Patent Application
20180351417
The present invention relates to a stator for a rotating electric machine, a rotating electric machine, and a method for manufacturing a stator for a rotating electric machine that prevent damage of coils and have excellent productivity.
In recent years, rotating electric machines such as electric motors and power generators have been required to cause less vibration and have high output. One method for achieving a motor that causes less vibration and has high output is a method in which the width of the slot opening of a stator is narrowed. If the slot opening width is narrowed, the saliency of the stator is decreased to inhibit vibration, and the surface on which a magnetic flux is generated increases, so that the gap between the stator and the rotor can be equivalently reduced to increase output. However, since it is necessary to insert a winding into the slot, the slot opening width needs to be equal to or larger than at least twice the wire diameter of a coil.
For these problems, for example, Patent Document 1 proposes a rotating electric machine configured by: using inner and outer divided cores obtained by connecting collar portions at tooth ends of a core and dividing tooth portions and a back yoke portion; and inserting a coil from the radially outer side.
Moreover, for example, Patent Document 2 proposes a method in which each tooth is divided and mounted to an opening portion later.
For the conventional core disclosed in Patent Document 1, it is necessary to insert the yoke portion for magnetically connecting the teeth, from the axial direction after insertion of the coil. For this, it is necessary to bend coil ends and bobbins radially inward as necessary, and thus the flexibility in design is reduced. In addition, if a step of inserting a rotor is present as a subsequent step, it is necessary to add a step of bending outward the coil ends that have been bent radially inward. Thus, there is a problem in that the productivity deteriorates.
In the method disclosed in Patent Document 2, the productivity is improved. However, since each tooth portion is mounted after a winding is provided, there is a problem in that a yoke portion may deform to damage a coil when each tooth is inserted.
The present invention has been made to solve the above-described problems, and an object of the present invention is to provide a stator for a rotating electric machine, a rotating electric machine, and a method for manufacturing a stator for a rotating electric machine that prevent damage of coils and have excellent productivity.
A stator for a rotating electric machine according to the present invention includes:
a core having
coils disposed in slots between the respective tooth portions, wherein
the core is formed of an outer core forming the yoke portion and an inner core forming the tooth portions and the connection portions,
the outer core is formed so as to be divided into a plurality of parts in the circumferential direction,
a first fitting portion for fitting the outer core and the inner core to each other is formed in the outer core and the inner core, and
a fitting surface in the radial direction of the first fitting portion is formed as a surface parallel to the radial direction at a center position in the circumferential direction of the divided outer core.
A rotating electric machine according to the present invention is a rotating electric machine including:
the stator described above; and
a rotor disposed so as to be concentric with the stator.
A method for manufacturing a stator for a rotating electric machine according to the present invention is a method for manufacturing the above stator for a rotating electric machine, the method including:
a first step of disposing the coils in the respective slots of the inner core; and
a second step of inserting the divided outer cores from an outer side in the radial direction of the inner core and fitting the inner core and the outer core at the first fitting portion.
The stator for a rotating electric machine, the rotating electric machine, and the method for manufacturing the stator for a rotating electric machine according to the present invention prevent damage of the coils and have excellent productivity.
Hereinafter, embodiments of the present invention will be described.
In
The rotor 101 is formed by: a rotor core 107 that is fixed to the rotation shaft 106 inserted at an axial position; and permanent magnets 108 that are embedded at the outer peripheral surface side of the rotor core 107 and arranged at predetermined intervals in a circumferential direction Z and that form magnetic poles. The rotor 101 is shown as a permanent-magnet-type rotor here, but is not limited thereto, and a squirrel-cage rotor in which conductor wires not provided with an insulating coating are accommodated in slots and short-circuited at both sides by short-circuit rings, or a wound rotor in which conductor wires provided with an insulating coating are mounted to slots of a rotor core, may be used.
In
In
In Embodiment 1, an example in which the inner core 8 is formed so as to be divided into four parts is shown.
The inner core 8 is formed of magnetic steel sheets stacked in an axial direction Y, and the magnetic steel sheets are connected to each other in the axial direction Y by swage portions 11 formed in the inner core 8. The connection portions 10 are collar portions formed at the inner side X1 in the radial direction X of the tooth portions 3, and are formed as thin portions at locations in the axial direction Y so as to partially connect the tooth portions 3.
