JP2009071948A - Stator for rotary electric machine and method of manufacturing the same - Google Patents
Stator for rotary electric machine and method of manufacturing the same Download PDFInfo
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- JP2009071948A JP2009071948A JP2007236458A JP2007236458A JP2009071948A JP 2009071948 A JP2009071948 A JP 2009071948A JP 2007236458 A JP2007236458 A JP 2007236458A JP 2007236458 A JP2007236458 A JP 2007236458A JP 2009071948 A JP2009071948 A JP 2009071948A
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 29
- 238000004804 winding Methods 0.000 claims abstract description 200
- 239000012778 molding material Substances 0.000 claims abstract description 54
- 238000000465 moulding Methods 0.000 claims abstract description 50
- 239000006247 magnetic powder Substances 0.000 claims abstract description 41
- 229920005989 resin Polymers 0.000 claims abstract description 40
- 239000011347 resin Substances 0.000 claims abstract description 40
- 239000000853 adhesive Substances 0.000 claims abstract description 21
- 230000001070 adhesive effect Effects 0.000 claims abstract description 21
- 230000002093 peripheral effect Effects 0.000 claims description 39
- 239000003365 glass fiber Substances 0.000 claims description 38
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 35
- 238000000034 method Methods 0.000 claims description 18
- 229910000831 Steel Inorganic materials 0.000 claims description 13
- 239000010959 steel Substances 0.000 claims description 13
- 238000010030 laminating Methods 0.000 claims description 12
- 239000000463 material Substances 0.000 claims description 12
- 229910052742 iron Inorganic materials 0.000 claims description 11
- 239000011248 coating agent Substances 0.000 claims description 7
- 238000000576 coating method Methods 0.000 claims description 7
- 229910000976 Electrical steel Inorganic materials 0.000 claims description 4
- 239000011162 core material Substances 0.000 description 61
- 239000004020 conductor Substances 0.000 description 4
- 230000035939 shock Effects 0.000 description 3
- 239000000428 dust Substances 0.000 description 2
- 230000009477 glass transition Effects 0.000 description 2
- 239000011810 insulating material Substances 0.000 description 2
- 238000007493 shaping process Methods 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- 239000004962 Polyamide-imide Substances 0.000 description 1
- 230000002730 additional effect Effects 0.000 description 1
- -1 and further Substances 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 229920002312 polyamide-imide Polymers 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
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- Iron Core Of Rotating Electric Machines (AREA)
- Manufacture Of Motors, Generators (AREA)
Abstract
Description
本発明は、回転電機の固定子及びその製造方法に関する。 The present invention relates to a stator for a rotating electrical machine and a method for manufacturing the same.
従来、圧粉磁心材料の成形によって固定子コアを作成し、その固定子コアに巻線を施してなる回転電機の固定子が提案されている（例えば、特許文献１等参照。）。
しかしながら、上述した従来技術における固定子は、固定子コアの成形後にコイルを巻線するものであり、間隔の狭い固定子コアのスロット内へ線材を挿入して巻線を施す作業が困難であり、多くの工数が必要とされるという問題がある。さらに、圧粉磁心材料を用いて成形した固定子コアでは、強度を十分に確保できないおそれがある。 However, the above-described stator in the prior art winds the coil after the stator core is formed, and it is difficult to insert the wire into the slot of the stator core having a narrow interval and perform the winding. There is a problem that many man-hours are required. Furthermore, there is a possibility that sufficient strength cannot be secured with a stator core molded using a dust core material.
本発明は上記課題に鑑みてなされたものであり、製造が容易であり且つ強度に優れた回転電機の固定子及びその製造方法を提供することを目的とする。 The present invention has been made in view of the above problems, and an object of the present invention is to provide a stator for a rotating electrical machine that is easy to manufacture and excellent in strength, and a method for manufacturing the same.
以下、上記課題を解決するのに適した各手段につき、必要に応じて作用効果等を付記しつつ説明する。 Hereinafter, each means suitable for solving the above-described problems will be described with additional effects and the like as necessary.
１．断面形状が略矩形状の線材を巻線して環状に形成され且つ接着剤により全体が固着された多相固定子巻線と、
前記多相固定子巻線の外形全体を磁性粉を含有する成形材によって成形してなる内側成形部、及び前記内側成形部の外周側に一体的に形成され径方向に所定幅を有する円筒状の空間を前記磁性粉を含有する樹脂によって成形してなる外側成形部からなる固定子コアと
を備えたことを特徴とする回転電機の固定子。
1. A multiphase stator winding in which a cross-sectional shape is formed by winding a substantially rectangular wire, and the whole is fixed by an adhesive;
An inner molded part formed by molding the entire outer shape of the multiphase stator winding with a molding material containing magnetic powder, and a cylindrical shape integrally formed on the outer peripheral side of the inner molded part and having a predetermined width in the radial direction And a stator core made of an outer molded part formed by molding the space with the resin containing the magnetic powder.
手段１によれば、多相固定子巻線は、断面形状が略矩形状の線材を予め巻線して環状に形成されているので、線材を固定子コアのスロットへ挿入する等の作業を伴うことなく、簡単な巻線作業で多相固定子巻線を作製することができる。また、多相固定子巻線全体が接着剤により固着されているので、巻線形状を確実に維持することができる。また、固定子コアは、多相固定子巻線の外形全体を磁性粉を含有する樹脂等の成形材によって成形してなる内側成形部、及び内側成形部の外周側に一体的に形成され径方向に所定幅を有する円筒状の空間を磁性粉を含有する樹脂等の成形材によって成形してなる外側成形部からなるので、固定子コアを樹脂等の成形材の成形によって簡単に作製できると共に、多相固定子巻線を構成する線材間に磁性粉を含有する樹脂等の成形材が隙間無く充填されるため、高い占積率を有する固定子を実現することができる。 According to the means 1, the multi-phase stator winding is formed in an annular shape by winding a wire having a substantially rectangular cross section in advance, so that an operation such as inserting the wire into a slot of the stator core is performed. Without this, a multiphase stator winding can be produced by a simple winding operation. Further, since the entire multiphase stator winding is fixed by the adhesive, the winding shape can be reliably maintained. Further, the stator core is integrally formed on the outer side of the inner molded portion and the inner molded portion formed by molding the entire outer shape of the multiphase stator winding with a molding material such as resin containing magnetic powder. Since the cylindrical space having a predetermined width in the direction is composed of an outer molded portion formed by molding a molding material such as resin containing magnetic powder, the stator core can be easily produced by molding a molding material such as resin. Since a molding material such as a resin containing magnetic powder is filled between the wires constituting the multiphase stator winding without any gap, a stator having a high space factor can be realized.
２．前記固定子コアは、取付け穴を有する取付部が前記外側成形部と一体成形されたことを特徴とする手段１に記載の回転電機の固定子。 2. The stator of a rotating electrical machine according to means 1, wherein the stator core has a mounting portion having a mounting hole formed integrally with the outer molded portion.
手段２によれば、固定子コアは、取付け穴を有する取付部が外側成形部と一体成形されているので、固定子を取付部でネジ部材等によりハウジング等へ確実に取付けることができる。また、固定子コアの成形と同時に取付部が樹脂等の成形材によって形成されるので、取付部の作製が容易であり且つ工数の増加を伴わない。 According to the means 2, the stator core can be securely attached to the housing or the like by a screw member or the like at the attachment portion since the attachment portion having the attachment hole is integrally formed with the outer molding portion. Further, since the attachment portion is formed of a molding material such as a resin simultaneously with the molding of the stator core, the attachment portion can be easily manufactured and the number of man-hours is not increased.
