AU2016284404B2

AU2016284404B2 - Rotating electrical machine stator, rotating electrical machine, rotating electrical machine stator production method

Info

Publication number: AU2016284404B2
Application number: AU2016284404A
Authority: AU
Inventors: Satoshi Hakoda
Original assignee: Mitsubishi Electric Corp
Current assignee: Mitsubishi Electric Corp
Priority date: 2015-06-24
Filing date: 2016-06-22
Publication date: 2019-04-18
Anticipated expiration: 2036-06-22
Also published as: TW201711344A; GB2553242A; AU2016284404A1; JPWO2016208629A1; TWI599142B; JP6334823B2; WO2016208629A1; GB201716302D0

Abstract

A rotating electrical machine is provided with: a divided laminated yoke section (31a); and two laminated teeth sections (31b, 31c) on both ends of the divided laminated yoke section (31a). In the two laminated teeth sections (31b, 31c) and the divided yoke section (31a), the longitudinal direction of each laminated teeth sections (31b, 31c) and the longitudinal direction of the divided laminated yoke section (31a) are the same direction, and from a state in which each of the laminated teeth sections (31b, 31c) are lined up straight on both ends of the divided laminated yoke section (31a) in the longitudinal direction, the two laminated teeth sections (31b, 31c) are bendably or rotatably coupled to the divided laminated yoke section (31a) so as to be in a state facing the inner side of the stator (3).

Description

[0001] The present invention relates to a stator for a rotating electrical machine, a rotating electrical machine, and a method for producing the stator for the rotating electrical machine.

BACKGROUND ART [0002] Conventionally, the stator of a brushless motor having a permanent magnet-type rotor includes a circular yoke and a plurality of pole arms that project radially inward from the yoke (see, for example, Patent Document 1).

Regarding the stator proposed in Patent Document 1, the outer peripheral shape of a cross-section perpendicular to an axial direction is changed from a circle to a rectangle, and the stator has a configuration in which two cores each of which includes a linear yoke and two pole arms extending from both end portions of the yoke in a direction perpendicular to the yoke and in each of which the outer peripheral shape of a cross-section perpendicular to an axial direction is a C shape, are arranged such that the pole arms thereof oppose each other.

[0003] By changing the outer peripheral shape of the

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2016284404 28 Feb 2019 stator from a circle to a rectangle, the filling factor of the stator (the proportion of the stator components relative to the outer shape of the stator) can be increased, resulting in a small-size and high-efficiency rotating electrical machine. In addition, regarding a stator having a circular outer peripheral shape, the operating range of a winding machine is limited in order to avoid interference between each of the pole arms adjacent to each other and the winding machine during winding of a coil. Meanwhile, regarding each pole arm in an outer peripheral shape that is a C shape, the operating range of the winding machine is not limited at a side at which the pole arms are not adjacent to each other. Accordingly, it becomes easier to wind a coil in a regularly aligned manner with respect to the pole arms, so that the density of the coil is increased.

CITATION LIST

PATENT DOCUMENT [0004] Patent Document 1: Japanese Utility Model

Registration No. 3193357, paragraphs 0002 to 0005 [0005] Regarding the stator of the rotating electrical machine disclosed in Patent Document 1, during winding of a coil, the operating range of a winding machine is not limited at the side at which the respective pole arms are not

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2016284404 28 Feb 2019 adjacent to each other. However, in slot spaces at the side at which the respective pole arms are adjacent to each other, a gap into which a nozzle of the winding machine is to be inserted is required between two tooth portions, and a space having a size corresponding to the width of the nozzle finally remains between a coil and a coil, so that there is a problem that the coil space factor cannot be improved.

SUMMARY OF THE INVENTION [0007] A stator for a rotating electrical machine according to a first broad aspect of the present invention includes :

a stacked core formed by stacking thin plate bandlike core pieces; and a coil wound on the stacked core, wherein:

the stacked core includes a yoke portion located at a center in a longitudinal direction of the core pieces, and a tooth portion rotatably connected to each of both ends in a longitudinal direction of the yoke portion, and the coil is formed by being wound on each tooth portion, the two tooth portions have joining portions, fixing members are provided so as to be fitted at both end portions thereof to the respective joining

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2016284404 28 Feb 2019 portions provided at the tooth portions of one of the two stacked cores adjacent to each other in a circumferential direction and the tooth portions of the other of the two stacked cores, and the tooth portions adjacent to each other in the circumferential direction are arranged with an interval maintained therebetween via the fixing member.

In an embodiment, the two tooth portions are respectively connected to the yoke portion via bendable thin portions.

In another embodiment, each of the two tooth portions is rotatably connected to the yoke portion by fitting recesses and projections provided on stacked surfaces of the core pieces.

[0008] A rotating electrical machine according to a second broad aspect of the present invention includes a rotor and the stator according to the first aspect, wherein the yoke portion is arranged such that the longitudinal direction of the yoke portion is directed along 20 a circumferential direction about a rotation shaft of the rotor, and each of the tooth portions is arranged so as to extend toward the rotor side such that a longitudinal direction of the tooth portion is perpendicular to the longitudinal direction of the yoke portion.

