CN109792167B - Stator, method of manufacturing the same, motor and compressor using the same - Google Patents
Stator, method of manufacturing the same, motor and compressor using the same Download PDFInfo
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- CN109792167B CN109792167B CN201780060118.5A CN201780060118A CN109792167B CN 109792167 B CN109792167 B CN 109792167B CN 201780060118 A CN201780060118 A CN 201780060118A CN 109792167 B CN109792167 B CN 109792167B
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- stator
- stator core
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/12—Stationary parts of the magnetic circuit
- H02K1/14—Stator cores with salient poles
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/12—Stationary parts of the magnetic circuit
- H02K1/18—Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/12—Impregnating, heating or drying of windings, stators, rotors or machines
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Iron Core Of Rotating Electric Machines (AREA)
- Manufacture Of Motors, Generators (AREA)
- Compressor (AREA)
- Insulation, Fastening Of Motor, Generator Windings (AREA)
Abstract
The invention provides a stator, which adopts a stator core that resin does not leak to the periphery when an insulator is molded. In the stator (51), only the outer periphery of one or more second electromagnetic sheets (602) is reduced from the end surface (60a) of the stator core (60) to the inner side to form a step part (611). Since the dimensional accuracy of the outer peripheral surface (611a) of the step part (611) is high, the gap between the cavity die of the insulator molding die and the outer peripheral surface (611a) of the step part (611) is easily maintained to such an extent that the molten resin does not leak out. Therefore, compared to a conventional method in which the end surface of the stator core is pressed by an insulator molding die, resin leakage to the outer periphery of the stator core during insulator molding can be suppressed.
Description
Technical Field
The present invention relates to a stator in which an insulator is integrally formed with a stator core by insert molding, and relates to a method of manufacturing the stator, a motor and a compressor employing the stator.
Background
A stator of a motor requires an insulator for insulating a stator core from a magnet wire, and a method of integrally molding the stator as a method of molding the insulator is known.
For example, according to patent document 1 (japanese patent No. 4936051), an insulator is molded by pressing an end surface of a cylindrical stator core with an injection mold for the insulator, and flowing a molten resin into a cavity surrounded by the end surface and a cavity (recess).
Disclosure of Invention
Problems to be solved by the invention
However, it is difficult to obtain the accuracy of the dimension between the end faces of the stator core, and when the gap between the end face of the stator core and the mold is increased beyond an allowable value, the molten resin leaks from the gap and adheres to the outer periphery of the stator core. In the case of a compressor, since the stator core is fixed to the cylindrical body portion of the compressor by shrink fitting or welding, the resin adhering to the outer periphery of the stator core at that time melts into dust, and there is a possibility that the piping and the like are clogged.
The invention provides a stator, which adopts a stator core that resin does not leak to the periphery when an insulator is molded.
Means for solving the problems
A stator according to a first aspect of the present invention includes a stator core and an insulator. The stator core is an annular member. The insulator is a resin member disposed on an end surface of the stator core in the axial direction. The stator core is disposed in a cylindrical main body portion inscribed in an outermost periphery thereof. The outer periphery of the end face of the stator core has an outer peripheral surface configured to be parallel to the axial direction. At least a part of the outer peripheral surface forms a step portion which is radially inward of the outermost periphery of the stator core. The outer periphery of the insulator is radially inward of the main body.
According to this stator, a stepped portion is formed on at least a part of the outer peripheral surface of the stator core, and the stepped portion is located radially inward of the outermost periphery of the stator core. Therefore, the following structure may be adopted: when the insulator is integrally molded with the stator core by insert molding, the gap between the cavity mold and the core mold of the insulator molding die is closed by the outer periphery of the stepped portion.
Since the outer peripheral surface of the stepped portion has high dimensional accuracy, the gap between the cavity die of the insulator molding die and the outer peripheral surface of the "stepped portion" is easily maintained to such an extent that the molten resin does not leak out. Therefore, compared to a conventional method in which the end surface of the stator core is pressed by an insulator molding die, resin leakage to the outer periphery of the stator core during insulator molding can be suppressed.
A stator according to a second aspect of the present invention is the stator according to the first aspect, wherein an outer peripheral surface of the stepped portion has the same shape as an outer periphery of the insulator when viewed in a plan view.
If the outer periphery of the stepped portion and the outer periphery of the insulator are not of the same shape when viewed in plan, a step is required between the portion of the cavity mold of the insulator mold into which the outer periphery of the stepped portion is fitted and the cavity into which the resin of the insulator is filled.
According to this stator, when the outer periphery of the stepped portion and the outer periphery of the insulator have the same shape in plan view, the portion into which the outer periphery of the stepped portion is fitted coincides with the cavity into which the resin of the insulator is filled, and this portion also serves as the cavity.
Further, since the outer peripheral surface of the stepped portion of the stator core is flush with the outer peripheral surface of the insulator after the insulator is molded, the processing quality is also good.
A stator according to a third aspect of the present invention is the stator according to the first or second aspect, wherein the step portion is formed only at one side end portion of the stator core.
According to this stator, since the cavity mold and the core mold of the insulator molding mold can be closed by the outer periphery of the stepped portion, and the end surface on the side where the stepped portion is provided does not need to be pressed by the mold, it is possible to suppress the resin from leaking to the outer periphery of the stator core during the insulator molding. Further, even if one end face of the stator core is pressed by a mold, since a space exists on the other end face side, mold clamping is not hindered even if there is a dimensional variation between the end faces.
A stator according to a fourth aspect of the present invention is the stator according to any one of the first to third aspects, wherein a plurality of core notches, which are notches extending in the axial direction, are formed in the outer peripheral surface of the stator core. The deepest region of the core slit coincides with the outer peripheral surface of the insulator when viewed in plan.
