Stator, rotating electrical machine and method for manufacturing the same

Abstract

The stator (1) is a stator (1) in which a plurality of iron core sheets (10) are arranged in a circular ring shape with an axis as the center, and is constructed as follows: between adjacent iron core sheets (10) in the circular ring shape, a columnar portion (2jmp) provided on the yoke side of one iron core sheet (10) and extending in a direction parallel to the axis and an open loop portion (2jfc) provided on the yoke side of the other iron core sheet (10) are snap-fitted together to form a connecting portion (10j) having a mating structure capable of rotation centered on the columnar portion (2jmp) and limiting displacement in the axial direction.

Description

Technical Field

[0001] The present application relates to a stator, a rotating electrical machine and a method for manufacturing the same. Background Art

[0002] In the stator of a rotating electric machine, there is disclosed a structure in which core sheets (sometimes referred to as split cores) divided into teeth are connected to each other in a bendable manner in a direction perpendicular to the axis (see, for example, Patent Documents 1 and 2). Adjacent teeth in the stator are close to each other on the inner side in the radial direction. According to the above structure, by changing the angle of the connection portion so that the teeth are located on the outer diameter side, winding can be performed without interfering with adjacent core sheets, and the space factor of the coil can be improved.

[0003] Prior Art Literature

[0004] Patent Literature

[0005] Patent Document 1: Japanese Patent Application Publication No. 2000-201458 (Paragraphs 0032 to 0036, Figure 1 to Figure 5 )

[0006] Patent Document 2: Japanese Patent Application Laid-Open No. 2006-254569 (Paragraphs 0045 to 0051, Figures 5 to 8 ) Summary of the invention

[0007] Problems to be solved by the invention

[0008] However, in Patent Document 1, since the laminated steel plates of the adjacent core sheets are meshed with each other at the connection portion, two laminated steel plates need to be prepared, and punched caulking etc. are required for connection, which increases the number of component types and complicates the process. In addition, in Patent Document 2, a mechanism for plugging and unplugging in the axial direction is provided for connection and rotation, but when the teeth are directed outward, a retaining mechanism etc. need to be prepared in order to prevent positional displacement in the axial direction after connection, which complicates the manufacturing process.

[0009] The present application discloses a technology for solving the above-mentioned problems, and an object of the present application is to obtain a high-performance stator and a rotating electrical machine without increasing the number of parts and the number of manufacturing steps.

[0010] Means for solving problems

[0011] The stator disclosed in the present application is a stator formed by a plurality of iron core sheets having a magnetic body and a coil arranged in a circular ring shape with an axis as the center, the magnetic body forming a yoke extending in a circular arc shape and teeth protruding from the yoke toward the axis, the coil being wound around the teeth, and characterized in that, between adjacent iron core sheets in the circular ring shape, a connecting portion having an interlocking structure capable of rotation around the columnar portion and limiting displacement in the axial direction is formed by a snap connection between a columnar portion provided on the yoke side of one iron core sheet and extending in a direction parallel to the axis and an open loop portion provided on the yoke side of the other iron core sheet, the open loop portion being provided with a gap between the magnetic body portion in the axial direction, the columnar portion extending from a base portion having a larger diameter than the columnar portion, and when the snap connection is performed, the base portion of the iron core sheet on the one side is sandwiched in the gap of the iron core sheet on the other side.

[0012] The manufacturing method of the stator disclosed in the present application is characterized in that it includes: a process of making an iron core component in which an insulating member is covered on a magnetic body portion, the magnetic body portion forming a yoke extending in a circular arc shape and teeth protruding from the yoke toward the axis; for a plurality of the iron core components, the teeth are oriented to the same side, the end surfaces of the yoke in the circumferential direction are arranged to face each other, and between adjacent iron core components, a columnar portion of the yoke portion of the iron core component provided on one side extending in a direction parallel to the axis is embedded in an open-loop portion of the yoke portion of the iron core component provided on the other side with a gap in the axial direction with respect to the magnetic body portion. A process of snap-fitting to form a connecting portion with an interlocking structure that can rotate around the columnar portion and limit displacement in the axial direction; a process of expanding the angle between the teeth of each of the multiple iron chip components connected by the connecting portion and the teeth of the adjacent iron chip components, winding a wire and forming a coil; and a process of making the teeth inside and connecting the iron chip components formed with the coil into a circular ring shape, wherein the columnar portion is extended from a base portion with a larger diameter than the columnar portion, and when the snap-fitting is performed, the base portion of the iron chip component on one side is clamped into the gap of the iron chip component on the other side.

[0013] Another stator manufacturing method disclosed in the present application is characterized in that it includes: a process of making an iron core component in which an insulating member is covered on a magnetic body portion, wherein the magnetic body portion forms a yoke extending in an arc shape and teeth protruding from the yoke toward an axis; a process of winding wire around the teeth of each of the plurality of iron core components to form a coil; and for the plurality of iron core components forming the coils, the teeth are oriented to the same side, the end surfaces of the yoke in the circumferential direction are arranged facing each other, and between adjacent iron core components, the yoke portion of the iron core component provided on one side is respectively connected to the yoke portion of the iron core component provided on the other side. The columnar portion extending in a direction parallel to the axis is embedded in a snap-fit ​​connection with an open-loop portion of a yoke portion of an iron chip component on the other side which is arranged in the axial direction with a gap between the magnetic body portion, thereby forming a connecting portion having an interlocking structure capable of rotating around the columnar portion and limiting displacement in the axial direction, and a process in which the teeth are made to become the inner side and connected in a circular ring shape, wherein the columnar portion is extended from a base portion having a larger diameter than the columnar portion, and when the snap-fit ​​connection is performed, the base portion of the iron chip component on one side is clamped in the gap of the iron chip component on the other side.

[0014] Effects of the Invention

[0015] According to the stator or the method for manufacturing the stator disclosed in the present application, since a connection portion that is rotatable and restricts axial displacement is formed by snap-fitting, a high-performance stator and rotating electrical machine can be obtained without increasing the number of parts and the number of manufacturing steps. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 This is a plan view showing the appearance of the stator according to the first embodiment before molding.

[0017] Figure 2 This is a perspective view showing the appearance of core sheets constituting the stator according to the first embodiment.

[0018] Figure 3 This is a perspective view showing the appearance of a magnetic body portion of a core piece constituting the stator according to the first embodiment.

[0019] Figure 4 This is a perspective view showing the appearance of an insulating member of a core sheet constituting the stator according to the first embodiment.

[0020] Figure 5 This is a side view showing the appearance of a core sheet member in which an insulator is attached to a magnetic body portion of the stator according to the first embodiment, as viewed from the outer peripheral surface side.

[0021] Figure 6 This is a cross-sectional view parallel to the axial direction and the radial direction of the core sheet member constituting the core sheet of the stator according to the first embodiment.

[0022] Figure 7 This is a plan view showing the appearance of the core pieces of the stator according to the first embodiment.

[0023] Figure 8 This is a plan view showing a state in which core sheet members of the stator according to the first embodiment are connected to each other.

[0024] Fig. 9 This is a flowchart showing the method for manufacturing the stator according to the first embodiment.

[0025] Fig.10 This is a plan view showing a state in which core sheet members constituting the stator of the first embodiment are connected for winding processing.

[0026] Fig.11 A. Fig.11 B and Fig.11 C is a schematic plan view showing the state before and after the wire is wound on each of the connected core sheet members when manufacturing the stator of the first embodiment, and a schematic plan view showing the state after the wire is wound on the core sheet members that are not connected.

[0027] Fig.12 The diagram is a schematic cross-sectional view taken along a plane including an axis for illustrating different shapes of a rotating electrical machine formed using a stator using magnetic parts formed by powder compacting as exemplified in the first embodiment and a stator using magnetic parts formed by laminating steel plates.

[0028] Fig.13 It is a plan view showing the appearance of the stator according to the second embodiment before molding.

[0029] Fig.14 A and Fig.14 B are perspective views showing the insulating material of the core sheet constituting the stator of the second embodiment from different angles.

