Stator manufacturing method, stator and motor

Abstract

The present invention provides a method for manufacturing a stator, the stator comprising: a laminated iron core obtained by deforming a plate-shaped iron core forming portion in one direction in the width direction and winding it into a spiral shape; and insulating paper inserted into a slot. The stator manufacturing method includes: a stamping process, punching out the iron core forming portion from a steel plate by stamping; an installation process, installing the insulating paper on a plurality of protrusions arranged in the circumferential direction and extending along the center axis on the outer peripheral surface of a cylindrical roller component rotating around a center axis; and a stacking process, in a state where the protrusion and the insulating paper are inserted into the slot, the iron core forming portion is deformed in one direction in the width direction by rotating the roller component, and spirally wound on the outer peripheral surface of the roller component, and the iron core forming portion is stacked in its thickness direction.

Description

Technical Field

[0001] The invention relates to a stator manufacturing method, a stator and a motor. Background Art

[0002] A stator is known, which includes a laminated iron core having a plurality of electromagnetic steel sheets laminated thereon and insulating paper received in slots of the laminated iron core. As such a stator, for example, a motor core is disclosed, which includes a laminated steel sheet portion having a plurality of electromagnetic steel sheets laminated thereon, the electromagnetic steel sheets including teeth for winding windings, and a sheet-shaped insulating member inserted in a slot provided between the teeth (for example, Patent Document 1). Prior art literature Patent Literature

[0003] Patent Document 1: Japanese Patent Application Publication No. 2016-171652

[0004] However, in general, in a method for manufacturing a stator, after forming a laminated core by laminating electromagnetic steel sheets, insulating paper is inserted into the slots of the laminated core in the axial direction. The electromagnetic steel sheets are formed, for example, by stamping. The electromagnetic steel sheets punched out by stamping have protrusions formed at their ends.

[0005] Therefore, when the insulating paper is inserted axially into the slot of the laminated iron core on which the electromagnetic steel sheets are stacked, the insulating paper may get caught on the protrusion. Therefore, a method for manufacturing a stator that can more easily insert the insulating paper into the slot of the laminated iron core is required. Summary of the invention

[0006] An object of the present invention is to provide a method for manufacturing a stator that can more easily insert insulating paper into slots of a laminated iron core.

[0007] A stator manufacturing method according to an exemplary embodiment of the present invention is a stator manufacturing method, the stator comprising: a laminated iron core obtained by deforming a plate-shaped iron core forming part having a strip-shaped back yoke forming part and a plurality of teeth protruding from the back yoke forming part to one side in the width direction of the back yoke forming part while winding it into a spiral shape; and insulating paper inserted into a slot located between the teeth. The stator manufacturing method includes: a stamping process, punching the iron core forming part from a steel plate by stamping; an installation process, installing the insulating paper on a plurality of protrusions arranged in the circumferential direction and extending along the center axis on the outer peripheral surface of a cylindrical roller component rotating around a center axis; and a stacking process, in a state where the protrusion and the insulating paper are inserted into the slot, the iron core forming part is deformed to one side in the width direction while being spirally wound on the outer peripheral surface of the roller component by rotating the roller component, thereby stacking the iron core forming part in its thickness direction.

[0008] A stator according to an exemplary embodiment of the present invention comprises: a laminated core having a cylindrical core back and a plurality of teeth extending radially inward from the radial inner circumference of the core back, and having steel plates laminated in the thickness direction; and insulating paper received in slots between the teeth. A surface on one side in the thickness direction of the steel plate has a curved surface at the end, and a surface on the other side in the thickness direction of the steel plate has a protrusion at the end. The surface on one side is located on one side of the stacking direction of a portion of the steel plates constituting the laminated core, and the surface on the other side is located on one side of the stacking direction of the other steel plates constituting the laminated core.

[0009] A motor according to an exemplary embodiment of the present invention is a motor including the above-mentioned stator.

[0010] According to the present invention, it is possible to provide a method for manufacturing a stator in which insulating paper can be inserted more easily into slots of a laminated iron core. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 This is a perspective view schematically showing the general structure of the stator according to the first embodiment. Figure 2 It is a plan view showing a schematic structure of a laminated core. Figure 3 It is a cross-sectional view schematically showing the shape of the end portion of the belt-shaped member. Figure 4A It is a figure explaining punching by a punching machine. Figure 4B It is a diagram for explaining the shape of the end portion of a material punched out by a press machine. Figure 5It is a perspective view schematically showing the general structure of the roller member. Figure 6 It is a top view of the roller component. Figure 7 This is a flowchart showing the method for manufacturing the stator according to the first embodiment. Figure 8 This is a blanking diagram of a steel plate. Fig. 9 It is a cross-sectional view schematically showing the shape of the end portion of the steel plate. Fig.10 It is a plan view showing a state where insulating paper is attached to a roller member. Fig.11 It is a plan view showing a schematic structure of a laminated core according to the second embodiment. Fig.12 It is a cross-sectional view of a laminated core. Fig.13 This is a blanking diagram of a steel plate. Fig.14 This is a plan view of a core sheet forming portion punched out from a steel plate. Fig.15 This is a diagram for explaining a case where one surface in the thickness direction of two core sheet forming portions is opposed to each other. Fig.16 It is a cross-sectional view schematically showing a state where two core sheet forming portions overlap. Fig.17 It is a diagram for explaining a state in which a core sheet forming portion is wound around a roller member. Fig.18 It is a diagram for explaining a state in which the core sheet forming portion moves in the axial direction relative to the roller member. DETAILED DESCRIPTION

[0012] Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings. In addition, the same reference numerals are used for the same or equivalent parts in the drawings, and their descriptions are not repeated. In addition, the dimensions of the components in each drawing do not faithfully show the dimensions of the actual components and the dimensional ratios of the components.