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2016284404 28 Feb 2019 [0009] A method for producing a stator for a rotating electrical machine according to a third broad aspect of the present invention includes:

a stacked core formed by stacking thin plate band5 like core pieces, and a coil wound on the stacked core, wherein:

the stacked core in which the core pieces are stacked includes a yoke portion located at a center in a longitudinal direction of the stacked core pieces, and a 10 tooth portion rotatably connected to each of both ends in the longitudinal direction of the yoke portion, and the method comprises:

a core piece production step of cutting out, from an electromagnetic steel plate, the core pieces each including a portion forming the yoke portion and portions forming the two tooth portions, in a state where the portion forming the yoke portion is interposed between the portions forming the tooth portions at both sides and is arranged such that longitudinal directions of the portion 20 forming the yoke portion and the portions forming the two tooth portions coincide with each other;

a stacking step of stacking the cut-out core pieces;

a first winding step of performing winding on one tooth portion of the two tooth portions;

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2016284404 28 Feb 2019 a second winding step of performing winding on the other tooth portion located at a side opposite to the one tooth portion across the yoke portion, of the two tooth portions;

a bending step of respectively bending the one tooth portion and the other tooth portion on which the coil has been wound, at a right angle in the same direction about connection portions of the yoke portion at both ends in the longitudinal direction; and a coupling step of fixing the tooth portions of one of the two stacked cores adjacent to each other in a circumferential direction and the tooth portions of the other of the two stacked cores to each other in the circumferential direction with an interval maintained therebetween in the circumferential direction.

[0010] A method for producing a rotating electrical machine according to a fourth broad aspect of the present invention includes :

a rotor, and a stator including a stacked core arranged along a circumferential direction about a rotation shaft of the rotor and formed by stacking thin plate band-like core pieces, and a coil wound on the stacked core, wherein:

the stacked core in which the core pieces are stacked includes a yoke portion located at a center in a

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2016284404 28 Feb 2019 longitudinal direction of the stacked core pieces, and a tooth portion rotatably connected to each of both ends in the longitudinal direction of the yoke portion, and the method comprises:

a core piece production step of cutting out, from an electromagnetic steel plate, the core pieces each including a portion forming the yoke portion and portions forming the two tooth portions, in a state where the portion forming the yoke portion is interposed between the portions forming the tooth portions at both sides and is arranged such that longitudinal directions of the portion forming the yoke portion and the portions forming the two tooth portions coincide with each other;

a stacking step of stacking the cut-out core pieces;

a first winding step of winding the coil on one tooth portion of the two tooth portions;

a second winding step of winding the coil on the other tooth portion located at a side opposite to the one tooth portion across the yoke portion, of the two tooth portions;

a bending step of respectively bending the one tooth portion and the other tooth portion on which the coil has been wound, at a right angle in the same direction about connection portions of the yoke portion at both ends in

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2016284404 28 Feb 2019 the longitudinal direction;

a step of arranging the stacked core on which the coil has been wound, along the circumferential direction about the rotation shaft such that a magnetic attraction portion provided at an end of each of the tooth portions opposes the rotor; and a coupling step of fixing the tooth portions of one of the two stacked cores adjacent to each other in a circumferential direction and the tooth portions 10 of the other of the two stacked cores to each other in the circumferential direction with an interval maintained therebetween in the circumferential direction.

In an embodiment, in the coupling step, both end portions of fixing members are fitted to joining portions 15 provided at the respective tooth portions of the two stacked cores adjacent to each other in the circumferential directions .

BRIEF DESCRIPTION OF THE DRAWINGS [0011] In order that the invention may be more clearly ascertained, embodiments will now be described, by way of example, with reference to the accompanying drawing, in which :

FIG. 1 is a cross-sectional schematic diagram showing the configuration of a rotating electrical machine

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2016284404 28 Feb 2019 according to Embodiment 1 of the present invention.

FIG. 2 is a flowchart showing a method for producing a stator of the rotating electrical machine according to Embodiment 1 of the present invention.

FIG. 3 is a blanking arrangement diagram of core pieces according to Embodiment 1 of the present invention.

FIG. 4 is a schematic diagram of a divided stacked core intermediate and a winding machine carrying out a first winding step according to Embodiment 1 of the present invention.

FIG. 5 is a cross-sectional view taken along the line X-X' in FIG. 4.

FIG. 6 is a schematic diagram of the divided stacked core intermediate and the winding machine carrying 15 out a second winding step according to Embodiment 1 of the present invention.

FIG. 7 is a cross-sectional view of a divided stacked core, having a coil wound thereon, according to Embodiment 1 of the present invention.

FIG. 8 is a blanking arrangement diagram of core pieces of a comparative example.

FIG. 9 is a schematic diagram of a divided stacked core intermediate and a winding machine carrying out a winding step according to Embodiment 2 of the present invention.