A plurality of slots 5 demarcated in the circumferential direction Z are formed between the tooth portions 3 adjacent to each other in the circumferential direction Z. First projections 31 are formed as the first fitting portions 40 at an outer side X2 in the radial direction X with respect to the slots 5 and on the tooth portions 3 at both sides in the circumferential direction Z of one inner core 8. A fitting surface 31A is formed on each first projection 31 in the radial direction X.
Next, the outer core 9 will be described. In Embodiment 1, an example in which the outer core 9 is formed so as to be divided into four parts is shown.
The four outer cores 9 form the annular yoke portion 2 and magnetically connect the respective tooth portions 3. First recesses 21 are formed as the first fitting portions 40 at the outer side X2 in the radial direction X with respect to the slots 5 in one outer core 9. As a matter of course, the first recesses 21 are formed at locations corresponding to the aforementioned first projections 31 of the inner core 8. Fitting surfaces 21A are formed on the first recesses 21 in the radial direction X.
The first recesses 21 are fitted to the aforementioned first projections 31 of the inner core 8. The first fitting portions 40 are formed by the first recesses 21 and the first projections 31. In this case, the fitting surfaces 31A of the first projections 31 and the fitting surfaces 21A of the first recesses 21 are in contact with each other. Second fitting portions 50 for fitting end portions 9A and 9B in the circumferential direction Z of the divided outer cores 9 are formed at the end portions 9A and 9B in the circumferential direction Z of one outer core 9.
Second projections 22 are formed as the second fitting portions 50 on the end portions 9A that are ends of the outer cores 9. Second recesses 23 are formed as the second fitting portions 50 on the end portions 9B that are the other ends of the outer cores 9. The second projection 22 of one outer core 9 and the second recess 23 of another outer core 9 adjacent thereto are fitted to each other, so that the second fitting portion 50 is formed by the second projection 22 and the second recess 23.
The directions in which the fitting surfaces 31A are formed in the inner cores 8 and the fitting surfaces 21A are formed in the outer cores 9 will be described with reference to
Next, the method for manufacturing the stator of the rotating electric machine of Embodiment 1 configured as described above will be described with reference to
Next, the coils 7 wound on the bobbins 6 are inserted to the radially arranged tooth portions 3 from the outer side X2 to the inner side X1 in the radial direction X. Accordingly, each bobbin 6 is disposed in the adjacent slots 5 as shown in
Next, after the coils 7 are inserted, the four outer cores 9 are inserted from the outer side X2 to the inner side X1 in the radial direction X as shown in
Furthermore, the first fitting portions 40 composed of the first projections 31 and the first recesses 21 are formed at the outer side X2 in the radial direction X with respect to the slots 5. Thus, when the first projections 31 and the first recesses 21 are fitted to each other, stress can be prevented from being applied to the coils 7 disposed within the slots 5.
Furthermore, at the end portions 9A and 9B in the circumferential direction Z of the respective outer cores 9, the second projections 22 and the second recesses 23 are fitted to each other, whereby the second fitting portions 50 are formed. When each outer core 9 is inserted and press-fitted from the outer side X2 to the inner side X1 in the radial direction X, the second projections 22 are press-fitted into the second recesses 23 so as to be squeezed thereinto, whereby the second projections 22 and the second recesses 23 are fitted to each other.
Thereafter, the coils 7 disposed on the respective tooth portions 3 are connected to each other by a predetermined method, so that the stator 1 (armature) of the rotating electric machine 100 is completed. As shown in
In a reference example of
According to the stator for a rotating electric machine, the rotating electric machine, and the method for manufacturing the stator for a rotating electric machine of Embodiment 1 configured as described above, since the outer core is divided in the circumferential direction and the fitting surfaces of the first fitting portions are formed parallel to the insertion direction of the outer core, simple assembling is enabled by press-fitting the outer core from the outer side in the radial direction. Furthermore, assembling is enabled without being influenced by the shape of an insulator for each coil, the shapes of the coil ends, and the like.
