to the core inner peripheral surface 44 , tooth side surface 45 and shoe outer peripheral surface 46 , but also to the shoe side surface 49 and further to the tip surface 48 . Alternatively, as shown in FIG. 16, the adhesive tape 92 is attached so as to completely cover the core inner peripheral surface 44, the tooth side surface 45, and the shoe outer peripheral surface 46, and the adhesive tape 92 is not attached to the other portions, leaving a little excess adhesive tape 92. You can also paste it like this:

As the adhesive tape 92, for example, a tape made of a polyimide or polyvinyl chloride (PVC) film as a base material and a silicone or acrylic adhesive can be used. The coil 33 is formed by directly winding the electric wire 60 multiple times around the adhesive tape 92 without interposing another insulator.

That is, the laminated core 50 is formed by laminating and fixing the core pieces 40 in the axial direction Y, and the adhesive tape 92 responsible for the fixing is the inner peripheral surface of the core, which is the surface forming the slot region 30. 44 , tooth side surfaces 45 , and shoe outer peripheral surface 46 . It has the function of insulation. By selecting the optimum type and thickness of the adhesive tape 92, the insulation performance required for the rotating electric machine can be satisfied.

Next, a method of manufacturing the stator of the rotating electrical machine 100 according to the third embodiment configured as described above will be described, focusing on steps different from those of the above embodiments. As shown in the flowchart of FIG. 17, instead of the fixing step ST30 having the coating step ST3 and the curing step ST4, the attaching step ST31 is performed as the fixing step ST30. ST1 to ST2 and ST5 to ST9 are the same as those in the above embodiments.

The sticking step ST31 performed using the sticking device for the adhesive tape 92 shown in FIGS. 18 and 19 will be described. The plurality of core pieces 40 move forward in FIG. 18 and in the fourth direction D in FIG. The sticking rollers 25 are arranged on both side surfaces of the advancing core piece 40 , and the adhesive tape 92 unwound in the fifth direction E from the adhesive tape roll 921 is applied to the inner core inside the side surface of the core piece 40 . At least three surfaces of the peripheral surface 44, the tooth side surface 45, and the outer peripheral surface 46 of the shoe are adhered and fixed.

In the second embodiment, the flowchart of FIG. 17 shows a method of performing the dividing step ST5 after the attaching step ST31 (fixing step ST30). The attaching step ST31 (fixing step ST30) may be performed later. In this case, the length of the adhesive tape 92 is cut to be longer than the length of the laminated core 50 in the axial direction Y, and the side surface of the laminated core 50 and both end surfaces of the laminated core 50 in the axial direction Y are continuously attached with the adhesive tape 92. Affixing becomes possible, and furthermore, the insulating performance can be improved.

According to the stator of the rotating electrical machine, the rotating electrical machine, the method of manufacturing the stator of the rotating electrical machine, and the method of manufacturing the rotating electrical machine of the third embodiment configured as described above, the same effects as those of the above embodiments can be obtained. Along with playing
The adhesive portion is composed of an insulating adhesive tape,
In addition, the fixing step includes:
Since an adhesive tape for insulation is adhered and fixed to the core pieces continuously in the axial direction on each of the surfaces forming the slot regions,
This eliminates the need for the step of curing the adhesive, improving productivity. In addition, since the bonded portion formed with the adhesive tape is more difficult to cut than the bonded portion formed with adhesive, defects such as cracking of the laminated core during the manufacturing process can be reduced.

In each of the above-described embodiments, an example of the laminated core 50 that is divided into each tooth in the circumferential direction Z is shown, but the present invention is not limited to this. Alternatively, various examples can be considered, such as the case where it is divided only at one place, the case where it is divided for each of a plurality of teeth, and the like.

Further, in each of the above-described embodiments, an example of a stator formed by concentrated winding in which a coil is wound around one tooth is shown, but the present invention is not limited to this, and the coil is wound across a plurality of teeth. A stator formed by distributed winding can also be applied in the same manner as the above embodiments.

In addition, although an example of a stator in which a plurality of laminated cores 50 each having an adhesive portion 9 fixed in the axial direction Y of the core piece 40 by the adhesive 91 or the adhesive tape 92 are arranged in the circumferential direction Z, the stator is limited to this. A stator formed by laminating a plurality of laminated cores 50 in the axial direction Y can also be applied in the same manner as the above embodiments.

