Armature and armature manufacturing method

Abstract

The present disclosure provides an armature and a method of manufacturing the armature capable of suppressing an increase in iron loss in a core block. In the armature (5), an iron core block (6) is formed by laminating a plurality of magnetic plates (63). The tooth insulation part (71) of the insulation sheet (7) is arranged between the tooth part (62) of the iron core block (6) and the coil part. The tooth insulation section (71) surrounds the tooth section (62) in a state in which the one or more insulation attachment sections (711) are disposed around the tooth section (62) and the first end section (711a) and the second end section (711b) overlap each other. A joining section (712) is formed in the tooth insulating section (71) by joining a first end section (711a) and a second end section (711b), which overlap each other, to each other. The tooth insulation part (71) integrates the plurality of magnetic plates (63) by surrounding the tooth part (62).

Description

Technical Field

[0001] The present disclosure relates to an armature and a method of manufacturing the armature. Background Art

[0002] Patent Document 1 discloses a rotating electrical machine having a stator annular core formed by connecting a plurality of split cores in an annular shape. Each split core is formed by stacking a plurality of core sheets. In each split core, adjacent core sheets in the stacking direction are fixed to each other by welding.

[0003] Prior art literature

[0004] Patent Literature

[0005] Patent Document 1: Japanese Patent Application Laid-Open No. 2017-169296 Summary of the Invention

[0006] Problems to be solved by the invention

[0007] In the conventional rotating electrical machine disclosed in Patent Document 1, a plurality of core pieces in a split core are electrically connected to each other by welding portions. This increases eddy currents generated in the split cores, and increases iron loss in the split cores.

[0008] The present disclosure is to solve the above-mentioned problems, and an object of the present disclosure is to provide an armature and a method for manufacturing the armature that can suppress an increase in iron loss in a core block.

[0009] Means for solving problems

[0010] The armature disclosed herein comprises a plurality of armature blocks, each of which comprises an iron core block, an insulating sheet and a coil portion. The iron core block is formed by stacking a plurality of magnetic plates. The iron core block comprises a yoke portion and a tooth portion protruding from the yoke portion. The coil portion is arranged on the tooth portion. The insulating sheet comprises a tooth insulation portion between the coil portion and the tooth portion. The tooth insulation portion comprises one or more insulating mounting portions, each of which comprises a first end portion and a second end portion. The tooth insulation portion surrounds the tooth portion in a state where the one or more insulating mounting portions are arranged around the tooth portion and the first end portion and the second end portion overlap with each other. In the tooth insulation portion, a joint portion is formed by joining the overlapping first end portion and second end portion to each other. The tooth insulation portion integrates the plurality of magnetic plates by surrounding the tooth portion.

[0011] In addition, the manufacturing method of the armature disclosed in the present invention includes: a stacking process, stacking multiple magnetic plates to produce an iron core block having a yoke and a tooth portion protruding from the yoke; an insulation assembly process, integrating the multiple magnetic plates by surrounding the tooth portion with the tooth insulation portion of the insulation sheet; and a winding process, after the insulation assembly process, arranging the coil portion on the tooth portion via the tooth insulation portion, the tooth insulation portion having one or more insulation mounting portions, the one or more insulation mounting portions having a first end portion and a second end portion, and in the insulation assembly process, arranging the one or more insulation mounting portions around the tooth portion, overlapping the first end portion and the second end portion, and joining the overlapping first end portion and the second end portion to form a joint portion in the tooth insulation portion.

[0012] Effects of the Invention

[0013] According to the present disclosure, it is possible to suppress an increase in iron loss in the core blocks. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 This is a partial cross-sectional view showing the electric device according to the first embodiment.

[0015] Figure 2 Yes Figure 1 A three-dimensional diagram of the armature.

[0016] Figure 3 Yes Figure 2 Side view of the core block.

[0017] Figure 4 Yes Figure 3 A perspective view of a magnetic plate.

[0018] Figure 5 Yes Figure 2 Exploded perspective view of the main parts of the armature block.

[0019] Figure 6 It means observing along the protruding direction of the tooth Figure 5 Schematic diagram of the teeth, insulating sheet and winding frame.

[0020] Figure 7 Yes Figure 5 A three-dimensional view of the insulating mounting portion, yoke insulating portion and end insulating portion.

[0021] Figure 8 Yes Figure 3 A three-dimensional view of the guide component.

[0022] Figure 9 This is a flowchart showing the method for manufacturing the armature according to the first embodiment.

[0023] Figure 10 It means in Figure 9A side view of a state in which a plurality of magnetic plates are stacked in the stacking step S1 of FIG.

[0024] Figure 11 It means in Figure 9 A side view of a state where the core blocks are pressurized in the pressurizing step S2.

[0025] Figure 12 It means in Figure 9 A schematic front view of a state before the tooth insulation portion surrounds the tooth portion in the insulation assembly step S3.

[0026] Figure 13 Yes Figure 12 A schematic front view of a state where the tooth insulation portion surrounds the tooth portion.

[0027] Figure 14 It means in Figure 9 A structural diagram of the state when the wire of the coil portion is wound around the teeth of the core block with the insulating sheet and the winding frame installed in the insulation assembly step S3.

[0028] Figure 15 It means in Figure 14 A structural diagram of the state when the conducting wire of the coil portion is wound around the teeth.

[0029] Figure 16 This is a front view showing another example of the joint portion in the armature according to the first embodiment.

[0030] Figure 17 Schematic diagram showing a state of the teeth, insulating sheet, and bobbin of the armature according to the second embodiment when viewed along the tooth protruding direction.

[0031] Figure 18 It means Figure 17 Schematic diagram of the state before the insulating sheet is installed on the core block.

[0032] Figure 19 It means Figure 18 Schematic diagram of the state when the insulating sheet is installed on the core block.

[0033] Figure 20 This is an exploded perspective view showing a main portion of an armature block in the armature according to the third embodiment.

[0034] Figure 21 It means observing along the protruding direction of the tooth Figure 20 Schematic diagram of the teeth, insulating sheet and winding frame.

[0035] Figure 22 It means Figure 21 Schematic diagram of the state before the insulating sheet is installed on the core block and the winding frame.