According to this stator, there are such advantages: by enlarging the outer periphery of the insulator to the deepest region of the core slit, a winding space can be secured. In the mold structure of the insulator molding mold, since the male mold for forming the core notch can be abutted against the mold surface of the outer edge of the female mold for fitting the stepped portion, the ridge line of the outer peripheral surface of the insulator, the outer peripheral surface of the stepped portion of the stator core, and the bottom surface of the core notch becomes a straight line after the resin injection molding, and the processing quality is good.
A stator of a fifth aspect of the present invention is the stator of any one of the first to fourth aspects, wherein the insulator includes: a first insulator disposed on one of end surfaces of the stator core; and a second insulator disposed on the other end surface. The first insulator and the second insulator are integrally connected at the inner side of the outermost peripheries thereof.
According to this stator, the first insulator and the second insulator are integrally connected to each other on the inner side of the outermost peripheries thereof, and therefore, the first insulator and the second insulator can be integrally molded by an injection molding die.
A stator according to a sixth aspect of the present invention is the stator according to any one of the first to fifth aspects, wherein the stator core is formed by stacking plate-like members.
According to this stator, for example, the outer periphery of one or more plate-like members can be narrowed inward from the end surface of the stator core to form the stepped portion. Therefore, when the insulator is integrally molded with the stator core by insert molding, a structure in which the space between the cavity mold and the core mold of the insulator molding die is closed by the outer periphery of the stepped portion can be adopted.
A method of manufacturing a stator of a seventh aspect of the present invention is the method of manufacturing a stator of any one of the first to sixth aspects, wherein the main body portion is formed by laminating a first electromagnetic steel sheet having the same planar shape as the main body portion except for the step portion in the stator core by a first predetermined amount. The step portion is formed by laminating a second magnetic steel sheet having the same planar shape as the step portion by a second predetermined amount smaller than the first predetermined amount on the body portion. Thereby, the stator core is formed.
According to this method for manufacturing a stator, the step portion can be formed by laminating the second electromagnetic steel sheets having a planar shape with the step portion in advance, and therefore, the manufacturing is easy.
A method of manufacturing a stator according to an eighth aspect of the present invention is the method of manufacturing a stator according to any one of the first to seventh aspects, wherein the insulator is molded by placing the stator core in a mold for injection molding the insulator such that the step portion fits into a cavity mold of the mold, and injecting molten resin into the mold.
Since the dimension of the outer periphery of the stepped portion is more stable and more accurate than the dimension between the end faces of the stator core, the gap between the cavity die of the insulator molding die and the outer periphery of the stepped portion is easily maintained to such an extent that the molten resin does not leak out.
Therefore, according to this stator manufacturing method, resin leakage at the time of insulator molding to the outer periphery of the stator core can be suppressed as compared with a conventional method in which the end face of the stator core is pressed by an insulator molding die.
A motor according to a ninth aspect of the present invention includes: the stator of any one of the first to eighth aspects; and a rotor disposed inside the stator.
According to this stator, resin during insulator molding can be prevented from leaking to the outer periphery of the stator core.
A method of manufacturing a compressor according to a tenth aspect of the present invention is a method of fixing the stator according to any one of the first to ninth aspects to a cylindrical body portion of the compressor by shrink fitting or welding.
According to the method for manufacturing the compressor, the resin can be prevented from leaking to the outer periphery of the stator core when the insulator is molded. As a result, when the stator core is fixed to the cylindrical body portion of the compressor by shrink fitting or welding, it is possible to prevent "the resin adhering to the outer periphery of the stator core melts to become dust and block the piping and the like".
Effects of the invention
According to the stator of the first aspect of the present invention, the stator core is arranged in the cylindrical main body portion inscribed in the outermost circumference thereof, the outer circumference of the end face of the stator core has the outer circumferential surface configured to be parallel to the axial direction, at least a part of the outer circumferential surface forms the step portion radially inward of the outermost circumference of the stator core, and the outer circumference of the insulator radially inward of the main body portion. Therefore, the following structure may be adopted: when the insulator is integrally molded with the stator core by insert molding, the gap between the cavity mold and the core mold of the insulator molding die is closed by the outer periphery of the stepped portion.
Since the outer peripheral surface of the stepped portion has high dimensional accuracy, the gap between the cavity die of the insulator molding die and the outer peripheral surface of the stepped portion is easily maintained to such an extent that the molten resin does not leak out. Therefore, compared to a conventional method in which the end surface of the stator core is pressed by an insulator molding die, resin leakage to the outer periphery of the stator core during insulator molding can be suppressed.
According to the stator of the second aspect of the present invention, when the outer periphery of the stepped portion and the outer periphery of the insulator have the same shape in plan view, the portion of the cavity mold into which the outer periphery of the stepped portion is fitted coincides with the cavity filled with the resin of the insulator, and the portion doubles as the cavity.
Further, since the outer peripheral surface of the stepped portion of the stator core is flush with the outer peripheral surface of the insulator after the insulator is molded, the processing quality is also good.
According to the stator of the third aspect of the present invention, since the cavity mold and the core mold of the insulator molding mold can be closed by the outer periphery of the stepped portion, it is not necessary to press the end surface on the side where the stepped portion is provided with the mold, and therefore, the resin can be prevented from leaking to the outer periphery of the stator core when the insulator is molded. Further, even if one end face of the stator core is pressed by a mold, since a space exists on the other end face side, mold clamping is not hindered even if there is a variation in the dimension between the end faces.
According to the stator of the fourth aspect of the present invention, in the mold structure of the insulator molding mold, since the male mold for forming the core notch can be abutted against the mold surface of the outer edge of the female mold for fitting the stepped portion, after the resin injection molding, the ridge lines of the outer peripheral surface of the insulator, the outer peripheral surface of the stepped portion of the stator core, and the bottom surface of the core notch are aligned, and the processing quality is good.
