This application is based upon and claims the benefit of priority of the prior Japanese Patent Application No. 2010-115144, filed on May 19, 2010; and Japanese Patent Application No. 2010-171781, filed on Jul. 30, 2010, the entire contents of all of which are incorporated herein by reference.
The embodiments discussed herein relates to a rotating electrical machine, a manufacturing method of a rotating electrical machine, and a wind power generator system.
A technique of using a directional magnetic steel sheet for a stator core of a rotating electrical machine has been conventionally known (see, for example, Japanese Patent Laid-open Publication No. H10-234159).
According to this conventional technique, a stator core of a stator is configured by a yoke core and a teeth member. The yoke core is configured by bending in circular shape band-shaped steel sheets punched out from a directional magnetic steel sheet and by stacking the bent band-shaped steel sheets. Plural notches are formed on the band-shaped steel sheets. To suppress reduction of efficiency due to magnetostriction, the band-shaped steel sheets are bent at notch portions. Plural engaging trenches are formed by the notches on the yoke core. An easy direction of magnetization of the yoke core coincides with a peripheral direction of the yoke core. The teeth member is configured by punching out from a directional magnetic steel sheet, band-shaped steel sheets that have a shape corresponding to plural teeth cores connected together at bridge parts, bending the band-shaped steel sheets in a circular shape, and stacking the bent band-shaped steel sheets. To suppress reduction of efficiency due to magnetostriction, the band-shaped steel sheets used for the teeth member are bent at portions corresponding to the bridge parts. The band-shaped steel sheets used for the teeth member are punched out from a directional magnetic steel sheet in a direction perpendicular to an easy direction of magnetization of the directional magnetic steel sheet. An easy direction of magnetization of each teeth core coincides with a radial direction of the teeth member.
After providing windings on the teeth cores configured as described above, one ends of the teeth cores at an opposite side of the bridge parts are engaged with the engaging trenches of the yoke core, thereby completing the stator.
The rotating electrical machine according to an aspect of an aspect of the embodiment includes a rotor and a stator that surrounds the rotor. The stator includes: a yoke core that is obtained by bending band-shaped non-directional magnetic steel sheets in a circular shape and by stacking the bent band-shaped non-directional magnetic steel sheets, or is obtained by bending a band-shaped non-directional magnetic steel sheet in a circular spiral shape; and plural teeth cores that are arranged in a peripheral direction of the yoke core, with one ends of the teeth cores fixed to an internal peripheral side of the yoke core, and with the other ends of the teeth cores set opposite to the rotor. The teeth cores are configured by a member obtained by stacking directional magnetic steel sheets.
A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
Exemplary embodiments will be explained below in detail with reference to the accompanying drawings. Like constituent elements are denoted by like reference numerals and redundant explanations thereof will be omitted.
A configuration of a rotating electrical machine according to a first embodiment is explained first.
The rotor 1 is in a cylindrical shape, and an external periphery of the rotor 1 is surrounded by the stator 2 via a space. The rotor 1 includes a rotor core 11 and a permanent magnet 12. The permanent magnet 12 is provided on an external periphery of the rotor core 11. A structure of the rotor 1 is not limited to a structure shown in
The stator 2 includes a stator core having a yoke core 21 and plural teeth cores 22, and windings 23.
The yoke core 21 is configured by punching out band-shaped steel sheets 31 from a non-directional magnetic steel sheet 3 as shown in
The teeth cores 22 are independent of each other and are arranged in a peripheral direction of the yoke core 21 as shown in
The teeth cores 22 are configured by stacking teeth steel sheets 41 that are punched out from a directional magnetic steel sheet 4 as shown in
By stacking the teeth steel sheets 41 that are configured as described above, a tapered part 221 and a cylindrical part 222 are formed at one end of each of the teeth cores 22 as shown in
The windings 23 are provided on the teeth cores 22. The rotor 1 is rotated by a rotating magnetic field that is generated by the windings 23. A winding method of the windings 23 can be a concentrated winding method or a distributed winding method.
A manufacturing method of the rotating electrical machine shown in
According to the manufacturing method of the rotating electrical machine, first, the band-shaped steel sheets 31 are punched out from the non-directional magnetic steel sheet 3 (
Next, as shown in
In the example shown in
According to a rotating electrical machine, there is a case that the band-shaped steel sheets for the yoke core 21 are bent at notch portions, and the band-shaped steel sheets for the teeth cores 22 are bent at portions corresponding to bridge parts, thereby suppressing reduction of efficiency due to magnetostriction. However, the notch portions and the portions corresponding to the bridge parts remain generating magnetostriction, and efficiency becomes poor due to this magnetostriction. Accordingly, there is a case that efficiency becomes poor despite increased cost of a material by using directional magnetic steel sheets for the yoke core 21 and the teeth cores 22. On the other hand, as described above, in the first embodiment, the yoke core 21 is configured by using the non-directional magnetic steel sheet 3. Consequently, increase of the material cost can be suppressed. The teeth cores 22 are configured by using the directional magnetic steel sheet 4. An easy direction of magnetization of each teeth core 22 coincides with a direction of a magnetic flux that flows in each teeth core 22. Therefore, according to the first embodiment, iron loss becomes small, magnetic flux densities can be increased by the same input, torque linearity is improved, and high torques can be achieved. Consequently, in the first embodiment, efficiency can be improved. Further, in the first embodiment, because the yoke core 21 is configured by using the non-directional magnetic steel sheet 3, no magnetostriction occurs even when the band-shaped steel sheets 31 that are punched out from the non-directional magnetic steel sheet 3 are bent in a circular shape and are stacked. According to the first embodiment, the teeth cores 22 are independent of each other, and bridge parts explained in the above description of the conventional technique are not present on the teeth cores 22. Therefore, magnetostriction at bridge parts does not occur. As explained above, according to the rotating electrical machine of the first embodiment, desired efficiency can be obtained while suppressing increase of its material cost.