[0036] Figure 23 It means in Figure 22 Schematic diagram of the state when the core block and the insulating sheet are installed on the winding frame.

[0037] Figure 24 This is a front view showing another example of the joint portion in the armature according to the third embodiment.

[0038] Description of labels

[0039] 1: Rotating electric machine (electrical equipment), 6: Core block, 7: Insulating sheet, 8: Winding frame, 9: Coil portion, 61: Yoke portion, 62: Tooth portion, 63: Magnetic plate, 71: Tooth insulation portion, 711: Insulating mounting portion, 711a: First end portion, 711b: Second end portion, 712: Joint portion, 713: Adhesive. DETAILED DESCRIPTION

[0040] The method for implementing the object of the present disclosure is described with reference to the accompanying drawings. In each figure, the same reference numerals are used to indicate the same or equivalent parts, and repeated descriptions are simplified or omitted as appropriate. In addition, the object of the present disclosure is not limited to the following embodiments, and any component elements of the embodiments can be modified or omitted without departing from the scope of the present disclosure.

[0041] Implementation method 1.

[0042] Figure 1 This is a partial cross-sectional view showing an electric device according to Embodiment 1. A rotating electrical machine 1 as an electric device includes a case 2 , a rotating shaft 3 , a rotor 4 , and an armature 5 .

[0043] The housing 2 includes a frame 21 and an end plate 22. The frame 21 is a housing having an opening 211. The end plate 22 is a cover that closes the opening 211. The end plate 22 is attached to the frame 21 in a state in which the opening 211 is closed.

[0044] The frame 21 and the end plate 22 are each provided with a through hole through which the rotating shaft 3 passes. Bearings 23 are disposed in each of the through holes of the frame 21 and the end plate 22. The rotating shaft 3 is rotatably supported by the housing 2 via the bearings 23.

[0045] The rotor 4 is fixed to the rotating shaft 3 as a movable element inside the housing 2. Thus, the rotor 4 rotates integrally with the rotating shaft 3 relative to the housing 2.

[0046] The rotor 4 includes a rotor core 41 and a plurality of permanent magnets 42. The rotor core 41 is made of a magnetic material. The rotating shaft 3 passes through the rotor core 41. The rotor core 41 is cylindrical in shape and is arranged coaxially with the rotating shaft 3.

[0047] The plurality of permanent magnets 42 are provided on the rotor core 41. The plurality of permanent magnets 42 are arranged at intervals from each other in the circumferential direction of the rotor 4. Thus, a plurality of magnetic poles are formed on the outer peripheral portion of the rotor 4.

[0048] Alternatively, a cage rotor, a wound-rotor rotor, or the like may be used as the rotor 4. A cage rotor is a rotor in which a plurality of uninsulated rotor conductors are provided on the rotor core 41, and a pair of short-circuit rings disposed at both ends of the rotor core 41 are short-circuited by each rotor conductor. A wound-rotor rotor is a rotor in which a rotor winding electrically insulated from the rotor core 41 is provided on the rotor core 41.

[0049] The armature 5 is fixed inside the housing 2, embedded in the inner circumference of the frame 21. The armature 5 is annular in shape and surrounds the outer circumference of the rotor 4. Thus, the inner circumference of the armature 5 faces the outer circumference of the rotor 4 with a gap therebetween. The armature 5 is coaxially arranged with the rotating shaft 3.

[0050] Figure 2 Yes Figure 1 A perspective view of the armature 5 is shown. The armature 5 includes a plurality of armature blocks 51. The plurality of armature blocks 51 are continuously connected in a ring shape along the circumference of the armature 5. The circumference of the armature 5 is along the circumference of a circle centered on the axis of the armature 5. Each of the armature blocks 51 includes a core block 6, an insulating sheet 7, a bobbin 8, and a coil portion 9.

[0051] The core block 6 includes a yoke 61 and teeth 62. The yoke 61 is arranged along the circumferential direction of the armature 5. The teeth 62 protrude from the center of the yoke 61 inward in the radial direction of the armature 5. The radial direction of the armature 5 is the direction along the radius of a circle centered on the axis of the armature 5.

[0052] Here, Figure 3 Yes Figure 2 A side view of the core block 6. The core block 6 is constructed by stacking a plurality of magnetic plates 63. Each magnetic plate 63 is made of a magnetic material. In this embodiment, electromagnetic steel plates are used as the magnetic plates 63. The plurality of magnetic plates 63 are stacked along the axial direction of the armature 5. Therefore, the stacking direction of the plurality of magnetic plates 63, i.e., the magnetic plate stacking direction, is perpendicular to both the circumferential direction of the armature 5 and the radial direction of the armature 5. The plurality of magnetic plates 63 are stacked so as not to be joined to one another.

[0053] Figure 4 Yes Figure 3 A three-dimensional view of the magnetic plates 63. Each magnetic plate 63 includes a yoke-forming plate portion 63a and a tooth-forming plate portion 63b. The tooth-forming plate portion 63b protrudes from the yoke-forming plate portion 63a within the same plane as the yoke-forming plate portion 63a. The yoke portion 61 is formed by stacking the yoke-forming plate portions 63a. The tooth portion 62 is formed by stacking the tooth-forming plate portions 63b.

[0054] like Figure 2 As shown, the coil portion 9 is provided on the tooth portion 62. When the armature block 51 is viewed along the direction in which the tooth portion 62 protrudes from the yoke portion 61, that is, the tooth protruding direction, the coil portion 9 surrounds the tooth portion 62.

[0055] The coil portion 9 is composed of a conductive wire wound around the teeth 62. The conductive wire of the coil portion 9 is a conductor wire covered with an insulating film having electrical insulation properties. As the conductor wire of the coil portion 9, copper wire, aluminum wire, etc. are used.

[0056] Figure 5 Yes Figure 2 An exploded perspective view of the main parts of the armature block 51. Figure 5 In the figure, the coil portion 9 is omitted. The insulating sheet 7 is attached to the core block 6. The insulating sheet 7 is made of an insulating material having electrical insulation properties. The insulating sheet 7 is interposed between the coil portion 9 and the core block 6. Thus, the insulating sheet 7 ensures electrical insulation between the coil portion 9 and the core block 6. As the insulating material constituting the insulating sheet 7, polyphenylene sulfide (PPS) resin, polyethylene terephthalate (PTE) resin, or the like is used.