[0030] Fig.15 This is a plan view showing the appearance of an insulating member of a core sheet constituting the stator according to the second embodiment.

[0031] Fig.16 A and Fig.16 B are plan schematic views showing a state where core sheet members are connected by snap-fitting in the first stage and a state where core sheet members are connected by snap-fitting in the final stage, respectively, when manufacturing the stator of the second embodiment.

[0032] Fig.17 This is a flowchart showing a method for manufacturing a stator according to the second embodiment. DETAILED DESCRIPTION

[0033] Implementation method 1.

[0034] Figures 1 to 12 For explaining the stator of the first embodiment, the structure of a rotating electric machine using the stator, or a method for manufacturing the stator, Figure 1 is a plan view showing the appearance of the stator before molding, showing the shape of a surface perpendicular to the axis, Figure 2 1 is a perspective view showing the appearance of the core pieces constituting the stator, viewed from the inner peripheral surface side. Figure 3 1 is a perspective view showing the appearance of a magnetic body portion formed by powder compaction constituting an iron core sheet, viewed from the inner peripheral surface side. Figure 4 This is a perspective view showing the appearance of an insulating material constituting the core sheet, viewed from the inner peripheral surface side on one side exposed when the core sheet is constituted.

[0035] in addition, Figure 5 1 is a side view showing the appearance of an iron core member in which an insulating member is attached to a magnetic body portion, viewed from the outer peripheral surface side. Figure 6 It is shown Figure 5 A cross-sectional view of the cut surface at line AA parallel to the axial and radial directions of the iron core component, Figure 7 is a top view showing the appearance of the core piece, Figure 8 It is a plan view showing a state in which the core sheet members are connected to each other by snap-fitting in a direction perpendicular to the axis.

[0036] and, Fig. 9 is a flow chart showing a method for manufacturing a stator, Fig.10 1 is a plan view showing a state in which core sheet members are connected by snap-fitting for winding processing in a manufacturing process of a stator. Fig.11 The figure shows the manufacturing process of the stator in order to wind the wire material on the Fig.10 Each of the core members connected in this way is set in a winding machine ( Fig.11 A) and the state of completed winding ( Fig.11 B) is a top view of the Figure 1 , Figure 7 , Fig.11 In the figure, the depiction of the winding portion in the circumferential direction of the coil is omitted.

[0037] and, Fig.12 In order to compare the structures of the stators using magnetic bodies formed by powder compacting and the stators using magnetic bodies formed by stacking steel plates, a schematic diagram of a cross section at a surface including the axis is shown, assuming that the rotating axis is used as the boundary and that the right half of the rotating electric machine uses a stator using magnetic bodies formed by powder compacting and the left half uses a stator using magnetic bodies formed by stacking steel plates.

[0038] Hereinafter, a stator, a rotating electrical machine having the stator, and a method for manufacturing the stator according to Embodiment 1 of the present application will be described with reference to the accompanying drawings. Figure 1 As shown in FIG. 1 , the 12 core sheets 10 of the stator 1 are connected to form a ring via a connection portion 10j using a snap-fit ​​connection by inserting in a direction perpendicular to the axis (rotation axis X). Figure 2 As shown, the core piece 10 has a yoke portion 10y having an arc-shaped outer peripheral surface 10fo, a tooth portion 10t protruding toward the axis from the central portion of the yoke portion 10y in the circumferential direction (φ direction), and a coil 3 wound around the tooth portion 10t. In addition, an insulating insulator 2 is interposed between the magnetic body portion 4 and the coil 3.

[0039] The members constituting the core sheet 10 will be described.

[0040] As the material of the wire 3F constituting the coil 3, a conductive wire made of a conductor such as copper or aluminum covered with an insulating material is used, and it may be a round wire with a circular cross-sectional shape or a flat wire with a rectangular cross-sectional shape.

[0041] <Magnetic Body>

[0042] The magnetic body 4 is formed by molding powder of soft magnetic material such as iron, Fe-Si, or amorphous metal. Of course, resin material may be added as needed. Figure 3 As shown, the tooth 4t having a T-shaped cross section perpendicular to the axis and the yoke 4y having an arc-shaped outer peripheral surface 4fo are integrated into one.

[0043] The outer peripheral surface 4fo of the yoke 4y is arc-shaped, and a groove 4g extending axially from the bottom surface 4fby to the top surface 4fty is formed in the center of the circumferential direction (φ direction). The groove 4g is continuous with the groove 2g of the insulating member 2 described later, and serves as a holding and positioning mechanism for the core sheet 10 when the wire 3F is wound.

[0044] In addition, the inner peripheral surface 4fi side of the tooth 4t in the magnetic body 4 is also formed into an arc shape. Figure 1 When the core pieces 10 are connected in this way, they become a perfect circle and are formed so as to be aligned with the rotor 5 ( Fig.12 ) with a certain gap between them. The outer peripheral surface 4fo is also formed into a perfect circle like the inner peripheral surface 4fi. At this time, the outer peripheral surface 4fo and the inner peripheral surface 4fi are designed to be coaxial with the rotation axis X as the center.

[0045] Furthermore, the top surface 4fty and the bottom surface 4fby of the yoke 4y of the magnetic body 4 are designed to protrude from the winding portion 4tw of the tooth 4t in the axial direction, and the top surface 4fte and the bottom surface 4fbe of the tooth tip 4te are also designed to protrude from the winding portion 4tw. Fig.12 ), but since the thickness of the insulating member 2 at the yoke portion 10y and the tooth tip portion 10te can be reduced and the height of the winding portion can be reduced, the stator 1 can be miniaturized and the amount of wire 3F used can be reduced.

[0046] <Insulation>

[0047] The insulating member 2 is formed into a shape covering one side of the axial direction (z direction) of the region surrounding the winding portion 4tw of the magnetic body 4 by molding an insulating thermoplastic resin, for example. Figure 4 As shown, it has: a U-shaped portion 2u covering the winding portion 4tw, an inner portion 2i connected to the U-shaped portion 2u on the inner side in the radial direction (ρ direction) and covering the surface of the winding portion 4tw side of the tooth front end portion 4te, and a yoke portion 2y connected to the outer side and covering the surface of the winding portion 4tw side of the yoke 4y.

[0048] Therefore, if Figure 5 , Figure 6 As shown, by installing two insulating members 2-U and 2-L on the top surface 4fty side and the bottom surface 4fby side of the magnetic body 4, respectively, a core piece component 10P is formed in which the winding portion 4tw of the magnetic body 4 and the area surrounding the winding portion 4tw are covered with an insulating material. In addition, in the present application, in order to explain the state before and after the coil is wound in the manufacturing process, the state before the winding of the coil 3 is distinguished as the core piece component 10P, and the state after the formation of the coil 3 is distinguished as the core piece 10, but both can also be referred to as the core piece. In addition, for ease of explanation, the top surface 4fty and the bottom surface 4fby are distinguished for recording, but the top surface 4fty side and the bottom surface 4fby side can be symmetrical relative to the plane perpendicular to the axis, and there is no need to distinguish the insulating member 2-U and the insulating member 2-L as items.

[0049] In addition, a groove portion 2g connected to the groove portion 4g is formed at the center of the arc-shaped outer peripheral surface 2fo in the circumferential direction (φ direction). In addition, a base portion 2jfb protruding in the circumferential direction and radial direction and having a C-shaped cross-sectional shape perpendicular to the axis is provided at the end of one side (right side in the figure) of the top surface 2fty, which is the end surface of the yoke portion 2y on the side away from the U-shaped portion 2u in the axial direction. An open ring portion 2jfc is formed in the C-shaped base portion 2jfb, which is an open ring portion 2jfa opened in the direction perpendicular to the axis, and functions as a snap-on recess 2jf for insertion and extraction in the direction perpendicular to the axis.

