JPH10136621A - Manufacturing method of split stator - Google Patents

Abstract

(57) [Summary] [Problem] To securely connect pole pieces by simple work while positioning pole pieces with high accuracy. SOLUTION: In manufacturing an iron core of a split type stator, a plurality of pole pieces each having a fitting portion formed on both sides near an inner magnetic pole portion are laminated and fixed to each other to form a plurality of pole piece laminates. By arranging in an annular shape and holding its outer periphery with a jig, and pressing a non-magnetic, high-rigidity connecting member in the stacking direction between the fitting portions of the plurality of adjacent pole piece laminates, a plurality of adjacent The iron pieces are manufactured by connecting the pole piece laminates to be positioned and connected to each other.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a split stator for a rotating electric machine, and more particularly to a method of positioning a pole piece with high precision and enabling strong connection by a simple operation.

[0002]

2. Description of the Related Art In a rotary electric machine, in order to simplify the winding of a coil of a stator, a plurality of pole piece laminates are arranged in an annular shape, and the inner magnetic poles thereof are connected with a synthetic resin material or the like to form an iron core. There has been proposed a split stator in which a coil is wound between slots of the iron core, and then the iron core is fitted into a cylindrical outer ring yoke (for example, actual open flat 2-44848).
JP-A-4-58746, etc.).

On the other hand, the present applicant has arranged a plurality of pole piece-shaped portions in an annular shape so as to accurately position the pole pieces with respect to each other and to assure the durability and reliability of the stator. An iron core element is integrally formed with a bridging portion projecting inward from the inner peripheral end or projecting outward from the outer peripheral end between adjacent ends of the inner peripheral end or outer peripheral end of the shape portion. By laminating a plurality of iron core elements and fixing them together, inserting them into a mold and connecting them with a synthetic resin material, then cutting the inward or outward projecting bridge A method for manufacturing an iron core was developed, and the application was filed (see Japanese Patent Application No. 4-117035).

[0004]

However, in the above-mentioned conventional manufacturing method, a plurality of iron core elements are stacked and charged in a molding die, and the magnetic pole portions of the pole piece-shaped portions are connected by a synthetic resin material. Therefore, a complicated work process of inserting the iron core material and injecting the synthetic resin material is required, and since the connection is made by covering the magnetic pole portions with the synthetic resin material, the pole piece shape portion is formed. However, there is a problem that the connection strength between the magnetic pole portions is low, and furthermore, the connection work of the magnetic pole portions and the cutting work of the bridge portion need to be performed in separate steps, so that the work is very complicated.

SUMMARY OF THE INVENTION In view of the above problems, it is an object of the present invention to provide a method of manufacturing a split stator in which a pole piece can be positioned with high precision and can be firmly connected by a simple operation.

[0006]

SUMMARY OF THE INVENTION Accordingly, a method of manufacturing a split type stator according to the present invention comprises arranging a plurality of pole pieces in a ring and interconnecting the inner magnetic pole portions of a plurality of adjacent pole pieces. In order to manufacture a split stator by winding the iron core into its outer peripheral slot and inserting it into the inner cylindrical outer ring yoke, fitting parts are formed on both sides near the inner magnetic pole part. The formed plurality of pole pieces are laminated and fixed to each other, the plurality of pole piece laminates are arranged in an annular shape, and the outer periphery thereof is held by a jig. By press-fitting a non-magnetic and high-rigidity connecting member in the laminating direction, a plurality of adjacent pole piece laminates are connected to each other while being positioned with respect to each other to produce an iron core.

[0007] The connecting member has only to be rigid and not deformed by press-fitting between the fitting portions. Specifically, the connecting member can be made of a hard synthetic resin material or a metal material. The connecting member and the fitting portion may be shaped to fit each other, for example, a projection may be formed on the connecting member, and the fitting portion may be concave.
A concave portion may be formed in the connecting member, and the fitting portion may have a projection shape. The jig may have a circular shape on the inner surface, and a concave portion into which the outer end of the pole piece is fitted may be formed to increase the positioning accuracy.

