JPH1084660A - Method of manufacturing stator for electric motor - Google Patents

Abstract

(57) Abstract: A coil can be quickly and easily wound over a plurality of divided stator cores, and an efficient winding operation can be performed. A plurality of air-core coils having a space therein are formed, and the air-core coils are linearly overlapped with a predetermined gap therebetween. Next, the air core coils 18 can be wound across a predetermined number of stator cores 14 simply by inserting the divided stator cores 14 into the respective gaps 34.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a motor stator having a plurality of divided stator cores.

[0002]

2. Description of the Related Art Conventionally, a stator of an electric motor has a plurality of radially-directed projections formed on an inner peripheral surface of a substantially cylindrical body, and a conductor is wound around grooves of the projections. For this reason, there was a problem that the operation of winding the conductor was extremely complicated.

Therefore, as disclosed in Japanese Patent Application Laid-Open No. 7-163070, a plurality of divided stator cores are prepared, and a conductor wire is wound around each stator core. Methods for manufacturing a stator are known.

[0004]

By the way, the stator employs a lap winding coil system in which a conductor is wound over a plurality of stator cores in addition to a concentrated winding coil system in which a conductor is wound for each stator core as described above. I have. However, it is difficult to use the above-mentioned conventional technology in this type of lap winding coil system.

[0005] For this reason, generally, an operation of integrally forming an open stator and applying a lap winding coil thereto is performed. However, it has been pointed out that in the press punching process for integrally forming the open stator, the yield of the material is low, and it is extremely uneconomical. In addition, there is a problem that the operation of winding the conductor is complicated and the productivity is low.

SUMMARY OF THE INVENTION The present invention solves this kind of problem, and enables a coil to be wound quickly and easily over a plurality of divided stator cores, so that an efficient and economical winding operation can be performed. An object of the present invention is to provide a method for manufacturing a stator for an electric motor.

[0007]

SUMMARY OF THE INVENTION In order to solve the above-mentioned problems, the present invention is directed to a plurality of frame-shaped air-core coils having a space therein, which are linearly overlapped with a predetermined gap therebetween. Therefore, each air-core coil can be wound across the plurality of stator cores simply by inserting the plurality of divided stator cores into the respective gaps.

Further, the air-core coils have a trapezoidal shape, and adjacent air-core coils are mutually overlapped with their short sides and long sides alternately arranged. Therefore, the short side of the other air-core coil is inserted into the wide space of one air-core coil, and the space factor of the winding coil in the slot is improved.

Furthermore, the mutually overlapping sides of the frame-shaped air-core coil overlapped on a straight line are connected by a connecting member. Accordingly, the air-core coils do not come off, and the gaps between the air-core coils can be reliably and appropriately maintained, so that the work of inserting a plurality of stator cores is efficiently performed.

[0010]

FIG. 1 is a schematic plan view of a stator 10 manufactured by a method for manufacturing a motor stator according to an embodiment of the present invention. The stator 10 has a cylindrical housing 12, a plurality of stator cores 14 disposed in an annular shape in the cylindrical housing 12, and a space 16 inside which is wound around a predetermined number of the stator cores 14. Multiple frame-shaped air-core coils 1
8 is provided.

The stator core 14 is formed by laminating a predetermined number of plates made of an iron-based material having the same shape and elasticity, or is integrally formed by casting with an iron-based material.
The stator core 14 is formed in a substantially T shape having a head portion 20 and a leg portion 22. The head portion 20 is provided with a concave portion 24 formed of an arc-shaped space at one end in a circumferential direction,
An arc-shaped convex portion 26 is provided at the other end in the circumferential direction.

Next, the stator 10 constructed as described above will be described.
A manufacturing method according to the present embodiment for manufacturing a semiconductor device will be described.

First, as shown in FIG. 2A, a predetermined number of frame-shaped air-core coils 18 having a space 16 therein are formed by winding the conductive wire 28 in a coil shape. Each air core coil 18 has a trapezoidal shape having a short side 30 and a long side 32.

Therefore, as shown in FIGS. 3A and 3B, a plurality of air-core coils 18 are linearly arranged in a state of being overlapped with a predetermined gap 34 therebetween. Here, the adjacent air-core coils 18 are arranged such that the short sides 30 and the long sides 32 are alternately arranged and overlap each other.

More specifically, as shown in FIG. 4, the first air-core coil 18a to the n-th air-core coil 18n are superposed, and the long side 32a of the first air-core coil 18a is 5
And the short side 30e of the air-core coil 18e overlaps with each other. Next, the long side 32a and the short side 30e are joined by a linear body (joining member) 36 such as a thread.

Furthermore, the short side 3 of the second air-core coil 18b
0b and the sixth air core coil 18 superimposed on the short side 30b
The long side 32f of f is connected with the linear body 36,
The long side 32c of the third air core coil 18c and the short side 30g of the seventh air core coil 18g are connected by the linear body 36. Hereinafter, similarly, the joining operation by the linear body 36 is performed up to the n-th air core coil 18n.

