JP2014079059A - Stator of motor and manufacturing method of the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To maintain high dimensional accuracy of a stator core and reduce the manufacturing costs.SOLUTION: A stator of a motor includes: a stator core which is formed by connecting multiple arc shaped split cores 201 in an annular manner; and an insulator 101 which covers at least an outer periphery of the stator core. Each split core 201 is formed by curving multiple teeth which continue in a linear manner. The insulator 101 has contact parts 104, each of which presses a connection part 208 of the respective split cores 201 in an inner peripheral direction.

Description

  The present invention relates to a stator for a motor and a method for manufacturing the same.

  Some motor stators are constructed by assembling divided cores in which the stator core is divided into a plurality of parts in order to increase the utilization rate of the steel sheet. In this case, when the dimensional accuracy of the assembled stator core is poor (particularly when the roundness of the stator inner diameter is poor), torque ripples such as cogging torque increase due to changes in magnetic flux density, and vibration and noise increase. Problems arise. Therefore, after assembling the split core, the core dimensional accuracy after assembly is corrected by uniformly applying stress to the outer periphery of the core in the inner diameter direction, and the core is fixed to obtain a stator core while maintaining the state. Technology is known. Specifically, the fixing of the core is performed by shrink fitting or resin molding of a housing expanded by heating (see, for example, Patent Document 1).

JP 2001-218429 A

  In the above conventional technique, in order to fix the core, it is necessary to shrink fit or resin mold the heated housing. However, such a fixing method has a problem that a dedicated facility is required and the operation is complicated, and the number of work steps is large, and thus the manufacturing cost is high.

  The present invention has been made in view of this point, and an object of the present invention is to make it possible to easily reduce the manufacturing cost while keeping the dimensional accuracy of the assembled stator core high.

The first invention is
A stator core formed by connecting a plurality of arc-shaped divided cores in an annular shape;
A stator of a motor having an insulator covering at least part or all of the outer periphery of the stator core,
Each of the split cores is formed by curving a plurality of linearly connected teeth in an arc shape,
The insulator has a contact portion that pushes the connecting portion of each divided core in the inner circumferential direction.

  This suppresses a relatively steep angle at the connecting part between the split cores or increases in curvature at other parts of the split core, so that the dimensional accuracy such as making the shape of the stator core close to a perfect circle can be improved. Can be easily raised.

The second invention is
A stator of a motor according to a first invention,
The insulator has a short portion and a long portion in the radial direction of the inner periphery,
The contact portion that pushes the connecting portion of the split core in the inner circumferential direction is a portion having a short length in the radial direction.

The third invention is
A stator of the motor of the second invention,
In the insulator, the portion having the short inner radial length and the long portion are provided by forming at least one of a convex portion and a concave portion on the inner peripheral surface of the insulator.

The fourth invention is:
The stator of any one of the first to third inventions,
In the insulator, a portion that does not oppose the connecting portion of each divided core has a gap between the divided core.

  Thus, by appropriately setting the shape of the insulator, it is possible to easily increase the dimensional accuracy of the stator core (make the inner diameter of the stator core close to a perfect circle) after the stator core is mounted on the insulator as described above.

The fifth invention is:
The stator of any one of the first to fourth inventions,
A truss structure is formed in at least a portion of the insulator covering the outer periphery of the stator core.

  Thereby, it is possible to easily increase the rigidity of the insulator and further increase the dimensional accuracy of the stator core.

The sixth invention is:
The stator of any one of the first to fifth inventions,
The contact portion of the insulator with the connecting portion of the split core is configured to correct the spring back force of the curved split core.

  Thereby, the influence of the springback force of the split core can be suppressed, and the dimensional accuracy of the stator core can be easily increased.

The seventh invention
A stator core formed by connecting a plurality of arc-shaped divided cores in an annular shape;
A stator of a motor having an insulator covering at least part or all of the inner periphery of the stator core,
Each of the split cores is formed by curving a plurality of straight teeth.
The insulator has a contact portion that pushes a portion between the connecting portions of the divided cores in the outer peripheral direction.

  Thereby, since the part between the connection parts of a split core is pushed to the outer peripheral direction from the inner peripheral side of a stator core, the roundness and dimensional accuracy of the stator core of a so-called outer rotor type motor can be easily increased. .

The eighth invention
A method for manufacturing a stator of a motor according to a first invention,
At least one of the stator core and the insulator is corrected and deformed, and the stator core is accommodated in the insulator.