One of the features of the present invention is to hold the outer periphery of an annular pole piece laminate with a jig, and press-fit a rigid connecting member in the laminating direction between fitting portions near the pole piece inner magnetic pole portion. The point is that they are connected. As a result, the pole piece laminates are accurately positioned with respect to each other and firmly connected. However, it is very troublesome to stack the pole pieces that are separated and accurately arrange them in a ring. Therefore, if the pole pieces are connected to each other in a ring shape in advance, accurate lamination and arrangement in a ring shape are easy, but in this case, the connection shape of the pole pieces is changed in order to perform the original function of the stator. It will be necessary to cut it. In the case of the present invention, since the rigid connection member is press-fitted, the pole pieces can be separated from each other by using the press-in force to break the connection shape. However, since the pole pieces are connected to each other in advance, the pole pieces cannot be separated from each other at the same position. Therefore, it is necessary to move the pole pieces radially outward by a predetermined distance by press-fitting the connecting members to separate the pole pieces from each other.

That is, in the method of manufacturing a split stator according to the present invention, a plurality of pole pieces are arranged in a ring, and the inner magnetic pole portions of a plurality of adjacent pole pieces are interconnected to form an iron core. When manufacturing the split stator by winding the iron core into its outer peripheral slot and inserting it into the inner cylindrical outer ring yoke, a plurality of fitting parts are formed on both sides near the inner magnetic pole part. An iron core element having a bridging portion that can be broken apart in the circumferential direction between the inside of each of the plurality of adjacent pole piece-shaped parts is formed by arranging the pole piece-shaped parts in an annular shape. The iron core element shapes are laminated and fixed to each other, and the outer periphery of the iron core element material laminate is held by a jig such that each pole piece-shaped portion can advance radially outward by a predetermined distance. , Non-magnetic between the mating parts of each・ By press-fitting a high-rigidity connecting member in the laminating direction, each pole piece-shaped portion is moved outward in the radial direction while being spaced apart from each other in the circumferential direction, thereby breaking the bridge portion and adjoining each other. An iron core is manufactured by connecting the pole piece-shaped portions while positioning them to each other.

In order to break the bridging portion by press-fitting the connecting member, the relationship between the length of the connecting member and the distance between adjacent fitting portions before press-fitting is set to be larger in the former than in the latter. is important. It is important that the jig is configured such that the outer end of the pole piece-shaped portion can be advanced outward by a predetermined distance in the radial direction. For example, the inner diameter of the jig is set slightly larger than the outer diameter of the iron core element, or the inner diameter of the jig is equal to or slightly smaller than the outer diameter of the iron core element,
A fitting recess may be formed in the inner peripheral edge so that the outer end of the pole piece-shaped portion can advance by a predetermined distance.

Although all the pole piece-shaped portions are connected to each other by a bridging portion to form an iron core element, if all the pole piece-shaped portions are connected in advance, the stacked poles must be connected unless the pressing force of the connecting member is increased. There is a possibility that the bridging part of the piece-shaped part cannot be broken. Therefore, when the laminated pole pieces are sandwiched by the iron core element members, the lamination and the arrangement in the annular shape are easy, and the bridging portion can be reliably broken without increasing the pressing force of the connecting member so much. .

That is, in the method for manufacturing a split stator according to the present invention, a plurality of pole pieces are arranged in an annular shape and the inner magnetic pole portions of a plurality of adjacent pole pieces are interconnected to form an iron core. When manufacturing the split stator by winding the iron core into its outer peripheral slot and inserting it into the inner cylindrical outer ring yoke, a plurality of fitting parts are formed on both sides near the inner magnetic pole part. The pole piece-shaped parts are arranged in an annular shape, and an iron core element having a bridging part that can be broken apart in the circumferential direction between the insides of a plurality of adjacent pole piece-shaped parts is integrally formed, and the inside thereof is formed. A plurality of pole pieces having fitting portions on both sides near the magnetic pole portion are stacked, and the plurality of pole piece laminates are arranged in a ring shape and sandwiched by at least two pole piece shaped portions of the iron core element material. Fixed to each other, said at least two iron cores The outer periphery of the profile and the plurality of pole piece laminates is held by a jig such that the respective pole piece shape portions and the pole piece laminates can advance radially outward by a predetermined distance, and a plurality of adjacent pole pieces are held. By pressing a non-magnetic, high-rigidity connecting member between the fitting portions of the shape part and the pole piece laminate in the laminating direction, each pole piece shape part and the pole piece laminate are moved forward in the radial direction while That the bridging portion is broken by separating them in the circumferential direction, and that a plurality of adjacent pole piece shapes and pole piece laminates are connected to each other while being positioned with each other to produce an iron core. Features.

