JPH0152989B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a stator in an inner rotor type synchronous motor in which a stator is disposed concentrically with a cylindrical rotor made of permanent magnets, and more specifically, A method for manufacturing a stator comprising a hollow drum-shaped stator body consisting of a body formed to be able to be wrapped with a body and flanges at both ends of the stator body, and a stator yoke bridged between both flanges of the stator body. Regarding.

As a stator in a conventional inner rotor type synchronous motor, there is a stator used in a motor roller motor disclosed in JP-A-60-122614, but this stator has a so-called single magnetic pole piece. Because it is a support structure, it is mechanically unstable, and if the air gap between the rotor and the rotor is small, there is a risk of it sticking to the rotor, so it is necessary to provide a fairly large air gap, and if this happens, the torque cannot be increased as much. I had a problem.

Therefore, an object of the present invention is to provide a method for manufacturing a stator, particularly a stator body, which can solve the problems of the conventional stator described above.
A plurality of strip-shaped magnetic pole pieces made of a high magnetic permeability material, each free end of which is cut diagonally inward, are attached to the inner peripheral edge of a collar piece made of a high magnetic permeability material at regular intervals in the circumferential direction and attached to the collar piece. The proximal end of each pole piece is welded to the inner circumferential edge of the collar piece at right angles, thereby forming a pair of cage-shaped stator members, with each pole piece of one stator member The stator members are fitted coaxially into each other so as to protrude between adjacent magnetic pole pieces with a certain gap in the circumferential direction, and
A mold is provided to form a cavity between the inner and outer peripheral surfaces of the magnetic pole pieces for the pair of stator members, and then molten synthetic resin is injected into the mold. , a resin insulating layer covering the outer circumferential surface of the magnetic pole pieces is integrally molded with the stator member to form a hollow drum-shaped stator body, a winding is wound around the stator body, and the winding is It is characterized in that an insulating tape is applied to the outer surface, and the stator yoke is further engaged with the engagement protrusion of the stator body.

An embodiment in which the present invention is applied to a motor roller will be described below with reference to the drawings.

Figure 1 is a vertical cross-sectional view of the motor roller, Figure 2 is
In these figures, 1 is a fixed shaft, 2 is a hollow cylindrical roller body, and roller body side sleeve members 3 and 4 are attached to the inner peripheral surface of both ends of this roller body 2, and the fixed shaft is 1, fixed shaft side sleeve members 5 and 6 are respectively fixed at positions facing the sleeve members 3 and 4, and the roller body side sleeve members 3 and 4 and the fixed shaft side sleeve members 5 and 6 are fixed to each other. Bearings 7 and 8 are interposed between them, and the fixed shaft side sleeve members 5 and 6 are formed relatively thickly.
A plurality of motor wire lead-out holes 9 are provided through the motor wire in the axial direction. 10 is an inner rotor type synchronous motor provided inside the roller body 2, and 11 is a rotation transmission mechanism inside the roller body 2 for transmitting the rotation of the motor 10 to the roller body 2.

The motor 10 includes a pair of left and right rotors 12A, 12B and stators 13A, 13B. The left and right rotors 12A, 12B are fitted with metal support tubes 14A, 14B which are loosely fitted and concentrically fitted around the fixed shaft 1, with both ends remaining on the support tubes 14A, 14B, respectively. rotor bodies 15A, 15B made of hollow cylindrical permanent magnets fixed with adhesive; and support tubes 14A, 1.
4B, and are joined to both end surfaces of the rotor bodies 15A and 15B, and are rotatably supported on the fixed shaft 1 by bearings 16, 17, 18, and 19. Synthetic resin end support tubes 20A ₁ , 20A ₂ , 20B ₁ ,
20B ₂ , and both rotors 12A, 12B have adjacent end bearing tubes 20A ₂
By abutting the end surfaces of 20B and 20B ₁ and connecting them with an adhesive or the like via a connecting ring 21 inserted inside this abutted portion, they are connected so as to be able to rotate together, and the right end of the rotor 12B is supported. The pipe 20B ₂ constitutes a so-called rotor output shaft portion, and a gear 22 for transmitting rotation to the rotational transmission mechanism 11 is formed at its tip.