[0013] In the following description, the direction parallel to the central axis P of the laminated core 10 is referred to as the axial direction, the direction orthogonal to the central axis P is referred to as the radial direction, and the direction along the arc centered on the central axis P is referred to as the circumferential direction.

[0014] In addition, in the following description, expressions such as "fixed", "connected" and "mounted" include not only cases where components are directly fixed to each other, but also cases where components are fixed via other components. That is, in the following description, expressions such as "fixed" include the meaning of direct and indirect fixing of components to each other.

[0015] (Implementation Method 1) Reference Figures 1 to 10 , a method for manufacturing a stator 1 according to an exemplary embodiment 1 of the present invention will be described. The stator 1 is a stator of a motor. The stator 1 is manufactured using a roller member 9. First, a roller member 9 is used. Figures 1 to 3 , the stator 1 manufactured in this embodiment is briefly described.

[0016] (Structure of stator) like Figure 1 As shown, the stator 1 includes a laminated core 10 and insulating paper 20. The laminated core 10 is cylindrical and extends along the central axis P. In the present embodiment, the laminated core 10 is a laminated body formed by laminating strip members 11 extending spirally about the central axis P in the thickness direction.

[0017] The laminated core 10 includes a cylindrical core back 12 and a plurality of teeth 13 extending radially inward from the radially inner peripheral side of the core back 12 .

[0018] When the laminated core 10 is viewed from the axial direction, slots 14 extending in the axial direction and opening radially inward are located between adjacent teeth 13. Insulating paper 20 is accommodated in the slots 14. Coil wires (not shown) are inserted inside the insulating paper 20.

[0019] Figure 2 1 is a plan view showing an exploded view of the laminated core 10. The strip plate member 11 is obtained by spirally winding a core sheet forming portion 71 punched out by a press machine.

[0020] like Figure 3 As shown, the strip member 11 has a first surface 11a on one side in the thickness direction and a second surface 11b on the other side in the thickness direction. The first surface 11a of the strip member 11 has a curved surface 111 at the end. The second surface 11b of the strip member 11 has a protrusion 112 at the end. The curved surface 111 and the protrusion 112 are formed by punching a steel plate using a press.

[0021] Figure 4A and Figure 4B This is a diagram illustrating punching using a general punching machine. Figure 4A As shown, when punching is performed using a punching machine, the punch X1 is moved downward relative to the die X2 to punch the material W placed on the die X2. The material W placed on the die X2 is sheared at the boundary between the punch X1 and the die X2.

[0022] Therefore, if Figure 4BAs shown, a curved portion W1 is formed at the end of a surface Wa in the thickness direction of the material W after punching. A protrusion W2 is formed at the end of a surface Wb in the thickness direction of the material W. In this way, in punching by a punching machine, the curved portion W1 is formed at the end of the surface in the thickness direction of the material W, which is on the rear side of the direction in which the punch X1 moves relative to the die X2. The protrusion W2 is formed at the end of the front side in the direction in which the punch X1 moves relative to the die X2.

[0023] like Figure 1 As shown, the insulating paper 20 is accommodated in the slot 14. Specifically, the insulating paper 20 is located between the inner surface of the slot 14 and the coil wire (not shown) inserted into the slot 14. The insulating paper 20 is in a rectangular shape that is long in the axial direction of the laminated core 10. The end 21 of the insulating paper 20 in the longitudinal direction protrudes from the slot 14 in the above-mentioned axial direction.

[0024] (Structure of roller member) Next, use Figure 5 and Figure 6 , the roller member 9 used when manufacturing the stator 1 will be briefly described.

[0025] like Figure 5 As shown in FIG. 1 , the roller member 9 is cylindrical. The roller member 9 has a main body 91 and a protruding portion 92. Figure 5 As shown, the core sheet forming portion 71 is wound around the outer peripheral surface of the roller member 9 .

[0026] The main body 91 of the roller member 9 is cylindrical. The axial length of the main body 91 is longer than the axial length of the laminated core 10. The diameter of the outer peripheral surface of the main body 91 is equal to the diameter of the inner circumference of the laminated core 10 formed by the radial inner end surfaces of the plurality of teeth 13 of the laminated core 10.

[0027] like Figure 5 and Figure 6 As shown, the protrusion 92 protrudes outward from the outer peripheral surface of the main body 91. The protrusion 92 is in the shape of a plate extending along the central axis Q of the main body 91. The thickness direction of the protrusion 92 is the circumferential direction of the main body 91. In the present embodiment, the axial length of the protrusion 92 is equal to the axial length of the main body 91. The protrusions 92 are arranged in the circumferential direction of the main body 91. The protrusions 92 have a shape and size that can be inserted into the slot 14 of the laminated core 10.

[0028] The roller member 9 has the same number of protrusions 92 as the number of the slots 14 of the laminated core 10 . The protrusions 92 are inserted between the plurality of teeth forming portions 73 in the core sheet forming portion 71 wound on the outer peripheral surface of the main body portion 91 .