  Thereby, interference with the connection part of a stator core and the contact part of an insulator can be avoided, and a stator core can be easily assembled | attached to an insulator.

The ninth invention
A method for manufacturing a stator of a motor according to an eighth aspect of the invention,
The stator core is corrected so as to move the connecting portion of the split core in the inner circumferential direction, and is accommodated in an insulator.

The tenth invention is
A method for manufacturing a stator of a motor according to a ninth aspect of the invention,
When the stator core moves in the direction of being accommodated in the insulator, a jig having an inclined surface that abuts on the connecting portion of the split core as it moves and presses the connecting portion in the inner circumferential direction,
The stator core is corrected by moving the connecting portion of the split core in the inner circumferential direction by the inclined surface of the jig, and is housed in an insulator.

The eleventh invention is
A method for manufacturing a stator of a motor according to a ninth aspect of the invention,
The stator core is corrected by pressing a part of the connecting portion of the split core in the thickness direction in the inner circumferential direction, and the stator core is accommodated in an insulator.

The twelfth invention
A method for manufacturing a stator of a motor according to an eighth aspect of the invention,
A portion of the insulator corresponding to the connecting portion of the split core is deformed so as to move to the outer peripheral side, and the stator core is accommodated in the insulator.

The thirteenth invention
A method for manufacturing a stator of a motor according to a twelfth aspect of the invention,
The positioning pin provided in the insulator is fitted into a hole formed in a jig, or the insulator is deformed by fitting the pin provided in the jig into a hole formed in the insulator. And

The fourteenth invention is
A method for manufacturing a stator of a motor according to a twelfth aspect of the invention,
A portion of the insulator corresponding to the connecting portion of the split core is moved to the outer peripheral side by pressing and moving a portion other than the portion corresponding to the connecting portion of the split core in the inner circumferential direction. It is characterized in that it is deformed.

  Accordingly, the stator core and the insulator can be corrected and deformed by using a relatively simple jig or the like, so that it is easy to avoid interference between the connecting portion of the stator core and the abutting portion of the insulator. Can be easily assembled.

  According to the present invention, the manufacturing cost can be easily reduced while keeping the dimensional accuracy of the stator core high.

FIG. 3 is a plan view showing the overall configuration of the stator according to the first embodiment. It is a top view which shows the shape of the division | segmentation core of the state pierce | punched from the steel plate. It is a top view which shows the shape of the division | segmentation core curved in circular arc shape. It is a bottom view which shows the structure of an insulator. It is a perspective view of the state where the insulator was turned down. It is an enlarged view of the A section of FIG. It is explanatory drawing which shows typically the relationship between a division | segmentation core and an insulator. It is explanatory drawing which shows typically the relationship between the split core of Embodiment 2, and an insulator. FIG. 10 is an explanatory diagram illustrating an example of an assembly process of a stator according to a third embodiment. It is a bottom view which shows the structure of the insulator of Embodiment 4. FIG. 10 is an explanatory diagram schematically illustrating an example of an assembly process of a stator according to a fourth embodiment. It is explanatory drawing which shows typically the relationship between the split core of Embodiment 5, and an insulator.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. In the following embodiments and modifications, components having functions similar to those of the other embodiments and modifications are denoted by the same reference numerals, and description thereof is omitted.

Embodiment 1 (stator)
As shown in FIG. 1, the stator according to the first embodiment includes an insulator having a cylindrical peripheral wall portion 102, a gap wall portion 103 that defines a gap around which a coil is wound, and a disk-like bottom wall portion 105. On 101, a stator core is provided in which three divided cores 201 each having a 1/3 arc shape are connected to each other by a connecting portion 208.

  More specifically, the split core 201 has a shape in which a plurality of (in this embodiment, 16) teeth portions 202 are connected by a yoke portion 203 as shown in FIG. Here, as shown in the figure, the shape in which the yoke portion 203 extends substantially linearly indicates the shape in which the split core 201 is punched from the steel plate. After a plurality of such punched steel plates are laminated, for example. The V-shaped cutout 205 formed in the yoke portion 203 is bent to be bent and formed into an arc shape as shown in FIG. At both ends of each divided core 201, a connecting convex portion 206 whose tip portion swells in a trapezoidal shape and a connecting concave portion 207 whose back portion expands in a trapezoidal shape are formed. A connecting portion 208 is formed by engaging with the concave portion 207 or the connecting convex portion 206.