[0057] The insulating sheet 7 includes a teeth insulating portion 71 , a pair of yoke insulating portions 72 , and a pair of terminal insulating portions 73 .

[0058] The tooth insulating portion 71 is interposed between the tooth portion 62 and the coil portion 9. Therefore, the coil portion 9 is provided on the tooth portion 62 via the tooth insulating portion 71. The tooth insulating portion 71 ensures an electrically isolated state between the tooth portion 62 and the coil portion 9.

[0059] The tooth insulation portion 71 surrounds the tooth portion 62 by passing along both outer sides of the tooth portion 62 in the direction in which the magnetic plates are stacked. Thus, when viewing the core block 6 along the tooth protruding direction, the tooth insulation portion 71 surrounds the tooth portion 62. The tooth insulation portion 71 overlaps the outer circumference of the tooth portion 62 without any looseness. By surrounding the tooth portion 62, the tooth insulation portion 71 integrates the multiple magnetic plates 63. Therefore, even if the core block 6 is subjected to a force that tends to separate the multiple magnetic plates 63, the tooth insulation portion 71 can maintain the stacked state of the multiple magnetic plates 63.

[0060] The tooth insulating portion 71 includes one or more insulating mounting portions 711. In this embodiment, the tooth insulating portion 71 includes two insulating mounting portions 711. Each insulating mounting portion 711 is a separate component. The two insulating mounting portions 711 surround the tooth portion 62, sandwiching the tooth portion 62 from both outer sides in the width direction. The width direction of the tooth portion 62 is perpendicular to both the direction in which the magnetic plates are stacked and the direction in which the teeth protrude.

[0061] Each insulating mounting portion 711 is strip-shaped. One of the two longitudinal ends of each insulating mounting portion 711 is a first end 711a, and the other is a second end 711b. In other words, each insulating mounting portion 711 has a first end 711a and a second end 711b.

[0062] Figure 6 It means observing along the protruding direction of the tooth Figure 5 Schematic diagram of the state of the tooth portion 62, insulating sheet 7, and winding frame 8. The tooth insulating portion 71 surrounds the tooth portion 62 with the first end portion 711a and the second end portion 711b overlapping each other and the two insulating mounting portions 711 arranged around the tooth portion 62. In the tooth insulating portion 71, the first end portion 711a of one insulating mounting portion 711 overlaps the second end portion 711b of the other insulating mounting portion 711, and the second end portion 711b of one insulating mounting portion 711 overlaps the first end portion 711a of the other insulating mounting portion 711.

[0063] The tooth insulating portion 71 is formed by joining the overlapping first end portion 711a and second end portion 711b to form a joint portion 712. This connects the two insulating mounting portions 711 continuously into a ring shape. The number of joint portions 712 formed on the tooth insulating portion 71 is the same as the number of insulating mounting portions 711. Therefore, at least one joint portion 712 is formed on the tooth insulating portion 71. In this embodiment, two joint portions 712 are formed on the tooth insulating portion 71.

[0064] In this embodiment, the joints 712 are located on both outer sides of the tooth portion 62 in the direction in which the magnetic plates are stacked. Furthermore, in this embodiment, one joint 712 overlaps with one of the two end faces of the tooth portion 62 in the direction in which the magnetic plates are stacked, while the other joint 712 overlaps with the other end face. Furthermore, in this embodiment, the first end 711a and second end 711b of each joint 712 are bonded to each other via an adhesive 713.

[0065] like Figure 5 As shown, a pair of yoke insulators 72 are provided at the end of the tooth insulator 71 on the yoke 61 side. One yoke insulator 72 is attached to one insulating mounting portion 711, and the other yoke insulator 72 is attached to the other insulating mounting portion 711. The pair of yoke insulators 72 are interposed between the yoke 61 and the coil 9. Thus, each yoke insulator 72 ensures electrical insulation between the yoke 61 and the coil 9.

[0066] A pair of terminal insulating portions 73 are provided at the end of the tooth insulating portion 71 opposite the yoke portion 61. One terminal insulating portion 73 is attached to one insulating mounting portion 711, while the other terminal insulating portion 73 is attached to the other insulating mounting portion 711. The pair of terminal insulating portions 73 are interposed between the terminal ends of the tooth portion 62 and the coil portion 9. Thus, each terminal insulating portion 73 ensures electrical insulation between the terminal ends of the tooth portion 62 and the coil portion 9.

[0067] Figure 7 Yes Figure 5 711, the yoke insulating portion 72 and the terminal insulating portion 73. The yoke insulating portion 72 and the terminal insulating portion 73 are provided on the insulating mounting portion 711, avoiding the first end portion 711a and the second end portion 711b. Figure 2 The coil portion 9 shown is arranged between the yoke insulating portion 72 and the terminal insulating portion 73 .

[0068] like Figure 2 As shown, the bobbin 8 is arranged between the core block 6 and the coil portion 9. The bobbin 8 is made of an insulating material having electrical insulation properties.

[0069] like Figure 5 and Figure 6 As shown, the winding frame 8 includes a pair of guide members 81. Each guide member 81 is attached to the core block 6 with its engaging portion (not shown) fitted into the core block 6. The pair of guide members 81 are arranged to sandwich the core block 6 in the direction in which the magnetic plates are stacked. The pair of guide members 81 are attached to the core block 6 so as to overlap with both end surfaces of the core block 6 in the direction in which the magnetic plates are stacked, with the tooth insulating portion 71 interposed therebetween.

[0070] One of the two joining portions 712 of the teeth insulating portion 71 is interposed between the teeth portion 62 and one guide member 81 , and the other joining portion 712 is interposed between the teeth portion 62 and the other guide member 81 .

[0071] Figure 8 Yes Figure 3 A three-dimensional view of the guide components 81. Each guide component 81 includes a winding body 82, a first limiting wall 83, and a second limiting wall 84. The winding body 82 overlaps with the end face of the core block 6 across the tooth insulating portion 71 in the tooth protruding direction. The first limiting wall 83 is provided at the end of the winding body 82 on the yoke 61 side. The second limiting wall 84 is provided at the end of the winding body 82 on the side opposite to the yoke 61 side. Thus, the first limiting wall 83 and the second limiting wall 84 are opposed to each other in the longitudinal direction of the winding body 82.