Moreover, although an example of a stator formed of the same type of laminated cores 50 divided in the circumferential direction Z has been shown, the present invention is not limited to this, and a stator is formed by combining a plurality of types of laminated cores 50. is also possible. For example, at both ends in the axial direction Y of the laminated core 50 fixed in the axial direction Y by the bonding portion 9 shown in the above embodiment, laminated cores fixed by conventional caulking or the like are arranged and fixed by caulking or the like. It may be configured such that the slot portion of the stacked core is covered with the axial end insulator 34 .

Embodiment 4.
FIG. 22 is a perspective view showing a state in which a shaft end insulator is attached to a laminated core according to Embodiment 4. FIG. 23 is an enlarged cross-sectional view taken along line RR of the state in which the axial end insulator is attached to the laminated core shown in FIG. 22. FIG. FIG. 24 is a cross-sectional view showing a state of the manufacturing apparatus shown in FIG. 8 according to Embodiment 4 when the adhesive is applied to both end sides in the axial direction of the laminated core along line NN. In the following, the description of the points that are the same as those of the above-described embodiments will be omitted as appropriate, and the description will focus on the points of difference. Also, the same reference numerals are given to the same parts as in the above embodiments, and the description thereof is omitted.

In the fourth embodiment, a case will be described in which the axial end insulators 34 are used to insulate a preset number of core pieces 40 on both end sides in the axial direction Y of the laminated core 50 . As a matter of course, the preset number is a number smaller than the number of the plurality of core pieces 40 of the laminated core 50. In the figure, as an example of the preset number, Two pieces of each core piece 40 on both end sides of are shown as an example.

As shown in FIGS. 22 and 23, the bonding portion 9 has a preset number of pieces on both end sides of the laminated core 50 in the axial direction Y, here, the thickness H4 of the portion formed on the two core pieces 40 is It has a thin adhesive portion 900 formed thinner than the thickness H5 of the portion formed in the core piece 40 other than that. The axial end insulator 34 is provided with an engaging portion 340 that engages on the thin adhesive portion 900 . The engaging portion 340 is formed to protrude and extend in the axial direction Y toward the laminated core 50 . The total value of the thickness H6 of the engaging portion 340 and the thickness H5 of the thin adhesive portion 900 is formed substantially equal to the thickness H4 of the adhesive portion 9 .

When the shaft end insulators 34 are attached to the laminated core 50, the engaging portions 340 of the shaft end insulators 34 engage with the portions of the thin adhesive portions 900 on both end sides in the axial direction Y of the laminated core 50. It covers the thin adhesive portion 900 and insulates the two core pieces 40 of the laminated core 50 at both ends in the axial direction Y. As shown in FIG.

As shown in FIG. 24, the method of forming the thin adhesive portion 900 of the adhesive portion 9 is such that the thickness of the adhesive portion 9 is reduced from the gap 234 in comparison with the case shown in FIG. 10 of the above-described embodiment. The thin adhesive portion 900 of the adhesive portion 9 is formed by narrowing the gap 236 to satisfy the relationship of gap 234>gap 236, applying and curing.

As a result, with the coil 33 arranged, the insulation creepage distance L1 (see FIG. 23) between the coil 33 and the laminated core 50 can be ensured without reducing the slot area 30 around which the coil 33 is wound. However, insulation performance can be secured. In addition, since the sum of the thickness H6 of the engaging portion 340 and the thickness H5 of the thin adhesive portion 900 is substantially the same as the thickness H4 of the adhesive portion 9, the slot area 30 around which the coil 33 is wound is reduced. The rotary electric machine 100 can be miniaturized and reduced in loss.

According to the stator of the rotating electrical machine, the rotating electrical machine, the method of manufacturing the stator of the rotating electrical machine, and the method of manufacturing the rotating electrical machine of the fourth embodiment configured as described above, the same effects as those of the above embodiments can be obtained. Along with playing
In the adhesive portion, the thickness of the portions formed on the predetermined number of core pieces on both axial end sides of the laminated core is formed to be thinner than the thickness of the portions formed on the other core pieces. has a thin adhesive part,
Since the shaft end insulator has an engaging portion that engages on the thin adhesive portion,
Since insulation performance can be ensured without reducing the slot area, it is possible to reduce the size and loss of the rotary electric machine.