[0029] The roller member 9 is rotated by a driving device (not shown) about the central axis Q. By the rotation of the roller member 9, the protrusion 92 moves in the rotation direction of the roller member 9. Thus, the tooth forming portion 73 moves in the above-mentioned rotation direction through the protrusion 92. Therefore, the core sheet forming portion 71 is wound on the outer peripheral surface of the main body portion 91.

[0030] (Manufacturing method of stator) Next, use Figure 1 , Figure 3 , Figure 5 , Figures 7 to 10 , an exemplary stator manufacturing method for manufacturing the stator 1 is described.

[0031] Figure 7 1 is a flow chart showing an example of a method for manufacturing the stator 1. Figure 7 As shown, the method for manufacturing the stator 1 includes a pressing step S1 , a mounting step S2 , and a laminating step S3 .

[0032] In the punching step S1 , a strip-shaped core sheet forming portion 71 is punched out from a steel plate 70 as a magnetic material by press forming. The core sheet forming portion 71 becomes the strip plate member 11 in the laminated core 10 .

[0033] Figure 8 This is an example of a punching diagram of a steel plate 70. Figure 8 In the figure, the region R of the punched steel plate 70 is marked with oblique lines. In the punching step S1, the region R of the steel plate 70 is punched out by a punch. Thus, a plate-shaped core sheet forming portion 71 having a band-shaped back yoke forming portion 72 and a plurality of tooth forming portions 73 protruding in one side of the width direction of the back yoke forming portion 72 is formed. The slots 14 of the laminated core 10 are formed between the adjacent tooth forming portions 73 in the arrangement direction of the plurality of tooth forming portions 73.

[0034] As described above, the core sheet forming portion 71 formed by press forming has the curved surface portion 111 and the protruding portion 112 at the end portion. Fig. 9 The shape of the end of the core sheet forming part 71 formed by press forming is schematically shown. The surface of the core sheet forming part 71 having the curved surface portion 111 at the end becomes the first surface 11a of the strip plate member 11 of the laminated core 10. The surface of the core sheet forming part 71 having the protrusion 112 at the end becomes the second surface 11b of the strip plate member 11 of the laminated core 10.

[0035] like Fig.10As shown, in the installation step S2, the insulating paper 20 is installed one by one to each of the plurality of protrusions 92 of the roller member 9. Specifically, the insulating paper 20 is bent at the center portion in the width direction. The insulating paper 20 is installed to the protrusion 92 in a posture where the bent portion is located at the front end portion of the protrusion 92 in the protruding direction and the both ends in the width direction are located at the base end portion of the protrusion 92. In this embodiment, as shown in FIG. Figure 5 As shown, the length of the insulating paper 20 in the longitudinal direction is equal to the length of the protrusion 92 in the axial direction.

[0036] As described above, the protrusion 92 is inserted between the plurality of tooth formation portions 73 in the core sheet formation portion 71. Therefore, in the lamination step S3 described later, when the core sheet formation portion 71 is wound around the roller member 9, the insulating paper 20 attached to the protrusion 92 is inserted into the groove 14.

[0037] like Figure 5 As shown, in the lamination process S3, the core sheet forming part 71 is wound into a spiral shape, and the core sheet forming part 71 is stacked in the thickness direction. Specifically, the protrusion 92 and the insulating paper 20 are inserted into the groove 14 formed between the adjacent tooth forming parts 73 in the core sheet forming part 71 formed by the punching process S1. Next, the roller member 9 is rotated. The core sheet forming part 71 is spirally wound on the outer peripheral surface of the roller member 9 while being deformed in one direction in the width direction by the rotation of the roller member 9.

[0038] The portion of the core sheet forming portion 71 newly wound on the outer peripheral surface of the roller member 9 pushes the core sheet forming portion 71 already wound spirally on the outer peripheral surface of the roller member 9 toward the winding start side. As a result, the core sheet forming portions 71 are stacked in the thickness direction to form the laminated core 10. The back yoke forming portion 72 stacked in the thickness direction becomes the core back 12 of the laminated core 10. The tooth forming portion 73 stacked in the thickness direction becomes the tooth portion 13 of the laminated core 10.

[0039] Then, the laminated core 10 and the insulating paper 20 are removed from the axial end of the roller member 9. Thus, the stator 1 having the laminated core 10 and the insulating paper 20 is manufactured. The laminated core 10 of the stator 1 has a cylindrical core back 12 and a plurality of teeth 13 extending radially inward from the radial inner circumference of the core back 12, and the strip plate members 11 are stacked in the thickness direction. The insulating paper 20 is accommodated in the grooves 14 located between the teeth 13.

[0040] The exemplary stator manufacturing method of the present embodiment described above is a method for manufacturing a stator 1 having a laminated iron core 10 and insulating paper 20, wherein the laminated iron core 10 is obtained by winding a plate-shaped iron core forming portion 71 having a strip-shaped back yoke forming portion 72 and a plurality of tooth forming portions 73 protruding from the back yoke forming portion 72 to one side in the width direction of the back yoke forming portion 72 into a spiral shape while deforming the plate-shaped iron core forming portion 71 to one side in the width direction, and the insulating paper 20 is inserted into a slot 14 located between the tooth forming portions 73. The manufacturing method of the stator 1 includes: a stamping step S1, in which an iron core forming portion 71 is punched out from a steel plate 70 by stamping; an installation step S2, in which insulating paper 20 is installed on a plurality of protrusions 92 arranged circumferentially and extending along the center axis Q on the outer peripheral surface of a cylindrical roller component 9 rotating around the center axis Q; and a stacking step S3, in which, with the protrusions 92 and the insulating paper 20 inserted into the groove 14, the roller component 9 is rotated to deform the iron core forming portion 71 to one side in the above-mentioned width direction while the iron core forming portion 71 is spirally wound on the outer peripheral surface of the roller component 9, so that the iron core forming portion 71 is stacked in its thickness direction.