３．前記固定子コアは、前記外側成形部が前記多相固定子巻線の外周にガラスファイバを巻付けた状態で成形されたことを特徴とする手段１又は２に記載の回転電機の固定子。 3. The stator of a rotating electrical machine according to means 1 or 2, wherein the stator core is formed in a state in which the outer molded portion is wound with a glass fiber around an outer periphery of the multiphase stator winding.
手段３によれば、固定子コアの外側成形部が、多相固定子巻線の外周に帯状等のガラスファイバを巻付けた状態で樹脂等の成形材によって成形されているので、強度の向上によって振動等の衝撃に耐えることが可能となる。 According to the means 3, the outer core molded portion of the stator core is molded with a molding material such as resin in a state where a glass fiber such as a belt is wound around the outer periphery of the multiphase stator winding, so that the strength is improved. Can withstand shocks such as vibration.
４．断面形状が略矩形状の線材を巻線して環状に形成され且つ接着剤により全体が固着された多相固定子巻線と、
電磁鋼板を積層してなり前記多相固定子巻線の外径以上の内径を有し前記多相固定子巻線の外周側に配置される円筒部材、及び前記多相固定子巻線の外形全体を含む前記多相固定子巻線の内周部と前記円筒部材の内周部との間の空間を磁性粉を含有する成形材によって成形してなる成形部からなる固定子コアと
を備えたことを特徴とする回転電機の固定子。
4). A multiphase stator winding in which a cross-sectional shape is formed by winding a substantially rectangular wire, and the whole is fixed by an adhesive;
A cylindrical member formed by laminating electromagnetic steel plates and having an inner diameter greater than or equal to the outer diameter of the multiphase stator winding and disposed on the outer peripheral side of the multiphase stator winding, and the outer shape of the multiphase stator winding A stator core comprising a molded part formed by molding a space between an inner peripheral part of the multiphase stator winding including the whole and an inner peripheral part of the cylindrical member with a molding material containing magnetic powder. A stator of a rotating electric machine characterized by that.
手段４によれば、多相固定子巻線は、断面形状が略矩形状の線材を予め巻線して環状に形成されているので、線材を固定子コアのスロットへ挿入する等の作業を伴うことなく、簡単な巻線作業で多相固定子巻線を作製することができる。また、多相固定子巻線全体が接着剤により固着されているので、巻線形状を確実に維持することができる。また、固定子コアは、電磁鋼板を積層してなり多相固定子巻線の外径以上の内径を有し多相固定子巻線の外周側に配置される円筒部材、及び多相固定子巻線の外形全体を含む多相固定子巻線の内周部と円筒部材の内周部との間の空間を磁性粉を含有する樹脂等の成形材によって成形してなる成形部からなるので、固定子コアを電磁鋼板を積層してなる円筒部材と樹脂等の成形材の成形とによって簡単に作製でき且つ固定子全体の強度を確実に確保することができると共に、多相固定子巻線を構成する線材間に磁性粉を含有する樹脂等の成形材が隙間無く充填されるため、高い占積率を有する固定子を実現することができる。 According to the means 4, since the multiphase stator winding is formed in an annular shape by winding a wire having a substantially rectangular cross section in advance, an operation such as inserting the wire into a slot of the stator core is performed. Without this, a multiphase stator winding can be produced by a simple winding operation. Further, since the entire multiphase stator winding is fixed by the adhesive, the winding shape can be reliably maintained. The stator core is formed by laminating electromagnetic steel plates, and has a cylindrical member that has an inner diameter greater than or equal to the outer diameter of the multiphase stator winding and is disposed on the outer peripheral side of the multiphase stator winding, and the multiphase stator Since the space between the inner peripheral part of the multiphase stator winding including the entire outer shape of the winding and the inner peripheral part of the cylindrical member is formed by a molding part formed by a molding material such as a resin containing magnetic powder. The stator core can be easily manufactured by forming a cylindrical member made by laminating electromagnetic steel plates and molding of a molding material such as resin, and the strength of the entire stator can be reliably ensured, and a multi-phase stator winding Since a molding material such as a resin containing magnetic powder is filled with no gap between the wire members constituting the stator, a stator having a high space factor can be realized.
５．前記固定子コアは、前記円筒部材が前記多相固定子巻線に対して非接触に配置されて前記成形材により連結されたことを特徴とする手段４に記載の回転電機の固定子。 5). The stator of a rotating electrical machine according to claim 4, wherein the stator core is configured such that the cylindrical member is arranged in a non-contact manner with respect to the multiphase stator winding and is connected by the molding material.
手段５によれば、固定子コアの円筒部材が多相固定子巻線に対して非接触に配置されて成形材により連結されることにより、巻線と円筒部材との強固な一体化が図られている。 According to the means 5, the cylindrical member of the stator core is arranged in a non-contact manner with respect to the multi-phase stator winding and is connected by the molding material, whereby the winding and the cylindrical member are firmly integrated. It has been.
６．前記固定子コアは、前記成形部が前記多相固定子巻線の外周にガラスファイバを巻付けた状態で成形されたことを特徴とする手段５に記載の回転電機の固定子。 6). The stator of a rotating electric machine according to claim 5, wherein the stator core is formed in a state in which the forming portion has a glass fiber wound around an outer periphery of the multiphase stator winding.
手段６によれば、固定子コアの成形部が多相固定子巻線の外周に帯状等のガラスファイバを巻付けた状態で樹脂等の成形材により成形されているので、円筒部材と多相固定子巻線とが確実に非接触に保たれると共に、強度の向上によって振動等の衝撃に耐えることが可能となる。 According to the means 6, the molded part of the stator core is formed of a molding material such as a resin in a state in which a glass fiber such as a band is wound around the outer periphery of the multiphase stator winding. The stator winding is reliably kept in non-contact, and the strength can be improved to withstand impacts such as vibration.
７．前記固定子コアは、前記円筒部材の内周面に凹凸形状が設けられたことを特徴とする手段５又は６に記載の回転電機の固定子。 7. The stator for a rotating electrical machine according to means 5 or 6, wherein the stator core is provided with an uneven shape on an inner peripheral surface of the cylindrical member.
手段７によれば、固定子コアの円筒部材の内周面に凹凸形状が設けられているので、樹脂等の成形材との抜け止めが図られて耐振動性が向上する。 According to the means 7, since the concave and convex shape is provided on the inner peripheral surface of the cylindrical member of the stator core, it can be prevented from coming off from a molding material such as resin, and the vibration resistance is improved.
８．前記磁性粉は、絶縁被膜が施された鉄粉からなることを特徴とする手段１乃至７のいずれかに記載の回転電機の固定子。 8). The stator of a rotating electrical machine according to any one of means 1 to 7, wherein the magnetic powder is made of iron powder with an insulating coating.
手段８によれば、磁性粉は、絶縁被膜が施された鉄粉からなるので、鉄粉の電気抵抗率を高めることにより、回転電機における鉄損を少なくすることできる。 According to the means 8, since the magnetic powder is made of iron powder with an insulating coating, the iron loss in the rotating electrical machine can be reduced by increasing the electric resistivity of the iron powder.