Embodiment 5.
FIG. 25 is a cross-sectional view showing a state in which the axial end insulator is attached to the laminated core according to the fifth embodiment. In the following, the description of the points that are the same as those of the above-described embodiments will be omitted as appropriate, and the description will focus on the points of difference. Also, the same reference numerals are given to the same parts as in the above embodiments, and the description thereof is omitted.

In the fifth embodiment, similarly to the fourth embodiment, the shaft end insulators 34 are used to insulate a preset number of core pieces 40 on both end sides of the laminated core 50 in the axial direction Y. do. As a matter of course, the preset number is a number smaller than the number of the plurality of core pieces 40 of the laminated core 50. In the figure, as an example of the preset number, Two pieces of each core piece 40 on both end sides of are shown as an example.

As shown in FIG. 25, the core pieces 40 of the laminated core 50 are composed of first core pieces 421 and second core pieces 422 . The width H12 in the circumferential direction Z of the tooth portions 42 of the second core pieces 422 is formed longer than the width H11 in the circumferential direction Z of the tooth portions 42 of the first core pieces 421 . The laminated core 50 is formed of the first core pieces 421 for a preset number of pieces on both end sides in the axial direction Y, here two pieces, and the second core pieces 422 for the rest. The adhesive portions 9 formed on the first core piece 421 and the second core piece 422 are formed with substantially the same thickness.

The axial end insulator 34 is provided with an engaging portion 342 that engages with the tooth side surface 45 of the tooth portion 42 of the first core piece 421 via the adhesive portion 9 . The engaging portion 342 is formed to protrude and extend in the axial direction Y toward the laminated core 50 . The sum of the width H13 and the width H14 in the circumferential direction Z on both sides of the engaging portion 342 and the difference between the width H11 of the first core piece 421 and the width H12 of the second core piece 422 is approximately formed identically.

After the axial end insulators 34 are attached to the laminated core 50 , the engaging portions 342 of the axial end insulators 34 are positioned at the bonding portions 9 of the first core pieces 421 on both end sides of the laminated core 50 in the axial direction Y. to insulate the two first core pieces 421 of the laminated core 50 on both end sides in the axial direction Y.

As a result, with the coil 33 arranged, the insulation creepage distance L2 (see FIG. 25) between the coil 33 and the laminated core 50 can be ensured without reducing the slot area 30 around which the coil 33 is wound. However, insulation performance can be secured. In addition, the sum of the width H13 and the width H14 in the circumferential direction Z of both sides of the engaging portion 342 in the circumferential direction Z and the difference between the width H11 of the first core piece 421 and the width H12 of the second core piece 422 are approximately Since the coils 33 are formed identically, it is possible to reduce the size and loss of the rotary electric machine 100 without reducing the slot area 30 around which the coil 33 is wound.

According to the stator of the rotating electrical machine, the rotating electrical machine, the method of manufacturing the stator of the rotating electrical machine, and the method of manufacturing the rotating electrical machine of the fifth embodiment configured as described above, the same effects as those of the above embodiments can be obtained. Along with playing
The core pieces of the laminated core have first core pieces and second core pieces, and the circumferential width of the tooth portions of the second core pieces is greater than the circumferential width of the tooth portions of the first core pieces. is formed long, and the laminated core is composed of the first core pieces for a predetermined number on both ends in the axial direction and the second core pieces for the rest,
Since the shaft end insulator includes an engaging portion that engages with the tooth side surface of the tooth portion of the first core piece via the adhesive portion,
Since insulation performance can be ensured without reducing the slot area, it is possible to reduce the size and loss of the rotary electric machine.

As shown above, countless variations not illustrated are envisioned within the scope of the art. For example, modification, addition, or omission of at least one component is included.