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2016284404 28 Feb 2019

FIG. 10 is a flowchart showing a coil winding step for a rotating electrical machine according to Embodiment 2 of the present invention.

FIG. 11 is a cross-sectional schematic diagram showing the configuration of a rotating electrical machine according to Embodiment 3 of the present invention.

FIG. 12 is a flowchart showing a coil winding step for the rotating electrical machine according to Embodiment 3 of the present invention.

FIG. 13 is a cross-sectional schematic diagram showing the configuration of a divided stacked core, having a coil wound thereon, of a rotating electrical machine according to Embodiment 4 of the present invention.

FIG. 14 is a cross-sectional schematic diagram showing the configuration of a rotating electrical machine according to Embodiment 5 of the present invention.

DESCRIPTION OF EMBODIMENTS [0012] Embodiment 1

Hereinafter, Embodiment 1 of the present invention will be described with reference to the drawings.

In the present specification, unless otherwise specified, the terms axial direction, circumferential direction, radial direction, inner peripheral side, outer peripheral side, inner peripheral surface, outer

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2016284404 28 Feb 2019 peripheral surface, inner side, and outer side refer to the axial direction, the circumferential direction, the radial direction, the inner peripheral side, the outer peripheral side, the inner peripheral surface, the outer peripheral surface, the inner side, and the outer side of a stator, respectively. In addition, when an up-down relationship such as upper and lower is mentioned, the side away from the center of the stator is defined as an upper side, and the side close to the center of the stator 10 is defined as a lower side.

[0013] FIG. 1 is a cross-sectional schematic diagram showing the configuration of a rotating electrical machine 100 according to Embodiment 1 of the present invention.

The rotating electrical machine 100 includes a rotor 2 and a stator 3. The rotor 2 includes a rotation shaft 21 and a permanent magnet 22 disposed on the outer circumference of the rotation shaft 21.

[0014] The stator 3 includes divided stacked cores 31 and each having a substantially U shape. The divided stacked core 31 includes a divided stacked yoke portion 31a and two stacked tooth portions 31b and 31c that bend at a right angle and project in the same direction from both ends of the divided stacked yoke portion 31a in the longitudinal direction thereof. Similarly, the divided stacked core 32 includes a divided stacked yoke portion 32a and two stacked

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2016284404 28 Feb 2019 tooth portions 32b and 32c that bend at a right angle and project in the same direction from both ends of the divided stacked yoke portion 32a. The divided stacked core 31 and the divided stacked core 32 have the same configuration, but will be described with different reference characters in the present specification, for the convenience of the following description .

[0015] A slot SI in which a coil 41b wound on the stacked tooth portion 31b and a coil 41c wound on the stacked tooth portion 31c are housed is formed between the stacked tooth portion 31b and the stacked tooth portion 31c. Similarly, a slot S2 in which a coil 42b wound on the stacked tooth portion 32b and a coil 42c wound on the stacked tooth portion 32c are housed is formed between the stacked tooth portion

32b and the stacked tooth portion 32c. The coils 41b, 41c,

42b, and 42c are wound on the stacked tooth portions 31b, 31c, 32b, and 32c with insulators 5 interposed therebetween. [0016] The divided stacked core 31 and the divided stacked core 32 are arranged, with the rotor 2 interposed therebetween, such that the stacked tooth portion 31b and the stacked tooth portion 32b are linearly aligned and oppose each other and the stacked tooth portion 31c and the stacked tooth portion 32c are linearly aligned and oppose each other. Magnetic attraction portions 31bz, 31cz, 32bz, and 32cz which are free end portions at the rotor 2 side of the stacked

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2016284404 28 Feb 2019 tooth portions 31b, 31c, 32b, and 32c extend along the outer peripheral surface of the rotor 2 and oppose the outer peripheral surface of the rotor 2.

[0017] The outer peripheral surfaces of the magnetic attraction portions 31bz, 31cz, 32bz, and 32cz have dovetail groove-like recesses 31bzr, 31czr, 32bzr, and 32czr (resin member joining portions) extending in the axial direction. Both end portions of a fixing member 7b (resin member) made of a resin are fitted to the recess 31bzr and the recess

32bzr in the axial direction to fix the stacked tooth portion 31b and the stacked tooth portion 32b to each other.

Similarly, both end portions of a fixing member 7c made of a resin are fitted to the recess 31czr and the recess 32czr in the axial direction to fix the stacked tooth portion 31c and the stacked tooth portion 32c, which are adjacent to each other in the circumferential direction, to each other. It is noted that projections may be formed instead of the recesses 31bzr, 31czr, 32bzr, and 32czr, and recesses may be provided at the fixing member side.

[0018] Next, a method for producing the stator 3 of the rotating electrical machine 100 will be described with reference to the drawings.

FIG. 2 is a flowchart showing the method for producing the stator 3 of the rotating electrical machine

100.

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2016284404 28 Feb 2019

FIG. 3 is a diagram showing an arrangement when a plurality of core pieces 6 are cut out from a single continuous electromagnetic steel plate P.