[0013] At least two iron core element members are required for sandwiching the pole piece laminate, and three or more iron core members may be arbitrarily inserted between the pole piece laminates. In order to surely break the bridge portion, it is preferable that the bridge portion has a shape having a thin portion between the insides of the adjacent pole piece-shaped portions. The thin portion preferably has a shape in which the width or thickness is minimized or reduced at the center of the bridging portion, both side portions, or an arbitrary portion. For example, when the bridging portion is made into a half-punched state at the time of punching and manufacturing an iron core element, both end portions of the bridging portion can be made thin. This half punching may be performed at the time of caulking. In addition, a bridge portion can be formed by punching an adjacent magnetic pole portion into a shape having a portion having a minimum or small width or thickness at the time of punching and manufacturing an iron core element.

The split stator generally comprises an iron core and an outer ring yoke into which the iron core is inserted. Therefore, the outer ring yoke can be used as a jig for holding the outer circumference of the iron core element laminate or the pole piece laminate.

That is, a fitting recess is formed in the inner peripheral edge so that the laminated pole piece-shaped portion, or the laminated pole piece-shaped portion and the outer end of the pole piece laminated body can be fitted forwardly by a predetermined distance. The yoke material is integrally formed,
A plurality of yoke base members are laminated and fixed to each other to form an outer ring yoke. The outer ring yoke is used instead of the jig, and the production of the iron core and the insertion of the iron core into the cylindrical yoke are simultaneously performed. Can be done. However, in this case, it is necessary to wind the stator winding around the slot before press-fitting the connecting member.

[0016]

According to the present invention, the annular outer periphery of a plurality of pole piece laminates, a laminate of iron core element shapes or a laminate of pole pieces and iron core element shapes is held by a jig, Since the non-magnetic and highly rigid connecting member is press-fitted between the adjacent fitting portions, the pole piece or the pole piece-shaped portion is accurately positioned at a predetermined position when the connecting member is press-fitted.

Moreover, since a plurality of adjacent pole piece laminates and / or pole piece shaped portions are connected to each other by fitting of a highly rigid connecting member, a high connection strength can be obtained as a whole as an integral structure. As a result, it is possible to manufacture a structurally stable and highly reliable stator.

Further, when the iron core element members are laminated or the pole piece laminate is sandwiched between the iron core element members, the pole pieces can be laminated very easily and with high precision. Moreover, since the bridging portion of the iron core element is broken by using the press-fitting of the connecting member, the connecting and breaking can be performed at the same time, and the manufacturing is performed as compared with the conventional manufacturing method that required two steps. The process can be simplified.

[0019]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to specific examples shown in the drawings. 1 to 9 show a preferred embodiment of a method for manufacturing a split stator according to the present invention. In FIG. 9, the rotating electric machine 10 includes an outer frame 20 in which an annular stator 30 and a rotor 40 are provided. The outer frame 20 is formed by fixing an end frame 22 to the front and rear of a cylindrical housing 21 with screws, and a rotor 40 is inserted into the stator 30.
Is rotatably supported on the end frame 22 by the bearing 11.

As shown in FIG. 7, the stator 30 is constructed by fitting an iron core 32 into an outer ring yoke 31, and a stator winding 310 is wound around each slot 39 of the iron core 32. Have been. The iron core 32 has a plurality of pole pieces 33.
Are laminated and fixed to each other by caulking or welding, and the plurality of pole piece laminates 34 are arranged in a ring shape. Each of the plurality of pole pieces 33 has a vertically long shape in the shape of a circular arc at the tip, and a magnetic pole portion 35 is formed at the rear end thereof so as to protrude to both sides. A fitting concave portion (fitting portion) 37 is formed, and has a substantially earth shape as a whole.

The plurality of pole piece laminates 34 arranged in a ring are connected between fitting recesses 37 of the adjacent pole piece laminates 34 by a connection fitting (connection member) 38 made of a non-magnetic metal material, for example, brass. Are press-fitted and connected to each other. The connection fitting 38 has a substantially I-shape, and has a length equal to the lamination thickness of the pole piece laminate 34.

On the other hand, fitting recesses 311 are formed on the inner peripheral edge of the outer ring yoke 31 so as to correspond to the respective pole piece laminates 34 of the iron core 32. The outer end portion is fitted, and the inward displacement of each pole piece laminate 34 is prevented in conjunction with the coupling action between adjacent pole piece laminates 34 due to the fitting of the connection fitting 38.