  More specifically, as shown in FIGS. 4 and 5, the insulator 101 has a cylindrical peripheral wall portion 102 and a disc-shaped bottom wall portion 105, and faces the inner peripheral side from the bottom wall portion 105. The cavity wall portion 103 and the tooth receiving portion 106 are formed so as to protrude. On the bottom wall portion 105, the yoke portion 203 of the split core 201 is placed, and the tooth portion 202 of the split core 201 is accommodated in a space surrounded by the gap wall portion 103 and the tooth receiving portion 106. It is like that. That is, three sides of the teeth portion 202 are surrounded by the gap wall portion 103 and the teeth receiving portion 106, and when a winding (not shown) is wound, insulation between the teeth portion 202 and the winding is ensured. It has become. Further, the tip end portion of the teeth portion 202 is exposed on the inner peripheral side, and a strong magnetic field can be applied to a rotor (not shown).

  The material of the insulator 101 is not particularly limited. For example, polyamide (PA), polybutylene terephthalate (PBT), polyphenylene sulfide (PPS), or the like is used. Further, the thickness of the insulator 101 is not particularly limited, but is formed to be about 0.5 to 1 mm, for example.

  The peripheral wall portion 102 of the insulator 101 is not particularly limited, but is formed in a truss structure as shown in FIG. 1 in order to increase the rigidity while reducing the weight. Further, the insulator 101 is provided with a bolt hole 107 for attaching the stator to a casing or the like (not shown). In addition, when assembling the insulator 101 and the split core 201, for example, as shown in FIG. 5, the insulator 101 may be turned down so as to cover the split core 201 placed on a work table or the like. However, in the following description, for the sake of convenience, the description will be made assuming that the split core 201 is fitted in a state where the insulator 101 is placed on a work table or the like in the opposite direction to FIG.

  As shown in an enlarged view in FIG. 6, the insulator 101 has contact portions 104 (convex portions) formed at three locations on the inner peripheral side of the peripheral wall portion 102, and the connection portion 208 of the split core 201 or the vicinity thereof. By bringing this into contact with the contact portion 104, the roundness of the split core 201 can be easily increased. That is, when the split core 201 as shown in FIG. 2 is bent at the position of the notch 205 to be bent into an arc shape as shown in FIG. 3, the split core 201 has a large curvature due to the spring back of the bent portion or the like. It tends to be. For this reason, for example, as shown exaggeratedly drawn with a two-dot chain line in FIG. 7, the connecting portion 208 between the split cores 201 has a relatively steep angle (the radius of curvature is small), while in other parts of the split core 201, The curvature increases, and the shape becomes closer to a polygon whose apex is the portion of the connecting portion 208 than the perfect circle. Therefore, when the contact portion 104 is provided on the inner peripheral side of the peripheral wall portion 102 in the insulator 101 and the connecting portion 208 of the split core 201 is pressed in the inner peripheral direction, the outer shape of the split core 201 is drawn by a solid line in FIG. As described above, the radius of curvature of the portion of the connecting portion 208 is increased, while the radius of curvature of the other portion is decreased and becomes close to a perfect circle.

  Therefore, the roundness of the split core 201 can be easily increased by appropriately setting the height of the contact portion 104. Here, the height of the contact portion 104 may be set to 0.15 mm, for example, according to the required roundness, the spring back force of the split core 201, and the like. That is, the position of the tip of the contact portion 104 is not limited to a position overlapping the perfect circle of the target diameter, but may be located outside the perfect circle position or located inside depending on other conditions. As a result, for example, the average diameter of the outer diameter and inner diameter of the split core 201 can be set to the target diameter with high accuracy, or the deviation of the outer diameter and inner diameter can be minimized.

<< Embodiment 2 >> (stator)
Instead of providing the convex contact portion 104 on the inner peripheral side of the peripheral wall portion 102 as described above, for example, as shown in FIG. 8, the contact portion 112 has a relatively smooth shape, while the connecting portion A recess 111 (relief) may be provided at a position away from 208. In other words, if a portion having a different distance from the center is provided on the inner periphery of the peripheral wall portion 102 and the portion of the connecting portion 208 of the split core 201 is pressed toward the inner periphery side, the other portion can escape to the outer periphery side. Good.