Insertion force applied when the outer core is inserted to the inner core can be smaller than that of when the outer core is inserted to the inner core in the axial direction, and thus the insertion force can be decreased and the effects such as inhibition of size increase of a facility and improvement of the productivity are achieved. In addition, since the first fitting portions are formed at the outer side in the radial direction of the coils, stress can be prevented from being applied to the coils disposed within the slots, so that damage of the coils is prevented and the productivity is excellent.
Since the first fitting portions are formed by the first recesses of the outer cores and the first projections of the inner cores, the first fitting portions can easily be formed at the outer side in the radial direction with respect to the coils.
Since the outer cores are fitted at the second fitting portions formed at the end portions in the circumferential direction of the outer cores, the outer cores can be assuredly fitted to each other, so that the rigidity thereof can be increased.
Since the division locations of the outer core are locations at which the slots are formed, in the circumferential direction, the outer core can be divided in a simple manner.
Since the coils are formed by being wound on the bobbins disposed in the slots, it is not necessary to take into consideration interference of the outer cores with the bobbins.
In Embodiment 1 described above, the example in which one divided inner core includes three tooth portions is shown. However, the present invention is not limited thereto, and even in the case where each inner core includes a plurality of tooth portions the number of which is different from three, similar formation is possible, and the same advantageous effects can be achieved.
In Embodiment 1 described above, the example in which the outer core is formed so as to be divided into four parts in the circumferential direction is shown. However, the present invention is not limited thereto, and when the outer core is divided into two or more parts the number of which is not greater than the number of tooth portions, the outer core can be formed in a manner similar to the above embodiment.
In Embodiment 1 described above, the example in which one divided inner core includes three tooth portions and no first fitting portion is formed at the tooth portion at the center in the circumferential direction is shown. This is shown as an example in which the inner cores and the outer cores are formed at low cost by setting provision of the first fitting portions at the tooth portions at both sides in the circumferential direction as the minimum requirement for fixing the inner cores and the outer cores.
However, the present invention is not limited thereto; the first fitting portions may be formed at all three tooth portions of one divided inner core, and the corresponding first fitting portions may also be formed at the outer cores. In this case, since the first fitting portions are formed at all the tooth portions unlike Embodiment 1 described above, it is possible to further firmly fix the inner cores and the outer cores.
The stator of Embodiment 1 described above is configured such that the divided inner cores are not in contact with each other at the connection portions for the tooth portions. However, the present invention is not limited thereto, and the divided inner cores may be configured to be in contact with each other at the connection portions for the tooth portions. In this case, a factor that contributes to an increase in cogging torque is reduced.
Embodiment 1 described above shows, as an example, a concentrated winding type configuration in which one coil is wound on one tooth portion in a concentrated manner. However, the present invention is not limited thereto, and even with a distributed winding type configuration in which a coil is disposed over a plurality of tooth portions, the coils can be formed similarly, and the same advantageous effects can be achieved.
In particular, in the case of a distributed winding type, it is not necessary to assemble the outer cores from the axial direction, and thus interference between the outer cores and coil ends protruding outward in the axial direction can be prevented. In the conventional art, in order to avoid this interference, the coil ends are bent radially inward. However, in this case, the rotor cannot be assembled later, and it is necessary to wind the coils in a state where the rotor is assembled. Therefore, there are large constraints on the configuration and the design of a winding machine. According to Embodiment 1, since the outer cores are moved from the outer side to the inner side in the radial direction and assembled, the assembling is enabled without interfering with axially outer protrusion of the coil ends.
These matters are the same as in the following embodiments, and thus the description thereof is omitted as appropriate.
In
In
In Embodiment 2, similar to Embodiment 1 described above, the inner core 8 and the outer core 9 are each divided at four locations in the circumferential direction Z, but, unlike Embodiment 1 described above, the division locations S of the outer core 9 are locations at which tooth portions 3 are formed, in the circumferential direction Z, as shown in
In Embodiment 1 described above, the example in which one divided inner core 8 is fitted to one divided outer core 9 at the first fitting portions 40 is shown. However, in Embodiment 2, an example in which two divided inner cores 8 adjacent to each other are fitted to one divided outer core 9 at the first fitting portions 40 such that half portions thereof in the circumferential direction Z extend over the outer core 9 is shown.