Next, the manufacturing method will be described. When manufacturing the rotating electric machine 1, a plurality of iron core base members 50 and pole pieces 33 are punched out of the electromagnetic steel strip (see step S1). As shown in FIG. 2, the iron core element 50 has the same shape as the pole piece 33, that is, a vertically long shape with a circular arc at the tip, and a magnetic pole part 51 protrudes to both sides at the rear end thereof. A plurality of pole piece-shaped portions 54 having a substantially earth shape as a whole are annularly arranged with a projecting portion 52 projecting upward and a fitting concave portion (fitting portion) 53 therebetween, and a plurality of adjacent pieces are provided. The magnetic pole portions 51 of the pole piece-shaped portion 54 are connected by a thin bridging portion 55 having a reduced width at the center.

When the iron core element 50 and the pole piece 33 are manufactured in this manner, as shown in FIG. 8A, a plurality of pole pieces 3 are interposed therebetween with the iron core element 50 interposed therebetween.
3 and the pole piece laminate 34 is sandwiched on both sides by an iron core material 50 and fixed to each other by caulking or welding in this state. Then, as shown in FIG. A stator winding 310 is applied to a slot between the pole piece-shaped portion 54 and the pole piece laminate 34 of the shaped material 50, and the winding is fixed with a varnish (see step S2).

On the other hand, for the outer ring yoke 31, a plurality of yoke base members 60 are punched out of the electromagnetic steel strip (step S3).
reference). As shown in FIG. 5, the yoke base material 60 has, at predetermined intervals, fitting recesses 61 on the inner peripheral edge thereof at which the outer ends of the pole piece laminates 34 of the iron core 32 can be fitted forward by a predetermined distance. Is formed in a ring. A plurality of yoke base members 60 are stacked while being aligned with each other, and are fixed to each other by caulking, thereby manufacturing the outer ring yoke 31 as shown in FIG. 6 (step S3).

When the material of the iron core 32 and the outer ring yoke 31 are manufactured as described above, the iron core 32 is placed in the outer ring yoke 31.
Is inserted, and the connecting metal fitting 38 is press-fitted in the laminating direction between the fitting recesses 311 and 53 of the adjacent pole piece laminate 34 and the iron core element 50, respectively. The pole piece-shaped portion 54 of the raw material 50 widens the gap between the inner end of the outer ring yoke 31 and the inner end of the fitting recess 311 while advancing radially outward, thereby widening the gap of the iron core raw material 50. The portion 55 is broken and the pole piece-shaped portion 54 becomes a part of the pole piece laminate 34,
The adjacent pole piece laminates 34 are connected to each other to produce the iron core 32, and the iron core 32 is fitted and fixed to the outer ring yoke 31 to manufacture the split type stator 30 (see steps S4 and S5). ).

Thereafter, as in the conventional case, the outer shell housing 2 is formed.
In addition, the annular stator 30 is inserted into the cylindrical housing 21 forming the cylindrical housing 21, and the rotor 40 is inserted into the stator 30.
Is inserted, the rotating shaft 41 of the rotor 40 is rotatably held on the frame 10 by the bearing 11, and the wiring 42 of the coil is pulled out from the drawing hole of the front frame 10.
1 can be manufactured.

[Brief description of the drawings]

FIG. 1 is a process chart showing a preferred embodiment of a method for manufacturing a split stator according to the present invention.

FIG. 2 is a view showing an iron core element in the production method.

FIG. 3 is a perspective view showing a pole piece laminate in the manufacturing method.

FIG. 4 is a perspective view showing an assembled state of the iron core element and the pole piece laminate.

FIG. 5 is a view showing a yoke base material in the manufacturing method.

FIG. 6 is a perspective view showing an outer ring yoke in the manufacturing method.

FIG. 7 is a front configuration diagram showing a split stator manufactured by the above method.

FIG. 8 is a view showing a state in which the iron core is being manufactured.

