Armature and manufacturing method thereof

Abstract

An armature and a method for manufacturing the same. The armature includes an iron core (20). The iron core (20) includes stacked iron core sheets (30) and includes slots (23). The iron core sheets (30) are all plate-shaped. The armature includes a coil (40) arranged in each slot (23) and an insulating sheet (50) arranged between the inner surface of each slot (23) and the outer surface of the coil (40). The insulating sheet (50) includes a main body (51) covering the inner surface of the slot (23). The insulating sheet (50) includes protrusions (52) protruding from the main body (51) toward the opposite side of the coil (40) and spaced apart from each other in the stacking direction of the iron core sheets (30). The protrusions (52) clamp one or more iron core sheets (30) in the stacking direction.

Description

Technical Field

[0001] The present disclosure relates to armatures and methods of manufacturing the same. Background Art

[0002] The armature (eg, stator) of a conventional rotating electric machine includes an iron core having slots and a coil formed of a conductor arranged in each slot (see, for example, PCT Publication No. WO2014041637). Each slot includes an insulating sheet that insulates the iron core and the coil.

[0003] This core is formed by stacking core sheets stamped from electrical steel sheets. Each core sheet includes a concave portion and a convex portion along its thickness. Two adjacent core sheets, as they are stacked, are joined together by swaging the core sheets at their concave portions and corresponding convex portions. This maintains the core's shape.

[0004] When joining the core sheets together by swaging them at their recesses and corresponding protrusions, a short circuit can occur when the recesses and protrusions electrically connect the core sheets. This can easily cause eddy currents in the core and increase core loss. However, if the recesses and protrusions are not swaged, the core sheets will not be joined together. Consequently, the core's shape may not be maintained. Therefore, in an armature, it is desirable to limit core loss and maintain its shape. Summary of the Invention

[0005] This summary is provided to introduce a series of concepts in a simplified form, which will be further explained in the detailed description below. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0006] An armature that solves the above-mentioned problem includes an iron core. The iron core includes stacked laminations and slots. Each lamination is plate-shaped. The armature includes a coil disposed in each slot and an insulating sheet disposed between the inner surface of each slot and the outer surface of the coil. The insulating sheet includes a body that covers the inner surface of each slot. The insulating sheet includes protrusions that protrude from the body toward the side opposite the coil and are spaced apart from each other in the stacking direction of the laminations. The protrusions sandwich one or more laminations in the stacking direction.

[0007] A method for manufacturing an armature that solves the above-mentioned problem is provided. The armature includes an iron core, which includes stacked iron core sheets and includes slots. The iron core sheets are all plate-shaped. The armature includes: a coil, which is arranged in each slot; and an insulating sheet, which is arranged between the inner surface of each slot and the outer surface of the coil. The method includes: an insulating sheet arrangement step, in which the insulating sheet is arranged in each slot; a coil arrangement step, in which the coil is arranged in the slot in which the insulating sheet is arranged; and a pressurizing step, in which the coil arranged in the slot is pressed against the inner surface of the slot so that the coil is plastically deformed along the inner surface of the slot and forms a protrusion. The protrusion protrudes from the insulating sheet toward the opposite side of the coil. The protrusion clamps one or more iron core sheets in the stacking direction of the iron core sheets.

[0008] Other features and aspects will be apparent from the following detailed description, drawings, and technical solutions. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 is a cross-sectional view showing a stator according to an embodiment.

[0010] Figure 2 It is an enlarged cross-sectional view showing a stator.

[0011] Figure 3 It is along Figure 2 A cross-sectional view taken along line 3-3 in FIG.

[0012] Figure 4 It is along Figure 2 A cross-sectional view taken along line 4-4 in FIG.

[0013] Figure 5 It is a cross-sectional view showing a state where the insulating sheets are arranged in the grooves in the insulating sheet arrangement step.

[0014] Figure 6 It is a cross-sectional view showing a state where coils are arranged in slots in a coil arrangement step.

[0015] Figure 7 It is a cross-sectional view showing a state where a plurality of arrangement portions are pressurized in the pressurizing step.

[0016] Figure 8 It is a cross-sectional view showing a state in which all arrangement portions are pressurized in the pressurizing step.