９．前記磁性粉は、低鉄損材料からなることを特徴とする手段１乃至８のいずれかに記載の回転電機の固定子。 9. The stator of a rotating electric machine according to any one of means 1 to 8, wherein the magnetic powder is made of a low iron loss material.
手段９によれば、磁性粉は、低鉄損材料からなるので、鉄損が少ない回転電機を実現することできる。 According to the means 9, since the magnetic powder is made of a low iron loss material, it is possible to realize a rotating electrical machine with less iron loss.
１０．前記磁性粉は、珪素鋼入り鉄粉からなることを特徴とする手段９に記載の回転電機の固定子。 10. The stator of a rotating electric machine according to means 9, wherein the magnetic powder is made of iron powder containing silicon steel.
手段１０によれば、磁性粉は、低鉄損材料である珪素鋼入り鉄粉からなるので、鉄損が少ない回転電機を確実に実現することできる。 According to the means 10, since the magnetic powder is made of iron powder containing silicon steel, which is a low iron loss material, it is possible to reliably realize a rotating electrical machine with less iron loss.
１１．断面形状が略矩形状の線材を巻線して環状の多相固定子巻線を形成する巻線形成工程と、
前記多相固定子巻線全体を接着剤により固着する巻線固着工程と、
前記多相固定子巻線の外形全体と前記多相固定子巻線の外周に隣接し径方向に所定幅を有する円筒状の空間とを前記磁性粉を含有する成形材によって一体的に成形して固定子コアを形成する成形工程と
を備えたことを特徴とする回転電機の固定子製造方法。
11. A winding forming step of winding a wire material having a substantially rectangular cross section to form an annular multiphase stator winding;
A winding fixing step of fixing the entire multiphase stator winding with an adhesive;
The entire outer shape of the multiphase stator winding and a cylindrical space adjacent to the outer periphery of the multiphase stator winding and having a predetermined width in the radial direction are integrally formed with the molding material containing the magnetic powder. A stator manufacturing method for forming a stator core.
手段１１によれば、巻線形成工程では、断面形状が略矩形状の線材を巻線して環状に形成するので、固定子コアへの巻装作業を伴うことなく、多相固定子巻線を容易に作製することができる。また、巻線固着工程では、多相固定子巻線全体を接着剤により固着することにより、巻線形状を確実に維持することができる。また、成形工程では、多相固定子巻線の外形全体と多相固定子巻線の外周に隣接し径方向に所定幅を有する円筒状の空間とを磁性粉を含有する樹脂によって一体的に成形することにより、固定子コアを樹脂等の成形材の成形によって簡単に作製できると共に、多相固定子巻線を構成する線材間に磁性粉を含有する樹脂等の成形材が隙間無く充填されるため、高い占積率を有する固定子を実現することができる。 According to the means 11, in the winding forming step, the wire having a substantially rectangular cross section is wound to form an annular shape, so that the multiphase stator winding is not involved in the winding work around the stator core. Can be easily manufactured. Further, in the winding fixing step, the entire multi-phase stator winding is fixed with an adhesive, so that the winding shape can be reliably maintained. In the molding process, the entire outer shape of the multiphase stator winding and the cylindrical space adjacent to the outer periphery of the multiphase stator winding and having a predetermined width in the radial direction are integrally formed by a resin containing magnetic powder. By molding, the stator core can be easily produced by molding a molding material such as resin, and the molding material such as resin containing magnetic powder is filled without gaps between the wires constituting the multiphase stator winding. Therefore, a stator having a high space factor can be realized.
１２．前記成形工程は、前記固定子コアの成形時に取付け穴を有する取付部を同時に成形することを特徴とする手段１１に記載の回転電機の固定子製造方法。 12 The method of manufacturing a stator for a rotating electrical machine according to claim 11, wherein the forming step simultaneously forms an attachment portion having an attachment hole when the stator core is formed.
手段１２によれば、成形工程において固定子コアの成形時に取付け穴を有する取付部を樹脂等の成形材により同時に成形するので、工数の増加を伴うことなく取付部を作製することができる。 According to the means 12, since the attachment portion having the attachment hole is simultaneously formed with a molding material such as a resin at the time of forming the stator core in the forming step, the attachment portion can be produced without increasing the number of man-hours.
１３．前記多相固定子巻線の外周にガラスファイバを巻付けるガラスファイバ巻付け工程を更に備え、
前記成形工程は、前記多相固定子巻線の外周にガラスファイバを巻付けた状態で成形を行うことを特徴とする手段１１又は１２に記載の回転電機の固定子製造方法。
13. A glass fiber winding step of winding a glass fiber around the outer periphery of the multiphase stator winding;
The method for manufacturing a stator of a rotating electric machine according to means 11 or 12, wherein the forming step is performed in a state where a glass fiber is wound around an outer periphery of the multiphase stator winding.
手段１３によれば、ガラスファイバ巻付け工程で、多相固定子巻線の外周にガラスファイバを巻付け、成形工程では、多相固定子巻線の外周に帯状等のガラスファイバを巻付けた状態で成形を行うので、固定子の強度を振動等の衝撃に耐えられるように向上させることができる。 According to the means 13, the glass fiber is wound around the outer periphery of the multiphase stator winding in the glass fiber winding step, and the glass fiber such as a belt is wound around the outer periphery of the multiphase stator winding in the molding step. Since the molding is performed in a state, the strength of the stator can be improved so as to withstand an impact such as vibration.
１４．断面形状が略矩形状の線材を巻線して環状の多相固定子巻線を形成する巻線形成工程と、
前記多相固定子巻線全体を接着剤により固着する巻線固着工程と、
電磁鋼板を積層してなり前記多相固定子巻線の外径以上の内径を有する円筒部材を、前記接着剤により固着された前記多相固定子巻線の外周側に配置し、この状態で、前記多相固定子巻線の外形全体を含む前記多相固定子巻線の内周部と前記円筒部材の内周部との間の空間を、磁性粉を含有する樹脂によって一体的に成形して固定子コアを形成する成形工程と
を備えたことを特徴とする回転電機の固定子製造方法。
14 A winding forming step of winding a wire material having a substantially rectangular cross section to form an annular multiphase stator winding;
A winding fixing step of fixing the entire multiphase stator winding with an adhesive;
A cylindrical member formed by laminating electromagnetic steel sheets and having an inner diameter equal to or larger than the outer diameter of the multiphase stator winding is disposed on the outer peripheral side of the multiphase stator winding fixed by the adhesive. The space between the inner peripheral portion of the multiphase stator winding and the inner peripheral portion of the cylindrical member including the entire outer shape of the multiphase stator winding is integrally formed with a resin containing magnetic powder. And a stator manufacturing method for forming a stator core.