FIG. 4 is a schematic diagram of a divided stacked core intermediate 30 and a winding machine 8 carrying out a first winding step.

FIG. 5 is a cross-sectional view taken along the line X-X' in FIG. 4.

[0019] First, a step of producing the divided stacked core 10 intermediate 30 from which the divided stacked cores 31 and are to be formed.

The core pieces 6 shown in FIG. 3 are plate-like members forming respective layers of the divided stacked cores 31 and 32 . At the time at which the core pieces 6 are 15 cut out from the electromagnetic steel plate P, the core pieces 6 are a single band-like member.

[0020] A required number of the core pieces 6 are cut out from the electromagnetic steel plate P in the arrangement shown in FIG. 3 (a core piece production step: S001) . Each 20 core piece 6 includes a divided yoke portion 6a at a center in the longitudinal direction thereof, and includes tooth portions 6b and 6c connected to both ends of the divided yoke portion 6a in the longitudinal direction by thin portions 6s. V-shaped cuts 6v are provided between the divided yoke portion 6a and the tooth portions 6b and 6c of the core piece

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2016284404 28 Feb 2019

6, and portions at which the divided yoke portion 6a and the tooth portions 6b and 6c are connected to each other are the thin portions 6s.

[0021] All the longitudinal directions of the divided yoke portion 6a and the two tooth portions 6b and 6c of each core piece 6 coincide with a feed direction in which the electromagnetic steel plate P is fed (the longitudinal directions = a rolling direction D in which the electromagnetic steel plate P is rolled).

[0022] Two core pieces 6 are arranged in parallel in a direction perpendicular to the rolling direction D of the electromagnetic steel plate P in the present embodiment. However, the number of core pieces 6 arranged in parallel may be greater than 2 as long as the longitudinal direction of each core piece 6 and the rolling direction D of the electromagnetic steel plate P coincide with each other.

[0023] Next, the cut-out band-like core pieces 6 are stacked in the axial direction, and recesses and projections provided at the upper and lower sides of stacked surfaces that are not shown are swaged to join the respective core pieces 6 together, thereby producing a divided stacked core intermediate 30 (a stacking step: S002). A portion in which the divided yoke portions 6a of the core pieces 6 are stacked becomes a divided stacked yoke portion 30a of the divided stacked core intermediate 30 shown in FIG. 4, and the divided

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2016284404 28 Feb 2019 stacked yoke portion 30a becomes the divided stacked yoke portion 31a or 32a of the divided stacked core 31 or 32 shown in FIG. 1. Similarly, portions in which the tooth portions 6b and 6c of the core pieces 6 are stacked become stacked tooth portions 30b and 30c of the divided stacked core intermediate 30, and the stacked tooth portions 30b and 30c become the stacked tooth portions 31b and 31c or 32b and 32c of the divided stacked core 31 or 32.

[0024] Next, an insulator molding step (S003) is carried out. In the insulator molding step, the insulators 5 which electrically insulate a coil 40 (the coils 41b, 41c, 42b, and 42c) and the divided stacked core intermediate 30 (the divided stacked cores 31 and 32) from each other are integrally molded on the outer peripheries of the stacked tooth portions 30b and 30c.

[0025] Next, the configuration of the winding machine 8 which winds the coil 40 on the divided stacked core intermediate 30 will be described.

The winding machine 8 shown in FIG. 4 includes: a rotary positioning mechanism 80 for fixing the divided stacked core intermediate 30; and a flyer 88 from which a wire 41 that is to be the coil 40 is fed. The rotary positioning mechanism 80 includes a disk-shaped base portion 81, a dogleg-shaped block 82, and a top plate 83 and two screws 84 for fixing the divided stacked yoke portion 30a

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2016284404 28 Feb 2019 such that the divided stacked yoke portion 30a is interposed between the base portion 81 and the top plate 83.

[0026] The base portion 81 of the rotary positioning mechanism 80 is rotatable about a rotation axis A in the direction of an arrow Al in FIG. 4. The dogleg-shaped block is used for positioning the divided stacked yoke portion

30a of the divided stacked core intermediate 30 at a predetermined position on a board surface of the base portion

81. Knock pins 85 are used for guiding a jumper wire connecting two coils 40 in continuously winding the coils 40 on the two stacked tooth portions 30b and 30c. Two knock pins 85 are provided to the base portion 81. The knock pins 85 are provided at the outer peripheral side of stacked thin connection portions 3s by which the divided stacked yoke portion 30a and the stacked tooth portions 30b and 30c of the divided stacked core intermediate 30 are bendably connected to each other. A rotation shaft B of the flyer 88 is located so as to be orthogonal to the rotation axis A of the rotary positioning mechanism 80, and the flyer 88 is movable forward and backward in an axial direction c of the rotation shaft B.

[0027]

Next, a coil winding step will be described.