<< Embodiment 3 >> (Assembly method)
When the contact portions 104 and 112 as in the first and second embodiments are provided, if the split core 201 is simply pushed into the insulator 101 during assembly, the connecting portion 208 of the split core 201 is connected to the contact portion 104 of the insulator 101. -It may be difficult to push in smoothly due to interference with 112. In such a case, it can be assembled relatively easily by using, for example, a jig 301 as shown in FIG. That is, the jig 301 is formed with an inclined surface 302 in the vicinity of the abutting portion 104 of the insulator 101 that becomes the inner peripheral side of the insulator 101 as the position of the inner peripheral surface is lower. Therefore, if the outer periphery of the split core 201 is moved in contact with the inner peripheral surface of the jig 301, the connecting portion 208 is deformed so as to move to the inner peripheral side with the downward movement. It can be easily pushed into the insulator 101 without interfering with the portion 104.

  Instead of using the jig 301 as described above, a part of the thickness of the split core 201, for example, the vicinity of the connecting portion 208 in the portion close to the upper surface is grasped with a jig from the outer peripheral direction and pressed to press the split core 201. In a deformed state, after the portion near the lower surface of the split core 201 is bitten into the insulator 101, the jig may be released and the split core 201 may be completely pushed into the insulator 101.

<< Embodiment 4 >> (Stator and assembly method)
The insulator may be provided with a positioning pin 121 as shown in FIG. 10, for example, in order to accurately position the motor when the motor is used. In such a case, the split core 201 can be easily assembled by deforming the insulator 101 using the positioning pins 121.

  Specifically, for example, as shown in FIG. 11, a jig having a jig hole 311 formed at a position slightly outside the position of the positioning pin 121 when no external force acts on the insulator 101 is used. The positioning pin 121 of the insulator 101 is inserted into the above. As a result, the insulator 101 is deformed so as to be drawn by a solid line in FIG. 11, and the split core 201 can be assembled to the insulator 101 when the contact portion 104 is outside the position of the connecting portion 208 of the split core 201 drawn by the solid line. Easy to do.

  Thereafter, when the positioning pin 121 is removed from the jig hole 311 of the jig, the contact portion 104 presses the connecting portion 208 of the divided core 201 in the inner circumferential direction as depicted by a two-dot chain line in FIG. 201 has a shape close to a perfect circle as depicted by a two-dot chain line in FIG.

  Even if the insulator 101 is not provided with the positioning pin 121 as described above, if the insulator 101 has a bolt hole 107 or another pin hole, a pin placed on a jig is inserted into the hole. Thus, the insulator 101 can be similarly deformed and the split core 201 can be easily assembled.

  Note that the holes and pins of the jig are not limited to being provided at fixed positions, and after being fitted with the pins and holes of the insulator, they may be moved to a predetermined position to deform the insulator.

  Further, instead of moving the portion corresponding to the connecting portion 208 of the split core 201 in the insulator 101 to the outer side as described above, or together with this, the portion between the connecting portions 208 is pressed in the inner circumferential direction. Accordingly, the insulator 101 may be similarly deformed.

<< Embodiment 5 >> (stator)
In the above example, a stator of a so-called inner rotor type motor in which a rotor is provided inside the stator has been described. However, the present invention is not limited to this, and the same technique can be applied to an outer rotor type motor. That is, in the stator of the outer rotor type motor, the teeth are provided toward the outer peripheral side. Therefore, as shown in FIG. 12, a contact portion 402 is provided at a portion between the connecting portions 508 of the split core 501 on the outer peripheral side of the insulator 401 located on the inner peripheral side of the split core 501, and on the outer side. Push out. As a result, the portion of the connecting portion 508 in the split core 501 changes in the inner circumferential direction. Therefore, the shape of the split core 501 close to a polygon as shown by a two-dot chain line in FIG. 12 can be made close to a perfect circle like the split core 501 shown by a solid line.

《Other matters》
In the above example, the divided core 201 is divided into three. However, the divided core 201 is not limited to three, and may be divided into four or six. If the contact portion 104 is formed, the same effect can be obtained. Further, the number of teeth is not particularly limited, and may be 24 sheets, for example.

  In addition, it is preferable that the positions of the contact portions 104 and 112 normally coincide with the position of the connecting portion 208, but the same effect can be obtained if the vicinity of the connecting portion 208 is pressed even if it does not necessarily match exactly. I can.

  Further, the shape of the connecting portion 208 in the split core 201 is not limited to the connecting convex portion 206 and the connecting concave portion 207 as described above, and various engaging shapes may be applied.