手段１４によれば、巻線形成工程では、断面形状が略矩形状の線材を巻線して環状に形成するので、固定子コアへの巻装作業を伴うことなく、多相固定子巻線を容易に作製することができる。また、巻線固着工程では、多相固定子巻線全体を接着剤により固着することにより、巻線形状を確実に維持することができる。また、成形工程では、電磁鋼板を積層してなり多相固定子巻線の外径以上の内径を有する円筒部材を、接着剤により固着された多相固定子巻線の外周側に配置し、この状態で、多相固定子巻線の外形全体を含む多相固定子巻線の内周部と円筒部材の内周部との空間を、磁性粉を含有する樹脂によって一体的に成形して固定子コアを形成することにより、電磁鋼板を積層してなる円筒部材と樹脂等の成形材の成形とによって全体の強度が優れた固定子を簡単に作製できると共に、多相固定子巻線を構成する線材間に磁性粉を含有する樹脂等の成形材が隙間無く充填されるため、高い占積率を有する固定子を実現することができる。 According to the means 14, in the winding forming step, the wire having a substantially rectangular cross section is wound to form an annular shape, so that the multiphase stator winding is not involved in the winding work around the stator core. Can be easily manufactured. Further, in the winding fixing step, the entire multi-phase stator winding is fixed with an adhesive, so that the winding shape can be reliably maintained. In the molding process, a cylindrical member having an inner diameter equal to or greater than the outer diameter of the multiphase stator winding formed by laminating electromagnetic steel sheets is disposed on the outer peripheral side of the multiphase stator winding fixed by an adhesive, In this state, the space between the inner peripheral portion of the multiphase stator winding including the entire outer shape of the multiphase stator winding and the inner peripheral portion of the cylindrical member is integrally formed with a resin containing magnetic powder. By forming the stator core, it is possible to easily produce a stator having excellent overall strength by forming a cylindrical member formed by laminating electromagnetic steel sheets and a molding material such as resin, and a multi-phase stator winding. Since a molding material such as a resin containing magnetic powder is filled between the constituent wires without gaps, a stator having a high space factor can be realized.
１５．前記成形工程は、前記円筒部材を前記多相固定子巻線に対して非接触に配置し、前記多相固定子巻線と前記円筒部材とを前記成形材により連結することを特徴とする手段１４に記載の回転電機の固定子製造方法。 15. The molding step includes disposing the cylindrical member in a non-contact manner with respect to the multiphase stator winding, and connecting the multiphase stator winding and the cylindrical member with the molding material. A method for manufacturing a stator of a rotating electric machine according to claim 14.
手段１５によれば、成形工程では、円筒部材を多相固定子巻線に対して非接触に配置し、多相固定子巻線と円筒部材とを樹脂等の成形材により連結するので、巻線と円筒部材とを強固に一体化することができる。 According to the means 15, in the molding process, the cylindrical member is disposed in a non-contact manner with respect to the multiphase stator winding, and the multiphase stator winding and the cylindrical member are connected by a molding material such as resin. The wire and the cylindrical member can be firmly integrated.
１６．前記多相固定子巻線の外周にガラスファイバを巻付けるガラスファイバ巻付け工程を更に備え、
前記成形工程は、前記多相固定子巻線の外周にガラスファイバを巻装した状態で成形を行うことを特徴とする手段１５に記載の回転電機の固定子製造方法。
16. A glass fiber winding step of winding a glass fiber around the outer periphery of the multiphase stator winding;
The method of manufacturing a stator for a rotating electrical machine according to claim 15, wherein the forming step is performed in a state where a glass fiber is wound around an outer periphery of the multiphase stator winding.
手段１６によれば、ガラスファイバ巻付け工程で、多相固定子巻線の外周にガラスファイバを巻付け、成形工程では、多相固定子巻線の外周に帯状等のガラスファイバを巻装した状態で成形を行うので、円筒部材と多相固定子巻線とを確実に非接触に保つことができると共に、振動等の衝撃に耐えられるように固定子の強度を向上させることができる。 According to the means 16, a glass fiber is wound around the outer periphery of the multiphase stator winding in the glass fiber winding step, and a glass fiber such as a belt is wound around the outer periphery of the multiphase stator winding in the molding step. Since the molding is performed in a state, the cylindrical member and the multiphase stator winding can be reliably kept in non-contact, and the strength of the stator can be improved so as to withstand an impact such as vibration.
１７．前記円筒部材の内周面に凹凸形状が設けられたことを特徴とする手段１５又は１６に記載の回転電機の固定子製造方法。 17. The method of manufacturing a stator for a rotating electric machine according to means 15 or 16, wherein an uneven shape is provided on an inner peripheral surface of the cylindrical member.
手段１７によれば、円筒部材の内周面に凹凸形状が設けられているので、成形工程において樹脂等の成形材との抜け止めが図られ、固定子の耐振動性が向上する。 According to the means 17, since the concave and convex shape is provided on the inner peripheral surface of the cylindrical member, it can be prevented from coming off with a molding material such as resin in the molding process, and the vibration resistance of the stator is improved.
以下、本発明の回転電機の固定子及びその製造方法を具体化した各実施形態について図面を参照しつつ具体的に説明する。 DESCRIPTION OF EMBODIMENTS Hereinafter, embodiments of a stator for a rotating electrical machine and a method for manufacturing the same according to the present invention will be described in detail with reference to the drawings.
最初に、第一の実施形態における回転電機の固定子１０の製造方法及び固定子１０の構成について説明する。図１は、本発明の第一の実施形態における固定子１０の製造工程を示すフローチャートである。 Initially, the manufacturing method of the stator 10 of the rotary electric machine in 1st embodiment and the structure of the stator 10 are demonstrated. FIG. 1 is a flowchart showing manufacturing steps of the stator 10 according to the first embodiment of the present invention.
本実施形態における固定子１０の製造工程には、図１に示すように、巻線形成工程Ｓ１と、巻線固着工程Ｓ２と、ガラスファイバ巻付け工程Ｓ３と、成形工程Ｓ４とが含まれる。 As shown in FIG. 1, the manufacturing process of the stator 10 in the present embodiment includes a winding forming process S1, a winding fixing process S2, a glass fiber winding process S3, and a forming process S4.
巻線形成工程Ｓ１では、線材３０を巻線して、図２に示す環状の三相固定子巻線２０を形成する。図２は、三相固定子巻線２０を示す斜視図である。図３は、線材３０を示す断面図である。図４は、線材３０の形状を示す斜視図である。尚、三相固定子巻線２０が、本発明の多相固定子巻線を構成するものである。 In the winding forming step S1, the wire 30 is wound to form the annular three-phase stator winding 20 shown in FIG. FIG. 2 is a perspective view showing the three-phase stator winding 20. FIG. 3 is a cross-sectional view showing the wire 30. FIG. 4 is a perspective view showing the shape of the wire 30. The three-phase stator winding 20 constitutes the multiphase stator winding of the present invention.