[0072] The coil portion 9 surrounds the teeth portion 62, the teeth insulating portion 71 and the bobbin 8. In each guide member 81, the coil portion 9 overlaps the winding body portion 82. Figure 2 As shown, in each guide member 81 , the coil portion 9 passes between the first restriction wall 83 and the second restriction wall 84 .

[0073] The plurality of armature blocks 51 connect adjacent yokes 61 to each other and form a ring shape. In the armature 5, the armature core is formed by connecting the core blocks 6 to form a ring shape. In the armature core, the plurality of yokes 61 are connected to form a ring shape, and the plurality of teeth 62 are arranged at intervals in the circumferential direction of the armature 5. In addition, in the armature 5, the armature winding is formed by electrically connecting the coil portions 9 of the plurality of armature blocks 51. By energizing the armature winding, the armature 5 generates a rotating magnetic field. The rotor 4 rotates integrally with the rotating shaft 3 relative to the armature 5 and the housing 2 due to the generation of the rotating magnetic field.

[0074] Next, a method for manufacturing the armature 5 will be described. Figure 9 This is a flowchart illustrating a method for manufacturing an armature according to Embodiment 1. The armature manufacturing method includes a lamination step S1, a pressurization step S2, an insulation assembly step S3, and a winding step S4. When manufacturing the armature 5, the lamination step S1, pressurization step S2, insulation assembly step S3, and winding step S4 are performed in this order.

[0075] <Lamination Step S1>

[0076] When manufacturing the armature 5 , a stacking step S1 is performed. In the stacking step S1 , a plurality of magnetic plates 63 are stacked to produce the core blocks 6 .

[0077] Figure 10 It means in Figure 9 This is a side view of the stacking process S1 of multiple magnetic plates 63. Each magnetic plate 63 is prefabricated by punching out a raw plate made of a magnetic material. In the stacking process S1, the yoke-forming plate portions 63a of the magnetic plates 63 are stacked, and the tooth-forming plate portions 63b of the magnetic plates 63 are stacked, thereby stacking the multiple magnetic plates 63.

[0078] In the stacking step S1 , in order to absorb the thickness deviation generated in one magnetic plate 63 , the magnetic plates 63 punched out from the raw plate can be alternately reversed to stack multiple magnetic plates 63 , or multiple magnetic plates 63 punched out from the raw plate using different dies can be mixed and stacked.

[0079] When the plurality of magnetic plates 63 are stacked in the stacking step S1, the portion formed by stacking the yoke-forming plate portions 63a becomes the yoke portion 61, and the portion formed by stacking the tooth-forming plate portions 63b becomes the tooth portion 62. Thus, the core block 6 is produced. In the stacking step S1, the plurality of magnetic plates 63 are stacked without being joined to each other.

[0080] <Pressure Step S2>

[0081] After the stacking step S1, the pressing step S2 is performed. In the pressing step S2, the core blocks 6 are pressed in a direction in which the plurality of magnetic plates 63 are pressed against each other. That is, in the pressing step S2, the core blocks 6 are pressed in the direction in which the magnetic plates are stacked.

[0082] Figure 11 It means in Figure 9 A side view of a state in which the core block 6 is pressurized in the pressurizing step S2 of FIG. In the pressurizing step S2, the core block 6 is pressurized by a pressurizing device having a plurality of pressurizing members 10. The pressurizing device pressurizes the core block 6 by pressing the pressurizing members 10 against the core block 6 from both outer sides in the direction of stacking of the magnetic plates of the core block 6. In the present embodiment, the end portion of the tooth portion 62 and the yoke portion 61 are pressurized separately by the pressurizing members 10. As a result, the gaps between the plurality of magnetic plates 63 caused by warping of the magnetic plates 63 or the like are reduced, and the space factor of the magnetic material in the core block 6 is increased.

[0083] <Insulation assembly process S3>

[0084] After the pressurization step S2, the insulation assembly step S3 is performed. In the insulation assembly step S3, the insulation sheet 7 is attached to the core block 6 while the core block 6 is pressurized, thereby integrating the plurality of magnetic plates 63. Specifically, in the insulation assembly step S3, the teeth 62 are surrounded by the tooth insulation portion 71 of the insulation sheet 7 while the core block 6 is pressurized, thereby integrating the plurality of magnetic plates 63.

[0085] Figure 12 It means in Figure 9 Schematic front view of the state before the tooth insulation portion 71 surrounds the tooth portion 62 in the insulation assembly step S3. Figure 13 Yes Figure 12Schematic front view of the state in which the tooth insulating portion 71 surrounds the tooth portion 62. In the insulating assembly process S3, the tooth portion 62 is clamped by two insulating mounting portions 711 from both outer sides in the width direction of the tooth portion 62, so that the two insulating mounting portions 711 are arranged around the tooth portion 62. At this time, the first end portion 711a and the second end portion 711b are overlapped with each other on both outer sides in the magnetic plate stacking direction of the tooth portion 62. In this way, in the insulating assembly process S3, the two insulating mounting portions 711 are arranged around the tooth portion 62, and the first end portion 711a and the second end portion 711b are overlapped with each other. At this time, the pair of yoke insulating portions 72 provided on the tooth insulating portion 71 overlap with the yoke portion 61. In addition, at this time, the pair of end insulating portions 73 provided on the tooth insulating portion 71 overlap with the end portion of the tooth portion 62.

[0086] Then, in the insulation assembly step S3, as shown in FIG. Figure 13 As shown, the overlapping first end portion 711a and second end portion 711b are bonded together using adhesive 713. This forms a bonded portion 712 in the tooth insulating portion 71. At this time, the first end portion 711a and second end portion 711b are bonded together while the core block 6 is pressurized. The pressurized state of the core block 6 is maintained until the adhesive 713 solidifies. Thus, the two insulating mounting portions 711 are connected in a ring shape. The stacked plurality of magnetic plates 63 are integrated because the teeth 62 are surrounded by the annular tooth insulating portion 71.