According to the stator of the fifth aspect of the present invention, since the first insulator and the second insulator are integrally connected to each other on the inner side of the outermost peripheries thereof, they can be integrally molded by an injection molding die.
According to the stator of the sixth aspect of the present invention, for example, the outer periphery of one or more plate-like members can be narrowed inward from the end surface of the stator core to form the stepped portion. Therefore, when the insulator is integrally molded with the stator core by insert molding, a structure in which the space between the cavity mold and the core mold of the insulator molding die is closed by the outer periphery of the stepped portion can be adopted.
According to the method of manufacturing a stator of the seventh aspect of the present invention, the step portion can be formed by laminating the second electromagnetic steel sheets having a planar shape with the step portion in advance, and therefore, the manufacturing is easy.
According to the method for manufacturing a stator of the eighth aspect of the present invention, resin leakage at the time of insulator molding to the outer periphery of the stator core can be suppressed as compared with a conventional method in which the end face of the stator core is pressed by an insulator molding die.
According to the motor of the ninth aspect of the present invention, the resin can be prevented from leaking to the outer periphery of the stator core when the insulator is molded.
According to the method of manufacturing a compressor of the tenth aspect of the present invention, the resin can be prevented from leaking to the outer periphery of the stator core when the insulator is molded. As a result, when the stator core is fixed to the cylindrical body portion of the compressor by shrink fitting or welding, it is possible to prevent "the resin adhering to the outer periphery of the stator core melts to become dust and block the piping and the like".
Drawings
Fig. 1 is a longitudinal sectional view of a rotary compressor.
Fig. 2 is a sectional view of the stator core taken along line a-a in fig. 1.
Fig. 3 is a plan view of the stator.
Fig. 4 is a sectional view of the stator taken along line B-B of fig. 3.
Fig. 5A is a plan view of the stator core.
Fig. 5B is a side view of the stator core.
Fig. 6 is a perspective view of the stator core and the insulator mounted on the upper end surface thereof.
Fig. 7 is a perspective view of the stator core and the insulator attached to the lower end surface thereof.
Fig. 8A is a schematic cross-sectional view showing a state where a stator core is provided in an insulator molding die.
Fig. 8B is a schematic cross-sectional view showing a state in which a stator core having stepped portions on both end surface sides is provided in a mold for an insulator.
Fig. 8C is a schematic cross-sectional view showing a state where a conventional stator core is provided in an insulator molding die.
Fig. 9 is a plan view of a stator core of a modification.
Detailed Description
A stator, a motor using the stator, and a compressor including the motor according to embodiments of the present invention will be described below with reference to the drawings. The following embodiments are specific examples of the present invention, and do not limit the technical scope of the present invention.
The motor using the stator of the present embodiment is a drive motor of a rotary compressor. The rotary compressor is connected to a refrigerant circuit provided in a refrigeration apparatus such as an air conditioner. The rotary compressor has a function of compressing a refrigerant gas flowing through a refrigerant circuit.
(1) Structure of rotary compressor 101
Fig. 1 is a longitudinal sectional view of a rotary compressor 101. In fig. 1, a rotary compressor 101 includes a casing 10, a compression mechanism 15, a motor 16, a crankshaft 17, an intake pipe 19, and a discharge pipe 20. The refrigerants compressed in the rotary compressor 101 are, for example, R410A, R22, R32 and carbon dioxide. Next, each component of the rotary compressor 101 will be described.
(1-1) case 10
The housing 10 is composed of a cylindrical body 11 having a cylindrical shape, a top 12 having a bowl shape, and a bottom 13 having a bowl shape. The top portion 12 is connected to an upper end portion of the cylindrical body portion 11. The bottom portion 13 is connected to the lower end portion of the cylindrical body portion 11.
Since the housing 10 is molded from a rigid member, deformation and breakage due to changes in pressure and temperature of the internal space and the external space of the housing 10 are less likely to occur. The housing 10 is provided such that the cylindrical axis of the cylindrical body 11 is along the vertical direction.
In the present embodiment, the cylindrical body 11 has a cylindrical shape, but the cylindrical body is not limited to a circular column, and may have a cylindrical structure other than a circular column such as an elliptic column or a prism.
The lower portion of the internal space of the housing 10 constitutes an oil reservoir 10a for storing lubricating oil. The lubricating oil is a refrigerating machine oil and is used to improve the lubricity of sliding portions existing in the internal space of the casing 10.
The housing 10 accommodates a compression mechanism 15, a motor 16, and a crankshaft 17. The compression mechanism 15 is connected to a motor 16 via a crankshaft 17. Suction pipe 19 and discharge pipe 20 are connected to casing 10 so as to penetrate casing 10.
(1-2) compression mechanism 15
The compression mechanism 15 is constituted by a front cylinder head 23, a cylinder block 24, a rear cylinder head 25, and a piston 21. The front cylinder head 23, the cylinder block 24, and the rear cylinder head 25 are integrally fastened by laser welding.
The compression mechanism 15 sucks and compresses low-pressure refrigerant gas, and discharges high-pressure refrigerant gas. The space above the compression mechanism 15 is a high-pressure space S1 in which the refrigerant compressed by the compression mechanism 15 is discharged. The compression mechanism 15 is immersed in the lubricating oil stored in the oil reservoir 10 a. The lubricating oil is supplied to the sliding portion of the compression mechanism 15.