FIG. 9 is a cross-sectional view showing a rotating electric machine manufactured by the above method.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 10 Rotating electric machine 20 Outer shell housing 21 Cylindrical housing 22 End frame 30 Stator 31 Outer ring yoke 32 Iron core 34 Pole piece laminated body 35 Magnetic pole part 37 Fitting concave part 38 Connection fitting (connection member) 39 Slot 310 Stator winding 311 Fitting recess 40 Rotor 50 Iron core element 51 Material of pole piece 53 Fitting recess (fitting part) 55 Bridge 60 Yoke element 61 Material fitting recess

Claims (6)

[Claims] A plurality of pole pieces are arranged in an annular shape, and inner pole portions of a plurality of adjacent pole pieces are interconnected to form an iron core, and the iron core is wound around its outer peripheral slot to form an inner surface. In manufacturing a split stator by inserting it into a cylindrical outer ring yoke, a plurality of pole pieces having fitting portions formed on both sides near the inner magnetic pole portion are stacked and fixed to each other, and a plurality of pole pieces are fixed to each other. The laminate is arranged in an annular shape, and its outer periphery is held by a jig. A plurality of non-magnetic, high-rigidity connection members are press-fitted in the laminating direction between the fitting portions of the plurality of adjacent pole piece laminates. Wherein the adjacent pole piece laminates are positioned and connected to each other to produce an iron core. 2. A plurality of pole pieces are arranged in an annular shape, and inner pole portions of a plurality of adjacent pole pieces are interconnected to form an iron core, and the iron core is wound around its outer peripheral slot to form an inner surface. In manufacturing a split stator by inserting it into a cylindrical outer ring yoke, a plurality of pole piece-shaped portions formed with fitting portions on both sides near the inner magnetic pole portion are arranged in a ring shape and a plurality of An iron core element having a bridging portion that can be broken apart in the circumferential direction between the insides of adjacent pole piece parts is integrally formed, and a plurality of iron core elements are laminated and fixed to each other. Holding the outer periphery of the iron core element laminate by a jig such that each of the pole piece-shaped portions can advance radially outward by a predetermined distance, and fitting the plurality of adjacent pole piece-shaped portions together Press a non-magnetic, high-rigidity connecting member between the parts in the stacking direction. By advancing each pole piece shape part radially outward, the inside is separated in the circumferential direction to break the bridge part, and connect adjacent pole piece shape parts while positioning each other. A method of manufacturing a split stator, wherein an iron core is manufactured. 3. A plurality of pole pieces are arranged in an annular shape, and inner pole portions of a plurality of adjacent pole pieces are interconnected to form an iron core, and the iron core is wound around its outer peripheral slot to form an inner surface. In manufacturing a split stator by inserting it into a cylindrical outer ring yoke, a plurality of pole piece-shaped portions formed with fitting portions on both sides near the inner magnetic pole portion are arranged in a ring shape and a plurality of An iron core element having a bridging part that can be broken apart in the circumferential direction between the insides of adjacent pole piece parts is integrally formed, and a plurality of fitting parts are provided on both sides near the inner magnetic pole part. Pole pieces are laminated, a plurality of pole piece laminates are arranged in a ring, and are fixed to each other by being sandwiched and fixed to at least two pole piece-shaped portions of the iron core element material. The outer circumference of the profile and multiple pole piece laminates Each jig is held by a jig such that each of the pole piece shape portions and the pole piece laminate can advance radially outward by a predetermined distance, and a plurality of adjacent pole piece shape portions and the fitting portion of the pole piece laminate are By press-fitting a non-magnetic, high-rigidity connecting member in the laminating direction into the laminating direction, each pole piece-shaped portion and the pole piece laminated body are moved outward in the radial direction while being spaced apart from each other in the circumferential direction to form a bridge portion. A plurality of adjacent pole piece-shaped portions and a plurality of pole piece laminates are connected to each other while being positioned with respect to each other to manufacture an iron core. 4. The method according to claim 2, wherein the bridging portion has a thin portion between the insides of the adjacent pole piece-shaped portions. 5. A fitting recess is formed on an inner peripheral edge of the stacked pole piece portion, or the stacked pole piece portion and the outer end of the pole piece stacked body can be fitted forwardly by a predetermined distance. A yoke element is integrally formed, a plurality of yoke elements are laminated and fixed to each other to form an outer ring yoke. The outer ring yoke is used in place of the jig, and the iron core is manufactured and the iron core is formed. 4. The method according to claim 2, wherein insertion into the cylindrical yoke is performed simultaneously. 6. The method according to claim 1, wherein a connecting member made of a non-magnetic metal material is used as the connecting member.