On the other hand, the left and right stators 13A and 13B have four hollow drum-shaped stator bodies 23A ₁ to 23A ₄ , 23B ₁ to each left and right, which are loosely fitted in series to the rotors 12A and 12B, respectively.
23B ₄ and winding 2 wound around each stator body
4... and four stator bodies 23A ₁ ~
three elongated yoke bands 25a, 25a, 25a, 25b, which are applied to the outer peripheral surfaces of _23A4 , _23B1 to _23B4 and hold them together;
Left and right stator yoke 2 consisting of 25b, 25b
5A and 25B, the left end portions of the left and right stator yokes 25A are fixed to a metal support cylindrical member 26 appropriately fixed to the fixed shaft 1, and the right end portion of the right stator yoke 25B is Rotor 12
The stator yokes 25A and 25B are fixed to a support sleeve 28 which is rotatably supported on the stator yokes 25A and 25B via a bearing 27, and the opposing ends of both stator yokes 25A and 25B are integrally connected to each other by adhesive or the like via a connecting ring 29. They are fixed to support sleeves 30, 30, respectively, and these support sleeves 30, 30 are rotatably supported on rotors 12A, 12B via bearings 31. The above hollow drum type stator body 23A ₁ to 2
3A ₄ , 23B ₁ to 23B ₄ have the same structure, so one stator body 23 will be explained with reference to FIGS. 3 to 5. This stator body 23 is made of a suitable high magnetic permeability material. A cage-shaped stator member in which six strip-shaped magnetic pole pieces 33 similarly made of a high magnetic permeability material are made to integrally protrude in the axial direction at regular intervals in the circumferential direction from the inner peripheral edge of the ring-shaped collar piece 32. 34, and the pair of squirrel cage stator members 34, 34 are arranged such that each magnetic pole piece 33 of one stator member 34 has a constant gap in the circumferential direction between adjacent magnetic pole pieces 33, 33 of the other stator member 34. At the same time, the resin insulating layer 35 is integrally inserted over the gap and outer peripheral surface of the magnetic pole pieces 33 and also over the opposing inner surfaces of the two collar pieces 32, 32. Molded into a hollow drum shape, the magnetic pole pieces 33 are arranged in a cylindrical shape, and the resin insulating layer 35 is formed on the outer peripheral surface or in the gap between the magnetic pole pieces 33.
The body portion of the stator main body 23 is formed by the portions, and the flange portion is formed by each flange piece 32 and the resin insulating layer 35 portion formed on the inner surface thereof.
Note that this resin insulating layer 35 is
3 and the squirrel cage stator member 3.
It has the function of insulating between the cage-shaped stator members 34, 34 and the function of integrally connecting the cage-shaped stator members 34, 34, and must be formed so as to continuously cover at least the outer peripheral surface of the magnetic pole pieces 33... There is.
Flange piece 32 constituting the above-mentioned cage-shaped stator member 34
On the outer periphery of the , a pair of engaging protrusions 36, 36 protruding from three places in the circumferential direction at regular intervals are provided, and each pair of engaging protrusions 3
6, 36 are both squirrel cage stator members 34, 3
4 are coaxially inserted into each other so that the respective magnetic pole pieces 33 protrude at regular intervals in the circumferential direction, so that they overlap in the axial direction with the engaging protrusion pairs 36, 36 of each pair of the opposing stator member 34. It is arranged so that it can be done. In addition, the stator yoke 25
Each yoke band 25a, 2 constituting A, 25B
5b is made of a suitable high magnetic permeability material and has an arcuate cross section corresponding to the outer peripheral shape of the flange piece 32 of the stator body 23, as is clear from FIG. 2 and also FIG. 4 arranged in series
stator bodies 23A ₁ to 23A ₄ or 23B ₁ to
Each engagement protrusion pair 36 of each collar piece 32 in 23B ₄ ,
36 and one pair of engagement holes 37, 37, 38, 38, 39, 39, 40, 4, respectively.
0 and 41, 41 are bored, and in the pair of engagement holes 37, 37, a pair of engagement protrusions 36, 36 on the left side flange piece 32 of the stator main body _23B1 at the left end with respect to FIG. engaged, and the engagement hole pair 3
8, 38, a pair of engagement protrusions 36, 36 on the right side flange piece 32 of the stator body 23B ₁ and the left side flange piece 3 of the right-adjacent stator body 23B ₂ .
The pair of engagement protrusions 36, 36 on the stator body 23B2 are engaged together in a circumferentially overlapping state, and the pair of engagement holes 39 are provided with the engagement protrusions ₃₆ , 36 on the right side flange 32 of the stator body 23B2. The pair of mating protrusions 36, 36 and the pair of mating protrusions 36, 36 on the left side flange piece ₃₂ of the stator main body 23B3 on the right side are engaged together with a certain angle deviation in the circumferential direction, and then further engaged. The pair of holes 40, 40 are provided with a pair of engagement protrusions 36, 36 on the right side flange piece ₃₂ of the stator body 23B3.
and the pair of engagement protrusions 36, 36 on the left flange piece 32 of the right end stator body _23B4 are engaged together in a circumferentially overlapping state, and the right flange of the right end stator body _23B4 Piece 3
The pair of engagement protrusions 36, 36 on 2 are connected to the pair of engagement holes 41, 4.
1. Although only one yoke band 25a or 25b has been described above, each yoke band 25a, 25b has exactly the same structure, and a set of three yoke bands 25a, 25a, 25a and 25b, 25b, 2
5b is attached to each of the four stator bodies 23A ₁ to 23A ₄ and 23B ₁ to 23B ₄ in the engagement manner as described above and in the arrangement state shown in FIG. The stator bodies 23A ₁ to 23A ₄ and 23B ₁ to 23B ₄ are immovably connected to each other in the axial direction, circumferential direction, and radial direction.
Between A ₁ , 23A ₂ and 23A ₃ , 23A ₄ , and 23
This results in a phase angle shift between B ₁ , 23B ₂ and 23B ₃ , 23B ₄ . In this case, the stator bodies 23A ₁ , 23A ₂ and the stator bodies 23B ₁ , 23B ₂ are in the same phase, that is, the respective engagement protrusion pairs 36 , 36 overlap on the same straight line, and there is no space between them. Assume that there is no phase angle shift. In addition, as shown in FIG. 1, each yoke band 2 in the left stator yoke 25A
Both ends of 5a are fixed to the support cylindrical member 26 and the support sleeve 30 with screws 43 through screw holes 42 (see FIG. 7), and are fixed to the right stator yoke 25.
Both ends of each yoke band 25b at B are similarly fixed to the support sleeves 30 and 28 with screws 43 through screw holes 42.