The compression mechanism 15 has a compression chamber 40. The compression chamber 40 is a space surrounded by the front cylinder head 23, the cylinder block 24, and the rear cylinder head 25. The compression chamber 40 is divided by the piston 21 into a suction chamber communicating with the suction pipe 19 and a discharge chamber communicating with the high-pressure space S1.
The piston 21 is fitted with an eccentric shaft portion 17a of the crankshaft 17. When the crankshaft 17 rotates, the piston 21 performs an orbital motion about the rotation axis of the crankshaft 17. By the revolution motion of the piston 21, the volumes of the suction chamber and the discharge chamber are changed.
(1-3) Motor 16
The motor 16 is a brushless DC (direct current) motor, and is disposed above the compression mechanism 15. The motor 16 is composed of a stator 51 and a rotor 52. The stator 51 is a cylindrical member fixed to the inner peripheral surface of the cylindrical body portion 11 of the housing 10.
The rotor 52 is a cylindrical member, which is disposed inside the stator 51. A minute gap is formed between the stator 51 and the rotor 52. The structure of the motor 16 will be described in detail in the second half.
(1-4) crankshaft 17
The crankshaft 17 is disposed such that its central axis is along the vertical direction. The crankshaft 17 has an eccentric shaft portion 17 a. The eccentric shaft portion 17a of the crankshaft 17 is coupled to a piston 21 of the compression mechanism 15. The rotor 52 of the motor 16 is coupled to an upper end of the crankshaft 17 in the vertical direction. The crankshaft 17 is supported by a front cylinder head 23 and a rear cylinder head 25.
(1-5) suction pipe 19
The suction pipe 19 is a pipe penetrating the cylindrical body portion 11 of the casing 10. In the inner space of the casing 10, an end of the suction pipe 19 is embedded in the compression mechanism 15. In the outer space of the casing 10, an end of the suction pipe 19 is connected to a refrigerant circuit. The suction pipe 19 is a pipe for supplying the refrigerant from the refrigerant circuit to the compression mechanism 15.
(1-6) discharge pipe 20
The drain 20 is a tube that passes through the top 12 of the housing 10. In the inner space of the housing 10, an end of the discharge pipe 20 is located above the motor 16. In the outer space of the casing 10, an end of the discharge pipe 20 is connected to the refrigerant circuit. The discharge pipe 20 is a pipe for supplying the refrigerant compressed by the compression mechanism 15 to the refrigerant circuit.
(2) Structure of the motor 16
Fig. 2 is a sectional view of the stator core 60 taken along line a-a in fig. 1. Fig. 3 is a plan view of the stator 51. Fig. 4 is a sectional view of the stator 51 taken along line B-B in fig. 3.
The motor 16 is a concentrated winding motor having 9 concentrated winding coils. The motor 16 is a variable speed motor driven by inverter control. The motor 16 is a three-phase motor having U-phase, V-phase, and W-phase.
(2-1) stator 51
The stator 51 has a stator core 60 and insulators 71 and 72. As shown in fig. 4, an insulator 71 is attached to the upper end surface 60a of the stator core 60 in the vertical direction, and an insulator 72 is attached to the lower end surface 60b of the stator core 60 in the vertical direction.
(2-1-1) stator core 60
Fig. 5A is a plan view of the stator core 60. Further, fig. 5B is a side view of the stator core 60. In fig. 5A and 5B, the stator core 60 is a cylindrical member formed by stacking a plurality of annular plates made of electromagnetic steel plates in the vertical direction. The cylindrical axial direction of the stator core 60 is the vertical direction.
The predetermined section D is narrowed from the upper end surface 60a of the stator core 60 in the axial direction to the inside of the outermost periphery of the stator core 60, thereby forming a step portion 611.
The stator core 60 is constituted by a first electromagnetic piece 601 and a second electromagnetic piece 602 that are different in shape from each other. The electromagnetic steel sheet is formed into the same shape as the planar shape in fig. 5A by punching, thereby forming the first electromagnetic sheet 601. The second magnet piece 602 is formed into a circumferential shape with an outer periphery inside the outer periphery of the first magnet piece 601 by punching, thereby forming the second magnet piece 602.
The main body portion 61 of the stator core 60 excluding the step portion 611 is formed by laminating the first electromagnetic sheets 601 by a first predetermined number. The second magnet pieces 602 are stacked on the body portion 61 by a second predetermined number to form the step portion 611. The number of the second predetermined pieces is smaller than the number of the first predetermined pieces, and may be about 1 to 5.
The stator core 60 is fixed to the casing 10 of the rotary compressor 101. The stator core 60 is fixed to the housing 10 by shrink fitting. First, the cylindrical body 11 of the housing 10 is heated to about 400 degrees to expand the inner diameter of the cylindrical body 11. Next, the stator core 60 is inserted into the cylindrical body 11 having an enlarged inner diameter, and the cylindrical body 11 is cooled. Further, the inner diameter of the cylindrical body 11 is contracted, and the outer periphery of the stator core 60 is fastened to the inner peripheral surface of the cylindrical body 11, whereby the fixation of the both is completed. The stator core 60 may be fixed to the housing 10 by press fitting or welding.
As shown in fig. 2, the stator core 60 has a main body portion 61 and 9 teeth 62. Each tooth 62 protrudes from the inner circumferential surface of the body portion 61 toward the inside in the radial direction of the body portion 61. The radial direction of the body portion 61 is in a horizontal plane orthogonal to the vertical direction. The 9 teeth 62 are arranged at equal intervals at angular intervals of 40 degrees in the circumferential direction of the body portion 61.
As shown in fig. 2, 9 core notches 61a are formed in the outer peripheral surface of the main body portion 61 of the stator core 60. Each core slit 61a is a notch formed along the central axis of the body 61 from the upper end surface to the lower end surface of the body 61.