The directions in which the fitting surfaces 31B and the fitting surfaces 31C are formed in the inner cores 8 and the fitting surfaces 21B and the fitting surfaces 21C are formed in the outer cores 9, will be described with reference to
It is noted that the fitting surfaces 31B and the fitting surfaces 31C formed on the inner cores 8 are on the two inner cores 8 adjacent to each other in the circumferential direction Z corresponding to one outer core 9 as shown in
At the locations of the end portions 9A and 9B in the circumferential direction Z of the outer cores 9, second projections 22 and second recesses 23 are formed as second fitting portions 50 and first recesses 21 are formed as the first fitting portions 40. The first recesses 21 formed at the end portions 9A and 9B in the circumferential direction Z of the outer cores 9 as described above are fitted in a corresponding manner to the first projections 31 formed on the central tooth portions 3 of the inner cores 8 shown in
The first recesses 21 and the first projections 31 formed at the end portions 9A and 9B in the circumferential direction Z of each outer core 9 are formed at positions most distant in the circumferential direction Z from the center position Q in the circumferential direction Z of the divided outer core 9 as shown in
Next, a method for manufacturing the stator for a rotating electric machine of Embodiment 2 configured as described above will be described with reference to
Next, the coils 7 wound on the bobbins 6 are inserted to the radially arranged tooth portions 3 from the outer side X2 to the inner side X1 in the radial direction X. Accordingly, each bobbin 6 is disposed in the adjacent slots 5 as shown in
Next, after the coils 7 are inserted, the four outer cores 9 are inserted from the outer side X2 to the inner side X1 in the radial direction X as shown in
Since each of the fitting surfaces 31B and the fitting surfaces 31C of the first projections 31 of the adjacent inner cores 8 and the fitting surfaces 21B and the fitting surfaces 21C of the first recesses 21 of the outer core 9 is formed as a surface in the axial direction Y at the parallel position R with respect to the center position Q in the circumferential direction Z of the outer core 9, that is, the insertion direction, it is easy to insert the outer cores 9 to the inner cores 8.
Furthermore, the first fitting portions 40 formed at the end portions 9A and 9B in the circumferential direction Z of each outer core 9 are more firmly fitted since the tapered shapes of the fitting surfaces 31B, 31C, 21B, and 21C of the first projections 31 and the first recesses 21 are formed in a shape having an acute angle.
Furthermore, similar to Embodiment 1 described above, the first fitting portions 40 composed of the first projections 31 and the first recesses 21 are formed at the outer side X2 in the radial direction X with respect to the slots 5. Thus, when the first projections 31 and the first recesses 21 are fitted to each other, stress can be prevented from being applied to the coils 7 disposed within the slots 5.
Furthermore, at the end portions 9A and 9B in the circumferential direction Z of the respective outer cores 9, the second projections 22 and the second recesses 23 are fitted to each other, whereby the second fitting portions 50 are formed. When each outer core 9 is inserted from the outer side X2 to the inner side X1 in the radial direction X, the second projections 22 are fitted into the second recesses 23 so as to be squeezed thereinto. The subsequent procedure is the same as in Embodiment 1 described above, and thus the description thereof is omitted as appropriate.
According to the stator for a rotating electric machine, the rotating electric machine, and the method for manufacturing the stator for a rotating electric machine of Embodiment 2 configured as described above, as a matter of course, the same advantageous effects as those in Embodiment 1 described above are achieved. In addition, since the first fitting portions are formed at the end portions in the circumferential direction of the outer cores, the inner cores and the outer cores are more firmly fitted to each other.
In the drawings, the same parts as in each embodiment described above are designated by the same reference characters, and the description thereof is omitted. In Embodiment 3, an inner core 81 is formed in a linear shape as shown in
According to the method for manufacturing the stator for a rotating electric machine of Embodiment 3 configured as described above, as a matter of course, the same advantageous effects as those in each embodiment described above are achieved. In addition, since the inner core is formed of one member, the number of components can be reduced, and the productivity can be improved. Moreover, since the inner core is formed in a linear shape, the yield is enhanced as compared to the case with an arc shape.
It is noted that, within the scope of the present invention, the above embodiments may be freely combined with each other, or each of the above embodiments may be modified or simplified as appropriate.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2016-028751 | Feb 2016 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2017/000211 | 1/6/2017 | WO | 00 |