Next, the stator 1 having the configuration as described above will be described.
3A and 13B, first, a metal plate of an appropriate thickness made of a high magnetic permeability material is punched, for example, to form a flange piece 32 having a shape as shown in FIG. As described above and further shown in FIG. 6, this collar piece 32 has three engagement protrusions 36, 36 arranged in pairs, which are arranged at regular intervals on the outer periphery and extend outward in the radial direction at equal pitches. Six magnetic pole piece attachment protrusions 32a are protruded from the inner peripheral edge at equal pitches and protrude radially inward. In addition, the mutual arrangement relationship of each engaging protrusion 36 and each engaging protrusion 36
The arrangement relationship between the magnetic pole piece mounting protrusion 32a and each magnetic pole piece mounting protrusion 32a is as follows.
As shown in the figure. On the other hand, a strip-shaped magnetic pole piece 33 as shown in FIG. 6, which is a metal plate made of a high magnetic permeability material and has a suitable thickness, has the required width and length, and has a predetermined arc-shaped cross section is formed. do. Six strip-shaped magnetic pole pieces 33 are attached to the inner peripheral edge of the collar piece 32.
... at right angles, and weld the base end of each strip-shaped magnetic pole piece 33 to one side of each magnetic pole piece attachment protrusion 32a by, for example, spot welding.
A squirrel cage stator member 34 as shown in the figure is formed. The cage-shaped stator member 3 thus formed
5, each magnetic pole piece 33 of one stator member 34 protrudes between adjacent magnetic pole pieces 33, 33 of the other stator member 34 with a constant gap in the circumferential direction. Then, while maintaining this state, predetermined molding molds are set on the pair of stator members 34, 34. That is, for this pair of stator members 34, 34, cavities (molding chambers) are provided between the inner circumferential surface side and the outer circumferential surface side of the magnetic pole pieces 33... and on the opposing inner surface sides of both collar pieces 32. A predetermined molding die (not shown) is provided to form a mold. Then, thermoplastic resin heated and melted by injection molding is injected into this mold, and as shown in FIG. A resin insulating layer 35 is formed over the inner surface of 32. In this case, glass fiber reinforced resin is used as the thermoplastic resin. In addition, in order to prevent each magnetic pole piece 33 from vibrating laterally due to the molding pressure during molding and causing deviation in circumferential gap dimension, a part of the mold is plunge-fitted between each magnetic pole piece 33. . Moreover, as is clear from FIG. 4, each magnetic pole piece 33
The tip portion (free end portion) of is formed diagonally so as to bite into the resin insulating layer 35 in a wedge shape so as to be reliably and firmly connected. By forming the resin insulating layer 35, the pair of stator members 34, 34 are joined together to form a hollow drum-shaped stator body 23 as shown in FIG. The winding 24 is wound around the stator body 23 formed in this way, and the winding 24 is wound around the stator body 23 formed in this way.
An insulating tape 44 is applied to the outer surface of 4. Then, a set of four stator bodies 23 is provided, and three yoke bands 25a... or 25
By attaching the stator yoke 25A or 25B consisting of b..., the stator 13A or 13B is completed.