Each core slit 61a is located radially outward of the main body portion 61 as viewed from the teeth 62. The 9 core cutouts 61a are arranged at equal intervals at 40-degree angular intervals along the circumferential direction of the main body portion 61. The core notch 61a is formed in a space extending in the vertical direction between the cylindrical body 11 and the stator 51 of the rotary compressor 101.
(2-1-2) winding 66
As shown in fig. 3 and 4, a winding 66 is wound around each tooth 62 of the stator core 60 with insulators 71 and 72 interposed therebetween. The stator 51 is provided with 9 coils U1, U2, and U3; v1, V2, V3; w1, W2, W3. In fig. 3, coils U1, W3, V1, U2, W1, V2, U3, W2, and V3 are arranged in this order in the clockwise direction.
The winding 66 is a copper wire or the like. The windings 66 are so-called concentrated winding coils in which 9 windings 66 are wound around each tooth 62 independently. Insulators 71, 72 insulate stator core 60 from windings 66. The winding 66 is wound in a clockwise direction along the blank arrow shown in fig. 3.
The coils U1, U2, and U3 are formed by winding the windings 66 around the teeth 62 arranged at angular intervals of 120 degrees in the circumferential direction of the stator core 60. The coils U1, U2, U3 are wired in parallel or in series, forming the U phase of the motor 16.
The coils V1, V2, and V3 are formed by winding the winding 66 around the teeth 62 arranged at angular intervals of 120 degrees in the circumferential direction of the stator core 60. The coils V1, V2, V3 are wired in parallel or in series, forming the V phase of the motor 16.
The coils W1, W2, and W3 are formed by winding the windings 66 around the teeth 62 arranged at angular intervals of 120 degrees in the circumferential direction of the stator core 60. The coils W1, W2, W3 are wired in parallel or in series, forming the W phase of the motor 16.
As shown in fig. 3, two coils U1, U2, U3 adjacent in the circumferential direction of the stator core 60; v1, V2, V3; gaps SL1 to SL9, which are gaps between coils, are formed among W1, W2, and W3. In the plan view of the stator 51 shown in fig. 3, the slot SL1 is a gap between the coil U1 and the coil W3, and the slots SL2 to SL9 are arranged clockwise from the slot SL 1.
(2-1-3) insulators 71, 72
The insulators 71 and 72 are insulators attached to both end surfaces 60a and 60b (see fig. 4) of the stator core 60 in the vertical direction, respectively. The insulators 71, 72 are molded from a resin having high heat resistance, such as Liquid Crystal Polymer (LCP), polybutylene terephthalate (PBT), polyphenylene sulfide (PPS), polyimide, and polyester.
Fig. 6 is a perspective view of an insulator 71 attached to the upper end surface 60a of the stator core 60. Fig. 7 is a perspective view of the insulator 72 attached to the lower end surface 60b of the stator core 60.
The insulator 71 is composed of an annular portion 71a, 9 protruding portions 71b, and 9 wall portions 71 c.
The annular portion 71a has an annular shape. The annular portion 71a contacts the upper end surface of the main body portion 61 of the stator core 60.
The protruding portion 71b protrudes from the inner peripheral surface of the annular portion 71a toward the radially inner side of the annular portion 71 a. The protruding portion 71b is arranged along the circumferential direction of the annular portion 71 a. The protruding portion 71b contacts the upper end face of the tooth 62 of the stator core 60. The number of the projections 71b is the same as the number of the teeth 62 of the main body 61. The coil 66 is wound around the projection 71b together with the teeth 62.
The wall portion 71c protrudes upward in the vertical direction from the end surface of the annular portion 71 a. The wall portion 71c is formed radially outward of the projection portion 71b and radially outward of the winding 66.
Similarly, the insulator 72 is also constituted by the annular portion 71a, the 9 protruding portions 71b, and the 9 wall portions 71c (see fig. 7).
The annular portion 72a has an annular shape. The annular portion 72a contacts the lower end surface of the main body portion 61 of the stator core 60.
The protruding portion 72b protrudes from the inner peripheral surface of the annular portion 72a toward the radial inside of the annular portion 72 a. The protruding portion 72b is arranged along the circumferential direction of the annular portion 72 a. The protruding portion 72b contacts the lower end surface of the tooth 62 of the stator core 60. The number of the projections 72b is the same as the number of the teeth 62 of the main body portion 61. The winding 66 is wound around the projection 72b together with the teeth 62.
The wall portion 72c protrudes from an end surface of the annular portion 72a in the vertical direction. Wall portion 72c is formed radially outward of projection 72b and radially outward of winding 66.
(2-2) rotor 52
In fig. 1, the rotor 52 has a rotor core 52a and a plurality of magnets 52 b. The rotor core 52a is formed of a plurality of metal plates stacked in the vertical direction. The magnet 52b is embedded in the rotor core 52 a. The magnets 52b are arranged at equal intervals in the circumferential direction of the rotor core 52 a.
The rotor 52 is coupled to the crankshaft 17. The crankshaft 17 penetrates the rotor 52 in the vertical direction. The rotor 52 is connected to the compression mechanism 15 via the crankshaft 17.
(3) Method for manufacturing insulators 71 and 72
Fig. 8A is a schematic cross-sectional view showing a state where stator core 60 is provided in a molding die for insulators 71 and 72. In fig. 8A, the upper mold MDA and the lower mold MDB are insert molding molds for injection molding the insulators 71, 72 in the stator core 60.
The upper mold MDA and the lower mold MDB are clamped after the stator core 60 is placed on the lower mold MDB.
A cavity SA is formed between the closed upper die MDA and the stator core 60. The molten resin is filled in the cavity SA, thereby molding the insulator 71.