The coil winding step includes a positioning/fixing

step	(S100) ,
step	(S102) ,
25 step	(S104) .

a second winding step (S103), and a removing

First, the screws 84 are inserted through two

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2016284404 28 Feb 2019 screw holes of the top plate 83 and through screw holes of the dogleg-shaped block 82 to fix the divided stacked yoke portion 30a to the base portion 81 with the divided stacked yoke portion 30a interposed between the base portion 81 and the top plate 83 in the axial direction (stacking direction) (the positioning/fixing step: S100).

[0028] At this time, the divided stacked core intermediate is positioned on the base portion 81 such that a corner portion, at the inner peripheral side, of the divided stacked yoke portion 30a is located so as to be in contact with a corner portion of a side surface, at the rotation axis A side, of the dogleg-shaped block 82. In addition, at this time, the divided stacked core intermediate 30 is arranged such that the free end portion side of the one stacked tooth portion 30b on which the coil 40 is to be wound earlier opposes the rotation shaft B of the flyer 88, and the other stacked tooth portion 30c faces at the opposite side. That is, the longitudinal direction of the divided stacked core intermediate 30 coincides with the axial direction of the rotation shaft B of the flyer 88.

[0029] Next, the first winding step (S101) is carried out on the stacked tooth portion 30b.

The coil 40 is wound by rotating the flyer 88 of the winding machine 8 around the stacked tooth portion 30b while moving the flyer 88 in the axial direction c of the

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2016284404 28 Feb 2019 rotation shaft B. At this time, a rotation plane Q on which an end of the flyer 88 rotates and the stacked tooth portion 30c at the opposite side, do not interfere with each other. [0030] FIG. 6 is a schematic diagram of the divided stacked core intermediate 30 and the winding machine 8 carrying out the second winding step. After the winding of the coil 40 on the stacked tooth portion 30b ends, the rotary positioning mechanism 80 is rotated 180 degrees in the direction of the arrow Al in FIG. 4 without cutting a winding end portion of the coil 40 where the winding ends (the core rotating step: S102). Accordingly, a jumper wire 42 shown in

FIG. 6 is extended along the outer side of the two knock pins which are provided to the base portion 81 of the rotary positioning mechanism 80.

[0031] Subsequently, the second winding step (S103) is carried out on the stacked tooth portion 30c.

The coil 40 is wound by rotating the flyer 88 of the winding machine 8 around the stacked tooth portion 30c while moving the flyer 88 in the right-left direction of the sheet surface of FIG. 6. The direction in which the flyer 88 is rotated is set to be the same as the direction of the above winding on the stacked tooth portion 30b. Similarly to the first winding step, the rotation plane Q on which the end of the flyer 88 rotates and the stacked tooth portion 30c at the opposite side, do not interfere with each other.

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2016284404 28 Feb 2019 [0032] After the coil 40 is wound on the two stacked tooth portions 30b and 30c of the divided stacked core intermediate 30 as described above, the divided stacked core intermediate 30 is removed from the rotary positioning mechanism 80 (the removing step: S104) .

[0033] FIG. 7 is a cross-sectional view of the divided stacked core 31 having the coil wound thereon.

Next, the stacked tooth portion 30b and the stacked tooth portion 30c of the divided stacked core intermediate 30 10 on which the winding has been performed and which has been removed from the rotary positioning mechanism 80 are bent at the stacked thin connection portions 3s in directions in which the cuts 6v of the core pieces 6 are closed, such that a substantially U shape is formed (a bending step: S004), thereby obtaining the divided stacked core 31. Then, the same step is repeated, thereby obtaining the divided stacked core 32 having the coil wound thereon.

[0034] Next, the divided stacked core 31 and the divided stacked core 32 are arranged such that the stacked tooth portion sides thereof oppose each other, and the fixing member 7b is fitted and fixed to the recess 31bzr and the recess 32bzr. An adhesive may be used for firmly fixing the fixing member 7b. Similarly, the fixing member 7c is fitted and fixed to the recess 31czr and the recess 32czr at the opposite side. In this manner, the stator 3 is obtained in

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2016284404 28 Feb 2019 which the two divided stacked cores 31 and 32 are coupled to each other via the fixing members 7b and 7c with a certain interval maintained therebetween (a coupling step: S005) .

The rotor 2 is inserted into the inner peripheral side of the stator 3, and the rotor 2 and the stator 3 are housed in a frame that is not shown, thereby obtaining the rotating electrical machine 100.

[0035] Next, advantageous effects regarding the shapes of the core pieces 6 used in the present embodiment will be described.

FIG. 8 is a diagram showing an arrangement when conventional integrated core pieces 60b are blanked out from an electromagnetic steel plate P2, as a comparative example.

The shape of each core piece 60b is the same as a shape obtained by bending the core piece 6 according to Embodiment at the thin connection portions 61.

[0036] When the core pieces 6 are blanked out from the electromagnetic steel plate P in FIG. 3 in the arrangement shown in the drawing, where the area of the single core piece 20 6 is denoted by A0, the length of the electromagnetic steel plate P in the longitudinal direction is denoted by LI, and the length of the electromagnetic steel plate P in a direction perpendicular to the longitudinal direction is denoted by L2, a material effective use rate (2AO/L1'L2) is

59%.