[0087] In the insulation assembly step S3, after the insulation sheet 7 is attached to the core block 6, the winding frame 8 is attached to the core block 6. At this time, the winding frame 8 may be attached to the core block 6 after it has been removed from the pressurizing device, or the winding frame 8 may be attached to the core block 6 while the core block 6 is pressurized by the pressurizing device.

[0088] When installing the winding frame 8, as shown in FIG. Figure 6 As shown, a pair of guide members 81 are attached to both end surfaces in the magnetic plate lamination direction of the core block 6. At this time, each guide member 81 overlaps with the tooth portion 62 with the tooth insulating portion 71 interposed therebetween.

[0089] <Winding Step S4>

[0090] After the insulation assembly step S3, the winding step S4 is performed. In the winding step S4, the coil portion 9 is placed on the tooth portion 62 via the tooth insulation portion 71. In the winding step S4, the conductive wire of the coil portion 9 is wound around the tooth portion 62 and the bobbin 8 at the same time, thereby placing the coil portion 9 on the tooth portion 62.

[0091] Figure 14 It means in Figure 9FIG. 1 is a structural diagram of a state in which the conductive wire of the coil portion 9 is wound around the teeth 62 of the core block 6 to which the insulating sheet 7 and the bobbin 8 are attached in the insulation assembly step S3. Figure 15 It means in Figure 14 This figure shows the state of the tooth portion 62 at the completion of winding the conductive wire of the coil portion 9. In the winding step S4, the coil portion 9 is set on the tooth portion 62 by the winding machine 11. The winding machine 11 includes a core holding portion 111 and a nozzle portion 112. The core holding portion 111 holds the core block 6. The nozzle portion 112 can move on a circumference centered on the core holding portion 111 while feeding the conductive wire of the coil portion 9.

[0092] In the winding process S4, Figure 14 As shown, the core block 6 with the insulating sheet 7 and the winding frame 8 mounted thereon is held in the core holding portion 111, and the conductive wire of the coil portion 9 fed from the nozzle portion 112 is hung on the core block 6. Thereafter, in the winding step S4, the conductive wire of the coil portion 9 is fed from the nozzle portion 112 while the nozzle portion 112 is moved on a circumference centered on the core holding portion 111. Figure 15 As shown, the conductive wire is wound around the teeth 62, and the coil 9 is provided on the teeth 62 via the insulating sheet 7 and the bobbin 8. In this way, the armature block 51 is manufactured.

[0093] After the winding step S4 , the plurality of armature blocks 51 are connected in a ring shape, and the plurality of coil units 9 are electrically connected.

[0094] In such an armature 5, a plurality of magnetic plates 63 are stacked to form the core block 6. The tooth insulation portion 71 surrounds the tooth portion 62 by overlapping the first end portion 711a and the second end portion 711b, and arranging the two insulating mounting portions 711 around the tooth portion 62. The tooth insulation portion 71 is formed by joining the overlapping first end portion 711a and the second end portion 711b to each other, forming a joint portion 712. The tooth insulation portion 71 integrates the plurality of magnetic plates 63 by surrounding the tooth portion 62. Therefore, the annular tooth insulation portion 71 can easily integrate the plurality of magnetic plates 63 without joining the plurality of magnetic plates 63 to each other through welding, riveting, etc. This can prevent the plurality of magnetic plates 63 from being electrically connected to each other, and can suppress the increase in eddy current generated in the core block 6. Therefore, the increase in iron loss in the core block 6 can be suppressed. In addition, the operation of attaching the insulating sheet 7 to the core block 6 and the operation of integrating the plurality of magnetic plates 63 can be performed simultaneously. This reduces the labor required to manufacture the armature 5 and improves the productivity of the armature 5. Furthermore, the first end 711a and the second end 711b of the insulating mounting portion 711 disposed around the tooth portion 62 can be overlapped and joined, making it easier to surround the tooth portion 62 with the tooth insulating portion 71. This further improves the productivity of the armature 5.

[0095] Furthermore, the joints 712 are located on both outer sides of the teeth 62 in the direction in which the magnetic plates are stacked. Therefore, the joints 712 can be arranged while avoiding the slots formed between the teeth 62. This increases the space factor of the coil 9 in the slots formed between the teeth 62, thereby increasing the torque generated by energizing the armature 5.

[0096] Furthermore, the first end portion 711a and the second end portion 711b are bonded to each other at the bonding portion 712 by the adhesive 713. Therefore, the first end portion 711a and the second end portion 711b that overlap each other can be easily bonded to each other.

[0097] Furthermore, in this armature manufacturing method, in the insulation assembly step S3, two insulation mounting portions 711 are arranged around the teeth 62, with the first end portion 711a and the second end portion 711b overlapping each other. Furthermore, in the insulation assembly step S3, the overlapping first end portion 711a and the second end portion 711b are joined together, thereby forming a joint portion 712 in the tooth insulation portion 71. Therefore, the annular tooth insulation portion 71 can easily integrate the multiple magnetic plates 63 without joining them together through welding, riveting, or the like. This can suppress increases in iron loss in the core block 6. Furthermore, the operations of attaching the insulation sheet 7 to the core block 6 and integrating the multiple magnetic plates 63 can be performed simultaneously. This reduces the labor involved in manufacturing the armature 5 and improves the productivity of the armature 5. Furthermore, the tooth insulation portion 71 can easily surround the teeth 62. This further improves the productivity of the armature 5.

[0098] Furthermore, after the lamination step S1 and before the insulation assembly step S3, a pressurization step S2 is performed to press the core blocks 6 in a direction that presses the plurality of magnetic plates 63 against each other. In the insulation assembly step S3, while the core blocks 6 are pressurized, the teeth 62 are surrounded by the tooth insulation 71. This reduces the gaps between the plurality of magnetic plates 63, increasing the space factor of the magnetic material in the core blocks 6. Consequently, the torque generated by energizing the armature 5 can be increased.