Rotor main body 15 of the rotor 12A, 12B
A, 15B have N poles along the circumferential direction, respectively.
It is magnetized so that 12 magnetic poles such as S pole, N pole, etc. appear, and this rotor body 15
On the outer periphery of A, 15B, stators 13A, 13B
12 stator bodies 23 are inserted alternately in opposing directions and arranged at regular intervals in the circumferential direction.
The magnetic pole pieces 33 of the book are arranged facing each other while maintaining a constant air gap.

Further, stator bodies 23A ₁ to 23A ₄ and 23B ₁ to 23 of the stators 13A and 13B, respectively.
The mutual connection state of the windings 24 wound around _B4 is as shown in the circuit diagram of FIG. still,
In this circuit diagram, 24A ₁ is the stator main body 23
The winding wound on A ₁ , 24A ₂ is the stator body 23
A ₂ is a winding, and 24A ₃ to 24B ₄ are windings corresponding to stator bodies 23A ₃ to 23B ₄ , respectively. Moreover, these windings 24A ₁ to 24A ₄ ,
Leading lines 45a, 45b from 24B ₁ to 24B ₄ ,
45c is pulled out of the roller body 2 through the motor wire lead-out hole 9 of the fixed shaft side sleeve member 5 fixed to one end of the fixed shaft 1, as shown in FIG. 46, a capacitor C is interposed between the lead wires 45a and 45b, and a switch Sw is provided between these lead wires 45a, 45b and another electric wire 45d. The electric wire and the lead wire 45c exit the control box 46 and are connected to the power source. In this case, the lead lines 45a, 4 from the roller body 2 to the control box 46
A connector (not shown) may be interposed in the middle of 5b and 45c. In this case, as mentioned above, the stator bodies 23A ₁ , 23A ₂ and 23A ₃ , 2
3A ₄ and the stator body 23B ₁ , 23B ₂
Since the phase angle is slightly shifted between the windings _{24A 1} and _{24A 2 and} the windings 24A ₃ and 24A ₄ ,
Also, the windings 24B ₁ , 24B ₂ and the windings 24B ₃ , 24
A rotating magnetic field is generated by the phase difference between the currents flowing through _B4 , and sufficient starting torque and operating torque can be obtained. In addition, _{in this} embodiment _, as _is clear from FIG _.
4B ₂ , 24B ₃ , and 24B ₄ are each connected in parallel, but they are connected in parallel only at startup, and during operation, they are switched to series connection to reduce the current during operation. It is also possible to do so.

The rotation transmission mechanism 11 that transmits the rotation of the motor 10 to the roller body 2 includes an end support tube (rotor output shaft portion) 2 connected to one end of the rotor body 15B.
A plurality of planetary gears 47 that can mesh with the outer periphery of the gear 22 formed in _0B2 are arranged at regular intervals in the circumferential direction, and each planetary gear 47 is attached to a support frame fixed to the fixed shaft 1. 48, each planetary gear 47 is meshed with an internal gear 50 formed on the inner peripheral surface of a hollow cylindrical support 49, and one end of this cylindrical support 49 is connected to a sleeve member integral with the roller body 2. Therefore, the rotation of the rotors 12A and 12B is caused by the rotor output shaft 20B ₂ - gear 22 - planetary gear 47 - internal gear 50 - cylindrical support 49 - sleeve. The speed is decelerated and transmitted to the roller body 2 via the member 4.