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2016284404 28 Feb 2019 [0037] On the other hand, when the core pieces 60b are blanked out in the arrangement shown in FIG. 8, the area of the single core piece 60b is A0 which is equal to that of the core piece 6. In this case, where the length of the electromagnetic steel plate P2 in the longitudinal direction is denoted by L3, and the length of the electromagnetic steel plate P2 in a direction perpendicular to the longitudinal direction is denoted by L4, a material effective use rate (2A0/L3'L4) is 52%. As described above, a higher material use rate is achieved when blanking-out is performed in the arrangement shown in FIG. 3.

[0038] In the core piece 6 according to the present embodiment, at both the tooth portions 6b and 6c and the divided yoke portion 6a, directions JI to J3 in which a magnetic flux flows therethrough coincide with the rolling direction D of the electromagnetic steel plate P. Generally, a magnet resistance is lower in a rolling direction than in a direction orthogonal to the rolling direction, so that iron loss occurring in a core can be reduced in the rolling direction. Therefore, as compared to the core piece 60b of the comparative example in which only either the tooth portions or the yoke portion can be caused to coincide with the rolling direction D, flow of a magnetic flux through the divided stacked cores 31 and 32 is made smooth by arranging the core piece 6 such that the rolling direction D of the

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2016284404 28 Feb 2019 electromagnetic steel plate P and the longitudinal direction of the core piece 6 coincide with each other, so that favorable magnetic characteristics are achieved.

[0039] In the stator of the rotating electrical machine, the rotating electrical machine, and the method for producing the stator of the rotating electrical machine according to Embodiment 1 of the present invention, since the divided stacked yoke portion 30a and the stacked tooth portions 30b and 30c of the divided stacked core intermediate 30 are arranged straight in a band shape in winding the coil 40, when the coil 40 is wound on one of the stacked tooth portions, the rotation plane Q on which the end of the flyer 88 rotates and the stacked tooth portion 30c at the opposite side, do not interfere with each other. Accordingly, since the operating range of the flyer 88 is not limited, the coil can easily be wound on the stacked tooth portions 30b and 30c in a regularly aligned manner, a gap does not occur between two coils housed in one slot, the coil space factor can be improved, and the filling factor of the stator 3 (the proportion of the stator components with respect to the outer shape of the stator 3) can be increased. In addition, since no obstacle is present around the flyer 88 in winding the coil 40, the coil can be wound at a high speed. Moreover, an operation for connecting coil end portions can be eliminated, so that the inexpensive stator 3 of the rotating electrical

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2016284404 28 Feb 2019 machine 100 can be obtained.

[0040] By fixing the magnetic attraction portion 31bz and

32bz and the magnetic attraction portions 31cz and 32cz of the divided stacked cores 31 and 32 to each other by means of the fixing members 7b and 7c, the accuracy of the positions of the magnetic attraction portions can be improved.

[0041] Since the coil 40 can be continuously extended without cutting the jumper wire 42 between the coils 40 which are wound on the two stacked tooth portions 30b and 30c, respectively, the productivity of the stator 3 and the rotating electrical machine 100 can be improved.

[0042] Embodiment 2

Hereinafter, Embodiment 2 of the present invention will be described mainly regarding differences from

Embodiment 1 with reference to the drawings .

FIG. 9 is a schematic diagram of the divided stacked core intermediate 30 and a winding machine carrying out a winding step.

FIG. 10 is a flowchart showing a coil winding step for a rotating electrical machine according to the present embodiment.

In FIG. 10, only a flowchart for a simultaneous winding step which is a difference from Embodiment 1 is shown .

In the coil winding step of Embodiment 1, the first

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winding step	and	the	second	winding	step	are sequentially
performed by	the	one	flyer 88 on the	two	stacked	tooth
portions 30b	and	30c	of the	divided	stacked core	intermediate
30 . However,	in	the	present	embodiment,	as shown	in FIG. 9,

operations for winding the coils 40 are simultaneously performed by two flyers 88a and 88b on the two stacked tooth portions 30b and 30c (the simultaneous winding step: S201). [0043] Rotation shafts Bl and B2 of the flyers 88a and 88b are located so as to oppose each other with the rotary positioning mechanism 80 interposed therebetween and so as to be orthogonal to the rotation axis A of the rotary positioning mechanism 80, and the flyers 88a and 88b are movable forward and backward in axial directions cl and c2 of the rotation shafts Bl and B2, respectively.

[0044] Fixing the divided stacked core intermediate 30 to the rotary positioning mechanism 80 is the same as in

Embodiment 1. In winding the coils 40, the free end portions of the two stacked tooth portions 30b and 30c oppose the rotation shafts Bl and B2 of the flyers 88a and 88b, respectively, and the operations for winding the coils 40 are simultaneously performed by the two flyers 88a and 88b.