[0017] Figure 9 is a cross-sectional view showing a stator according to a modified example.

[0018] Figure 10 is a cross-sectional view showing a stator according to another modified example.

[0019] Throughout the drawings and detailed description, like reference numerals refer to like elements. The drawings may not be drawn to scale, and the relative sizes, proportions, and depictions of elements in the drawings may be exaggerated for clarity, illustration, and convenience. DETAILED DESCRIPTION

[0020] This description provides a comprehensive understanding of the methods, apparatuses, and / or systems described herein. Variations and equivalents of the methods, apparatuses, and / or systems described herein will be readily apparent to those skilled in the art. Except for operations that must occur in a specific order, the order of operations is illustrative and may be varied as would be apparent to one skilled in the art. Descriptions of functions and structures well known to those skilled in the art may be omitted.

[0021] Example embodiments may have different forms and are not limited to the described examples. However, these examples are thorough and complete, and will convey the full scope of this disclosure to those skilled in the art.

[0022] In the present specification, “at least one of A and B” should be understood to mean “only A, only B, or both A and B”.

[0023] Now refer to Figures 1 to 8 An embodiment in which an armature and a method for manufacturing the same are applied to the stator 10 and a method for manufacturing the same will be described.

[0024] For the purpose of illustration, some parts of the structure in the drawings may be exaggerated or simplified. In addition, the size ratios of various parts may be different in various drawings.

[0025] stator 10

[0026] like Figure 1 and Figure 2 As shown, the stator 10 of the rotating electric machine includes a cylindrical stator core 20, coils 40, and insulating sheets 50. The stator core 20 includes a central hole 20a. The coils 40 are wound around the stator core 20. Each insulating sheet 50 covers the outer surface of the coil 40. Figure 1 The insulating sheet 50 is not shown.

[0027] The stator 10 of this embodiment is used for a three-phase synchronous rotating electrical machine and is arranged so as to surround a rotor (not shown). The stator core 20 corresponds to an iron core.

[0028] stator core 20

[0029] The stator core 20 includes an annular yoke 21 and teeth 22. The teeth 22 extend from the yoke 21 toward the radially inner side of the yoke 21. The teeth 22 are spaced apart from each other in the circumferential direction of the yoke 21.

[0030] The slots 23 are arranged between the teeth 22 adjacent to each other in the circumferential direction of the yoke 21. The slots 23 are open radially inward and extend radially. The stator core 20 of this embodiment includes a total of 48 slots 23.

[0031] like Figure 3 As shown, the stator core 20 is formed by stacking plate-shaped core sheets 30. Each core sheet 30 is formed by punching an electrical steel sheet.

[0032] The stacking direction of the core sheets 30 is hereinafter referred to as the stacking direction. The circumferential direction of the stator core 20 around the axis of the stator core 20 is referred to as the circumferential direction. The radial direction of the stator core 20 around the axis is referred to as the radial direction. The core sheets 30 at opposite ends in the stacking direction of the core sheets 30 may be referred to as core sheets 30a. The core sheets 30 between the core sheets 30a may be referred to as core sheets 30b.

[0033] Coil 40

[0034] like Figure 2 As shown, the coils 40 are arranged in eight rows in the radial direction, for example, in each slot 23. In this embodiment, the coils 40 of the U phase, V phase, and W phase are wound around the teeth 22 by distributed winding.

[0035] The coil 40 includes a rectangular wire made of metal (eg, aluminum alloy) and an insulating film covering the outer surface of the rectangular wire. The insulating film is not shown in the drawings.

[0036] like Figure 3 As shown, the coil 40 includes a placement portion 41 and coil ends 42. The placement portion 41 is placed in each slot 23. The coil ends 42 are continuous with each placement portion 41 and protrude from the slot 23 on opposite sides in the stacking direction of the coil 40.

[0037] The arrangement portion 41 extends straight in the stacking direction. Although not shown in the drawings, the arrangement portions 41 arranged in two different slots 23 are coupled to each other through the coil ends 42.

[0038] like Figure 2 As shown, each slot 23 includes eight configurations 41 adjacent to each other in the radial direction.