[0099] In addition, in the first embodiment, the first end portion 711a and the second end portion 711b at the joint portion 712 are joined to each other by the adhesive 713. However, the joining method of the first end portion 711a and the second end portion 711b at the joint portion 712 is not limited to this. For example, the first end portion 711a and the second end portion 711b at the joint portion 712 may be joined to each other by welding the first end portion 711a and the second end portion 711b. In this case, in the insulating assembly step S3, as shown in FIG. Figure 16As shown, the first end portion 711a and the second end portion 711b are welded together by a welding machine 714 to form a welded portion 715. At the welded portion 712, the first end portion 711a and the second end portion 711b are welded together via the welding machine 715. As the welding machine 714, an ultrasonic horn or the like is used.

[0100] Implementation method 2.

[0101] In the first embodiment, the number of the insulating attachment portions 711 included in the teeth insulating portion 71 is two. However, the number of the insulating attachment portions 711 included in the teeth insulating portion 71 may be one.

[0102] Right now, Figure 17 Schematic diagram showing the state of the tooth portion 62, the insulating sheet 7 and the winding frame 8 of the armature according to the second embodiment when viewed along the tooth protruding direction. Figure 17 Same as in Implementation 1 Figure 6 In this embodiment, the tooth insulating portion 71 includes a single insulating mounting portion 711. The single insulating mounting portion 711 is disposed around the tooth portion 62 to surround the tooth portion 62. The first end portion 711a and the second end portion 711b of the single insulating mounting portion 711 overlap with each other.

[0103] The tooth insulating portion 71 is formed by joining the overlapping first end portion 711a and second end portion 711b to form a joint portion 712. There is only one joint portion 712 formed in the tooth insulating portion 71. The joint portion 712 is located only on one of the two outer sides of the tooth portion 62 in the direction of stacking the magnetic plates. The remaining structure is the same as that of the first embodiment.

[0104] Figure 18 It means Figure 17 Schematic diagram of the state before the insulating sheet 7 is installed on the core block 6. Figure 19 It means Figure 18 Schematic diagram of the insulating sheet 7 mounted on the core block 6. During the manufacturing of the armature block 51, in the insulation assembly step S3, the insulating mounting portion 711 is bent to increase the distance between the first end portion 711a and the second end portion 711b, and the tooth portion 62 is inserted into the inner side of the insulating mounting portion 711. The first end portion 711a and the second end portion 711b are then brought closer together and overlapped. As a result, the insulating mounting portion 711 is positioned around the tooth portion 62, surrounding the tooth portion 62 with the first end portion 711a and the second end portion 711b overlapping.

[0105] Then, in the insulation assembly step S3, the insulation sheet 7 is attached to the core block 6 by joining the first end portion 711a and the second end portion 711b. With the insulation sheet 7 attached to the core block 6, the teeth 62 are surrounded by the annular tooth insulation portion 71, thereby integrating the plurality of magnetic plates 63. The remaining steps in the armature manufacturing method are the same as those in the first embodiment.

[0106] In this way, even if the tooth insulating portion 71 includes only one insulating mounting portion 711, the plurality of magnetic plates 63 can be easily surrounded by the tooth insulating portion 71. Thus, the plurality of magnetic plates 63 can be integrated without joining them together through welding, riveting, or the like. Therefore, an increase in iron loss in the core block 6 can be suppressed. Furthermore, the number of locations where the first end portion 711a and the second end portion 711b are joined together can be reduced, further improving the productivity of the armature 5.

[0107] In the second embodiment, the first end portion 711a and the second end portion 711b at the joint portion 712 are joined to each other by the adhesive 713. However, the first end portion 711a and the second end portion 711b at the joint portion 712 may be joined to each other by welding the first end portion 711a and the second end portion 711b. In this case, in the insulating assembly step S3, Figure 16 Similarly, the first end portion 711 a and the second end portion 711 b are joined to each other.

[0108] Implementation method 3.

[0109] Figure 20 It is an exploded perspective view showing the main parts of the armature block 51 in the armature according to the third embodiment. Figure 21 It means observing along the protruding direction of the tooth Figure 20 Schematic diagram of the state of the teeth 62, the insulating sheet 7 and the winding frame 8. In addition, Figure 20 Compared with the embodiment 1 Figure 5 correspond, Figure 21 Compared with the embodiment 1 Figure 6 The pair of guide members 81 in the winding frame 8 is arranged to sandwich the core block 6 in the magnetic plate stacking direction. The pair of guide members 81 overlaps with both end surfaces of the core block 6 in the magnetic plate stacking direction. In this embodiment, the guide members 81 are not provided with a fitting portion for fitting into the core block 6.

[0110] The two joints 712 of the tooth insulation portion 71 are positioned on either side of the tooth portion 62 in the direction of magnetic plate stacking. One guide member 81 of the pair of guide members 81 is interposed between one joint 712 and the tooth portion 62, while the other guide member 81 is interposed between the other joint 712 and the tooth portion 62. Thus, the tooth insulation portion 71 surrounds both the tooth portion 62 and the bobbin 8. Each joint 712 overlaps with the winding body 82 of the guide member 81.

[0111] The bobbin 8 and the plurality of magnetic plates 63 are integrated by being surrounded by the tooth insulating portion 71. That is, the tooth insulating portion 71 integrates the bobbin 8 and the plurality of magnetic plates 63 by surrounding both the teeth 62 and the bobbin 8. The remaining structure is the same as that of the first embodiment.

[0112] Figure 22 It means Figure 21 Schematic diagram of the state before the insulating sheet 7 is installed on the core block 6 and the winding frame 8. Figure 23 It means in Figure 22 Schematic diagram of the state when the insulating sheet 7 is installed on the core block 6 and the winding frame 8. When manufacturing the armature block 51, in the insulation assembly step S3, as shown in FIG. Figure 22 As shown, the pair of guide members 81 of the bobbin 8 are overlapped with both end surfaces in the magnetic plate lamination direction of the core block 6. At this time, the core block 6 is kept in a pressurized state.

[0113] Then, in the insulation assembly step S3, as shown in FIG. Figure 23 As shown, the two insulating mounting portions 711 are used to clamp the tooth portion 62 from both outer sides in the width direction of the tooth portion 62, so that the two insulating mounting portions 711 are arranged around the tooth portion 62 and the winding frame 8. At this time, the first end portion 711a and the second end portion 711b are overlapped with each other on both outer sides in the magnetic plate stacking direction of the tooth portion 62 and the winding frame 8. Therefore, in this embodiment, the first end portion 711a and the second end portion 711b overlap with the winding body portion 82 of each guide member 81. In this way, in the insulating assembly step S3, the two insulating mounting portions 711 are arranged around the tooth portion 62 and the winding frame 8, and the first end portion 711a and the second end portion 711b are overlapped with each other.