Next, as shown in FIG. 5, the leg portions 22 of the stator core 14 are sequentially inserted into the respective gaps 34 of the plurality of air-core coils 18 which are linearly overlapped and arranged. Recess 24 provided in head 20
The protrusion 26 provided on the head 20 of the other stator core 14 is fitted to the second protrusion. Each stator core 14 is inserted into the gap 34 of the air-core coil 18 and the heads 20 are fitted to each other, so that the stator core 14 is arranged in an arc as shown in FIG.

In this case, in this embodiment, the air-core coil 1
8 overlap the short side 30 and the long side 32 with each other.
6. Thereby, the air-core coil 18
Are not separated, and the gaps 34 between the air core coils 18 can be reliably and appropriately maintained, so that the work of inserting the plurality of stator cores 14 into the gaps 34 is efficiently performed. The effect is obtained.

Further, each air core coil 18 is connected to the linear body 3
6 are firmly connected. For this reason, when the stator core 14 is arranged in an arc shape, each air core coil 18
Are formed in an arc shape integrally with the stator core 14 without detachment.

As shown in FIG. 7, after the air core coils 18 arranged before and after the straight line are overlapped with each other and all the air core coils 18 are arranged in an annular shape, the remaining three stator cores 14 are formed. Are inserted into the gaps 34 of the air-core coil 18. At this time, as shown in FIG. 8, by inclining the head 20 of the last stator core 14, the head 20 of the other stator core 14 adjacent on both sides can be smoothly fitted. After all the stator cores 14 are inserted into the air core coil 18 to form the annular stator 10a, the annular stator 10a is disposed in the cylindrical housing 12 to obtain the stator 10 (FIG. 1).

As described above, in the present embodiment, first, a plurality of air-core coils 18 having the space portions 16 therein are formed, and each air-core coil 18 is linearly formed with a predetermined gap 34 therebetween. Polymerized. Therefore, the air core coils 18 can be wound over a predetermined number of stator cores 14 simply by inserting the plurality of split stator cores 14 into the gaps 34.

As a result, in the present embodiment, it is possible to effectively prevent a decrease in the yield of the material as in the conventional integral molding of the open stator, thereby obtaining an effect of being extremely economical and improving the productivity at once. There is an advantage of doing so.

The air-core coil 18 has a trapezoidal shape, and each adjacent air-core coil 18 has a short side 30
And the long sides 32 are alternately arranged and overlap each other.
Therefore, the short side 30 of the other air-core coil 18 is inserted into the wide space 16 of the one air-core coil 18, and the space factor of the winding coil in the cylindrical housing 12 is effectively improved. I do.

[0024]

As described above, in the method for manufacturing a motor stator according to the present invention, a plurality of frame-shaped air-core coils having a space therein are linearly overlapped with a predetermined gap therebetween. Therefore, each air-core coil can be wound across the plurality of stator cores simply by inserting the plurality of divided stator cores into the respective gaps. Thereby, the lap winding coil system in which the conductor is wound over the plurality of stator cores is easily and quickly performed, and the productivity is effectively improved.

[Brief description of the drawings]

FIG. 1 is a schematic plan view of a stator to which a manufacturing method according to an embodiment of the present invention is applied.

FIG. 2 is a schematic perspective view of an air-core coil constituting the stator.

FIG. 3 is an explanatory view of a state in which a plurality of the air-core coils are superposed on a straight line, FIG. 3A is a plan view of the superposed plurality of air-core coils, and FIG. It is a side view of a plurality of air core coils.

FIG. 4 is a partially enlarged explanatory view of FIG. 3A.

FIG. 5 is a partial explanatory view of a state where an operation of inserting the stator core into the air-core coil has been started;

FIG. 6 is an explanatory view showing a state where a plurality of theta cores inserted into the air-core coil are arranged in a substantially arc shape;

FIG. 7 is an explanatory view of a state where all of the air-core coils are arranged in an annular shape.

FIG. 8 is an explanatory diagram when the last stator core is inserted into the air-core coil.

[Explanation of symbols]

10, 10a ... Stator 12 ... Cylindrical housing 14 ... Stator core 16 ... Space 18 ... Air-core coil 20 ... Head 22 ... Leg 24 ... Concave 26 ... Convex 30 ... Short side 32 ... Long side 34 ... Gap 36 ... Linear body

Claims (3)

[Claims] A step of forming a frame-shaped air-core coil having a space therein; and a step of superposing a plurality of said frame-shaped air-core coils on a straight line with a predetermined gap therebetween. Inserting the plurality of stator cores thus formed into the gap and connecting the stator cores to each other to form an annular stator. 2. The manufacturing method according to claim 1, wherein the frame-shaped air-core coil has a trapezoidal shape, and the adjacent frame-shaped air-core coils have respective short sides and long sides. A method for manufacturing a stator for an electric motor, wherein the stator is alternately arranged and superposed on a straight line. 3. The method for manufacturing a stator for an electric motor according to claim 1, wherein mutually overlapping sides of the frame-shaped air-core coil superposed on the straight line are joined by a joining member. .