While this application describes various exemplary embodiments and examples, various features, aspects, and functions described in one or more embodiments may not apply to particular embodiments. can be applied to the embodiments singly or in various combinations.
Therefore, countless modifications not illustrated are envisioned within the scope of the technology disclosed in the present application. For example, modification, addition or omission of at least one component, extraction of at least one component, and combination with components of other embodiments shall be included.

1 Frame, 10 Stator, 100 Rotating electric machine, 2 Upper bracket, 20 Rotor, 21 Press machine, 22 Mold, 23 Bonding device, 231 Positioning jig, 232 Application jig, 233 Hole, 234 Gap, 235 Recess, 236 gap, 24 dividing device, 25 pasting roller, 3 lower bracket, 30 slot area, 301 plate material, 33 coil, 34 axial end insulator, 340 engaging portion, 341 convex portion, 342 engaging portion, 4 bearing, 40 core piece , 401 core side surface, 402 chamfered portion, 41 core back portion, 411 lamination surface, 412 sag, 413 burr, 414 gap, 42 tooth portion, 421 first core piece, 422 second core piece, 43 shoe portion, 44 inside core Peripheral surface, 45 Teeth side surface, 46 Shoe outer peripheral surface, 47 Core outer peripheral surface, 471 Core outer peripheral groove, 48 Tip surface, 49 Shoe side surface, 5 Bearing, 50 Laminated core, 6 Rotating shaft, 60 Electric wire, 601 Core material, 602 Surface Film, 7 Rotor core, 8 Permanent magnet, 9 Adhesive part, 901 Reservoir part, 902 Convex part, 91 Adhesive, 92 Adhesive tape, 900 Thin adhesive part, 921 Adhesive tape winding, A First direction, B Second direction , C third direction, D fourth direction, E fifth direction, X radial direction, X1 outer side, X2 inner side, Y axial direction, Y stacking direction, Z circumferential direction.

Claims (19)