After the coils 40 are simultaneously wound, the coils 40 wound on the two stacked tooth portions 30b and 30c are connected to each other by connecting winding end portions or winding start portions of the two stacked tooth portions

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2016284404 28 Feb 2019 where the winding ends or starts.

[0045] In the stator of the rotating electrical machine, the rotating electrical machine, and the method for producing the stator of the rotating electrical machine according to

Embodiment 2 of the present invention, the coils 40 can be simultaneously wound by the two flyers 88a and 88b on the two stacked tooth portions 30b and 30c, and thus the time for the operations for winding the coils 40 can be reduced by half or more of that in Embodiment 1.

[0046] Embodiment 3

Hereinafter, Embodiment 3 of the present invention will be described mainly regarding differences from Embodiment 1 with reference to the drawings .

FIG. 11 is a cross-sectional schematic diagram showing the configuration of a rotating electrical machine

300 according to Embodiment 3 of the present invention.

FIG. 12 is a flowchart showing a coil winding step for the rotating electrical machine according to the present embodiment.

In FIG. 12, only a flowchart for a molding step which is a difference from Embodiment 1 is shown.

In the stator 3 of Embodiment 1, the two divided stacked cores 31 and 32 are coupled to each other by the fixing members 7b and 7c. In the present embodiment, as shown in FIG. 11, the outer periphery of the rotating

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2016284404 28 Feb 2019 electrical machine 300 is molded by a mold member 307 made of a resin (the molding step: S305).

[0047] The mold member 307 may cover the entirety of a stator 303 as shown in FIG. 11, or may be molded so as to cover the peripheries of the coils 41b, 41c, 42b, and 42c, at least the free end portions of the stacked tooth portions 31b and 32b of the divided stacked cores 31 and 32, and the free end portions of the stacked tooth portions 31c and 32c.

[0048] In the stator of the rotating electrical machine, the rotating electrical machine, and the method for producing the stator of the rotating electrical machine according to Embodiment 3 of the present invention, the mold member 307 is integrally molded with the divided stacked cores 31 and 32. Thus, as compared to the rotating electrical machine 100 of

Embodiment 1 in which the divided stacked cores 31 and 32 are fixed and assembled by using the fixing members 7b and 7c, assembling is easy, and the productivity of the stator 303 and the rotating electrical machine 300 is good. In addition, high-accuracy positioning can be performed by using a mold.

[0049] When a resin is filled into the dovetail groovelike recesses 31bzr, 31czr, 32bzr, and 32czr to which the fixing members 7b and 7c are fitted in Embodiment 1, and integral molding is performed, the rigidity and the accuracy 25 of the stator 303 can be further increased.

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2016284404 28 Feb 2019 [0050] Embodiment 4

Hereinafter, Embodiment 4 of the present invention will be described mainly regarding differences from Embodiment 1 with reference to the drawings .

FIG. 13(a) is a cross-sectional schematic diagram showing the configuration of a divided stacked core 331, having a coil wound thereon, of a rotating electrical machine according to Embodiment 4 of the present invention.

FIG. 13(b) is an enlarged cross-sectional view taken along the line Y-Y' in FIG. 13(a) .

[0051] In the divided stacked core 31 of Embodiment 1, the divided stacked yoke portion 31a and the stacked tooth portions 31b and 31c are bendably connected to each other by the stacked thin connection portions 3s. However, in the present embodiment, as shown in FIGS. 13(a) and 13(b), a divided stacked yoke portion 331a and stacked tooth portions 331b and 331c are rotatably connected to each other by swaging recesses and projections provided to each of thin plate-like core pieces 306a forming respective layers of the divided stacked core 331 and core pieces 306b and 306c (actually, there are two types for each) forming respective layers of the stacked tooth portions 331b and 331c.

[0052] Specifically, as shown in FIG. 13(b), projections

306cp are provided on the lower surfaces of the core pieces

306c of the stacked tooth portion 331c, and a rotatable

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2016284404 28 Feb 2019 connection portion R is formed by swaging the projections 306cp to recesses 306ar on the upper surfaces of the core pieces 306a of the divided stacked yoke portion 331a which are alternately stacked. In winding the coil 40 (41b, 41c) on the stacked tooth portions 331b and 331c, similarly to Embodiment 1, the connection portion R may be rotated to be opened such that the divided stacked yoke portion 331a and the stacked tooth portions 331b and 331c are straight in a band shape.

[0053] In the stator of the rotating electrical machine, the rotating electrical machine, and the method for producing the stator of the rotating electrical machine according to Embodiment 4 of the present invention, handling in returning the respective stacked tooth portions 331b and 331c into a substantially U-shaped state after the coil 40 is wound is easy as compared to bending at the thin portions in Embodiment 1, so that the productivity of the stator of the rotating electrical machine and the rotating electrical machine can be further improved.

[0054] Embodiment 5

Hereinafter, Embodiment 5 of the present invention will be described mainly regarding differences from Embodiment 1 with reference to the drawing.