[0050] Furthermore, a snap-on protrusion 2jm is provided at the end of the other side (left side in the figure) of the top surface 2fty, and the snap-on protrusion 2jm has a base 2jmb protruding in the circumferential direction and radial direction and a columnar portion 2jmp extending in the axial direction from the base 2jmb. In addition, the base 2jmb protrudes from a position (a position corresponding to the position of the lower surface 2sjf of the base 2jfb) descending from the top surface 2fty to the bottom surface 2fby, corresponding to the thickness of the base 2jfb of the snap-on recess 2jf. In addition, the outer diameter of the columnar portion 2jmp is designed to be greater than the inner diameter of the open loop portion 2jfc of the snap-on recess 2jf when it is free. This is to prevent the columnar portion 2jmp from detaching from the open loop portion 2jfc when the columnar portion 2jmp described later is embedded in the open loop portion 2jfc and the connecting portion 10j is formed.

[0051] In addition, the opening 2jfa of the snap recess 2jf is designed to have a width when free that is less than the diameter of the columnar portion 2jmp. This is also to prevent the connection portion 10j that is connected by snap fastening from being easily detached after it is formed. Thus, the columnar portion 2jmp is inserted into the opening 2jfa of the adjacent iron core sheet 10 described later from a direction perpendicular to the axis, thereby forming a connection portion 10j that is connected by a strong snap fastening, and as described later, it is maintained in the open loop portion 2jfc so as to be rotatable.

[0052] In addition, in the buckle recess 2jf, a cutout 2jfn may be provided on the side facing the opening 2jfa as required. The cutout 2jfn has the following effects: the force for expanding the opening 2jfa can be reduced, the columnar portion 2jmp can be smoothly embedded in the open loop 2jfc, and the base 2jfb can be prevented from breaking when a force is applied from the inner peripheral surface side to the outer peripheral surface side of the open loop 2jfc.

[0053] Here, the opening direction of the opening portion 2jfa of the buckle recess 2jf (the direction of a straight line extending from the center of the open loop portion 2jfc to the center of the opening portion 2jfa) is set to Figure 7 Specifically, it is a range in the clockwise direction starting from a tangent line Lt drawn at the center of the open loop portion 2jfc on the arc formed by the outer peripheral surface 2fo (outer peripheral surface 10fo in the figure) and ending at a line from the center of the open loop portion 2jfc to the center of the arc (rotation axis X). In addition, depending on the accuracy of the arc, a line along the side surface 2fsi may be set as the end point instead of the center of the arc.

[0054] The center of the columnar portion 2jmp is designed to be perpendicular to the axis and to coincide with an end portion 4cy ( 4c y ) on the outer peripheral surface 4fo side of the magnetic body 4 when the insulator 2 is assembled to the magnetic body 4. Figure 3Similarly, the center of the open loop portion 2jfc is also designed to coincide with the other end 4cy when the insulator 2 is assembled to the magnetic body portion 4.

[0055] Next, a structure in which the core sheet members 10P are connected by snap-fitting by assembling the insulator 2 on the top surface 4fty and the bottom surface 4fby of the magnetic body 4 so as to be rotatable around the connection portion 10j when the connection portion 10j is formed will be described.

[0056] Arrange a plurality of core components 10P in such a manner that the inner peripheral surfaces 10fi or the outer peripheral surfaces 10fo face the same side and the side end surfaces 4sy of the yoke 4y face each other. Thus, between adjacent core components 10P, the top surface 10ft side and the bottom surface side without a reference numeral make the snap protrusion 2jm adjacent to the snap recess 2jf. At this time, the direction of the opening 2jfa relative to the other columnar portion 2jmp also becomes the same (same up and down) on the top surface 10ft side and the bottom surface side.

[0057] Therefore, the angle between the core sheet components 10P is adjusted so that the upper and lower openings 2jfa are located on the line connecting the center of the adjacent columnar portion 2jmp and the center of the open loop portion 2jfc, and the columnar portion 2jmp is pushed into the center of the open loop portion 2jfc. That is, by inserting in a direction perpendicular to the axis, a connection portion 10j that is connected by snap-fit ​​is formed on both the top and bottom sides. At this time, it can be assembled by manual operation, but it can also be embedded using a clamp or the like.

[0058] Here, the buckle recess 2jf and the buckle protrusion 2jm are engaged at an angle gentler than the plane perpendicular to the release direction, and the release direction is the opposite direction to the insertion direction, and by pulling in the release direction, a force in the direction of opening the opening 2jfa is generated. Thus, the connected iron core component 10P can be disassembled, that is, the buckle connection can be released.

[0059] However, in a general snap-fit ​​connection, the snap-fit ​​convex part is disengaged by applying a force in a direction perpendicular to the release direction and moving the snap-fit ​​convex part from the concave part. In contrast, in a case where the connection can be released by pulling in the release direction, it is necessary to set the pushing force during embedding to be relatively large so that the connection will not be accidentally released after the connection. Therefore, a relatively strong force is required to embed the upper and lower parts simultaneously, but if, for example, the snap-fit ​​connection is performed only on the top surface 10ft side, and then the snap-fit ​​connection is performed on the bottom surface side, the snap-fit ​​connection can be performed with a relatively small force. Alternatively, it is also possible to simply perform axial insertion on the top surface 10ft side instead of snapping, and then perform snap-fit ​​connection on the bottom surface side.

[0060] In this case, by bringing the columnar portion 2jmp closer to the opening portion 2jfa with the axis tilted on the top surface 10ft side, it is possible to embed with a smaller force than when the axis is aligned. Also, when embedding the bottom surface side, the connecting portion 10j on the top surface 10ft side is used as a fulcrum for embedding, so that it can be easily embedded without causing a deviation in the angle between the core sheet members 10P.

[0061] Furthermore, since the columnar portion 2jmp is embedded in the open loop portion 2jfc, which is unique to the present application, Figure 8 As shown, the base 2jmb can be freely rotated around the columnar portion 2jmp between each iron core component 10P (as shown by the arrow). On the other hand, the base 2jmb is embedded in the gap 10jc ( Figure 5 ). Therefore, when the iron chip component 10P wants to move toward the top surface 10ft, the movement is restricted by making the axially outer surface 2sjmx of the base 2jmb of the iron chip component 10P abut against the lower surface 2sjf of the base 2jfb of the adjacent iron chip component 10P. In addition, when the iron chip component 10P wants to move toward the bottom surface (the back side of the top surface 10ft), the movement is restricted by making the axially inner surface 2sjmi of the base 2jmb of the iron chip component 10P abut against the top surface 4fty of the magnetic body 4 of the adjacent iron chip component 10P.

[0062] That is, the axial movement between the core pieces 10P is restricted, and the axial displacement between the core pieces 10P can be prevented from causing the core pieces 10P to fall off. Therefore, it is easy to maintain the state in which a plurality of core pieces 10P or core pieces 10 are connected (see Fig.10 , Fig.11 ), it is also possible to easily Figure 1 The connection is shown as a ring.

[0063] In addition, as long as the columnar portion 2jmp can rotate, the inner circumference of the open loop portion 2jfc does not need to be an arc. In addition, as for the columnar portion 2jmp, as long as the required rotation range can be ensured, it does not need to be a cylinder. For example, in the case where it is desired to maintain a certain angle, the cross-sectional shape can be an ellipse, a shape obtained by cutting off a part, etc., and can be appropriately changed.

[0064] Next, refer to Fig. 9 The flowchart of the present invention is used to illustrate the manufacturing method of the stator 1 of the first embodiment. First, a magnetic body 4 is manufactured by compression molding using a powdered iron core material as a soft magnetic material (step S110). In addition, although not shown in the figure, the insulating member 2 is manufactured by molding an insulating resin such as a thermoplastic resin.

[0065] Then, the insulating member 2 is installed on the top surface 4fte, 4fty side and the bottom surface 4fbe, 4fby side of the magnetic body 4, respectively, to form the iron core component 10P. If a certain amount of iron core components 10P can be prepared, the directions of the required number of iron core components 10P are aligned as described above, so that the snap-in recesses 2jf of the adjacent insulating member 2 are snap-fitted with the snap-in protrusions 2jm. Then, for example, in the case where N (=12) iron core components 10 are required as the stator 1, as shown in FIG. Fig.10 As shown, the core sheet members 10P (10P-1, 10P-N) at the end positions of the N core sheet members 10P are released to form an open ring-shaped connected body instead of a ring-shaped body (step S130).