[0041] Generally, the core sheet forming portion 71 formed by stamping has a protrusion 112 formed by stamping at the end thereof. Therefore, when the insulating paper 20 is inserted axially into the slot 14 of the laminated core 10 obtained by deforming the core sheet forming portion 71 in one direction in the width direction and winding it into a spiral shape, the insulating paper 20 may get stuck on the protrusion 112.

[0042] In contrast, according to the above method, when the core sheet forming portion 71 formed by press forming is deformed in one direction in the width direction and wound into a spiral shape, the insulating paper 20 can be inserted into the slot 14. Therefore, the insulating paper 20 can be easily inserted into the slot 14 without being affected by the protruding portion 112 of the core sheet forming portion 71. Thus, a method for manufacturing the stator 1 that can more easily insert the insulating paper 20 into the slot 14 of the laminated core 10 can be provided.

[0043] (Implementation Method 2) Reference Figures 11 to 18 , a method for manufacturing a stator according to an exemplary embodiment 2 of the present invention will be described. The laminated core 110 of the stator manufactured in this embodiment includes two strip plate members 121 and 122. Hereinafter, the same reference numerals are given to the same structures as those in the first embodiment, and description thereof will be omitted.

[0044] (Structure of stator) The stator manufactured in this embodiment has a laminated core 110 and insulating paper 20. The laminated core 110 is a laminated body formed by laminating two strip plate members 121 and 122 extending spirally around the central axis P in the thickness direction. The laminated core 110 has a cylindrical core back 12, a plurality of teeth 13, and a plurality of slots 14, similarly to the first embodiment. Fig.11 1 is a plan view showing the laminated core 110 in an exploded manner.

[0045] The strip plate members 121 and 122 have the same structure as the strip plate member 11 of the first embodiment. Fig.12 As shown, the strip members 121 and 122 have a first surface 11a on one side in the thickness direction and a second surface 11b on the other side in the thickness direction. The first surface 11a of the strip members 121 and 122 has a curved surface 111 at the end. The second surface 11b of the strip members 121 and 122 has a protrusion 112 at the end.

[0046] like Fig.12 As shown, when the laminated core 110 is viewed in cross section, the strip plate members 121 and the strip plate members 122 are alternately stacked in the thickness direction. The first surface 11a of the strip plate member 121 is located on one side in the stacking direction. The second surface 11b of the strip plate member 122 is located on the above-mentioned one side in the stacking direction.

[0047] That is, in the present embodiment, the first surface 11a of one of the two strip plate members 121 is located on one side in the stacking direction. The second surface 11b of the other of the two strip plate members 122 is located on one side in the stacking direction. In this way, in the laminated core 110, the surfaces of the strip plate members 121 and 122 are not aligned in one direction in the stacking direction. In this specification, the surfaces of the strip plate members are not aligned in one direction in the stacking direction means that the surface of the strip-shaped member having the curved surface portion at the end and the surface of the strip-shaped member having the protruding portion at the end are located on the same side in the stacking direction.

[0048] (Manufacturing method of stator) Next, an exemplary stator manufacturing method for manufacturing the stator of the present embodiment will be described. The stator manufacturing method includes a pressing step S11, a mounting step S12, and a stacking step S13.

[0049] In the punching step S11 of the present embodiment, a plurality of strip-shaped core sheet forming parts 71 are punched out from a steel plate 70 as a magnetic material by punching. In the present embodiment, a case where two core sheet forming parts 71 are punched out in the punching step S11 is described. The two core sheet forming parts 71 become the strip plate members 121 and 122 in the laminated core 110.

[0050] Fig.1370 is an example of a blanking diagram of a steel plate. Fig.13 As shown, the back yoke forming parts 72 of the two core sheet forming parts 71 extend in the length direction of the steel plate 70. The multiple tooth forming parts 73 of one core sheet forming part 71 of the two core sheet forming parts 71 protrude toward the back yoke forming part 72 of the other core sheet forming part 71. The multiple tooth forming parts 73 of the other core sheet forming part 71 of the two core sheet forming parts 71 protrude toward the back yoke forming part 72 of the one core sheet forming part 71.

[0051] In addition, the tooth forming portion 73 of one core sheet forming portion 71 is located between the tooth forming portions 73 adjacent in the length direction in the other core sheet forming portion 71. In this way, the directions in which the multiple tooth forming portions 73 of the two core sheet forming portions 71 protrude are opposite to each other. Therefore, by punching out the region R, two opposing core sheet forming portions 71 are formed. Fig.14 Two core sheet forming portions 71 punched out from a steel plate 70 are shown.

[0052] In relation to the punch Fig.13 When the steel plate 70 shown in the figure moves to punch out the region R, Fig.14 The surface pressed by the punch among the surfaces in the thickness direction of the core sheet forming portion 71 shown in the figure has a curved surface portion 111 formed at the end. Therefore, the surface pressed by the punch becomes the first surface 11a of the strip plate members 121 and 122. The surface on the opposite side to the surface pressed by the punch has a protrusion 112 formed at the end. Therefore, the surface on the opposite side becomes the second surface 11b of the strip plate members 121 and 122.