線材３０は、断面形状が略矩形状の線材（平角線）であって、銅製の導体３２と、導体３２の外周を覆い導体３２を絶縁する内層３４および外層３６からなる絶縁被覆とから形成されている。内層３４は導体３２の外周を覆い、外層３６は内層３４の外周を覆っている。内層３４および外層３６を合わせた絶縁被覆の厚みは、１００μｍ〜２００μｍの間に設定されている。このように、内層３４および外層３６からなる絶縁被覆の厚みが厚いので、線材３０同士を絶縁するめに線材３０同士の間に絶縁紙等を挟み込んで絶縁する必要がない。外層３６はナイロン等の絶縁材、内層３４は外層よりもガラス転移温度の高い熱可塑性樹脂またはガラス転移温度の無いポリアミドイミド等の絶縁材で形成されている。 The wire rod 30 is a wire rod (flat wire) having a substantially rectangular cross-sectional shape, and is formed of a copper conductor 32 and an insulating coating composed of an inner layer 34 and an outer layer 36 that cover the outer periphery of the conductor 32 and insulate the conductor 32. ing. The inner layer 34 covers the outer periphery of the conductor 32, and the outer layer 36 covers the outer periphery of the inner layer 34. The thickness of the insulating coating including the inner layer 34 and the outer layer 36 is set between 100 μm and 200 μm. As described above, since the thickness of the insulating coating composed of the inner layer 34 and the outer layer 36 is thick, it is not necessary to insulate by interposing insulating paper or the like between the wire members 30 in order to insulate the wire members 30 from each other. The outer layer 36 is formed of an insulating material such as nylon, and the inner layer 34 is formed of a thermoplastic resin having a glass transition temperature higher than that of the outer layer or an insulating material such as polyamideimide having no glass transition temperature.
また、線材３０は、図４に示すように、後述する固定子コア１２内に配置される直線部４０と、固定子コア１２の外に突出し、周方向に異なる位置に配置されている直線部４０同士を接続しているターン部４２とを有しており、環状に波巻されることにより固定子巻線２０を形成している。ターン部４２は、固定子巻線２０の軸方向両側にそれぞれ形成されている。ターン部４２の略中央部にはねじりを伴わないクランク部４４が形成されている。クランク部４４は、固定子コア１２端面に沿うクランク形状に形成されている。このクランク部４４のクランク形状によるずれ量は、線材３０の略幅分である。これにより、径方向に隣接している線材３０のターン部４２同士を密に巻回できる。その結果、コイルエンドの径方向の幅が小さくなるので、固定子巻線２０が径方向外側に張り出すことを防止する。また、固定子コア１２内から固定子コア１２外に突出するターン部４２の突出箇所に、固定子コア１２軸方向両側端面に沿うクランク部４６が形成されている。 As shown in FIG. 4, the wire 30 includes a straight portion 40 that is disposed in the stator core 12 described later, and a straight portion that protrudes outside the stator core 12 and is disposed at a different position in the circumferential direction. The stator windings 20 are formed by being wound in an annular shape. The turn portions 42 are respectively formed on both sides of the stator winding 20 in the axial direction. A crank portion 44 without twisting is formed at a substantially central portion of the turn portion 42. The crank portion 44 is formed in a crank shape along the end face of the stator core 12. The amount of deviation of the crank portion 44 due to the crank shape is approximately the width of the wire 30. Thereby, the turn parts 42 of the wire 30 adjacent to each other in the radial direction can be densely wound. As a result, since the radial width of the coil end is reduced, the stator winding 20 is prevented from projecting radially outward. In addition, crank portions 46 are formed along the axially opposite end surfaces of the stator core 12 at the projecting portions of the turn portions 42 that project from the stator core 12 to the outside of the stator core 12.
さらに、線材３０には、ターン部４２の略中央部のクランク部４４と、ターン部４２の突出箇所に形成したクランク部４６との間に、それぞれ２個のクランク部４８が形成されている。つまり、固定子コア１２の一方の軸方向の端面側の線材３０のターン部４２には、合計７個のクランク部が形成されている。これにより、クランク部を形成しない三角形状のターン部の高さに比べ、ターン部４２の高さが低くなる。クランク部４８のクランク形状も、クランク部４４、４６と同様に、固定子コア１２の端面に沿ったクランク形状に形成されている。したがって、線材３０のターン部４２は、クランク部４４を挟んで両側を階段状に形成している。 Further, two crank portions 48 are formed on the wire 30 between a crank portion 44 at a substantially central portion of the turn portion 42 and a crank portion 46 formed at a protruding portion of the turn portion 42. That is, a total of seven crank portions are formed in the turn portion 42 of the wire 30 on one axial end face side of the stator core 12. Thereby, the height of the turn part 42 becomes lower than the height of the triangular turn part that does not form the crank part. The crank shape of the crank portion 48 is also formed in a crank shape along the end surface of the stator core 12, similarly to the crank portions 44 and 46. Therefore, the turn part 42 of the wire 30 is formed in a stepped shape on both sides with the crank part 44 in between.
次に、巻線固着工程Ｓ２では、巻線形成工程Ｓ１において形成された三相固定子巻線２０の巻線形状を維持するために、三相固定子巻線２０全体を接着剤により固着する。 Next, in the winding fixing step S2, in order to maintain the winding shape of the three-phase stator winding 20 formed in the winding forming step S1, the entire three-phase stator winding 20 is fixed with an adhesive. .
次に、ガラスファイバ巻付け工程Ｓ３では、強度の向上を図るために、接着剤で固着された三相固定子巻線２０外周に帯状のガラスファイバ１９を巻付ける。図５は、ガラスファイバ巻付け工程Ｓ３を説明するための説明図である。また、三相固定子巻線２０と樹脂等の成形材との密着性を確保するために、ガラスファイバ１９は、三相固定子巻線２０の外周全体を覆うのではなく、例えば、外周全体の半分程度を覆うように巻付けること（所謂、ハーフラップ）が好ましい。 Next, in the glass fiber winding step S3, in order to improve the strength, a belt-like glass fiber 19 is wound around the outer periphery of the three-phase stator winding 20 fixed with an adhesive. FIG. 5 is an explanatory diagram for explaining the glass fiber winding step S3. Further, in order to ensure the adhesion between the three-phase stator winding 20 and a molding material such as resin, the glass fiber 19 does not cover the entire outer periphery of the three-phase stator winding 20, for example, the entire outer periphery. It is preferable to wind so as to cover about half (so-called half wrap).
次に、成形工程Ｓ４では、外周にガラスファイバ１９が巻付けられた三相固定子巻線２０を図示しない成形型内に配置し、三相固定子巻線２０の外形全体と三相固定子巻線２０の外周に隣接し径方向に所定幅を有する円筒状の空間とを、磁性粉を含有する樹脂等の成形材によって一体的に成形して固定子コア１２を形成する。図６は、成形材によって成形される部分を示す説明図である（成形される部分を点線で示す）。成形工程Ｓ４では、固定子コア１２の成形と同時に、取付け穴１２ｄを有する取付部１２ｄを成形材により一体的に成形する。 Next, in the molding step S4, the three-phase stator winding 20 with the glass fiber 19 wound around the outer periphery is disposed in a molding die (not shown), and the entire outer shape of the three-phase stator winding 20 and the three-phase stator are arranged. The stator core 12 is formed by integrally molding a cylindrical space adjacent to the outer periphery of the winding 20 and having a predetermined width in the radial direction with a molding material such as resin containing magnetic powder. FIG. 6 is an explanatory view showing a portion molded by the molding material (the portion to be molded is indicated by a dotted line). In the molding step S4, simultaneously with the molding of the stator core 12, the mounting portion 12d having the mounting holes 12d is integrally molded with the molding material.