As explained above, the present invention has a plurality of strip-shaped magnetic pole pieces made of a high magnetic permeability material with each free end cut diagonally inward on the inner peripheral edge of a collar piece made of a high magnetic permeability material in the circumferential direction. The base end of each magnetic pole piece is welded to the inner peripheral edge of the collar piece at regular intervals and at right angles to the collar piece, and a pair of cage-shaped stator members thus formed are attached to one side. The magnetic pole pieces of one stator member are coaxially fitted into each other so that each magnetic pole piece of the other stator member protrudes between the adjacent magnetic pole pieces of the other stator member with a constant gap in the circumferential direction. A mold is provided to form a cavity between the inner and outer peripheral surfaces of the magnetic pole piece, and then molten synthetic resin is injected into the mold to cover the outer peripheral surface of the magnetic pole piece. A resin insulating layer is integrally molded with the stator member,
After forming a hollow drum-shaped stator body and winding a winding around the stator body, an insulating tape is applied to the outer surface of the winding, and the stator yoke is further engaged with the engagement protrusion of the stator body. , each magnetic pole piece can be supported at both ends.
A stator with mechanically stable pole pieces can be provided. In particular, in the present invention, the flange piece and each magnetic pole piece constituting the squirrel-cage stator member are made separately without deep drawing, etc., and are integrally joined by welding, so that the length of the magnetic pole piece The pole piece can be made as long as desired without being restricted by the diameter of the flange piece, and the thickness of the pole piece can be made uniform over its entire length, and materials can also be used effectively. In addition, since the free end of each magnetic pole piece that forms the stator member is cut diagonally inward, each magnetic pole piece bites into the resin insulation layer in a wedge shape, ensuring a secure and strong connection. can do.

[Brief explanation of drawings]

The drawings show one embodiment of the present invention; FIG. 1 is a longitudinal sectional view of a motor roller, FIG. 2 is an enlarged sectional view taken along the line - - in FIG. FIG. 4 is an enlarged vertical sectional view of the stator body of FIG. 3, FIG. 5 is a perspective view showing a pair of squirrel cage stator members constituting the stator body, and FIG. The figure is an explanatory perspective view for explaining the manufacturing method of the cage-shaped stator member, FIG. 7 is an enlarged perspective view showing a yoke band constituting the stator yoke, and FIG. 8 is an electric circuit diagram. 10...Inner rotor type synchronous motor, 11...
...Rotation transmission mechanism, 12A, 12B...Rotor, 1
3A, 13B...Stator, 15A, 15B...
Rotor body, 23, 23A ₁ ~ 23A ₄ , 23B ₁ ~
23B ₄ ...Hollow drum type stator body, 24,
24A ₁ to 24A ₄ , 24B ₁ to 24B ₄ ...Winding, 2
5a, 25b...Yoke band, 25A, 25B
... Stator yoke, 32 ... Flange piece, 33 ... Strip-shaped magnetic pole piece, 34 ... Squirrel-cage stator member, 35 ...
...resin insulating layer, 36...engaging protrusion (engaging protrusion),
37-41...Engagement hole, 44...Insulating tape.

Claims (1)

[Claims] 1. A hollow drum-shaped stator body consisting of a cylindrical rotor made of a permanent magnet, a body formed to be able to be wound with windings, and flanges at both ends of the body, and a bridge between the flanges of the stator body. A method for manufacturing a stator in an inner rotor type synchronous motor in which a stator constituted by a stator yoke is fitted concentrically to the outside, and each free end is attached to the inner peripheral edge of a collar piece made of a high magnetic permeability material. Multiple strip-shaped magnetic pole pieces made of high magnetic permeability material are cut diagonally in the direction of
The base end of each magnetic pole piece is welded to the inner peripheral edge of the flange piece at regular intervals in the circumferential direction and at right angles to the flange piece, thereby forming a pair of cage-shaped stator members. , the magnetic pole pieces of one stator member are fitted coaxially with each other so that each magnetic pole piece of the other stator member protrudes between adjacent magnetic pole pieces of the other stator member with a certain gap in the circumferential direction, and A mold is provided to form a cavity between the inner circumferential surface side and the outer circumferential surface side of the magnetic pole pieces, and then a molten synthetic resin is injected into this mold, and the outer circumferential surface of the magnetic pole pieces is A hollow drum-shaped stator body is formed by integrally molding a resin insulating layer covering the stator member, and after winding the winding around the stator body, an insulating tape is coated on the outer surface of the winding. A method for manufacturing a stator in an inner rotor type synchronous motor, comprising the steps of: attaching the stator to the stator body; and further engaging a stator yoke to an engaging protrusion of a stator body.