A cavity SB is formed between the lower mold MDB and the stator core 60 after the mold is closed. The molten resin is filled in the cavity SB, and the insulator 72 is molded. Further, the insulator 71 and the insulator 72 are integrally connected at the inner side of the outermost peripheries thereof.
(conventional method)
Here, differences from the conventional method will be described. Fig. 8C is a schematic cross-sectional view showing a state where a conventional stator core is provided in an insulator molding die. In fig. 8C, conventionally, end surface 160a of stator core 160 is pressed by upper die MDA to fill cavities SA and SB with molten resin.
However, since stator core 160 is formed by laminating electromagnetic steel plates, height dimension L is unstable, and when gap CL between upper mold MDA and end face 160a of stator core 160 after mold clamping is enlarged, molten resin leaks therefrom and is fixed to the outer peripheral surface of stator core 160.
Since the outer peripheral surface of the stator core 160 is thermally mounted in the casing 10 of the rotary compressor 101, there is a possibility that a trouble such as a pipe clogging may occur when such a resin adheres thereto.
(novel Process)
In the present embodiment, in order to prevent the resin leakage, as shown in fig. 5B, a step portion 611 is provided on the upper end surface 60a side of the main body portion 61 of the stator core 60, and the step portion 611 has an outer periphery smaller than the outer periphery of the main body portion 61, and as shown in fig. 8A, a method of making the outer periphery of the step portion 611 face the inner peripheral surface of the cavity SA of the upper mold MDA is adopted.
Since the stator core 60 is a laminate of electromagnetic steel plates, the dimension between the end faces is unstable, but the dimension in the radial direction of the step portion can be determined with high accuracy by punching, and therefore, the dimensional variation between the lots is extremely small. Therefore, the clearance between the inner peripheral surface of the cavity SA of the upper mold MDA and the outer peripheral surface 611a of the step portion 611 can be controlled within the allowable range.
As a result, the molten resin can be prevented from leaking from the gap and adhering to the outer peripheral surface of main body portion 61 of stator core 60.
(others)
In the present embodiment, since no gap is formed between the lower end surface 60b of the stator core 60 and the lower die MDB, the step portion 611 is not provided on the lower end surface 60b side, but the step portion 611 may be provided on the lower end surface 60b side.
Fig. 8B is a schematic cross-sectional view showing a state in which the stator core 60 having the step parts 611 provided on both end surface sides is provided in the molding dies of the insulators 71 and 72. In fig. 8B, the principle of preventing the molten resin from leaking out is the same as that in fig. 8A, which has been described above, and therefore, the description thereof is omitted.
On the other hand, as an advantage of providing the step parts 611 on both end surface sides of the stator core 60, there are the following points: when the stator core 60 is placed on the lower mold MDB by the robot arm, the stator core 60 can be disposed on the conveyor that supplies the stator core 60 to the robot arm side without concern for the upper and lower sides of the stator core 60, and the workability is good.
(4) Operation of the compressor
The operation of the rotary compressor 101 will be described with reference to fig. 1. When the motor 16 is started, the eccentric shaft portion 17a of the crankshaft 17 coupled to the rotor 52 eccentrically rotates about the rotation axis of the crankshaft 17.
By the rotation of the crankshaft 17, the piston 21 coupled to the eccentric shaft portion 17a performs an orbital motion in the compression chamber 40 around the rotation axis of the crankshaft 17. By the revolution motion of the piston 21, the volumes of the suction chamber and the discharge chamber of the compression chamber 40 are changed.
The low-pressure gas refrigerant is sucked into the suction chamber of the compression chamber 40 through the suction pipe 19. The volume of the suction chamber is reduced by the revolving motion of the piston 21. Thereby, the refrigerant in the suction chamber is compressed, and the suction chamber becomes a discharge chamber filled with a high-pressure gas refrigerant. The high-pressure gas refrigerant is discharged from the discharge chamber into the high-pressure space S1. The discharged refrigerant passes through an air gap, which is a space between the stator 51 and the rotor 52, upward in the vertical direction. Then, the refrigerant is discharged from the discharge pipe 20 to the outside of the casing 10.
The lubricating oil stored in the oil reservoir 10a of the housing 10 is mainly supplied to the sliding portion of the compression mechanism 15. The lubricating oil supplied to the sliding portion of the compression mechanism 15 flows into the compression chamber 40. In the compression chamber 40, the lubricating oil is mixed into the refrigerant gas as fine oil droplets. Therefore, the compressed refrigerant discharged from the compression mechanism 15 includes lubricating oil. A part of the lubricating oil contained in the compressed refrigerant is separated from the refrigerant by the centrifugal force generated by the refrigerant flow in the high-pressure space S1 above the motor 16, and adheres to the inner circumferential surface of the casing 10. The lubricating oil adhered to the inner peripheral surface of the housing 10 drops down along the inner peripheral surface of the housing 10 to reach the height position of the upper surface of the stator 51 of the motor 16. Further, the lubricating oil drops through the core slits 61a of the stator core 60. The lubricating oil having passed through the core slit 61a is finally returned to the oil reservoir 10 a.
Further, according to the rotary compressor 101, since a new method is adopted in which the molten resin does not leak to the outer peripheral surface of the stator core 60 at the time of molding the insulator 71, it is possible to prevent a situation such as "when the stator core 60 is hot-fitted or welded to the casing 10 of the rotary compressor 101, the resin is scattered and remains in the casing 10 and flows together with the refrigerant and the lubricating oil to block the piping and the like" and thus reliability is high.
(5) Feature(s)
(5-1)
According to the stator 51, the step portion 611 is formed by reducing only the outer circumference of the one or more second magnet pieces 602 inward from the end surface 60a of the stator core 60. Therefore, a structure may be adopted in which: when the insulator 71 is integrally molded with the stator core 60 by insert molding, the space between the cavity mold and the core mold of the insulator molding die is closed by the outer peripheral surface 611a of the step portion 611.