磁性粉としては、絶縁被膜が施された鉄粉を用いることが好ましく、鉄粉として低鉄損材料（例えば、珪素鋼入り鉄粉）を用いることが特に好ましい。絶縁被膜が施された鉄粉によれば、鉄粉の電気抵抗率を高めることにより、回転電機における鉄損を少なくすることできる。また、鉄粉として低鉄損材料を用いることによって、鉄損が少ない回転電機をより確実に実現することできる。 As the magnetic powder, it is preferable to use iron powder coated with an insulating film, and it is particularly preferable to use a low iron loss material (for example, iron powder containing silicon steel) as the iron powder. According to the iron powder to which the insulating coating is applied, the iron loss in the rotating electrical machine can be reduced by increasing the electric resistivity of the iron powder. Further, by using a low iron loss material as the iron powder, a rotating electrical machine with less iron loss can be realized more reliably.
成形工程Ｓ４が終了すると、本実施形態の固定子１０が完成する。図７は、固定子１０を示す斜視図である。図８は、図７におけるＡ−Ａ線断面図である。固定子１０は、図７に示すように、線材３０を巻線して環状に形成され且つ接着剤により全体が固着された三相固定子巻線２０と、三相固定子巻線２０の外形全体を磁性粉を含有する成形材によって成形してなる内側成形部１２ａ、及び内側成形部１２ａの外周側に一体的に形成され径方向に所定幅を有する円筒状の空間を磁性粉を含有する成形材によって成形してなる外側成形部１２ｂからなる固定子コア１２とを備えている。内側成形部１２ａの上部からは、２本×３組の入力端子２０ａが径外方向へ引き出されている。また、外側成形部１２ｂ外周には、径外方向へ突出して軸方向に貫通する取付け穴１２ｄを有する３個の取付部１２ｃが、周方向に等間隔で設けられている。 When the molding step S4 is completed, the stator 10 of the present embodiment is completed. FIG. 7 is a perspective view showing the stator 10. 8 is a cross-sectional view taken along line AA in FIG. As shown in FIG. 7, the stator 10 includes a three-phase stator winding 20 that is formed in an annular shape by winding a wire 30 and is fixed to the whole by an adhesive, and an outer shape of the three-phase stator winding 20. The inner molded portion 12a formed entirely by a molding material containing magnetic powder, and a cylindrical space integrally formed on the outer peripheral side of the inner molded portion 12a and having a predetermined width in the radial direction contains magnetic powder. And a stator core 12 including an outer molded portion 12b formed by a molding material. From the upper part of the inner molded part 12a, 2 × 3 sets of input terminals 20a are drawn out in the radially outward direction. Further, on the outer periphery of the outer molded portion 12b, three attachment portions 12c having attachment holes 12d that protrude in the radially outward direction and penetrate in the axial direction are provided at equal intervals in the circumferential direction.
以上詳述したことから明らかなように、本実施形態によれば、三相固定子巻線２０は、断面形状が略矩形状の線材３０を予め巻線して環状に形成されているので、線材３０を固定子コアのスロットへ挿入する等の作業を伴うことなく、簡単な巻線作業で三相固定子巻線２０を作製することができる。また、三相固定子巻線２０全体が接着剤により固着されているので、巻線形状を確実に維持することができる。また、固定子コア１２は、三相固定子巻線２０の外形全体を磁性粉を含有する樹脂等の成形材によって成形してなる内側成形部１２ａ、及び内側成形部１２ａの外周側に一体的に形成され径方向に所定幅を有する円筒状の空間を磁性粉を含有する樹脂等の成形材によって成形してなる外側成形部１２ｂからなるので、固定子コア１２を樹脂等の成形材の成形によって簡単に作製できると共に、三相固定子巻線２０を構成する線材３０間に磁性粉を含有する樹脂等の成形材が隙間無く充填されるため、高い占積率を有する固定子１０を実現することができる。 As is clear from the above detailed description, according to the present embodiment, the three-phase stator winding 20 is formed in an annular shape by winding the wire 30 having a substantially rectangular cross section in advance. The three-phase stator winding 20 can be produced by a simple winding operation without the operation of inserting the wire 30 into the slot of the stator core. In addition, since the entire three-phase stator winding 20 is fixed by an adhesive, the winding shape can be reliably maintained. Further, the stator core 12 is integrally formed on the outer side of the inner molded portion 12a formed by molding the entire outer shape of the three-phase stator winding 20 with a molding material such as resin containing magnetic powder, and the inner molded portion 12a. The stator core 12 is formed of a molding material such as a resin because the cylindrical space having a predetermined width in the radial direction is formed by an outer molding portion 12b formed by a molding material such as a resin containing magnetic powder. The stator 10 having a high space factor can be realized because the molding material such as a resin containing magnetic powder is filled between the wire rods 30 constituting the three-phase stator winding 20 without gaps. can do.
また、取付部１２ｃが外側成形部１２ｂと一体成形されているので、固定子１０を取付部１２ｃでネジ部材等によりハウジング等へ確実に取付けることができる。また、固定子コア１２の成形と同時に取付部１２ｃが樹脂等の成形材によって形成されるので、取付部１２ｃの作製が容易であり且つ工数の増加を伴わない。 In addition, since the mounting portion 12c is integrally formed with the outer molded portion 12b, the stator 10 can be securely mounted to the housing or the like by the mounting portion 12c with a screw member or the like. In addition, since the attachment portion 12c is formed of a molding material such as resin simultaneously with the molding of the stator core 12, the attachment portion 12c can be easily manufactured and the number of man-hours is not increased.
また、固定子コア１２の外側成形部１２ｂが、三相固定子巻線２０の外周に帯状等のガラスファイバ１９を巻付けた状態で樹脂等の成形材によって成形されているので、強度の向上によって振動等の衝撃に耐えることが可能となる。 Further, since the outer molded portion 12b of the stator core 12 is molded by a molding material such as a resin in a state where the belt-shaped glass fiber 19 is wound around the outer periphery of the three-phase stator winding 20, the strength is improved. Can withstand shocks such as vibration.
次に、本発明の第二の実施形態における回転電機の固定子１１の製造方法及び固定子１１の構成について説明する。図９は、第二の実施形態における円筒部材１５を示す平面図である。図１０は、第二の実施形態の成形工程Ｓ４において成形される部分を示す説明図である。尚、第一の実施形態と同一部材には同一の符号を付しそれらについての詳細な説明を省略する。 Next, the manufacturing method of the stator 11 of the rotating electrical machine and the configuration of the stator 11 in the second embodiment of the present invention will be described. FIG. 9 is a plan view showing the cylindrical member 15 in the second embodiment. FIG. 10 is an explanatory view showing a portion molded in the molding step S4 of the second embodiment. In addition, the same code | symbol is attached | subjected to the same member as 1st embodiment, and detailed description about them is abbreviate | omitted.
上述した第一の実施形態では、固定子コア１２全体（内側成形部１２ａ及び外側成形部１２ｂ）を成形材によって形成する構成としたが、本実施形態では、第一の実施形態における外側成形部１２ｂに略相当する部分を、電磁鋼板を軸方向に積層してなる円筒部材１５により構成し、内側成形部１２ａに略相当する部分のみを成形材によって形成する構成としたものである。尚、本実施形態における製造工程は、第一の実施形態における製造工程とは成形工程Ｓ４の内容が異なるのみであるので、フローチャートの図示を省略する。 In the first embodiment described above, the entire stator core 12 (the inner molded portion 12a and the outer molded portion 12b) is formed of a molding material. In the present embodiment, the outer molded portion in the first embodiment is used. A portion substantially corresponding to 12b is constituted by a cylindrical member 15 formed by laminating electromagnetic steel plates in the axial direction, and only a portion substantially corresponding to the inner molded portion 12a is formed by a molding material. In addition, since the manufacturing process in this embodiment is different from the manufacturing process in the first embodiment only in the contents of the molding step S4, the illustration of the flowchart is omitted.