[0066] Then, in order to make the grooves 2g and 4g on the outer peripheral surface 10fo side of the iron core member 10P facing the connected body function as a positioning mechanism, as shown in FIG. Fig.11 As shown in A, an open-loop connection body is provided in such a manner that the outer peripheral surface 10fo faces the rotating roller 90 of the winding machine. That is, a protrusion 90p for positioning and fixing the core piece component 10P is provided on the rotating roller 90, and the position of the core piece component 10P is fixed by making the protrusion 90p contact with the groove portion 4g and the groove portion 2g on the outer peripheral surface 10fo side of the core piece component 10P. The connection body of the core piece component 10P provided in the winding machine is automatically rotated and conveyed (clockwise in the figure) by the rotating roller 90 in such a manner that the core piece components 10P are located one by one in front of the flyer 80 of the winding machine.

[0067] The connecting body of the rotating roller 90 provided on the winding machine is bent at the connecting portion 10j so that the inner peripheral surface 10fi side is directed outward in such a manner that the angle between the teeth 4t of the adjacent iron core components 10P on the left and right becomes wider. Therefore, the wire 3F is wound around the target iron core component 10P at a high density via the flyer 80 to form the coil 3 without interfering with the iron core components 10P on both sides (step S140). After the winding, in order to wind the next iron core component 10P, the rotating roller 90 of the winding machine is rotated and automatically rotated and conveyed until the target iron core component 10P comes in front of the flyer 80. Then, the flyer 80 is used again to wind the wire 3F around the target iron core component 10P to form the coil 3.

[0068] In this way, by repeatedly performing the rotation conveyance by the rotating roller 90 of the winding machine and the winding of the wire 3F via the flyer 80, the wire 3F is wound as shown in FIG. Fig.11 As shown in FIG. 3B , the wire 3F is wound around all the core sheet members 10P to form the core sheet 10 having the coil 3. In addition, the wire 3F may be cut between the core sheets 10 as necessary.

[0069] In addition, in this example, an example is shown in which the number of (N=12) core sheet components 10P required for the structure of the stator 1 is connected and the wire 3F is wound to form the required number of core sheets 10 at one time, but the present invention is not limited to this. For example, it is also possible to form a connection body of 12 core sheets 10 by winding the wire 3F after the connection body of the core sheet components 10P of the required number is divided into two as a set and then connecting the connection bodies of the core sheets 10 of the two sets.

[0070] Alternatively, step S130 may be omitted, and after individually winding the core pieces 10, the required number (12) of core pieces 10 that are individually wound may be connected. That is, after making a plurality of connected bodies of more than one core piece component 10P and winding the connected bodies, the plurality of connected bodies may be connected to each other. In addition, in the case of individually winding the core pieces 10, as Fig.11 As shown in C, a mandrel method may be used in which the core sheet 10 is mounted on a rotation drive device 91 and the core sheet 10 itself is rotated without rotating the flyer to perform winding.

[0071] As described above, after the number of core sheets 10 required for the structure of the stator 1 is prepared, the core sheets 10 are rotated and connected so that the inner peripheral surface 10fi side (tooth side) of the core sheets 10 is on the inner side, thereby forming a ring shape (step S150). After that, after necessary insulation treatment and wiring treatment (step S160), the ring-shaped core sheets 10 are placed in a mold and molded with resin (step S170), thereby completing the stator 1.

[0072] Furthermore, by using a frame having bearings (not shown), the completed stator 1 is held on the inner wall of the frame, and the rotor 5 ( Fig.12 ) is assembled to the inner peripheral surface side of the stator 1 in a rotatably supported manner, thereby completing the rotating electrical machine.

[0073] As described above, according to the stator 1 of the first embodiment, the snap-fit ​​convex portion 2jm and the snap-fit ​​concave portion 2jf for forming the connection portion 10j using the snap-fit ​​are provided adjacent to each other in the insulating member 2 of each core sheet 10. Furthermore, the columnar portion 2jmp and the open loop portion 2jfc in the snap-fit ​​convex portion 2jm and the snap-fit ​​concave portion 2jff are engaged by insertion in a direction perpendicular to the axial direction, thereby forming the connection portion 10j that can rotate and restricts displacement in the axial direction.

[0074] Furthermore, the rotation axis of the connection portion 10j is made consistent with the end portion 4cy of the arc along the outer peripheral surface 10fo of the core piece member 10P or the magnetic body 4. Therefore, by providing the connection and rotation mechanism only on the insulating member 2, it is possible to easily connect each core piece 10, and rotation after connection is possible, without providing a complex shape for forming the rotation and connection mechanism on the magnetic body 4. In addition, by simply adjusting the rotation angle at the connection portion 10j of the core piece 10 so that the tooth 4t is on the inner side, the side end faces 4sy of the yoke 4y of the adjacent core pieces 10 can be brought into close contact with each other.

[0075] In contrast, for example, in the structure disclosed in Patent Document 1 in which the laminated cores constituting adjacent core sheets are meshed with each other, it is necessary to use a plurality of laminated cores and perform stamping and riveting. Therefore, there are the following problems: the forward-feeding mold for making the laminated core is complicated, a riveting device is also required, the introduction cost becomes expensive, and the number of parts increases. On the other hand, according to the stator 1 of the present application, since a mechanism that enables the core sheet 10 to be connected and rotated is provided on the insulating member 2, there is no need to use the aforementioned complex device for processing the steel plate, which is effective in reducing the equipment cost. Furthermore, since the connection operation can be performed even without using special equipment or fixtures in the connection of the core sheet 10, it leads to an improvement in material handling.

[0076] In addition, as in the present application, since the connection and rotation mechanism are formed in the insulating member 2 as a resin component, it is not necessary to form the connection and rotation mechanism in the magnetic body 4, and the magnetic body 4 can be formed by powder molding, which has poor mechanical strength relative to the steel plate. Since there is no need to use a complex and expensive mold such as a forward-feeding type in powder molding, a single-type mold can be used, so there is an effect of reducing the cost of the device. In addition, when using laminated steel plates, since the steel plates are punched by a punching machine, unnecessary components become more and the material utilization rate becomes worse, but in powder molding, since the required amount of powder can be used for molding, the material utilization rate can be kept high.

[0077] In addition, for example, in the structure disclosed in Patent Document 2 in which a connection and rotation mechanism is provided on the insulating member, there are the following problems: the types of components are increased, and different types need to be arranged alternately, which makes the manufacturing process complicated. In addition, there are the following problems: since the convex portion is inserted into the insertion hole in the axial direction, when the teeth are directed outward and the adjacent steel plates are not meshed with each other, the axial position between the core sheets is uncertain, and sometimes they fall off, making the manufacturing difficult.

[0078] On the other hand, according to the stator 1 of the present application, the snap-fit ​​structure that is inserted and removed in the direction perpendicular to the axial direction can be formed in an alternating manner, and the same type of core sheet components 10P can be connected to each other by insertion in the direction perpendicular to the axial direction. In addition, since it is inserted and removed perpendicular to the axial direction, it is possible to easily form a meshing structure that restricts axial movement while connecting, so there is no axial positional offset between the core sheet components 10P after connection, and the workability is also good.

[0079] Furthermore, the magnetic body 4 of the core piece 10 constituting the stator 1 of the present application can also be formed by stacking steel plates instead of using powder compaction. Fig.12 The advantages of using pressed powder for forming are explained. Fig.12 In the figure, it is assumed that the stators 1S and 1M are made of a magnetic body 4S formed by stacking steel plates and a magnetic body 4M formed by powder compacting. In this case, the cross-sectional schematic diagram of the rotating electric machine is switched with the rotation axis as the boundary and the rotor 5 having a magnet 51 on the outer peripheral surface side is arranged rotatably on the same axis of the stator 1, assuming that the stators 1S and 1M are respectively subjected to the same amount of magnetic flux. Here, in the case where the magnetic body is formed by stacking steel plates (the left side in the figure), "S" is recorded at the end of the figure mark to distinguish it, and in the case where the magnetic body is formed by powder compacting (the right side in the figure), "M" is recorded at the end of the figure mark to distinguish it.