[0039] The cross-sectional shape of coil 40 of this embodiment, perpendicular to the longitudinal direction of coil 40, is rectangular with long and short sides. The long side of the cross-sectional shape of each arrangement portion 41 extends along the width direction of slot 23. The short side of the cross-sectional shape of each arrangement portion 41 extends in the radial direction. The width direction of slot 23 is perpendicular to the stacking direction and the radial direction.

[0040] Insulation sheet 50

[0041] The insulating sheet 50 is located between the inner surface of each slot 23 and the outer surface of the coil 40. The insulating sheet 50 is covered so as to surround the entire inner surface of the slot 23. The insulating sheet 50 is opened radially inward in the same manner as the slot 23.

[0042] Each insulating sheet 50 includes a plastic base (not shown) and an insulating layer (not shown) disposed on the opposite side of the base. The insulating layer is formed by, for example, impregnating non-woven fabric with a plastic material.

[0043] like Figure 3 and Figure 4 As shown, the insulating sheet 50 includes a main body 51 and protrusions 52. The main body 51 covers the outer surface of the coil 40. The protrusions 52 protrude from the main body 51 toward the opposite side of the coil 40 and are spaced apart from each other in the stacking direction.

[0044] The main body 51 extends in the stacking direction along the arrangement portion 41. Opposite ends of the main body 51 in the stacking direction protrude from the groove 23.

[0045] The protrusion 52 is formed by a portion of the insulating layer that protrudes toward the opposite side of the coil 40. The protrusion 52 includes two outer protrusions 52a and a plurality of inner protrusions 52b. The inner protrusion 52b is located between the two outer protrusions 52a in the stacking direction.

[0046] The two outer protrusions 52a sandwich the entire stator core 20 from opposite sides in the stacking direction of the core sheets 30. The outer protrusions 52a protrude from a portion of the body 51 outside the slots 23. Each outer protrusion 52a contacts the outer surface of the corresponding core sheet 30a.

[0047] Each inner protrusion 52b is located between adjacent core sheets 30 in the stacking direction. The inner protrusions 52b and core sheets 30b are alternately arranged in the stacking direction. Thus, two adjacent inner protrusions 52b in the stacking direction sandwich one core sheet 30b. Each core sheet 30a is sandwiched between a corresponding outer protrusion 52a and a corresponding inner protrusion 52b.

[0048] A gap G is provided between two core sheets 30 that hold each inner protrusion 52b and are located on opposite sides of the inner protrusion 52b in the stacking direction. The gap G is provided over the entire section between the two core sheets 30. Therefore, the core sheets 30 are spaced apart from each other in the stacking direction.

[0049] The outer protrusion 52a and the inner protrusion 52b extend over substantially the entire circumference of each groove 23. That is, the outer protrusion 52a and the inner protrusion 52b are formed so that portions protruding radially outward from the main body 51 are continuous with portions protruding from the main body 51 in the width direction toward opposite sides of the groove 23. In a plan view, the outer protrusion 52a and the inner protrusion 52b are substantially U-shaped.

[0050] Stator manufacturing method

[0051] A method of manufacturing the stator 10 will now be described.

[0052] First, if Figure 5 As shown, an insulating sheet 50 is arranged in each slot 23 of the stator core 20 (insulating sheet arrangement step). The insulating sheet 50 can be inserted into the slot 23 from the radial inside or can be inserted into the slot 23 along the stacking direction. The core sheets 30 adjacent in the stacking direction are in contact with each other in the stacking direction.

[0053] The holding jigs 60 are respectively arranged on opposite sides of the core sheets 30 in the stacking direction. Each holding jig 60 is in contact with a portion of the corresponding core sheet 30a that defines the yoke 21 and the teeth 22. Figures 6 to 8 The holding fixture 60 is not shown.

[0054] Then, if Figure 6 As shown, the arrangement portions 41 of the coils 40 are arranged in the slots 23 where the insulating sheet 50 is arranged (coil arrangement step). The arrangement portions 41 are arranged in the slots 23 so that the radial direction is aligned with the direction in which the long sides of the arrangement portions 41 extend. In the coil arrangement step of this embodiment, the arrangement portions 41 are first arranged in the slots 23 in five radial rows.