[0053] The mounting step S12 of the present embodiment is the same as the mounting step S2 of the first embodiment, and therefore the description thereof will be omitted.

[0054] In the lamination step S13 of this embodiment, Fig.15 and Fig.16 As shown, the first surfaces 11 a of the two core sheet forming portions 71 are made to face each other, and the two core sheet forming portions 71 are overlapped in the thickness direction.

[0055] Then, if Fig.17 As shown, the two core sheet forming parts 71 are overlapped in the thickness direction, and deformed in one direction in the width direction by the rotation of the roller member 9, and are spirally wound on the outer peripheral surface of the roller member 9. When the roller member 9 rotates, as shown in FIG. Fig.18 As shown, the two core sheet forming parts 71 newly wound on the outer circumference of the roller member 9 push the core sheet forming part 71 already spirally wound on the outer circumference of the roller member 9 toward the winding start side. Therefore, the core sheet forming parts 71 are stacked in the thickness direction.

[0056] like Fig.18As shown, the first surfaces 11a of the two core sheet forming parts 71 are opposite to each other. That is, the second surfaces 11b on the outer sides of the two core sheet forming parts 71 in the thickness direction are opposite to the second surfaces 11b of the core sheet forming parts 71a adjacent to each other in the stacking direction of the two core sheet forming parts 71. Therefore, by the rotation of the roller component 9, the two core sheet forming parts 71 move in the thickness direction, so that the second surface 11b of the core sheet forming part 71 contacts the second surface 11b of the core sheet forming part 71a. As a result, the protrusion 112 of the core sheet forming part 71 contacts the protrusion 112 of the core sheet forming part 71a, and the two protrusions 112 protrude in a direction intersecting with the thickness direction of the two core sheet forming parts 71. As a result, the insulating paper 20 can be prevented from falling off the groove 14.

[0057] In addition, in the present embodiment, the two core sheet forming parts 71 are overlapped in the thickness direction in such a manner that the first surfaces 11a face each other. However, the two core sheet forming parts may be overlapped in the thickness direction in such a manner that the second surfaces 11b face each other. The first surface 11a of one core sheet forming part 71 and the second surface 11b of the other core sheet forming part 71 may also be overlapped in the thickness direction in such a manner that the first surface 11a of the two core sheet forming parts 71 face each other.

[0058] In the punching step S11 of the exemplary stator manufacturing method of the present embodiment described above, two core sheet forming parts 71 are punched out in parallel from the steel plate 70. In the stacking step S13, the two core sheet forming parts 71 are stacked in their thickness direction by being deformed in one direction in the width direction by the rotation of the roller member 9 and spirally wound on the outer peripheral surface of the roller member 9 while being overlapped in the thickness direction.

[0059] Thus, the two core sheet forming portions 71 punched out from the steel plate 70 can be spirally stacked in an overlapping state to form a laminated core 110 . Therefore, the laminated core 110 can be efficiently formed.

[0060] Furthermore, when the laminated core 110 is formed by spirally winding the two core sheet forming parts 71 , the insulating paper 20 can be inserted into the slot 14 . Thus, the insulating paper 20 can be easily inserted into the slot 14 without being affected by the protrusions 112 of the two core sheet forming parts 71 .

[0061] In addition, in the stacking step S13 of the present embodiment, the two iron core sheet forming parts 71 are overlapped in the thickness direction in such a manner that the second faces 11b on one side of the thickness direction of the protrusions 112 formed at their ends by the stamping step S11 are opposite to each other, or the first faces 11a on the other side of the thickness direction of the curved surface parts 111 formed at their ends by the stamping step S11 are opposite to each other. In this state, the two iron core sheet forming parts 71 are deformed in one side of the above-mentioned width direction by the rotation of the roller part 9, and the two iron core sheet forming parts 71 are spirally wound on the outer peripheral surface of the roller part 9, thereby stacking the two iron core sheet forming parts 71 in their thickness direction.

[0062] Thus, the two core sheet forming parts 71 punched out from the steel plate 70 overlap in the thickness direction in a state where the second surfaces 11b having the protruding parts 112 formed at the ends by the punching process S11 are opposite to each other or the first surfaces 11a having the curved surface parts 111 formed at the ends by the punching process S11 are opposite to each other, and are spirally wound on the roller member 9. Therefore, in the formed laminated core 110, the protruding parts 112 are located at opposite positions in the two core sheet forming parts 71. In this way, when the insulating paper 20 is inserted into the slot 14 along the axial direction of the laminated core 110, the insulating paper 20 is easily stuck on the protruding parts 112.

[0063] On the other hand, when the two core sheet forming parts 71 are spirally wound around the roller member 9 , the insulating paper 20 is inserted into the groove 14 . Thus, the insulating paper 20 can be easily inserted into the groove 14 without being affected by the protrusions 112 of the two core sheet forming parts 71 .

[0064] In addition, the stator manufactured by the exemplary manufacturing method of the present embodiment is a stator having a laminated core 110 and an insulating paper 20, wherein the laminated core 110 has a cylindrical core back 12 and a plurality of teeth 13 extending radially inward from the radial inner circumference of the core back 12, and two strip plate members 121 and 122 are stacked in the thickness direction, and the insulating paper 20 is accommodated in the groove 14 located between the teeth 13. The first surface 11a, which is one surface in the thickness direction of the strip plate members 121 and 122, has a curved surface 111 at the end. The second surface 11b, which is the other surface in the thickness direction of the strip plate members 121 and 122, has a protrusion 112 at the end. The first surface 11a is located on one side of the stacking direction of one of the two strip plate members 121 and 122 constituting the laminated core 110. The second surface 11 b is located on one side in the lamination direction of the other strip plate member 122 of the two strip plate members 121 and 122 constituting the laminated core 110 .