[0114] Subsequently, in the insulation assembly step S3, the overlapping first end portion 711a and second end portion 711b are bonded together using an adhesive 713. This forms a bonded portion 712 in the tooth insulation portion 71. In this embodiment, two bonded portions 712 are formed in the tooth insulation portion 71. Each bonded portion 712 overlaps the wound main body 82 of each guide member 81.

[0115] The two insulating mounting portions 711 are connected to form a ring shape by being engaged with each other. Figure 21As shown, the bobbin 8 and the plurality of magnetic plates 63 are integrated by the bobbin 8 and the teeth 62 being surrounded by the annular teeth insulating portion 71. The other steps in the method of manufacturing the armature are the same as those in the first embodiment.

[0116] In such an armature 5, the tooth insulating portion 71 surrounds the tooth portion 62 and the winding frame 8, thereby integrating the winding frame 8 and the plurality of magnetic plates 63. Therefore, not only the plurality of magnetic plates 63 but also the winding frame 8 can be easily integrated together by the tooth insulating portion 71. As a result, the increase in iron loss in the core block 6 can be suppressed, and the productivity of the armature 5 can also be improved. In addition, it is not necessary to provide an interlocking portion for embedding the core block 6 in each guide component 81 of the winding frame 8, and the structure of each guide component 81 can be simplified. As a result, the cost of the winding frame 8 can be reduced.

[0117] Furthermore, in this method of manufacturing the armature 5, after the bobbin 8 is placed on the tooth portion 62 in the insulation assembly step S3, the bobbin 8 and the tooth portion 62 are surrounded by the tooth insulation portion 71, thereby integrating the bobbin 8 and the plurality of magnetic plates 63. Therefore, it is possible to suppress an increase in iron loss in the core block 6. Furthermore, the operation of placing the coil portion 9 on the tooth portion 62 in the winding step S4 is also facilitated, thereby further improving the productivity of the armature 5. Furthermore, the structure of each guide component 81 in the bobbin 8 can be simplified, thereby reducing the cost of the bobbin 8.

[0118] In the third embodiment, the first end portion 711a and the second end portion 711b at the joint portion 712 are joined to each other by the adhesive 713. However, the first end portion 711a and the second end portion 711b at the joint portion 712 may be joined to each other by welding the first end portion 711a and the second end portion 711b. In this case, in the insulating assembly step S3, as shown in FIG. Figure 24 As shown, the first end portion 711a and the second end portion 711b are welded together by a welding machine 714 to form a welded portion 715. At the welded portion 712, the first end portion 711a and the second end portion 711b are welded together via the welding machine 715. As the welding machine 714, an ultrasonic horn or the like is used.

[0119] In the third embodiment, the joint portion 712 may be joined to the bobbin 8. In this case, the joint portion 712 is joined to the winding body portion 82 of the guide member 81. In this case, the joint portion 712 may be joined to the bobbin 8 by an adhesive or by welding the joint portion 712 and the bobbin 8.

[0120] In addition, in embodiment 3, the number of insulating mounting portions 711 included in the tooth insulating portion 71 is two. However, as in embodiment 2, the number of insulating mounting portions 711 included in the tooth insulating portion 71 may be one. In this case, one insulating mounting portion 711 is arranged around the tooth portion 62 in a state of surrounding the winding frame 8 and the tooth portion 62. In this case, the first end portion 711a and the second end portion 711b of one insulating mounting portion 711 overlap with each other. Moreover, in this case, in the tooth insulating portion 71, a joint portion 712 is formed by joining the overlapping first end portion 711a and second end portion 711b to each other. The joint portion 712 is located only on one of the two outer sides of the tooth portion 62 in the direction of stacking the magnetic plates. In this way, the winding frame 8 and the plurality of magnetic plates 63 can be integrated through the tooth insulating portion 71. As a result, the increase in iron loss in the core block 6 can be suppressed, and the productivity of the armature 5 can also be improved. Furthermore, the structure of each guide member 81 in the bobbin 8 can be simplified, and the cost of the bobbin 8 can be reduced.

[0121] In Embodiments 1 and 3, the tooth insulating portion 71 includes two insulating mounting portions 711. However, the tooth insulating portion 71 may include three or more insulating mounting portions 711. In this case, the first end portion 711a and the second end portion 711b overlap, and three or more insulating mounting portions 711 are arranged around the tooth portion 62, so that the tooth portion 62 is surrounded by the tooth insulating portion 71.

[0122] In each of the above embodiments, the joint portion 712 is located on at least one of the two outer sides of the tooth portion 62 in the direction of magnetic plate stacking. However, the position of the joint portion 712 is not limited to this. Therefore, the joint portion 712 can be located anywhere as long as it is around the tooth portion 62.

[0123] In each of the above embodiments, the pressurizing step S2 is performed after the stacking step S1 and before the insulating assembly step S3 to pressurize the core blocks 6. However, the pressurizing step S2 may be omitted as long as the stacked state of the plurality of magnetic plates 63 is maintained during the insulating assembly step S3.

[0124] In each of the above-described embodiments, the armature 5, which is composed of a plurality of armature blocks 51 connected in a ring shape, is used as the armature of a rotating electric machine as an electrical device. However, this is not limiting. For example, the armature 5, which is composed of a plurality of armature blocks 51 connected continuously in a straight line, can also be used as the armature of a linear motor as an electrical device. In this case, the movable element moves along the armature 5 due to the movement of the magnetic field generated by energizing the armature windings of the armature 5.

[0125] The above-mentioned structure shown in the embodiment is an example of the content of the present disclosure. The embodiment can be combined with other well-known technologies. Within the scope of not departing from the gist of the present disclosure, part of the structure of the embodiment can be omitted or changed.

[0126] Hereinafter, examples of possible aspects of the present disclosure will be explicitly described as supplementary notes.

[0127] (Note 1)

[0128] An armature comprises a plurality of armature blocks.