According to the first embodiment, the yoke core 21 is configured by bending in a circular shape the band-shaped steel sheets 31 that are punched out from the non-directional magnetic steel sheet 3 and by stacking the bent band-shaped steel sheets 31. Therefore, in the first embodiment, unused steel sheets can be reduced and yield can be improved as compared with a case where circular non-directional magnetic steel sheets are stacked.
In the first embodiment, because the teeth cores 22 are independent of each other (that is, because the teeth cores 22 are not connected at bridge parts), the teeth steel sheets 41 constituting the teeth cores 22 can be sequentially punched out along with an easy direction of magnetization of the directional magnetic steel sheet 4. A directional magnetic steel sheet has a general characteristic that an easy direction of magnetization of the directional magnetic steel sheet is arranged in only a rolling direction. Therefore, it is difficult to increase a width of the directional magnetic steel sheet (a width perpendicular to an easy direction of magnetization). According to the conventional technique described above, because the teeth cores are connected to each other at bridge parts, band-shaped steel sheets need to be used. In this case, to match an easy direction of magnetization of each teeth core with a radial direction of the yoke core, a longitudinal direction of each band-shaped steel sheet needs to be set in a direction perpendicular to an easy direction of magnetization of the directional magnetic steel sheet. Therefore, according to the conventional technique, it is difficult to manufacture a large rotating electrical machine that has a large length in a longitudinal direction of the band-shaped steel sheets. On the other hand, according to the first embodiment, the teeth steel sheets 41 can be sequentially punched out along an easy direction of magnetization of the directional magnetic steel sheet 4. Consequently, in the first embodiment, even a large rotating electrical machine can be easily manufactured.
According to the first embodiment, the cylindrical parts 222 that have larger widths in a peripheral direction than those of the front ends of the tapered parts 221 are formed at one ends of the teeth cores 22. Accordingly, in the first embodiment, the teeth cores 22 can be prevented from being extracted from the yoke core 21. According to the first embodiment, the yoke core 21 is formed with the engaging trenches 211 that have shapes in which the engaging trenches 211 can be engaged with the cylindrical parts 222. The band-shaped steel sheets 31 constituting the yoke core 21 are formed with the notches 311 corresponding to the engaging trenches 211. That is, according to the first embodiment, as shown in
According to the first embodiment, the teeth cores 22 are independent of each other. Therefore, when external force in a peripheral direction acts on the teeth cores 22, there is a risk that one ends of the teeth cores 22 are deformed. On the other hand, according to the first embodiment, the cylindrical parts 222 are formed at the one ends of the teeth cores 22. The external force that acts on the cylindrical parts 222 is dispersed based on the shape of the cylindrical parts 222 as compared with external force that is applied when the teeth cores 22 do not have a cylindrical shape. As a result, according to the first embodiment, deformation of the one ends of the teeth cores 22 can be suppressed. According to the first embodiment, a contact area between the one ends of the teeth cores 22 and the engaging trenches 211 increases by forming the tapered parts 221 on the one ends of the teeth cores 22. As a result, the external force that acts on the one ends of the teeth cores 22 is dispersed to the cylindrical parts 222 and the engaging trenches 211. Consequently, deformation of the one ends of the teeth cores 22 can be further suppressed.
In a second embodiment, a manufacturing method of a rotating electrical machine that is different from the method according to the first embodiment is explained.
According to the manufacturing method of the rotating electrical machine in the second embodiment, the teeth steel sheets 41 are first punched out from the directional magnetic steel sheet 4 (
Next, as shown in
Next, as shown in
Subsequently, the band-shaped steel sheets 31 are punched out from the non-directional magnetic steel sheet 3 (
In the example shown in
The shape of the tool 51 is not limited to that shown in
In
As shown in
As explained above, according to the second embodiment, the yoke core 21 is formed after the teeth cores 22 are provided on the external periphery of the tool 51 or the tool 52. Therefore, according to the second embodiment, roundness of a circle formed by the other ends of the teeth cores 22 becomes higher than that when one ends of the teeth cores 22 are inserted into the engaging trenches 211 as explained in the first embodiment. As a result, in the second embodiment, occurrence of cogging torques, torque ripples, and speed ripples attributable to roundness of the circle can be suppressed. In the second embodiment, manufacturing becomes easy by using the tool 51 or the tool 52. In the second embodiment, because the band-shaped steel sheets 31 are bent in a circular shape and are stacked while engaging the notches 311 of the band-shaped steel sheets 31 with one ends of the teeth cores 22 and fixing the notches 311, shrink fitting is not necessary.
In the first and second embodiments described above, it has been explained that the rotor 1 is rotated by a rotating magnetic field that is generated by the windings 23 and that rotating electrical machines are electric motor drives. However, the rotating electrical machines according to the first and second embodiments are not limited to electric motor drives, and can be power generators.
Further, the rotating electrical machines according to the first and second embodiments can be applied to an electric motor drive of vehicles or an AC servomotor. For example, the rotating electrical machines according to the first and second embodiments can be also applied to a power generator for a wind power generator system or vehicles. An example that the rotating electrical machines according to the first and second embodiments are applied to a power generator for a wind power generator system is explained below with reference to
The wind power generator system shown in
According to the wind power generator system described above, when a power generation capacity is large (for example, when a power generation capacity is several megawatts), both the power generators 63 and 73 shown in
The configuration of the wind power generator system is not limited to those shown in
Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.
Number | Date | Country | Kind |
---|---|---|---|
2010-115144 | May 2010 | JP | national |
2010-171781 | Jul 2010 | JP | national |