FIG. 14 is a cross-sectional schematic diagram showing the configuration of a rotating electrical machine

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2016284404 28 Feb 2019

500 according to Embodiment 5 of the present invention.

The stator 3 of Embodiment 1 includes the two divided stacked cores 31 and 32. However, in the present embodiment, as shown in FIG. 14, a stator 503 includes three divided stacked cores 331, 332, and 333 each having a substantially U shape. The other configuration is the same as in Embodiment 1.

[0055] In the stator 503 of the rotating electrical machine 500, the rotating electrical machine 500, and the method for producing the stator 503 of the rotating electrical machine 500 according to Embodiment 5 of the present invention, torque ripples occurring in the rotating electrical machine 500 can be reduced by increasing the number of the stacked tooth portion as compared to that in

Embodiment 1 to increase the number of poles.

[0056] It is noted that, within the scope of the present invention, the respective embodiments may be freely combined with each other, or each of the respective embodiments may be modified or abbreviated as appropriate.

[0057] Modifications within the scope of the invention may be readily effected by those skilled in the art. It is to be understood, therefore, that this invention is not limited to the particular embodiments described by way of example hereinabove .

[0058] In the claims that follow and in the preceding

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2016284404 28 Feb 2019 description of the invention, except where the context requires otherwise owing to express language or necessary implication, the word comprise or variations such as comprises or comprising is used in an inclusive sense, that is, to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.

[0059] Further, any reference herein to prior art is not intended to imply that such prior art forms or formed a part 10 of the common general knowledge in any country.

Claims

1. A stator for a rotating electrical machine, comprising :

the stacked core includes a yoke portion located at a center in a longitudinal direction of the core pieces, and a tooth portion rotatably connected to each of both ends in a longitudinal direction of the yoke portion, and the coil is formed by being wound on each tooth portion, the two tooth portions have joining portions, fixing members are provided so as to be fitted at both end portions thereof to the respective joining portions provided at the tooth portions of one of the two stacked cores adjacent to each other in a circumferential direction and the tooth portions of the other of the two stacked cores, and the tooth portions adjacent to each other in the circumferential direction are arranged with an interval maintained therebetween via the fixing member.

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2016284404 28 Feb 2019

2. The stator for a rotating electrical machine according to claim 1, wherein the two tooth portions are respectively connected to the yoke portion via bendable thin portions .

3. The stator for a rotating electrical machine according to claim 1, wherein each of the two tooth portions is rotatably connected to the yoke portion by fitting recesses and projections provided on stacked surfaces of the core pieces .

4. A rotating electrical machine comprising:

a rotor; and the stator according to any one of claims 1 to 3, wherein the yoke portion is arranged such that the longitudinal direction of the yoke portion is directed along a circumferential direction about a rotation shaft of the rotor, and each of the tooth portions is arranged so as to extend toward the rotor side such that a longitudinal direction of the tooth portion is perpendicular to the longitudinal direction of the yoke portion.

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2016284404 28 Feb 2019

5. A method for producing a stator for a rotating electrical machine, the stator including a stacked core formed by stacking thin plate bandlike core pieces, and a coil wound on the stacked core, wherein:

the stacked core in which the core pieces are stacked includes a yoke portion located at a center in a longitudinal direction of the stacked core pieces, and a tooth portion rotatably connected to each of both ends in the longitudinal direction of the yoke portion, and the method comprises:

a stacking step of stacking the cut-out core pieces;

a second winding step of performing

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2016284404 28 Feb 2019 winding on the other tooth portion located at a side opposite to the one tooth portion across the yoke portion, of the two tooth portions;

6. A method for producing a rotating electrical machine including a rotor, and a stator including a stacked core arranged along a circumferential direction about a rotation shaft of the rotor and formed by stacking thin plate band-like core pieces, and a coil wound on the stacked core, wherein:

the stacked core in which the core pieces are stacked includes a yoke portion located at a center in a longitudinal direction of the stacked core pieces, and a

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2016284404 28 Feb 2019 tooth portion rotatably connected to each of both ends in the longitudinal direction of the yoke portion, and the method comprises:

a stacking step of stacking the cut-out core pieces;

a bending step of respectively bending the one tooth portion and the other tooth portion on which the coil has been wound, at a right angle in the same direction about connection portions of the yoke portion at both ends in the longitudinal direction;

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2016284404 28 Feb 2019 a step of arranging the stacked core on which the coil has been wound, along the circumferential direction about the rotation shaft such that a magnetic attraction portion provided at an end of each of the tooth portions opposes the rotor; and a coupling step of fixing the tooth portions of one of the two stacked cores adjacent to each other in a circumferential direction and the tooth portions of the other of the two stacked cores to each other in the circumferential direction with an interval maintained therebetween in the circumferential direction.

7 . The method for producing a rotating electrical machine according to claim 6, wherein in the coupling step, both end portions of fixing members are fitted to joining portions provided at the respective tooth portions of the two stacked cores adjacent to each other in the circumferential directions .