[0055] Then, if Figure 7 As shown, a pressing jig 70 is inserted into the groove 23 to press the arrangement portion 41. The pressing jig 70 includes a pressing surface 70a extending on the groove 23 in the stacking direction.

[0056] The placement portions 41 placed in the groove 23 are then pressed by the press jig 70 toward the inner surface of the groove 23; more specifically, toward the radially outer side. This causes the placement portions 41 to plastically deform along the inner surface of the groove 23. The placement portions 41 are plastically deformed so that their radial thickness decreases and their widthwise thickness increases. This results in each placement portion 41 having a long side extending in the width direction of the groove 23 and a short side extending in the radial direction of the groove 23.

[0057] During the plastic deformation of the arrangement portion 41, the insulating sheet 50 is pressed toward the inner surface of the groove 23 by the arrangement portion 41. The insulating sheet 50 is pressed toward the radially outer side and the opposite sides in the width direction. Figure 3 and Figure 4 As shown, this forms a protrusion 52 that protrudes from the main body 51 of the insulating sheet 50 toward the opposite side of the coil 40 (pressing step). In this step, the main body 51 extends in the stacking direction.

[0058] During the pressurization step, as Figure 3 and Figure 4 As shown by the dotted line in , the outer protrusion 52a is formed by a portion of the insulating sheet 50 in a section that enters between the holding jig 60 and the core sheet 30a. The holding jig 60 and the core sheet 30a move away from each other in the stacking direction.

[0059] Furthermore, the inner protrusion 52b is formed by a portion of the insulating sheet 50 that enters a section between two core sheets 30 adjacent in the stacking direction. The two core sheets 30 are moved away from each other in the stacking direction.

[0060] Likewise, if Figure 8 As shown, the three additional arrangement portions 41 are pressurized by the press jig 70 and plastically deformed, and the outer protrusions 52a and the inner protrusions 52b are formed over substantially the entire circumference of the groove 23. In this embodiment, two of the three arrangement portions 41 are first arranged in the groove 23 and pressurized by the press jig 70. Then, the remaining arrangement portion 41 is arranged in the groove 23 and pressurized by the press jig 70.

[0061] The stator 10 is thus manufactured.

[0062] The operation of this embodiment will now be described.

[0063] The two outer protrusions 52a sandwich the entire stator core 20 from opposite sides in the stacking direction of the core sheets 30. Therefore, the core sheets 30 are positioned in the stacking direction. This reduces the area of ​​the entire stator core 20 where the core sheets 30 are swaged to each other (operation 1).

[0064] In addition, the inner protrusions 52b are each located between the core sheets 30 adjacent in the stacking direction to clamp the core sheets 30b in the stacking direction. This reduces the area of ​​each core sheet 30b held between the two inner protrusions 52b being swaged to the adjacent core sheet 30b (operation 2).

[0065] Advantages of the embodiment will now be described.

[0066] (1) The stator 10 includes a stator core 20 having slots 23, a coil 40 arranged in each slot 23, and an insulating sheet 50 arranged between the inner surface of each slot 23 and the outer surface of the coil 40. The stator core 20 includes stacked core sheets 30. Each core sheet 30 is plate-shaped. The insulating sheet 50 includes a main body 51 and a protrusion 52. The main body 51 covers the inner surface of the slot 23. The protrusions 52 protrude from the main body 51 toward the opposite side of the coil 40 and are spaced apart from each other in the stacking direction of the core sheets 30. The protrusions 52 include two outer protrusions 52a and a plurality of inner protrusions 52b. The two outer protrusions 52a clamp the entire stator core 20 from opposite sides of the core sheets 30 in the stacking direction. The inner protrusions 52b are each located between adjacent core sheets 30 in the stacking direction to clamp the core sheets 30.

[0067] This structure produces the above-described operations 1 and 2, thereby limiting the iron loss of the stator core 20 and maintaining the shape of the stator core 20 .

[0068] (2) The gap G is provided between the two core sheets 30 which hold each inner protrusion 52 b and are located on opposite sides in the stacking direction of the inner protrusions 52 b.

[0069] This structure allows a cooling medium (for example, oil) to flow into the gap G between the core sheets 30. Thus, the stator core 20 is cooled.