すなわち、本実施形態の成形工程Ｓ４では、外周にガラスファイバ１９が巻付けられた三相固定子巻線２０を図示しない成形型内に配置し、さらに、電磁鋼板を軸方向に積層してなり三相固定子巻線２０の外径よりも僅かに大きい内径を有する円筒部材１５を、三相固定子巻線２０の外周側に非接触に配置する。図９に示すように、円筒部材１５の内周面には、複数の楔状の凹凸形状１５ａが設けられている。また、円筒部材１５外周には、径外方向へ突出して軸方向に貫通する取付け穴１５ｄを有する３個の取付部１５ｃが、周方向に等間隔で設けられている。 That is, in the forming step S4 of the present embodiment, the three-phase stator winding 20 with the glass fiber 19 wound around the outer periphery is disposed in a forming die (not shown), and the electromagnetic steel plates are laminated in the axial direction. A cylindrical member 15 having an inner diameter slightly larger than the outer diameter of the three-phase stator winding 20 is disposed in a non-contact manner on the outer peripheral side of the three-phase stator winding 20. As shown in FIG. 9, a plurality of wedge-shaped irregularities 15 a are provided on the inner peripheral surface of the cylindrical member 15. Further, on the outer periphery of the cylindrical member 15, three attachment portions 15 c having attachment holes 15 d that protrude in the radially outward direction and penetrate in the axial direction are provided at equal intervals in the circumferential direction.
そして、成形工程Ｓ４では、円筒部材１５が三相固定子巻線２０の外周側に配置された状態で、三相固定子巻線２０の外形全体を含む三相固定子巻線２０の内周部と円筒部材１５の内周部との間の空間を、磁性粉を含有する樹脂等の成形材によって一体的に成形し、成形部１４と円筒部材１５とからなる固定子コア１３を形成する。図１０は、成形材によって成形される部分を示す説明図である（成形される部分を点線で示す）。 In the molding step S4, the inner circumference of the three-phase stator winding 20 including the entire outer shape of the three-phase stator winding 20 in a state where the cylindrical member 15 is disposed on the outer circumference side of the three-phase stator winding 20. The space between the part and the inner peripheral part of the cylindrical member 15 is integrally formed with a molding material such as a resin containing magnetic powder to form the stator core 13 composed of the molded part 14 and the cylindrical member 15. . FIG. 10 is an explanatory view showing a portion molded by the molding material (the portion to be molded is indicated by a dotted line).
成形工程Ｓ４が終了すると、本実施形態の固定子１１が完成する。図１１は、固定子１１を示す斜視図である。図１２は、図１１におけるＡ−Ａ線断面図である。固定子１０は、図１１，１２に示すように、線材３０を巻線して環状に形成され且つ接着剤により全体が固着された三相固定子巻線２０と、成形部１４及び円筒部材１５からなる固定子コア１３とを備えている。 When the molding step S4 is completed, the stator 11 of the present embodiment is completed. FIG. 11 is a perspective view showing the stator 11. 12 is a cross-sectional view taken along line AA in FIG. As shown in FIGS. 11 and 12, the stator 10 includes a three-phase stator winding 20 that is formed in an annular shape by winding a wire 30 and is fixed to the whole by an adhesive, a molding portion 14, and a cylindrical member 15. The stator core 13 which consists of these is provided.
固定子コア１３の外周部分を構成する円筒部材１５は、電磁鋼板を軸方向に積層してなり、三相固定子巻線２０の外径以上の内径を有し三相固定子巻線２０の外周側に配置される。また、円筒部材１５外周には、上述したとおり、３個の取付部１５ｃが周方向に等間隔で設けられている。 The cylindrical member 15 constituting the outer peripheral portion of the stator core 13 is formed by laminating electromagnetic steel plates in the axial direction, and has an inner diameter equal to or larger than the outer diameter of the three-phase stator winding 20. It is arranged on the outer peripheral side. Further, as described above, the three attachment portions 15c are provided on the outer periphery of the cylindrical member 15 at equal intervals in the circumferential direction.
一方、固定子コア１３の内周部分を構成する成形部１４は、三相固定子巻線２０の外形全体を含む三相固定子巻線２０の内周部と円筒部材１５の内周部との間の空間を磁性粉を含有する成形材によって成形してものである。成形部１４上部には、２本×３組の入力端子２０ａが径外方向へ引き出されている。 On the other hand, the molding portion 14 constituting the inner peripheral portion of the stator core 13 includes an inner peripheral portion of the three-phase stator winding 20 including the entire outer shape of the three-phase stator winding 20 and an inner peripheral portion of the cylindrical member 15. The space between them is formed by a molding material containing magnetic powder. In the upper part of the molding part 14, 2 × 3 sets of input terminals 20a are drawn out in the radially outward direction.
以上詳述したことから明らかなように、本実施形態によれば、固定子コア１３は、電磁鋼板を積層してなり三相固定子巻線２０の外径以上の内径（外径よりも僅かに大きい内径）を有し三相固定子巻線２０の外周側に配置される円筒部材１５、及び三相固定子巻線２０の外形全体を含む三相固定子巻線２０の内周部と円筒部材１５の内周部との間の空間を磁性粉を含有する樹脂等の成形材によって成形してなる成形部１４からなるので、固定子１１全体の強度を確実に確保することができると共に、固定子コア１３を電磁鋼板を積層してなる円筒部材１５と樹脂等の成形材の成形とによって簡単に作製でき、さらに、三相固定子巻線２０を構成する線材３０間に磁性粉を含有する樹脂等の成形材が隙間無く充填されるため、高い占積率を有する固定子１１を実現することができる。 As is clear from the above detailed description, according to the present embodiment, the stator core 13 is formed by laminating electromagnetic steel plates and has an inner diameter that is equal to or larger than the outer diameter of the three-phase stator winding 20 (slightly smaller than the outer diameter). A cylindrical member 15 disposed on the outer peripheral side of the three-phase stator winding 20 and an inner peripheral portion of the three-phase stator winding 20 including the entire outer shape of the three-phase stator winding 20. Since the space between the inner peripheral portion of the cylindrical member 15 is formed by the molded portion 14 formed by a molding material such as resin containing magnetic powder, the strength of the entire stator 11 can be ensured reliably. The stator core 13 can be easily manufactured by forming a cylindrical member 15 formed by laminating electromagnetic steel plates and a molding material such as a resin, and further, magnetic powder can be applied between the wire materials 30 constituting the three-phase stator winding 20. Since the molding material such as resin is filled without gaps, it has a high space factor. It is possible to realize the stator 11.
また、円筒部材１５が三相固定子巻線２０に対して非接触に配置されて成形材により連結されることにより、巻線２０と円筒部材１５との強固な一体化が図られている。特に、固定子コア１３の成形部１４は、三相固定子巻線２０の外周に帯状等のガラスファイバを巻装した状態で樹脂等の成形材により成形されているので、円筒部材１５と三相固定子巻線２０とが確実に非接触に保たれると共に、強度の向上によって振動等の衝撃に耐えることが可能となる。 Further, the cylindrical member 15 is arranged in a non-contact manner with respect to the three-phase stator winding 20 and is connected by a molding material, so that the winding 20 and the cylindrical member 15 are firmly integrated. In particular, the molding portion 14 of the stator core 13 is formed of a molding material such as a resin in a state where a glass fiber such as a belt is wound around the outer periphery of the three-phase stator winding 20. The phase stator winding 20 is surely kept in non-contact and can withstand shocks such as vibrations by improving the strength.