1. A core piece having an annular core-back portion and a plurality of tooth portions protruding radially inwardly from a core inner peripheral surface radially inward of the core-back portion at intervals in the axial direction. a laminated core in which a plurality of sheets are laminated;
   Of the slot regions surrounded by the tooth portions and the core back portion of the laminated core, each of the surfaces forming at least one of the slot regions is provided with the an adhesive portion for axially fixing the core pieces;
   axial end insulators that are in contact with one axial end and the other axial end of the bonding portion and are arranged at both axial ends of the laminated core;
   A stator for a rotary electric machine, comprising: a coil formed in the slot region by winding an electric wire around the tooth portion.
2. The stator for a rotary electric machine according to claim 1, wherein the axially adjacent core pieces have lamination surfaces in contact with each other without an adhesive.
3. A width H1 is the width in the circumferential direction of the portion of the shaft-end insulator facing the laminated core,
   The width of the tooth portion in the circumferential direction is the width H2,
   Assuming that the total value of the circumferential widths of the bonding portions formed on both sides of the tooth portion in the circumferential direction is H3,
   H1≧H2+H3 (Formula 1)
   3. The stator for a rotary electric machine according to claim 1, wherein the stator of a rotary electric machine is constructed so that (Equation 1) of is satisfied.
4. In the adhesive portion, the thickness of the portions formed on the predetermined number of core pieces on both axial end sides of the laminated core is formed to be thinner than the thickness of the portions formed on the other core pieces. has a thin adhesive part,
   3. The stator for a rotary electric machine according to claim 1, wherein said shaft end insulator has an engaging portion that engages on said thin adhesive portion.
5. The core pieces of the laminated core have first core pieces and second core pieces, and the circumferential width of the tooth portions of the second core pieces is greater than the circumferential width of the tooth portions of the first core pieces. formed long,
   The laminated core comprises a predetermined number of the first core pieces on both ends in the axial direction, and the second core pieces on the rest,
   3. The stator for a rotary electric machine according to claim 1, wherein the shaft-end insulator includes an engaging portion that engages with a tooth side surface of the tooth portion of the first core piece through the adhesive portion. .
6. The stator for a rotary electric machine according to any one of claims 1 to 5, wherein the adhesive portion is formed on a surface forming all of the slot regions.
7. The tooth portion has a shoe portion extending in a circumferential direction from a radially inner end,
   The stator for a rotary electric machine according to any one of claims 1 to 6, wherein the slot region is formed surrounded by the tooth portion, the core-back portion, and the shoe portion.
8. The stator for a rotary electric machine according to any one of claims 1 to 7, wherein the laminated core is formed by dividing each tooth portion in the circumferential direction.
9. 9. The adhesive portion according to any one of claims 1 to 8, wherein the adhesive portion is composed of any one of an ultraviolet curable adhesive that is cured by irradiation with ultraviolet rays, an anaerobic adhesive, and a thermosetting adhesive. The stator of the rotary electric machine according to .
10. A convex portion extending in the axial direction is provided on the surface of the adhesive portion formed on the tooth portion,
    10. The stator of a rotary electric machine according to claim 9, wherein the wires forming the first layer of the coil are installed in contact with the radially adjacent projections.
11. The stator for a rotary electric machine according to any one of claims 1 to 8, wherein the adhesive portion is composed of an insulating adhesive tape.
12. A rotary electric machine comprising: the stator for the rotary electric machine according to any one of claims 1 to 11; and a rotor facing the stator with a gap therebetween.
13. In the method for manufacturing a stator for a rotary electric machine according to any one of claims 1 to 12,
    A punching step of punching out a plurality of the core pieces from a plate;
    an aligning step of axially laminating and aligning the punched core pieces;
    a fixing step of axially arranging the adhesive portions continuously on each of the surfaces forming the slot regions to fix the core pieces in the axial direction;
    a dividing step of cutting the core pieces laminated in the axial direction into a plurality of the laminated cores by cutting them in a predetermined length in the axial direction;
    A method of manufacturing a stator for a rotating electrical machine, comprising: placing the axial end insulators in contact with one axial end and the other axial end of the bonded portion and arranging the shaft end insulators at both axial ends of the laminated core.
14. The fixing step includes
    14. The stator for a rotary electric machine according to claim 13, wherein the core pieces are fixed in close contact with each other in the axial direction so that the axially adjacent core pieces have laminated surfaces in contact with each other without an adhesive. manufacturing method.
15. The fixing step includes
    an application step of applying an adhesive to the surface forming the slot region;
    15. The method of manufacturing a stator for a rotary electric machine according to claim 13, further comprising a curing step of curing said adhesive.
16. The coating step includes
    An application jig is placed on the surface forming the slot region so as to face each other with a predetermined distance therebetween, and the adhesive is filled in a gap of the distance between the surface forming the slot region and the application jig. 16. The method of manufacturing a stator for a rotary electric machine according to claim 15, wherein the coating is spread by capillary action and formed with a film thickness equal to or less than the gap.
17. The fixing step includes
    15. The stator for a rotary electric machine according to claim 13, further comprising an affixing step of affixing an insulating adhesive tape to the core pieces continuously in the axial direction on each of the surfaces forming the slot regions. manufacturing method.
18. In the method for manufacturing a stator for a rotary electric machine according to claim 10,
    A punching step of punching out a plurality of the core pieces from a plate;
    an aligning step of axially laminating and aligning the punched core pieces;
    a fixing step of axially arranging the adhesive portions continuously on each of the surfaces forming the slot regions to fix the core pieces in the axial direction;
    a dividing step of cutting the core pieces laminated in the axial direction into a plurality of the laminated cores by cutting them in a predetermined length in the axial direction;
    an arranging step of arranging the axial end insulators on both axial ends of the laminated core while being in contact with one axial end and the other axial end of the adhesive portion;
    The fixing step includes
    an application step of applying an adhesive to the surface forming the slot region;
    and a curing step of curing the adhesive,
    The coating step includes
    A coating jig having a predetermined distance secured on the surface forming the slot region and having a concave portion formed in a portion of the bonding portion facing the convex portion is arranged to form the slot region. The adhesive is spread in the gap of the distance between the surface and the application jig by capillary action to form a film thickness equal to or less than the gap, and the adhesive is applied to the concave portion of the application jig. A method of manufacturing a stator for a rotary electric machine in which the convex portion is formed.
19. A method for manufacturing a rotating electric machine, wherein the rotating electric machine is manufactured using the stator manufactured using the method for manufacturing a stator for a rotating electric machine according to any one of claims 13 to 18.

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