[0070] (3) In the insulating sheet placement step, the insulating sheet 50 is placed in each slot 23. In the coil placement step, the coil 40 is placed in the slot 23 in which the insulating sheet 50 is placed. In the pressing step, the coil 40 placed in the slot 23 is pressed against the inner surface of the slot 23, so that the coil 40 is plastically deformed along the inner surface of the slot 23 and forms the protrusion 52. The protrusion 52 protrudes from the insulating sheet 50 toward the side opposite to the coil 40 and sandwiches the core sheets 30 in the stacking direction.

[0071] In this method, in the insulating sheet placement step, insulating sheet 50 is placed in slot 23. Next, in the coil placement step, coil 40 is placed in slot 23 where insulating sheet 50 is placed. Then, in the pressurizing step, coil 40 placed in slot 23 is pressed against the inner surface of slot 23. This causes coil 40 to plastically deform along the inner surface of slot 23. Furthermore, protrusions 52 protrude from insulating sheet 50 toward the side opposite to coil 40 and sandwich core sheets 30 in the stacking direction.

[0072] In the stator 10 manufactured in this manner, the core sheets 30 are held by the protrusions 52 of the insulating sheets 50 so that the core sheets 30 are positioned in the stacking direction. This reduces the area of ​​each core sheet 30 held between the protrusions 52 that is swaged to the adjacent core sheets 30, thereby limiting the iron loss of the stator core 20 and maintaining the shape of the stator core 20.

[0073] Modifications

[0074] This embodiment can be modified as follows: This embodiment and the following modifications can be combined as long as they remain technically consistent with each other.

[0075] In the pressurizing step, the arrangement portions 41 may be pressurized one by one or may be pressurized collectively.

[0076] like Figure 9 As shown, the inner surface of each slot 23 may include a recess 23a that is recessed toward the opposite side of the coil 40. Each recess 23a may be formed by two core sheets 30 that are in contact with each other in the stacking direction. Each inner protrusion 52b is located in the corresponding recess 23a. Each recess 23a of the modified example is formed by configuring a notch 31 in the corresponding core sheet 30. For example, each notch 31 is formed by chamfering the edge of the inner surface of the corresponding core sheet 30 that defines the slot 23 over the entire circumference of the slot 23. In this structure, each inner protrusion 52b is located in the corresponding recess 23a. When the core sheets 30 are in contact with each other in the stacking direction, this allows the core sheets 30 to be easily clamped by the inner protrusion 52b. Therefore, the shape of the stator core 20 is maintained in an advantageous manner.

[0077] exist Figure 9 In a modified example, the stator core 20 can be formed by stacking the core sheets 30 with different orientations in the stacking direction by stacking the gaps 31. Figure 10 As shown, the stator core 20 can be formed by stacking a first stacking portion 20A and a second stacking portion 20B. The first stacking portion 20A is a stacking portion of the core sheets 30 with the notches 31 oriented toward one side in the stacking direction. The second stacking portion 20B is a stacking portion of the core sheets 30 with the notches 31 oriented toward the other side in the stacking direction. In this case, the first and second stacking portions 20A, 20B are easily pressed by the inner protrusions 52b, bringing the first and second stacking portions 20A, 20B closer to each other in the stacking direction. This maintains the shape of the stator core 20.

[0078] The recess 23a in the above-described modified example can be formed by bringing two core sheets 30, each having an edge of a different shape on the inner surface defining the slot 23, into contact in the stacking direction. In this case, the edge of one core sheet 30 is located on the outer peripheral side of the other core sheet 30. As a result, the edges of the two core sheets 30 form a step in the inner surface of the slot 23. This step forms the recess 23a. This structure also allows the core sheets 30 to be easily clamped by the inner protrusion 52b when the core sheets 30 are in contact with each other in the stacking direction. Therefore, the shape of the stator core 20 is maintained in an advantageous manner.

[0079] Each gap G may be provided only at a portion close to the inner protrusion 52 b . That is, the two core sheets 30 may be in contact with each other at a position away from the inner protrusion 52 b .

[0080] The insulating sheet 50 does not necessarily need to include the inner protrusion 52b. That is, the insulating sheet 50 may include only the outer protrusion 52a.