Since the outer peripheral surface 611a of the step portion 611 has high dimensional accuracy, the gap between the cavity mold of the insulator molding mold and the outer peripheral surface 611a of the step portion 611 is easily maintained to such an extent that the molten resin does not leak out. Therefore, compared to a conventional method in which the end surface of the stator core is pressed by an insulator molding die, resin leakage to the outer periphery of the stator core during insulator molding can be suppressed.
(5-2)
According to the stator 51, when the outer periphery of the step portion 611 and the outer periphery of the insulator have the same shape in plan view, the portion of the cavity mold into which the outer peripheral surface 611a of the step portion 611 fits coincides with the cavity filled with the resin of the insulator, and this portion also serves as the cavity, so that the number of processing steps for manufacturing the mold does not increase, and the cost of the mold does not increase.
Further, after the insulator 71 is molded, the outer peripheral surface 611a of the step portion 611 of the stator core 60 is flush with the outer peripheral surface of the annular portion 71a of the insulator 71, and therefore, the processing quality is also good.
(5-3)
According to the stator 51, since the cavity mold and the core mold of the insulator molding mold can be closed by the outer periphery of the step portion 611, it is not necessary to press the end surface on the side where the step portion 611 is provided with the mold, and therefore, the resin at the time of molding the insulator can be suppressed from leaking to the outer periphery of the stator core. Further, according to stator 51, even if one end surface of stator core 60 is pressed by a mold, since there is a space on the other end surface side, mold clamping is not hindered even if there is a difference in dimension between the end surfaces.
(5-4)
According to the method of manufacturing the stator 51, the step portion 611 can be formed by laminating the second electromagnetic sheets 602 having the planar shape of the step portion 611 in advance, and therefore, the manufacturing is easy.
(5-5)
According to the method of manufacturing the stator 51, since the resin can be prevented from leaking to the outer periphery of the stator core 60 at the time of molding the insulator, the motor using the stator 51 has high reliability.
(5-6)
According to the manufacturing method of the rotary compressor 101, the resin can be prevented from leaking to the outer periphery of the stator core 60 when the insulator is molded. As a result, when the stator core 60 is fixed to the cylindrical body 11 of the rotary compressor 101 by shrink fitting or welding, a situation in which "the resin adhering to the outer periphery of the stator core 60 melts to become dust and clog pipes or the like" can be prevented.
(6) Modification example
In the present embodiment, as shown in fig. 5A and 6, the deepest region of the core notch 61a of the stator core 60 does not coincide with the outer peripheral surface 611a of the step portion 611 in a plan view. However, it is not limited thereto.
Fig. 9 is a plan view of a stator core 60 of a modification. In fig. 9, the bottom of the core notch 61a may be made deep so that the deepest region of the core notch 61a coincides with the outer peripheral surface 611a of the step portion 611 in a plan view.
In this case, there is an advantage in that: by enlarging the outer peripheries of insulator 71 and insulator 72 to the deepest region of core slit 61a, a winding space can be secured.
In the mold structure of the insulator molding mold, since the male mold forming the core notch 61a can be abutted against the mold surface of the outer edge of the female mold into which the step portion 611 is fitted, the outer peripheral surface of the insulator 71, the outer peripheral surface of the step portion 611, and the bottom-surface-side ridge line of the core notch 61a are aligned after the resin injection molding, and the processing quality is good.
(7) Other constructions
(7-1)
In the above embodiment, the explanation was made on the premise that "the outer periphery of the stator core 60 is larger than the outer periphery of the insulator 71", but the outer periphery of the insulator 71 may be larger than the outer periphery of the stator core 60 as long as the insulator 71 is located inside without contacting the cylindrical body portion 11. For example, the insulator 71 may be in a notch portion of the core slit 61 a.
(7-2)
In the present embodiment, the stator core 60 is formed by laminating electromagnetic steel sheets, and the outer periphery of one or more electromagnetic steel sheets is aligned with the outer periphery of the insulator 71 in a plan view, thereby forming the step portion 611 from the end surface.
However, the stator core 60 may be formed not only by laminating electromagnetic steel plates but also by molding a so-called dust core made of a dust magnetic body obtained by bonding metal magnetic powder with a resin.
In this case, the step portion 611 may be formed so that the outer periphery of the predetermined section of the stator core 60 in the axial direction from the end face enters the insulator 71 in a direction closer to the insulator 71 than the outermost circumferential direction, and preferably, the outer periphery of the step portion 611 and the outer periphery of the insulator 71 may have the same shape in plan view.
Industrial applicability
In the embodiments, the stator used for the motor of the rotary compressor is used for the description, but the stator of the present invention is not limited to the rotary compressor, and is also useful for other compressors such as a scroll compressor.
Description of the reference symbols
11 body part
16 motor
51 stator
52 rotor
60 stator core
60a end face
61 body part
61a core incision
71. 72 insulator
101 compressor
601 first electromagnetic sheet (plate-like member, first electromagnetic steel plate)
602 second electromagnetic sheet (plate-like member, second electromagnetic steel plate)
611 step part
611a outer peripheral surface (outer peripheral)
Documents of the prior art
Patent document
Patent document 1: japanese patent No. 4936051
Claims (10)
1. A stator (51), the stator (51) comprising:
an annular stator core (60); and
a resin insulator disposed on an axial end surface of the stator core (60),
the stator core (60) is disposed in a cylindrical main body part inscribed in the outermost periphery thereof,
an outer peripheral surface that is configured to be parallel to the axial direction is provided on the outer periphery of the end surface of the stator core (60),
a step part (611) is formed on at least the upper end surface side of the outer peripheral surface, the step part (611) is located radially inward of the outermost periphery of the stator core (60),
the outer periphery of the insulator is radially inward of the cylindrical body,
the insulator includes:
an annular portion having an annular shape and contacting an upper end surface of the stator core (60);
a protruding portion that is arranged along a circumferential direction of the annular portion and protrudes radially inward from an inner circumferential surface of the annular portion; and
and a wall portion that protrudes upward in the vertical direction from the upper end of the annular portion on a radially outer side of the protruding portion and on a radially inner side of the outer peripheral surface of the stepped portion (611).