[0129] Each of the plurality of armature blocks includes a core block, an insulating sheet, and a coil portion.

[0130] The core block is composed of a plurality of stacked magnetic plates.

[0131] The core block has a yoke and a tooth portion protruding from the yoke,

[0132] The coil portion is provided on the tooth portion,

[0133] The insulating sheet has a tooth insulating portion interposed between the coil portion and the tooth portion.

[0134] The tooth insulating portion has one or more insulating mounting portions, each of the one or more insulating mounting portions having a first end and a second end.

[0135] The tooth insulating portion surrounds the tooth portion in a state where the one or more insulating mounting portions are arranged around the tooth portion and the first end portion and the second end portion overlap each other.

[0136] The tooth insulating portion includes a joint portion formed by joining the first end portion and the second end portion that overlap each other.

[0137] The tooth insulating portion integrates the plurality of magnetic plates by surrounding the tooth portion.

[0138] (Note 2)

[0139] The armature according to Supplementary Note 1, wherein:

[0140] The engaging portion is located on at least one of both outer sides of the teeth portion in the stacking direction of the plurality of magnetic plates.

[0141] (Note 3)

[0142] The armature according to Supplementary Note 1 or 2, wherein:

[0143] The first end portion and the second end portion at the joint portion are joined to each other by an adhesive.

[0144] (Note 4)

[0145] The armature according to Supplementary Note 1 or 2, wherein:

[0146] The first end portion and the second end portion at the joint portion are joined to each other by welding the first end portion and the second end portion.

[0147] (Note 5)

[0148] The armature according to any one of Supplementary Notes 1 to 4, wherein:

[0149] Each of the plurality of armature blocks has a bobbin.

[0150] The tooth insulating portion surrounds the tooth portion and the bobbin together, thereby integrating the bobbin and the plurality of magnetic plates.

[0151] (Note 6)

[0152] A method for manufacturing an armature, comprising:

[0153] a lamination step of laminating a plurality of magnetic plates to produce a core block having a yoke portion and teeth protruding from the yoke portion;

[0154] an insulating assembly step of integrating the plurality of magnetic plates by surrounding the teeth with teeth insulating portions of an insulating sheet; and

[0155] a winding step, after the insulation assembly step, of placing the coil portion on the tooth portion via the tooth insulation portion;

[0156] The tooth insulating portion has one or more insulating mounting portions, each of the one or more insulating mounting portions having a first end and a second end.

[0157] In the insulation assembly step, the one or more insulation mounting portions are arranged around the tooth portion, the first end portion and the second end portion are overlapped with each other, and the overlapped first end portion and the second end portion are joined to each other to form a joint portion in the tooth insulation portion.

[0158] (Note 7)

[0159] The method for manufacturing an armature according to Supplementary Note 6, wherein:

[0160] After the stacking step and before the insulating assembly step, a pressing step of pressing the core blocks in a direction in which the plurality of magnetic plates are pressed against each other is provided.

[0161] In the insulation assembly step, the teeth are surrounded by the teeth insulation portion while the core blocks are pressurized.

[0162] (Note 8)

[0163] The method for manufacturing an armature according to Supplementary Note 6 or 7, wherein:

[0164] In the insulating assembly step, after the bobbin is placed on the tooth portion, the tooth insulating portion surrounds the bobbin and the tooth portion together, thereby integrating the bobbin and the plurality of magnetic plates.

Claims

1. An armature comprising a plurality of armature blocks, Each of the plurality of armature blocks includes a core block, an insulating sheet, and a coil portion. The core block is composed of a plurality of stacked magnetic plates. The core block has a yoke and a tooth portion protruding from the yoke, The coil portion is provided on the tooth portion, The insulating sheet has a tooth insulating portion interposed between the coil portion and the tooth portion. The tooth insulating portion has one or more insulating mounting portions, each of the one or more insulating mounting portions having a first end and a second end. The tooth insulating portion surrounds the tooth portion in a state where the one or more insulating mounting portions are arranged around the tooth portion and the first end portion and the second end portion overlap each other. The tooth insulating portion includes a joint portion formed by joining the first end portion and the second end portion that overlap each other. The tooth insulating portion integrates the plurality of magnetic plates by surrounding the tooth portion.

2. The armature according to claim 1, wherein The engaging portion is located on at least one of both outer sides of the teeth portion in the stacking direction of the plurality of magnetic plates.

3. The armature according to claim 1 or 2, wherein: The first end portion and the second end portion at the joint portion are joined to each other by an adhesive.

4. The armature according to claim 1 or 2, wherein: The first end portion and the second end portion at the joint portion are joined to each other by welding the first end portion and the second end portion.

5. The armature according to any one of claims 1 to 4, wherein Each of the plurality of armature blocks has a bobbin. The tooth insulating portion surrounds the tooth portion and the bobbin together, thereby integrating the bobbin and the plurality of magnetic plates.

6. A method for manufacturing an armature, comprising: a lamination step of laminating a plurality of magnetic plates to produce a core block having a yoke portion and teeth protruding from the yoke portion; an insulating assembly step of integrating the plurality of magnetic plates by surrounding the teeth with the teeth insulating portion of an insulating sheet; as well as a winding step, after the insulation assembly step, of placing the coil portion on the tooth portion via the tooth insulation portion; The tooth insulating portion has one or more insulating mounting portions, each of the one or more insulating mounting portions having a first end and a second end. In the insulation assembly step, the one or more insulation mounting portions are arranged around the tooth portion, the first end portion and the second end portion are overlapped with each other, and the overlapped first end portion and the second end portion are joined to each other to form a joint portion in the tooth insulation portion.

7. The method for manufacturing an armature according to claim 6, wherein: After the stacking step and before the insulating assembly step, a pressing step of pressing the core blocks in a direction in which the plurality of magnetic plates are pressed against each other is provided. In the insulation assembly step, the teeth are surrounded by the teeth insulation portion while the core blocks are pressurized.

8. The method for manufacturing an armature according to claim 6 or 7, wherein: In the insulating assembly step, after the bobbin is placed on the tooth portion, the tooth insulating portion surrounds the bobbin and the tooth portion together, thereby integrating the bobbin and the plurality of magnetic plates.

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