[0081] The insulating sheet 50 does not necessarily need to include the outer protrusion 52a. That is, the insulating sheet 50 may include only the inner protrusion 52b.

[0082] Two inner protrusions 52b adjacent to each other in the stacking direction can sandwich a plurality of core sheets 30b. That is, the number and positions of the inner protrusions 52b in the stator core 20 can be changed.

[0083] Each core sheet 30 may include a concave portion and a convex portion, so that the core sheets 30 are joined to each other by swaging the core sheets 30 at their concave portions and corresponding convex portions. In this case, the shape of the stator core 20 is maintained by swaging the concave portions and corresponding convex portions and by using the protrusions 52.

[0084] The protrusions 52 may be arranged at locations of the groove 23 in the circumferential direction, or may be arranged in a discontinuous manner in the circumferential direction.

[0085] In this embodiment, a stator for a rotating electrical machine is described as an example of an armature. Alternatively, the structure of the stator can be applied to a rotor for a rotating electrical machine. In this embodiment, a method for manufacturing a stator for a rotating electrical machine is described as an example of a method for manufacturing an armature. Alternatively, the method for manufacturing a stator can be applied to a method for manufacturing a rotor for a rotating electrical machine.

[0086] Various changes in form and details may be made to the above examples without departing from the spirit and scope of the claims and their equivalents. These examples are for illustration only and not for limitation. The description of the features in each example should be considered to be applicable to similar features or aspects in the other examples. Appropriate results can be achieved if the sequences are performed in a different order, and / or if the components in the described systems, architectures, devices or circuits are combined in different ways, and / or replaced or supplemented by other components or their equivalents. The scope of the present disclosure is not limited by the specific embodiments, but by the claims and their equivalents. All changes within the scope of the claims and their equivalents are included in the present disclosure.

Claims

1. An armature comprising: An iron core comprising stacked iron core sheets and slots, wherein the iron core sheets are all in a plate shape; a coil disposed in each of the slots; and an insulating sheet disposed between an inner surface of each slot and an outer surface of the coil, the insulating sheet including a main body covering the inner surface of the slot and protrusions protruding from the main body toward the opposite side of the coil and spaced apart from each other in the stacking direction of the core sheets, wherein The protrusions clamp one or more core sheets in the stacking direction. The insulating sheet is composed of a plastic base and an insulating layer arranged on opposite sides of the base and formed by impregnating a nonwoven fabric with a plastic material, The protrusion is formed by the insulating layer.

2. The armature according to claim 1, characterized in that The protrusions include two outer protrusions that sandwich the entire core from opposite sides in the stacking direction of the core.

3. The armature according to claim 1 or 2, characterized in that The protrusions include inner protrusions, each of which is located between the adjacent core sheets in the stacking direction to clamp one or more core sheets.

4. The armature according to claim 3, characterized in that A gap is provided between two of the core sheets that hold each of the inner protrusions and are located on opposite sides in the stacking direction of the inner protrusions.

5. The armature according to claim 3, characterized in that The core sheets adjacent to each other in the stacking direction are in contact with each other in the stacking direction, The inner surface of each slot includes a recess formed by two adjacent core sheets in the stacking direction, the recess being recessed toward the opposite side of the coil, and Each of the inner protrusions is located in a corresponding one of the recesses.

6. A method for manufacturing an armature, the armature comprising: An iron core comprising stacked iron core sheets and slots, wherein the iron core sheets are all in a plate shape; a coil disposed in each of the slots; and an insulating sheet disposed between an inner surface of each of the slots and an outer surface of the coil, the insulating sheet being composed of a plastic base and insulating layers disposed on opposite sides of the base and formed by impregnating a nonwoven fabric with a plastic material, the method comprising: an insulating sheet arranging step of arranging the insulating sheet in each of the slots; a coil placement step of placing the coil in the slot where the insulating sheet is placed; and A pressurizing step is performed to press the coil arranged in the slot toward the inner surface of the slot so that the coil is plastically deformed along the inner surface of the slot and forms a protrusion, wherein the protrusion protrudes from the insulating sheet toward the opposite side of the coil, and the protrusion clamps one or more iron core sheets in the stacking direction of the iron core sheets, and the protrusion is formed by the insulating layer.

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