[0065] The laminated core 110 of the present embodiment can be formed by laminating the strip plate members 121 and 122 formed by punching with a press machine so that the surfaces thereof are not aligned in one direction in the lamination direction. Therefore, the laminated core 110 that can be easily manufactured can be realized.

[0066] Moreover, the surface of the strip plate parts 121 and 122 constituting the laminated core 110 on one side in the stacking direction includes: a first surface 11a having a curved surface portion 111 at the end formed by punching with a punching machine; and a second surface 11b having a protrusion 112 at the end formed by punching with the above-mentioned punching machine. Therefore, compared with the case where the surfaces of the strip plate parts 121 and 122 constituting the laminated core 110 on one side in the stacking direction are all the first surface 11a having the curved surface portion 111, the insulating paper 20 accommodated in the slot 14 is not easy to fall off to one side in the stacking direction. As a result, a structure that can more reliably hold the insulating paper 20 in the slot 14 can be achieved.

[0067] In the present embodiment, the strip plate members 121 and 122 are members that extend spirally with the axis as the center and can be stacked in the thickness direction. In the present embodiment, the laminated core 110 is a laminated body formed by stacking the strip plate members 121 and 122 in the thickness direction. Thus, the laminated core 110 that can be easily formed can be realized. Therefore, a stator that can improve productivity can be obtained.

[0068] In the present embodiment, the laminated core 110 is a laminated body in which two strip plate members 121 and 122 are laminated in the thickness direction in a state where they are overlapped in the thickness direction.

[0069] In the laminated core 110 of the present embodiment, the surfaces of the two core sheet forming parts 71 formed by punching with a punching machine are not aligned in one direction of the stacking direction, but the two core sheet forming parts 71 are stacked in the thickness direction in a state of overlapping in the thickness direction to form the laminated core 110. Therefore, it is possible to realize the laminated core 110 that can be formed more easily. Therefore, it is possible to obtain a stator that can further improve productivity.

[0070] Moreover, compared with the case where all the surfaces of the strip plate members 121 and 122 constituting the laminated core 110 on one side in the lamination direction are the first surface 11a having the curved surface portion 111, the insulating paper 20 inserted into the slot 14 is less likely to fall off to one side in the lamination direction. Thus, a structure that can more reliably hold the insulating paper 20 in the slot 14 can be achieved.

[0071] (Other embodiments) The embodiments of the present invention have been described above, but the above embodiments are merely examples for implementing the present invention. Therefore, the present invention is not limited to the above embodiments, and the above embodiments can be appropriately modified and implemented within the scope of the present invention.

[0072] In the above-mentioned embodiments, the central axis Q of the roller member 9 extends in the vertical direction. However, the central axis Q of the roller member may extend in the horizontal direction. The central axis Q of the roller member may extend in a direction inclined relative to the vertical direction or in a direction inclined relative to the horizontal direction.

[0073] In the above-mentioned embodiments, the axial length of the protrusion 92 is equal to the axial length of the main body 91. However, the axial length of the protrusion may be shorter than the axial length of the main body. The axial length of the protrusion may be longer than the axial length of the main body.

[0074] In the above embodiments, the length of the insulating paper 20 in the longitudinal direction is equal to the axial length of the protrusion 92. However, the length of the insulating paper in the longitudinal direction may be shorter than the axial length of the protrusion. The length of the insulating paper in the longitudinal direction may be longer than the axial length of the protrusion.

[0075] In the above-mentioned embodiments, in the stacking direction of the laminated cores 10 and 110, the end 21 of the insulating paper 20 protrudes from the slot 14 of the laminated cores 10 and 110 in the stacking direction. However, the end of the insulating paper in the stacking direction may not protrude from the slot in the stacking direction. The insulating paper 20 protrudes from the slot 14 in the stacking direction immediately after the laminated cores 10 and 110 are manufactured through the stacking steps S3 and S13, and the portion protruding from the slot may be cut off afterwards.

[0076] In the above embodiments, the ends 21 of the insulating paper 20 in the lamination direction protrude axially from the slots 14 of the laminated core 10, 110. However, when the stator is viewed in the lamination direction, the ends of the insulating paper 20 in the lamination direction may be bent toward the outside of the slots.

[0077] Thus, the ends 21 of the insulating paper 20 in the stacking direction are easily caught by the ends of the laminated cores 10 and 110 in the stacking direction. Therefore, the insulating paper 20 is less likely to fall out of the slots 14 of the laminated cores 10 and 110 in the stacking direction.

[0078] In addition, the end portions 21 of the insulating paper 20 in the stacking direction may be bent toward the inside of the slot 14 when the stator is viewed in the stacking direction. Thus, the insulating paper 20 can be easily attached to the roller member 9 when the stator is manufactured.

[0079] In the installation steps S2 and S12 of the above-mentioned embodiments, the insulating paper 20 having a length equal to the axial length of the protrusion 92 is installed on the protrusion 92. That is, when the insulating paper 20 is installed on the protrusion 92, the end 21 of the insulating paper 20 in the longitudinal direction is located at the end of the axial direction of the protrusion 92. However, in the installation step, the insulating paper 20 longer than the axial length of the protrusion 92 may be installed on the protrusion 92. In this case, the portion of the end of the insulating paper located in the axial direction of the central axis Q of the roller member may be installed on the protrusion in a state of being bent toward the side opposite to the protrusion side, that is, toward the outside.