2. The stator (51) of claim 1,
the outer peripheral surface of the step portion (611) has the same shape as the outer periphery of the insulator in a plan view.
3. The stator (51) of claim 1 or 2,
the step part (611) is formed only at one side end of the stator core (60).
4. The stator (51) of claim 1 or 2,
a plurality of core notches (61a) which are notches extending in the axial direction are formed on the outer peripheral surface of the stator core (60),
the deepest region of the core slit (61a) coincides with the outer peripheral surface of the insulator in plan view.
5. The stator (51) of claim 1 or 2,
the insulator includes: a first insulator (71) disposed on one of the end faces of the stator core (60); and a second insulator (72) disposed on the other end surface,
the first insulator (71) and the second insulator (72) are integrally connected at the inner side of the outermost peripheries thereof.
6. The stator (51) of claim 1 or 2,
the stator core is formed by laminating plate-like members.
7. A method of manufacturing a stator according to any one of claims 1 to 6,
the manufacturing method of the stator forms the stator core by the following modes:
forming a main body portion (61) by laminating a first magnetic steel sheet (601) by a first prescribed amount, wherein the first magnetic steel sheet (601) has the same planar shape as the main body portion (61) except for the step portion (611) in the stator core (60),
the step portion (611) is formed by laminating a second magnetic steel sheet (602) having the same planar shape as the step portion (611) by a second predetermined amount that is less than the first predetermined amount on the main body portion (61).
8. A method of manufacturing a stator according to any one of claims 1 to 6,
the insulator is molded by placing the stator core (60) in a mold for injection molding the insulator such that the step portion (611) fits in a cavity mold of the mold, and injecting a molten resin into the mold.
9. A motor (16), the motor (16) comprising:
a stator (51) as claimed in any one of claims 1 to 6; and
and a rotor (52) disposed inside the stator.
10. A method for manufacturing a compressor, wherein,
-fixing the stator (51) according to any one of claims 1 to 6 to the cylindrical body portion (11) of the compressor by shrink fitting or welding.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2016194416 | 2016-09-30 | ||
| JP2016-194416 | 2016-09-30 | ||
| PCT/JP2017/032319 WO2018061701A1 (en) | 2016-09-30 | 2017-09-07 | Stator, method for manufacturing stator, and motor and compressor using stator |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN109792167A CN109792167A (en) | 2019-05-21 |
| CN109792167B true CN109792167B (en) | 2021-08-10 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201780060118.5A Active CN109792167B (en) | 2016-09-30 | 2017-09-07 | Stator, method of manufacturing the same, motor and compressor using the same |
Country Status (3)
| Country | Link |
|---|---|
| JP (1) | JP6489183B2 (en) |
| CN (1) | CN109792167B (en) |
| WO (1) | WO2018061701A1 (en) |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP6900988B2 (en) | 2019-10-15 | 2021-07-14 | ダイキン工業株式会社 | Rotary compressor |
| JP7049620B2 (en) * | 2020-03-31 | 2022-04-07 | ダイキン工業株式会社 | Rotary electric machines, compressors, refrigeration equipment, vehicles |
Family Cites Families (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP3801132B2 (en) * | 2002-12-26 | 2006-07-26 | 三菱電機株式会社 | Electric motor, refrigeration / air conditioner, and electric motor manufacturing method |
| JP4758484B2 (en) * | 2008-01-24 | 2011-08-31 | ダイキン工業株式会社 | Compressor |
| EP2312727A4 (en) * | 2008-08-07 | 2016-11-09 | Daikin Ind Ltd | Stator, motor, and compressor |
| JP2010068699A (en) * | 2008-09-12 | 2010-03-25 | Fanuc Ltd | Electric motor equipped with fitting unit for combining stator core and end covers |
| JP5363255B2 (en) * | 2009-09-18 | 2013-12-11 | 株式会社ミツバ | Stator manufacturing method and stator |
| JP5738208B2 (en) * | 2012-01-27 | 2015-06-17 | 三菱電機株式会社 | Stator for rotating electrical machine and method for manufacturing stator for rotating electrical machine |
| JP2015109783A (en) * | 2013-12-06 | 2015-06-11 | 日立オートモティブシステムズ株式会社 | Rotary electric machine |
| JP2016086508A (en) * | 2014-10-24 | 2016-05-19 | 株式会社三井ハイテック | Armature core and method of manufacturing armature core |
| JP2016149823A (en) * | 2015-02-10 | 2016-08-18 | ダイキン工業株式会社 | Stator, motor, and compressor |
-
2017
- 2017-09-07 JP JP2017171704A patent/JP6489183B2/en active Active
- 2017-09-07 CN CN201780060118.5A patent/CN109792167B/en active Active
- 2017-09-07 WO PCT/JP2017/032319 patent/WO2018061701A1/en active Application Filing
Also Published As
| Publication number | Publication date |
|---|---|
| CN109792167A (en) | 2019-05-21 |
| JP2018061420A (en) | 2018-04-12 |
| JP6489183B2 (en) | 2019-03-27 |
| WO2018061701A1 (en) | 2018-04-05 |
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