[0080] When the magnetic body 4S is formed by using laminated steel plates, it is difficult to configure the yoke 4yS and the front end 4teS of the teeth to be different in height from the winding part 4twS. Therefore, the following structure is adopted: the thickness of the insulating member 2S covering the yoke 4yS and the front end 4teS of the teeth is made higher than the thickness covering the winding part 4twS, thereby forming a wall portion for preventing the winding collapse of the coil 3S. Accordingly, the amount of resin required to form the insulating member 2S tends to increase.

[0081] On the other hand, when the magnetic body 4M is formed by powder compacting, the iron powder or the like is compressed and formed, so the degree of freedom of the structure is high. Therefore, since the height of the yoke 4yM and the front end 4teM of the tooth can be made higher than the winding part 4twM in the magnetic body 4M itself, a structure for preventing the winding collapse of the coil 3M can be formed. Therefore, since the thickness of the insulating member 2M only needs to be a thickness that does not impair the insulating function, the covering thickness can be thinned compared to the case of using the magnetic body 4S based on the laminated steel plate, and the amount of resin required for forming the insulating member 2M can be reduced.

[0082] In addition, in the magnetic body 4M formed by powder compacting, the tooth tip 4teM can be included in the region where the coil 3M is formed in the axial direction. As a result, since the density of the magnetic flux interlinked with the winding part 4twM can be increased by receiving the magnetic flux in this region, there is no problem even if the height of the winding part 4twM is reduced compared to the magnetic body 4S using laminated steel plates. When the height of the winding part 4twM is formed to be low, the height of the winding part of the wire 3F can be suppressed to be low, so compared with the stator 1S, the amount of wire 3F used can be reduced and the stator 1 can be miniaturized.

[0083] Of course, in the stator 1 of the present application, the magnetic body 4M formed by powder pressing is not essential as the magnetic body 4. However, since the core pieces 10 (core piece members 10P) can be connected to each other rotatably by the insulating member 2, the magnetic body 4 formed by powder pressing can be used, and the amount of resin used in the insulating member 2 can be reduced and the material utilization rate of the magnetic material can be improved. In addition, the amount of wire 3F used can be reduced and the stator 1 can be miniaturized.

[0084] In addition, as an advantage of manufacturing the magnetic body 4 by powder compacting, the structure in which the axial height of the yoke side and the tooth tip portion is higher than the tooth winding portion has been described, but the invention is not limited to this. As in the case where the magnetic body 4 can also be formed by stacking steel plates, the height of the yoke side or the tooth tip portion can also be set to the same height as the tooth winding portion.

[0085] In addition, when forming the coil 3 on the iron core component 10P, the number of the flyers 80 for winding is only one, but in order to reduce the cycle time, multiple flyers 80 can also be used to wind multiple iron core components 10P at the same time. In addition, as illustrated in Embodiment 2, for the columnar portion 2jmp of the snap-on protrusion 2jm at the connecting portion 10j, a portion (an enlarged portion 2jmpw described later) that is sufficiently larger than the inner diameter of the open loop portion 2jfc of the snap-on recess 2jf can also be formed at the front end. In this case, even if the gap 10jc between the base 2jfb and the top surface 4fty is not provided, the position with a larger diameter plays the role of a hook, which can prevent the axial position displacement between adjacent iron core components 10P.

[0086] Implementation method 2.

[0087] In the first embodiment, an example in which the connection portion protrudes from the arc formed on the outer peripheral surface of the yoke is described. In the second embodiment, an example in which the connection portion is accommodated inside the arc formed on the outer peripheral surface of the yoke is described. Figure 13 to Figure 17 For explaining the stator or the method for manufacturing the stator according to the second embodiment, Fig.13 is the same as in Implementation 1 Figure 1The corresponding top view shows the appearance of the stator before molding, Fig.14 A and Fig.14 B are perspective views when viewed from different angles on the inner peripheral surface side of the side exposed when the insulating member covers the magnetic body portion, Fig.15 It is a plan view of the side exposed when the insulating member covers the magnetic body portion.

[0088] in addition, Fig.16 The figures show the state after the two core pieces are connected by the first stage snap-fit ​​connection ( Fig.16 A) After the final snap connection ( Fig.16 B) is a top view of the Fig.17 is a flowchart showing a method for manufacturing a stator. In addition, for the same structure as that of the first embodiment, the drawings and descriptions used in the first embodiment are cited, and the same reference numerals are given to the same parts, and the description will be centered on the parts different from the first embodiment. Fig.13 , Fig.16 A. Fig.16 B, for ease of explanation, a part (coil 3, enlarged portion 2jmpw) is omitted.

[0089] In implementation mode 1, Figure 1 As described above, an example is described in which the connecting portion 10j connected by snap-fitting between the iron core pieces 10 connected in an annular shape protrudes outward from the arc forming the outer peripheral surface 10fo (the same as the outer peripheral surface 4fo of the magnetic body 4). That is, when the iron core pieces 10 are connected in an annular shape, the connecting portion 10j formed by the resin material of the insulating member 2 at the outermost periphery protrudes from the outer peripheral surface 10fo in a protruding shape. Therefore, in order to fix the annular iron core pieces 10, hot-fitting cannot be performed. In addition, during molding, the outer peripheral surface 10fo of the tubular connecting body also becomes a structure floating from the mold due to the connecting portion 10j, so it is easy to rotate, the fixation is not sufficient, and sometimes molding becomes difficult.

[0090] On the other hand, in the stator 1 of the second embodiment, in order to solve the problem of not being able to be shrunk and the problem of insufficient fixation, Fig.13 As shown in FIG. 1 , the connection portion 10j is configured not to protrude from the outer peripheral surface 10fo when the core piece 10 is made annular. Fig.14 , Fig.15 As shown, the buckle recess 2jf is configured as a two-stage structure having a first open loop portion 2jfc1 and a second open loop portion 2jfc2 and a gourd-shaped shape perpendicular to the axis, and is configured to be able to transition from a rotatable connected state to a non-rotatable fixed connected state.

[0091] Specifically, similarly to the first embodiment, the magnetic body 4 is configured to have a top surface 4fty side and a bottom surface 4fby side ( Figure 3 ) are covered, but the structure for forming the connecting portion 10j is different. As the snap-fit ​​protrusion 2jm, the columnar portion 2jmp protrudes in the axial direction from the top surface 2fty of the yoke portion 2y, and does not extend to the radially outer side of the outer peripheral surface 2fo. Moreover, the center of the columnar portion 2jmp is located on the side surface portion 2fsy (side end surface 4sy), and the semicircular portion protrudes from the side surface portion 2fsy.

[0092] On the other hand, as the snap-on recess 2jf, the base 2jfb is located above the top surface 2fty of the yoke portion 2y in the axial direction, but does not extend radially outward from the outer peripheral surface 2fo. Moreover, the first open loop portion 2jfc1 is located circumferentially outward from the side surface 2fsy of the yoke portion 2y. On the other hand, the center of the second open loop portion 2jfc2 connected to the inner side of the first open loop portion 2jfc1 via the second opening portion 2jfa2 is located on the side surface 2fsy (side end surface 4sy), and the cross-sectional shape perpendicular to the axial direction is a semicircular groove in the area below the top surface 2fty.

[0093] In addition, in the second embodiment, the inner diameters of the first open loop portion 2jfc1 and the second open loop portion 2jfc2 (collectively referred to as the open loop portion 2jfc) in the free state are also designed to be less than the diameter of the columnar portion 2jmp. This is to prevent the buckle protrusion 2jm (columnar portion 2jmp) engaged with the buckle recess 2jf from falling off easily. In addition, the opening widths of the first opening portion 2jfa1 and the second opening portion 2jfa2 in the free state are also designed to be less than the diameter of the columnar portion 2jmp. This is also to prevent the buckle protrusion 2jm installed in the buckle recess 2jf from falling off easily.