[0080] Thus, the bent portion of the axial end portion of the insulating paper inserted into the slot is caught by the laminated iron core, so that the insulating paper can be less likely to fall off from the laminated iron core in the axial direction.

[0081] Furthermore, in the mounting step, the portion of the insulating paper located at the end portion in the axial direction of the central axis Q of the roller member may be mounted on the protruding portion while being bent toward the protruding portion. This makes it possible to easily mount the insulating paper on the roller member.

[0082] In the above-mentioned Embodiment 1, the laminated core 10 has one strip plate member 11. However, the laminated core may have two strip plate members or more than two strip plate members. In this case, the surfaces of the plurality of strip plate members may not be aligned in one direction.

[0083] In the above-mentioned Embodiment 2, the laminated core 110 has two strip plate members 121 and 122. However, the laminated core may have three strip plate members or more. In this case, the surfaces of the plurality of strip plate members may not be aligned in one direction.

[0084] In the punching step S11 of the second embodiment, two core sheet forming parts 71 are punched out in a row. However, in the punching step, three or more core sheet forming parts may be punched out in a row. In this case, in the stacking step S13, the surfaces of the plurality of core sheet forming parts may not be aligned in one direction.

[0085] In the first embodiment, the stator 1 includes a laminated core 10 formed by laminating in the thickness direction a strip plate member 11 extending spirally about the central axis P. In the second embodiment, the stator includes a laminated core 110 formed by laminating in the thickness direction two strip plate members 121 and 122 extending spirally about the central axis P. However, the stator may include a laminated core in which plate-shaped steel plates are laminated in the thickness direction.

[0086] That is, the stator may also be a stator having a laminated iron core and insulating paper, wherein the laminated iron core has a cylindrical core back and a plurality of teeth extending radially inward from the radial inner circumference of the core back, and steel plates are laminated in the thickness direction, and the insulating paper is accommodated in the grooves between the teeth. In this case, the surface of one side in the thickness direction of the steel plate has a curved surface at the end, and the surface of the other side in the thickness direction of the steel plate has a protrusion at the end. Alternatively, the surface of one side is located on one side of the stacking direction of a portion of the steel plates constituting the laminated iron core, and the surface of the other side is located on one side of the stacking direction of the other steel plates constituting the laminated iron core.

[0087] The steel plates stacked on the laminated core are formed by punching with a punching machine. Therefore, the steel plates have a curved surface on one surface in the thickness direction and a protrusion on the other surface. The laminated core can be formed by stacking the surfaces of the steel plates formed by punching with a punching machine without aligning them in one direction of the stacking direction. Therefore, a laminated core that can be easily manufactured can be realized.

[0088] Moreover, the surface of the steel plate constituting the above-mentioned laminated core on one side in the stacking direction includes: a surface on one side in the thickness direction having a curved portion at the end formed by punching of a punching machine; and a surface on the other side in the thickness direction having a protrusion at the end formed by punching of the above-mentioned punching machine. Therefore, compared with the case where all the surfaces of the steel plate constituting the above-mentioned laminated core on one side in the stacking direction are surfaces on one side in the thickness direction having a curved portion, the insulating paper accommodated in the slot is not easy to fall off to one side in the stacking direction. Thus, a structure that can more reliably keep the above-mentioned insulating paper in the above-mentioned slot can be achieved.

[0089] (Structure example) Note that the present technology can adopt the following configurations.

[0090] (1) A method for manufacturing a stator, the stator comprising: a laminated iron core obtained by deforming a plate-shaped iron core forming portion having a strip-shaped back yoke forming portion and a plurality of tooth forming portions protruding from the back yoke forming portion to one side in the width direction of the back yoke forming portion and winding it into a spiral shape; and insulating paper inserted into slots located between the tooth forming portions. The stator manufacturing method includes: a stamping step of punching the iron core forming portion from a steel plate by stamping; a mounting step of mounting the insulating paper on a plurality of protrusions arranged in the circumferential direction and extending along the center axis on the outer peripheral surface of a cylindrical roller member rotating around a center axis; and a stacking step of rotating the roller member with the protrusions and the insulating paper inserted in the slot, deforming the iron core forming portion to one side in the width direction, and spirally winding it on the outer peripheral surface of the roller member, thereby stacking the iron core forming portion in the thickness direction thereof.

[0091] (2) In the stator manufacturing method described in (1), in the punching step, a plurality of the core sheet forming parts are punched out from the steel plate in an aligned manner. In the stacking step, the plurality of core sheet forming parts are stacked in their thickness direction by being deformed in one direction of the width direction by the rotation of the roller member and spirally wound around the outer peripheral surface of the roller member.

[0092] (3) In the stator manufacturing method described in (2), in the stacking step, the plurality of iron core sheet forming portions are overlapped in the thickness direction in such a manner that the surfaces on one side of the thickness direction of the protrusions formed at their ends by the stamping step are opposite to each other, or the surfaces on the other side of the thickness direction of the curved surface portions formed at their ends by the stamping step are opposite to each other. In this state, the plurality of iron core sheet forming portions are deformed in one side of the width direction by the rotation of the roller component and are spirally wound on the outer peripheral surface of the roller component, thereby stacking the plurality of iron core sheet forming portions in their thickness direction.