また、円筒部材１５の内周面に複数の楔状の凹凸形状１５ａが設けられているので、樹脂等の成形材との抜け止めが図られて耐振動性が向上する。 In addition, since a plurality of wedge-shaped irregularities 15a are provided on the inner peripheral surface of the cylindrical member 15, it can be prevented from coming off from a molding material such as resin, and vibration resistance is improved.
尚、本発明は上述した各実施の形態に限定されるものではなく、本発明の主旨を逸脱しない範囲で種々の変更を施すことが可能であることは云うまでもない。 Note that the present invention is not limited to the above-described embodiments, and various modifications can be made without departing from the spirit of the present invention.
例えば、上述した各実施形態の製造方法では、三相固定子巻線２０外周にガラスファイバ１９を巻付けるガラスファイバ巻付け工程Ｓ３を実施する例を説明したが、必要な強度を確保することが可能であれば、ガラスファイバ巻付け工程Ｓ３を省略して実施しても構わない。 For example, in the manufacturing method of each embodiment described above, the example in which the glass fiber winding step S3 for winding the glass fiber 19 around the outer periphery of the three-phase stator winding 20 has been described, but the necessary strength can be ensured. If possible, the glass fiber winding step S3 may be omitted.
本発明は、強度に優れた回転電機の固定子を簡単に製造することが必要とされる場合に利用可能である。 The present invention can be used when it is necessary to easily manufacture a stator of a rotating electrical machine having excellent strength.
１０ 固定子
１１ 固定子
１２ 固定子コア
１２ａ 内側成形部
１２ｂ 外側成形部
１３ 固定子コア
１４ 成形部
１５ 円筒部材
１５ａ 凹凸形状
１９ ガラスファイバ
２０ 三相固定子巻線
３０ 線材
DESCRIPTION OF SYMBOLS 10 Stator 11 Stator 12 Stator core 12a Inner molding part 12b Outer molding part 13 Stator core 14 Molding part 15 Cylindrical member 15a Uneven shape 19 Glass fiber 20 Three-phase stator winding 30 Wire material
Claims (17)
前記多相固定子巻線の外形全体を磁性粉を含有する成形材によって成形してなる内側成形部、及び前記内側成形部の外周側に一体的に形成され径方向に所定幅を有する円筒状の空間を前記磁性粉を含有する樹脂によって成形してなる外側成形部からなる固定子コアと
を備えたことを特徴とする回転電機の固定子。 A multiphase stator winding in which a cross-sectional shape is formed by winding a substantially rectangular wire, and the whole is fixed by an adhesive;
An inner molded part formed by molding the entire outer shape of the multiphase stator winding with a molding material containing magnetic powder, and a cylindrical shape integrally formed on the outer peripheral side of the inner molded part and having a predetermined width in the radial direction And a stator core made of an outer molded part formed by molding the space with the resin containing the magnetic powder.
電磁鋼板を積層してなり前記多相固定子巻線の外径以上の内径を有し前記多相固定子巻線の外周側に配置される円筒部材、及び前記多相固定子巻線の外形全体を含む前記多相固定子巻線の内周部と前記円筒部材の内周部との間の空間を磁性粉を含有する成形材によって成形してなる成形部からなる固定子コアと
を備えたことを特徴とする回転電機の固定子。 A multiphase stator winding in which a cross-sectional shape is formed by winding a substantially rectangular wire, and the whole is fixed by an adhesive;
A cylindrical member formed by laminating electromagnetic steel plates and having an inner diameter greater than or equal to the outer diameter of the multiphase stator winding and disposed on the outer peripheral side of the multiphase stator winding, and the outer shape of the multiphase stator winding A stator core comprising a molded part formed by molding a space between an inner peripheral part of the multiphase stator winding including the whole and an inner peripheral part of the cylindrical member with a molding material containing magnetic powder. A stator of a rotating electric machine characterized by that.
前記多相固定子巻線全体を接着剤により固着する巻線固着工程と、
前記多相固定子巻線の外形全体と前記多相固定子巻線の外周に隣接し径方向に所定幅を有する円筒状の空間とを前記磁性粉を含有する成形材によって一体的に成形して固定子コアを形成する成形工程と
を備えたことを特徴とする回転電機の固定子製造方法。 A winding forming step of winding a wire material having a substantially rectangular cross section to form an annular multiphase stator winding;
A winding fixing step of fixing the entire multiphase stator winding with an adhesive;
The entire outer shape of the multiphase stator winding and a cylindrical space adjacent to the outer periphery of the multiphase stator winding and having a predetermined width in the radial direction are integrally formed with the molding material containing the magnetic powder. A stator manufacturing method for forming a stator core.
前記成形工程は、前記多相固定子巻線の外周にガラスファイバを巻付けた状態で成形を行うことを特徴とする請求項１１又は１２に記載の回転電機の固定子製造方法。 A glass fiber winding step of winding a glass fiber around the outer periphery of the multiphase stator winding;
13. The method of manufacturing a stator for a rotating electrical machine according to claim 11, wherein the forming step is performed in a state where a glass fiber is wound around an outer periphery of the multiphase stator winding.
前記多相固定子巻線全体を接着剤により固着する巻線固着工程と、
電磁鋼板を積層してなり前記多相固定子巻線の外径以上の内径を有する円筒部材を、前記接着剤により固着された前記多相固定子巻線の外周側に配置し、この状態で、前記多相固定子巻線の外形全体を含む前記多相固定子巻線の内周部と前記円筒部材の内周部との間の空間を、磁性粉を含有する樹脂によって一体的に成形して固定子コアを形成する成形工程と
を備えたことを特徴とする回転電機の固定子製造方法。 A winding forming step of winding a wire material having a substantially rectangular cross-sectional shape to form an annular multiphase stator winding;
A winding fixing step of fixing the entire multiphase stator winding with an adhesive;
A cylindrical member formed by laminating electromagnetic steel sheets and having an inner diameter equal to or larger than the outer diameter of the multiphase stator winding is disposed on the outer peripheral side of the multiphase stator winding fixed by the adhesive. The space between the inner peripheral portion of the multiphase stator winding and the inner peripheral portion of the cylindrical member, including the entire outer shape of the multiphase stator winding, is integrally formed with a resin containing magnetic powder. And a stator manufacturing method for forming a stator core.
前記成形工程は、前記多相固定子巻線の外周にガラスファイバを巻装した状態で成形を行うことを特徴とする請求項１５に記載の回転電機の固定子製造方法。 A glass fiber winding step of winding a glass fiber around the outer periphery of the multiphase stator winding;
The method for manufacturing a stator of a rotating electric machine according to claim 15, wherein the forming step is performed in a state where a glass fiber is wound around an outer periphery of the multiphase stator winding.
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| JP2019154105A (en) * | 2018-03-01 | 2019-09-12 | 三菱電機株式会社 | Fuel supply device |
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