[0094] Furthermore, in the second embodiment, an expansion portion 2jmpw having a larger diameter than the diameter of the cylindrical portion is formed at the front end of the columnar portion 2jmp. The expansion portion 2jmpw is located on the upper surface side of the base 2jfb of the buckle recess 2jf, and is formed at a position protruding above the base 2jfb when the buckle protrusion 2jm is inserted into the buckle recess 2jf. Furthermore, the cylindrical portion is set to have a larger diameter than the first open loop portion 2jfc1 or the second open loop portion 2jfc2 when it is expanded through the first opening portion 2jfa1 or the second opening portion 2jfa2.

[0095] The insulating member 2 is made to cover the upper and lower parts of the magnetic body 4 in the same manner as in the first embodiment, and the core piece 10P is manufactured. In the second embodiment, the core piece 10P manufactured in this way is also configured such that when the directions of the teeth are aligned and arranged, the snap-fit ​​protrusion 2jm of the core piece 10P on one side is adjacent to the snap-fit ​​recess 2jf of the core piece 10P on the other side. However, the snap-fit ​​recess 2jf and the snap-fit ​​protrusion 2jm do not extend from the outer peripheral surface 10fo, but protrude circumferentially from the outside in the axial direction relative to each top surface 2fty.

[0096] With such a structure, the columnar portion 2jmp of the buckle protrusion 2jm is inserted in the direction perpendicular to the axial direction to fit the adjacent buckle recess 2jf. Fig.16 As shown in A, the columnar portion 2jmp passes through the first opening portion 2jfa1 and is inserted into the first open loop portion 2jfc1, and is stably held in the first open loop portion 2jfc1, and the two core sheet members 10P are connected by snap-fit ​​connection.

[0097] When the connection is set to the single connection state Sj1, the outer periphery of the columnar portion 2jmp and the inner periphery of the first open loop portion 2jfc1 are both circular, and at the connection portion 10j in the single connection state Sj1, the columnar portion 2jmp is maintained in a state of being able to rotate around the first open loop portion 2jfc1. And, as mentioned above, since the center of the first open loop portion 2jfc1 is located at a position separated from the side portion 2fsy in the circumferential direction, the side portions 2fsy on the yoke side of the adjacent iron core component 10P are separated from each other in the single connection state. That is, in Fig.16 In the primary connection state Sj1 shown in A, the adjacent core sheet members 10P are in a state where there is no contact in the direction perpendicular to the axis except for the columnar portion 2jmp and the first open loop portion 2jfc1 located coaxially.

[0098] As a result, when the teeth are directed outward, the outer peripheral surfaces 10fo of the adjacent core sheet members 10P can be rotated until they come into contact with each other. On the other hand, when the teeth are directed inward, the side surfaces 2fsi ( Fig.14 , Fig.15 ) are in contact with each other.

[0099] From the first connection state Sj1, rotate it so that the teeth are on the inner side, as shown in FIG. Fig.16 As shown in B, when the columnar portion 2jmp is inserted into the second open loop portion 2jfc2 through the second opening portion 2jfa2, it is stably held in the second open loop portion 2jfc2. At this time, the two core pieces 10 are also connected by snap-fit ​​connection. In addition, in this case, as described later, after the coil 3 is wound, Fig.16In B, the coil 3 is not shown, but is given a reference numeral as the core piece 10 .

[0100] When the connection is set to the secondary connection state Sj2, the outer periphery of the columnar portion 2jmp and the inner periphery of the second open loop portion 2jfc2 are both circular, and at the connection portion 10j in the secondary connection state Sj2, the columnar portion 2jmp should be maintained in a state where it can rotate around the second open loop portion 2jfc2. However, as described above, since the center of the second open loop portion 2jfc2 is located on the side portion 2fsy, in the secondary connection state Sj2, the side portions 2fsy (side end faces 4sy) on the yoke side of the adjacent iron core member 10P are in contact with each other, and the side faces 2fsi on the tooth side are also close to each other.

[0101] That is to say, Fig.16 In the secondary connection state Sj2 shown in B, the adjacent iron core components 10P have the columnar portion 2jmp embedded in the second open loop portion 2jfc2 on the outer peripheral surface 2fo side, so that the side portions 2fsy are closely attached to each other and positioned, and cannot rotate. Therefore, when the connection portion 10j is in the primary connection state Sj1, a certain degree of range is allowed as the angle between the adjacent iron core components 10P. However, when it is transferred to the secondary connection state Sj2, only the angle range in which the side surfaces 2fsi are close to each other is allowed.

[0102] In addition, Fig.16 In the figure, for the snap-fit ​​protrusion 2jm located between the adjacent core sheet components 10P or core sheets 10, the description of the enlarged portion 2jmpw is omitted in order to show the position of the columnar portion 2jmp relative to the first open loop portion 2jfc1 and the second open loop portion 2jfc2. Fig.16 A. Fig.16 In each connection state shown in FIG. 1B , the enlarged portion 2jmpw faces the upper surface of the base portion 2jfb in the axial direction above the first open loop portion 2jfc1 to restrict axial displacement (positional deviation) between adjacent core sheets 10 or core sheet members 10P.

[0103] In addition, a "stopper" that prevents the semicircular groove of the side portion 2fsy from passing through the lower surface side of the buckle recess 2jf may be provided instead of the above-mentioned expansion portion 2jmpw. In this case, the semicircular protrusion protruding from the side portion 2fsy of the buckle convex portion 2jm can also be used to prevent the axial positional displacement of the iron core components 10P from each other.

[0104] Alternatively, although two types of insulating members are required, a first insulating member having snap-fit ​​recesses 2jf at both ends and a second insulating member having snap-fit ​​protrusions 2jm at both ends are made. Then, an iron core component using only the first insulating member and an iron core component using only the second insulating member are made and arranged alternately. In this case, even if the enlarged portion 2jmpw or "blocking member" is not provided, axial displacement can be prevented while snap-fitting.

[0105] Thus, even in a structure that holds the cylinder in an open loop, a mechanism that prevents positional deviation in the axial direction after connection can be formed by adopting a structure that switches the connection establishment and release of the buckle by plugging and pulling in a direction perpendicular to the axis. In contrast, for example, in a structure disclosed in Patent Document 2 that switches the connection establishment and release by plugging and pulling in the axial direction, positional deviation in the axial direction cannot be prevented if only the connection is made, and a clamp or the like for holding is required.

[0106] Next, refer to Fig.17 The flowchart of the present invention mainly describes the manufacturing method of the stator 1 of the second embodiment, focusing on the parts different from the first embodiment. In the second embodiment, the insulating member 2 is also assembled to the magnetic body 4 and the core component 10P is manufactured in the same manner as the first embodiment (steps S110 to S120). Then, the adjacent snap-fit ​​protrusions 2jm and snap-fit ​​recesses 2jf are engaged when the core components 10P are aligned and arranged, thereby forming a connection portion 10j that is connected by snap-fit.

[0107] However, the connection portion 10j in this stage remains in a primary connection state Sj1 in which the columnar portion 2jmp is maintained in the first open loop portion 2jfc1, forming an open loop connection body (step S135). At this time, as described above, the connection body can also be divided, and in the connected state, the iron core component 10P can be rotated around the first open loop portion 2jfc1.

[0108] Then, as in embodiment 1 Fig.11 As described above, the coupled body is set in the winding machine so that the outer peripheral surface 10fo of each core sheet member 10P faces the rotating roller 90, and the wire 3F is wound on each core sheet member 10P to produce the core sheet 10 having the coil 3 (step S140).

[0109] As described above, after the required number of core sheets 10 of the stator 1 is prepared, the core sheets 10 are rotated in such a way that the inner peripheral surface 10fi side of the core sheets 10 becomes the inner side, and the core sheets 10 at the end are connected to each other to form a ring. Then, each columnar portion 2jmp is moved from the first open loop portion 2jfc1 portion to the second open loop portion 2jfc2 portion, and transferred to the secondary connection state Sj2 (step S155). As a result, the side surface portions 2fsy (side end surfaces 4sy) of the adjacent core sheets 10 are closely attached to each other, and the side surfaces 2fsi are close to each other at a certain interval, and become a fixed state in which rotation around the connection portion 10j is not possible.