[0093] (4) In the stator manufacturing method described in any one of (1) to (3), in the installation step, the portion of the insulating paper located at the axial end of the center axis is installed on the protrusion in a state of being bent toward the side opposite to the protrusion, i.e., toward the outside.

[0094] (5) A stator, comprising: a laminated iron core having a cylindrical iron core back and a plurality of teeth extending radially inward from the radial inner circumference of the iron core back, and having steel plates laminated in the thickness direction; and insulating paper received in slots between the teeth. A surface on one side in the thickness direction of the steel plate has a curved surface at the end, and a surface on the other side in the thickness direction of the steel plate has a protrusion at the end. The surface on one side is located on one side of the stacking direction of a portion of the steel plates constituting the laminated iron core, and the surface on the other side is located on one side of the stacking direction of the other steel plates constituting the laminated iron core.

[0095] (6) In the stator described in (5), when the stator is viewed in the stacking direction, an end portion of the insulating paper in the stacking direction is bent toward an outside of the slot.

[0096] (7) In the stator described in (5) or (6), the steel plate is a strip plate member that extends spirally about the axis and can be stacked in the thickness direction. The laminated core is a laminated body in which the steel plates are stacked in the thickness direction.

[0097] (8) In the stator described in (7), the laminated core is a laminated body in which a plurality of the steel plates are laminated in the thickness direction in a state where the steel plates overlap in the thickness direction.

[0098] (9) A motor comprising the stator according to any one of (5) to (8).

[0099] The present invention can be applied to a method for manufacturing a stator in which insulating paper is accommodated in slots. Explanation of symbols

[0100] 1 Stator 10, 110 laminated core 11, 121, 122 with plate parts 11a Side 1 11b Side 2 111 curved face 112 protrusion 12 Core back 13 teeth 14 slots 20 Insulation Paper 21 end 9-roller assembly 91 Main body 92 protrusion 70 steel plate 71, 71a core sheet forming portion 72 rear yoke forming part 73 tooth forming portion.

Claims

1. A method for manufacturing a stator, The stator has: A laminated iron core obtained by spirally winding a plate-shaped iron core forming portion having a band-shaped back yoke forming portion and a plurality of tooth forming portions protruding from the back yoke forming portion toward one side in the width direction of the back yoke forming portion while deforming toward the one side in the width direction; as well as Insulating paper is inserted into the grooves between the tooth-forming portions. It is characterized in that have: A stamping step of punching out the core sheet forming portion from a steel plate by stamping; A mounting step of mounting the insulating paper on a plurality of protrusions arranged in a circumferential direction and extending along the central axis on an outer peripheral surface of a cylindrical roller member rotating around a central axis; as well as In the stacking process, with the protrusion and the insulating paper inserted in the groove, the roller component is rotated to cause the iron core sheet forming portion to be deformed in one direction of the width direction while being spirally wound on the outer peripheral surface of the roller component, thereby stacking the iron core sheet forming portion in its thickness direction.

2. The stator manufacturing method according to claim 1, characterized in that: In the punching step, a plurality of the core sheet forming portions are punched out from the steel plate in an aligned manner. In the stacking process, while the multiple iron core sheet forming parts are overlapped in the thickness direction, the multiple iron core sheet forming parts are deformed toward one side of the width direction while being spirally wound on the outer peripheral surface of the roller part by rotating the roller part, thereby stacking the multiple iron core sheet forming parts in their thickness direction.

3. The stator manufacturing method according to claim 2, characterized in that: In the stacking process, the plurality of iron core sheet forming portions are overlapped in the thickness direction in such a manner that surfaces on one side of the thickness direction of the protrusions formed at their ends by the stamping process are opposite to each other, or surfaces on the other side of the thickness direction of the curved surface portions formed at their ends by the stamping process are opposite to each other. In this state, the plurality of iron core sheet forming portions are deformed toward one side of the width direction while being spirally wound on the outer peripheral surface of the roller member by the rotation of the roller member, thereby stacking the plurality of iron core sheet forming portions in their thickness direction.

4. The stator manufacturing method according to any one of claims 1 to 3, characterized in that: In the mounting step, a portion of the insulating paper located at an end portion in the axial direction of the central axis is mounted on the protruding portion in a state of being bent toward the outer side, which is the side opposite to the protruding portion.

5. A stator having: a laminated core having a cylindrical core back and a plurality of teeth extending radially inward from a radially inner peripheral side of the core back, and having steel plates laminated in a thickness direction; and Insulating paper is received in the grooves between the teeth. It is characterized in that The steel plate has a curved surface at one end of one surface in the thickness direction. The other surface of the steel plate in the thickness direction has a protrusion at the end. The one surface is located on one side in the lamination direction of a portion of the steel plates constituting the laminated core, The other surface is located on one side in the lamination direction of the other steel plates among the steel plates constituting the laminated core.

6. The stator according to claim 5, characterized in that: The end portions of the insulating paper in the stacking direction are bent toward the outside of the slot when the stator is viewed along the stacking direction.

7. The stator according to claim 5, characterized in that: The steel plate is a strip member extending spirally with the axis as the center and capable of being stacked in the thickness direction. The laminated core is a laminated body in which the steel plates are laminated in the thickness direction.

8. The stator according to claim 7, characterized in that: The laminated core is a laminated body in which a plurality of the steel plates are laminated in the thickness direction in a state where the steel plates overlap in the thickness direction.

9. A motor, characterized in that: A stator according to any one of claims 5 to 8 is provided.

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