  Further, the shape and depth of the notch 205 are also exemplary, and it is only necessary to be able to make an arc shape by bending the divided core 201. If the influence of the spring back occurs at that time, the influence is reduced as described above. be able to.

  As described above, the present invention is useful for motor stators and the like.

DESCRIPTION OF SYMBOLS 101 Insulator 102 Perimeter wall part 103 Cavity wall part 104 Contact part 105 Bottom wall part 106 Teeth receiving part 107 Bolt hole 111 Concave part 112 Contact part 121 Positioning pin 201 Divided core 202 Teeth part 203 Yoke part 205 Notch 206 Connecting convex part 207 Connection concave portion 208 Connection portion 301 Jig 302 Inclined surface 311 Jig hole 401 Insulator 402 Abutting portion 501 Split core 508 Connection portion

Claims (14)

A stator core formed by connecting a plurality of arc-shaped divided cores in an annular shape;
A stator of a motor having an insulator covering at least part or all of the outer periphery of the stator core,
Each of the split cores is formed by curving a plurality of linearly connected teeth in an arc shape,
The said insulator has a contact part which presses the connection part of each division | segmentation core to an inner peripheral direction. The stator of the motor characterized by the above-mentioned. The stator of the motor according to claim 1,
The insulator has a short portion and a long portion in the radial direction of the inner periphery,
The stator of the motor, wherein the contact portion that pushes the connecting portion of the split core in the inner circumferential direction is a portion having a short length in the radial direction. A stator for a motor according to claim 2,
A portion of the insulator having a short inner circumferential radial length and a long portion are provided by forming at least one of a convex portion and a concave portion on the inner peripheral surface of the insulator. Stator. A motor stator according to any one of claims 1 to 3,
A stator of a motor, wherein a gap is formed between a portion of the insulator that is not opposed to a connecting portion of each divided core and the divided core. A motor stator according to any one of claims 1 to 4,
A stator for a motor, wherein a truss structure is formed on at least a portion of the insulator covering the outer periphery of the stator core. A motor stator according to any one of claims 1 to 5,
The stator of the motor, wherein a contact portion of the insulator with the connecting portion of the split core is configured to correct a springback force of the curved split core. A stator core formed by connecting a plurality of arc-shaped divided cores in an annular shape;
A stator of a motor having an insulator covering at least part or all of the inner periphery of the stator core,
Each of the split cores is formed by curving a plurality of straight teeth.
The said insulator has the contact part which presses the part between the connection parts of each division | segmentation core to an outer peripheral direction. The stator of the motor characterized by the above-mentioned. A method for manufacturing a stator of a motor according to claim 1,
A method for manufacturing a stator of a motor, wherein at least one of the stator core and the insulator is deformed and the stator core is accommodated in the insulator. A method for manufacturing a stator of a motor according to claim 8,
A stator manufacturing method for a motor, wherein the stator core is deformed and accommodated in an insulator so that the connecting portion of the split core is moved in an inner circumferential direction. A method of manufacturing a stator for a motor according to claim 9,
When the stator core moves in the direction of being accommodated in the insulator, a jig having an inclined surface that abuts on the connecting portion of the split core as it moves and presses the connecting portion in the inner circumferential direction,
A stator manufacturing method for a motor, wherein the stator core is deformed and accommodated in an insulator by moving the connecting portion of the split core in an inner circumferential direction by the inclined surface of the jig. A method of manufacturing a stator for a motor according to claim 9,
A method for manufacturing a stator of a motor, wherein the stator core is deformed and accommodated in an insulator by pressing a part of the connecting portion of the split core in the thickness direction in an inner circumferential direction. A method for manufacturing a stator of a motor according to claim 8,
A method for manufacturing a stator of a motor, wherein a portion of the insulator corresponding to the connecting portion of the split core is deformed so as to move to the outer peripheral side, and the stator core is accommodated in the insulator. A method of manufacturing a stator of a motor according to claim 12,
The positioning pin provided in the insulator is fitted into a hole formed in a jig, or the insulator is deformed by fitting the pin provided in the jig into a hole formed in the insulator. A method for manufacturing a stator of a motor. A method of manufacturing a stator of a motor according to claim 12,
A portion of the insulator corresponding to the connecting portion of the split core is moved to the outer peripheral side by pressing and moving a portion other than the portion corresponding to the connecting portion of the split core in the inner circumferential direction. A method of manufacturing a stator for a motor, characterized by comprising:

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