[0110] After that, after the insulation treatment or wiring process (step S160) as required, the core piece 10 is completely fixed by heat-fitting and the stator 1 is manufactured. In the second embodiment, unlike the first embodiment, since the buckle structure does not protrude from the outer peripheral surface 10fo of the core piece 10, even without using a fixture for positioning, the rotation in the circumferential direction can be suppressed, so heat-fitting can be easily performed. In addition, in the second embodiment, if the secondary connection state Sj2 is achieved, the core pieces 10 can be fixed without changing the angle between them, so that the appropriate annular shape can be maintained.

[0111] Therefore, it is possible to perform molding with good precision even in molding without being limited to shrink fitting. Therefore, in step S175, at least one of shrink fitting and molding may be performed.

[0112] In addition, the present application describes exemplary embodiments, but the various features, schemes, and functions described in the embodiments are not limited to the application of specific embodiments, and can be applied to the embodiments alone or in various combinations. Therefore, countless unillustrated variations can be envisioned within the scope of the technology disclosed in the specification of the present application. For example, it includes the case where at least one component such as the number of poles, the positioning grooves 4g, 2g, etc. is deformed, added, or omitted.

[0113] In particular, regarding the rotating electrical machine, since the structure of the rotor 5 is not a characteristic part, the arrangement and use of the magnet 51 are not limited to Fig.12 , can be any. However, it is preferred that the specification corresponds to the high performance of the above-mentioned stator 1. In other words, as long as the structure of the connecting portion 10j that can rotate around the columnar portion 2jmp and fix the axial position relationship is formed by using the snap connection in the direction perpendicular to the rotation axis X of the columnar portion 2jmp extending parallel to the rotation axis X and the open ring portion 2jfc is formed.

[0114] Furthermore, for example, a snap-fit ​​connection portion can be provided at the front end of the columnar portion 2jmp by providing a claw portion that is larger than the diameter of the open loop portion 2jfc and smaller than the diameter of the open loop portion 2jfc when it is opened. In this case, although the snap-fit ​​connection is performed by axial insertion and extraction, the columnar portion 2jmp can be prevented from axially disengaging from the open loop portion 2jfc by the claw portion, so that a connection that can rotate and prevent axial positional displacement between adjacent iron core components 10P can be performed.

[0115] As described above, according to the stator 1 of each embodiment, since it is a stator 1 in which a plurality of core pieces 10 having a magnetic body 4 and a coil 3 are arranged in a circular ring shape with an axis (rotation axis X) as the center, the magnetic body 4 forms a yoke 4y extending in a circular arc shape and teeth 4t protruding from the yoke 4y toward the axis (rotation axis X), and the coil 3 is wound around the teeth 4t, between adjacent core pieces 10 in the circular ring shape, a yoke side (near the circumferential end of the yoke portion 10y or the yoke portion 2y) of one core piece is provided in parallel with the axis. The columnar portion 2jmp extending in the direction and the open loop portion 2jfc provided on the yoke side (same as above) of the other iron core sheet are combined by snap-fit ​​(using embedding), and a connecting portion 10j having a fitting structure (for example, a gap 10jc relative to the base 2jmb or a base 2jfb relative to the enlarged portion 2jmpw and the top surface 2fty) that can rotate around the columnar portion 2jmp and restrict displacement in the axial direction is formed, so that the coil 3 with a high winding density can be formed without increasing the number of parts and without using a clamp for fixing. Therefore, a high-performance stator 1 and a rotating electric machine can be obtained without increasing the number of parts and the number of manufacturing processes.

[0116] Since the open-loop portion 2jfc is configured to have a gap 10jc between the open-loop portion 2jfc and the magnetic body portion 4 in the axial direction, and the columnar portion 2jmp is extended from a base 2jmb having a larger diameter than the columnar portion 2jmp, when the above-mentioned snap-fit ​​connection is performed, the base 2jmb of the iron core sheet on one side is clamped into the gap 10jc of the iron core sheet on the other side, so that the axial movement can be reliably restricted.

[0117] If the direction in which the columnar portion 2jmp is embedded in the open ring portion 2jfc is perpendicular to the extending direction of the columnar portion 2jmp, the axial displacement can be firmly restricted regardless of the force required for inserting or removing the buckle. In addition, the fitting structure for restricting the axial displacement (for example, the gap 10jc relative to the base 2jmb or the base 2jfb relative to the enlarged portion 2jmpw and the top surface 2fty) can also be easily formed without deformation of the components in the formation of the structure.

[0118] Since the columnar portion 2jmp and the open loop portion 2jfc are provided as an integrally molded member formed integrally with the resin insulating member 2 interposed between the magnetic body portion 4 and the coil 3, a snap-fit ​​structure requiring both deformability and mechanical strength can be easily realized.

[0119] When a compression-molded product using powder is used as the magnetic body portion 4 , it is possible to easily produce a shape most suitable for the magnetic body.

[0120] Since the center of the open loop portion 2jfc is located at the circumferential end 4cy on the outer peripheral surface 4fo of the yoke 4y, the core pieces 10 can be easily connected and can be rotated after connection. In addition, the side end faces 4sy of the yoke 4y of the adjacent core pieces 10 can be brought into close contact with each other simply by adjusting the rotation angle at the connecting portion 10j of the core piece 10 so that the teeth 4t are on the inner side.

[0121] On the other hand, if the open loop portion 2jfc and the columnar portion 2jmp are formed radially inward of the outer peripheral surface 4fo of the yoke 4y, the portion protruding from the outer peripheral surface 4fo of the yoke 4y disappears when connected in a ring shape, so that shrink fitting can be performed. Alternatively, rotation relative to the mold can also be prevented during molding, and appropriate molding can be performed.

[0122] At this time, if the open loop portion 2jfc is constructed to be composed of a first open loop portion 2jfc1 whose center is located at a position farther outside than the end face (side end face 4sy) of the yoke 4y in the circumferential direction, and a second open loop portion 2jfc2 connected to the first open loop portion 2jfc1 and whose center overlaps with the end face (side end face 4sy), the center of the columnar portion 2jmp (of the adjacent iron core sheet 10 or iron core sheet component 10P) overlaps with the end face (side end face 4sy) of the yoke 4y in the circumferential direction, then when the coil 3 is wound and embedded in the first open loop portion 2jfc1 and freely rotated to form a ring shape, the second open loop portion 2jfc2 can be embedded and the ring shape can be fixed, and the side end faces 4sy of the yoke 4y of the adjacent iron core sheet 10 can be made to fit tightly against each other.

[0123] In addition, according to the rotating electric machine of each embodiment, since it is constructed to include the above-mentioned stator 1, the rotor 5 coaxially arranged on the inner circumferential surface side of the stator 1, and a frame that holds the stator 1 and has a bearing (not shown) that supports the rotor 5 rotatably, it is possible to obtain a cheap and high-performance rotating electric machine or a cheap and small rotating electric machine.

[0124] As described above, according to the manufacturing method of the stator 1 of each embodiment, it includes: a process (steps S110 to S120) of making an iron core component 10P in which the insulating member 2 is covered on the magnetic body 4, and the magnetic body 4 is formed into a yoke 4y extending in an arc shape and teeth 4t protruding from the yoke 4y toward the axis (rotation axis X); for a plurality of iron core components 10P, the teeth 4t are oriented to the same side, and the end surfaces (side end surfaces 4sy) in the circumferential direction of the yoke 4y are arranged facing each other, and between adjacent iron core components 10P, a columnar portion 2jmp extending in a direction parallel to the axis (rotation axis X) of a yoke portion (near the circumferential end of the yoke portion 10y or the yoke portion 2y) of an iron core component provided on one side is embedded in the iron core component provided on the other side. The process of forming a connecting portion 10j having a fitting structure capable of rotating about the columnar portion 2jmp and limiting displacement in the axial direction by snap-fitting the open loop portion 2jfc of the yoke portion (same as above) of the chip member (step S130 or step S135); the process of expanding the angle of the teeth 4t of each of the plurality of core members 10P connected by the connecting portion 10j with the teeth 4t of the adjacent core members 10P, winding the wire 3F and forming the coil 3 (step S140); and the process of connecting the core members 10P formed with the coil 3 in a circular ring shape by making the teeth 4t inside (step S150 or step S155), so that the coil 3 with a high winding density can be formed without increasing the number of parts and without using a fixture for fixing. Therefore, a high-performance stator 1 and a rotating electric machine can be obtained without increasing the number of parts and the number of manufacturing processes.

[0125] As described above, another manufacturing method of the stator 1 according to each embodiment is set to include: a process (steps S110 to S120) of making an iron core component 10P in which the insulating member 2 is covered on the magnetic body 4, wherein the magnetic body 4 forms a yoke 4y extending in an arc shape and teeth 4t protruding from the yoke 4y toward the axis (rotation axis X); a process (step S140) of winding wire around the teeth 4t of each of the plurality of iron core components 10P to form a coil 3; and for the plurality of iron core components 10P formed with the coil 3, the teeth 4t are oriented to the same side, the end faces (side end faces 4sy) of the yoke 4y in the circumferential direction are arranged facing each other, and the adjacent Between the core sheet components 10P, the columnar portion 2jmp extending in the direction parallel to the axis of the yoke 4y portion provided on one core sheet component is inserted into the open loop portion 2jfc of the yoke 4y portion provided on the other core sheet component by snap-fitting, thereby forming a connecting portion 10j having a fitting structure capable of rotating around the columnar portion 2jmp and limiting displacement in the axial direction, and the steps (steps S130 / step S135 and step S150 / step S155) of connecting the teeth 4t to the inner side in an annular shape can form a coil 3 with a high winding density without increasing the number of components and without using a clamp for fixing. Therefore, a high-performance stator 1 and a rotating electric machine can be obtained without increasing the number of components and manufacturing processes.

[0126] In addition, if it is set to include a process of forming the stator 1 using the above-mentioned stator manufacturing method (step S110 to step S170) and a process of arranging the rotor 5 coaxially and rotatably on the inner circumferential surface side of the formed stator 1, the above-mentioned cheap and high-performance rotating electric machine or cheap and small rotating electric machine can be obtained.

[0127] Description of Reference Numerals

[0128] 1: stator, 2: insulator, 2jf: snap-on recess, 2jfb: base, 2jfc: open loop portion, 2jfc1: first open loop portion, 2jfc2: second open loop portion, 2jm: snap-on protrusion, 2jmb: base, 2jmp: columnar portion, 3: coil, 4: magnetic body portion, 4cy: end portion, 4fo: outer peripheral surface, 4sy: side end surface (end surface), 4t: tooth, 4y: yoke, 5: rotor, 10: core piece, 10fo: outer peripheral surface, 10jc: gap, 10P: core piece component, 10t: tooth portion, 10y: yoke portion, X: rotation axis (axis).

Claims

1. A stator, wherein a plurality of core pieces having a magnetic body and a coil are arranged in a circular ring shape with an axis as the center, wherein the magnetic body forms a yoke extending in an arc shape and teeth protruding from the yoke toward the axis, and the coil is wound around the teeth, characterized in that: Between adjacent iron core sheets in the annular configuration, a connecting portion having a fitting structure capable of rotation about the columnar portion and limiting displacement in the axial direction is formed by snap-fitting a columnar portion that is arranged on the yoke side of one iron core sheet in a manner fixed relative to the yoke of the iron core sheet on one side and extends in a direction parallel to the axis and an open-loop portion that is arranged on the yoke side of the other iron core sheet in a manner fixed relative to the yoke of the other iron core sheet, The open ring portion is provided with a gap between the open ring portion and the magnetic body portion in the axial direction. The columnar portion is extended from a base portion having a larger diameter than the columnar portion, When the snap-fit ​​connection is performed, the base portion of the one core sheet is sandwiched in the gap of the other core sheet.

2. The stator according to claim 1, characterized in that: The direction in which the columnar portion is embedded in the open loop portion is perpendicular to the extending direction of the columnar portion.

3. The stator according to claim 1 or 2, characterized in that: The columnar portion and the open loop portion are provided as an integrally molded member integrally molded with a resin insulating member interposed between the magnetic body portion and the coil.

4. The stator according to claim 1 or 2, characterized in that: The magnetic body is a compression-molded product using powder.

5. The stator according to claim 1 or 2, characterized in that: The center of the open loop portion is located at an end portion in the circumferential direction of the outer peripheral surface of the yoke.

6. The stator according to claim 1 or 2, characterized in that: The open ring portion and the columnar portion are formed radially inward of an outer peripheral surface of the yoke.

7. The stator according to claim 6, characterized in that The open loop portion is composed of a first open loop portion whose center in the circumferential direction is located outside the circumferential end surface of the yoke, and a second open loop portion connected to the first open loop portion and whose center overlaps with the circumferential end surface of the yoke. The center of the columnar portion overlaps with an end surface of the yoke in the circumferential direction in the circumferential direction.

8. A rotating electrical machine, characterized in that: The rotating electrical machine comprises: The stator according to any one of claims 1 to 7; a rotor coaxially arranged on the inner peripheral surface side of the stator; and A frame holds the stator and has a bearing that rotatably supports the rotor.

9. A method for manufacturing a stator, characterized in that: Include: A step of manufacturing an iron core member in which an insulating member covers a magnetic body portion, wherein the magnetic body portion is formed into a yoke extending in an arc shape and teeth protruding from the yoke toward the shaft; For the plurality of the iron core components, the teeth are oriented toward the same side, the end faces of the yoke in the circumferential direction are arranged to face each other, and between adjacent iron core components, a connecting portion having a fitting structure capable of rotation around the columnar portion and limiting displacement in the axial direction is formed by respectively embedding a columnar portion extending in a direction parallel to the axis and provided on the yoke portion of one iron core component in a manner fixed to the yoke portion of the other iron core component in an axial direction with a gap between the magnetic body portion and an open-loop portion provided on the yoke portion of the other iron core component in a manner fixed to the yoke portion of the other iron core component by snap-fitting; A step of winding a wire around teeth of each of the plurality of core members connected by the connecting portion so as to increase the angle with respect to teeth of adjacent core members to form a coil; and a step of connecting the core member having the coil formed thereon into a circular ring shape with the teeth being placed inside. The columnar portion is extended from a base portion having a larger diameter than the columnar portion, When the snap-fit ​​connection is performed, the base portion of the one core sheet member is sandwiched in the gap of the other core sheet member.

10. A method for manufacturing a rotating electrical machine, characterized in that: Include: A step of forming the stator using the stator manufacturing method according to claim 9; and A step of rotatably disposing a rotor coaxially on the inner peripheral surface side of the formed stator.

11. A method for manufacturing a stator, characterized in that: Include: A step of manufacturing an iron core member in which an insulating member covers a magnetic body portion, wherein the magnetic body portion is formed into a yoke extending in an arc shape and teeth protruding from the yoke toward the shaft; A step of winding a wire material around teeth of each of the plurality of core pieces to form a coil; as well as For a plurality of iron core components formed with the coils, the teeth are oriented to the same side, the end faces of the yoke in the circumferential direction are arranged facing each other, and between adjacent iron core components, a columnar portion extending in a direction parallel to the axis and provided on the yoke portion of one iron core component in a manner fixed to the yoke portion of one iron core component is embedded in a snap-fit ​​connection with an open loop portion of the yoke portion of the other iron core component in an axial direction and provided in a manner fixed to the yoke portion of the other iron core component with a gap between the magnetic body portion, thereby forming a connecting portion having a fitting structure capable of rotating around the columnar portion and limiting displacement in the axial direction, and a process for making the teeth become the inner side and connected in a circular ring shape, The columnar portion is extended from a base portion having a larger diameter than the columnar portion, When the snap-fit ​​connection is performed, the base portion of the one core sheet member is sandwiched in the gap of the other core sheet member.

12. A method for manufacturing a rotating electrical machine, characterized in that: Include: A step of forming the stator using the stator manufacturing method according to claim 11; and A step of rotatably disposing a rotor coaxially on the inner peripheral surface side of the formed stator.

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