Method for producing stator, stator, and motor

Abstract

To provide a method for producing a stator capable of inserting insulating paper into slots of a laminated core further easily.SOLUTION: A method for producing a stator that includes a laminated core obtained by spirally winding a plate-shaped core piece forming part while deforming the same in one direction of the width direction, and insulating paper that is inserted into slots has a pressing step in which the core piece forming part is punched out of a steel plate by press molding, an attachment step in which the insulating paper is attached onto multiple protrusion parts that are arranged in the circumferential direction on an outer peripheral surface of a cylindrical roll member that rotates about a central axis and extend along the central axis, and a lamination step in which the roll member is rotated with the protrusion parts and the insulating paper inserted into the slots, and thereby deforming the core piece forming part in one direction of the width direction and winding the same spirally around the outer peripheral surface of the roll member, and laminating the core piece forming part in the thickness direction.SELECTED DRAWING: Figure 5

Description

[Technical field]

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

[0002] There is known a stator that includes a laminated core in which a plurality of electromagnetic steel sheets are laminated, and insulating paper housed in the slots of the laminated core. For example, a motor core that includes a laminated steel sheet portion in which a plurality of electromagnetic steel sheets are laminated, the electromagnetic steel sheets including teeth portions around which windings are wound, and a sheet-like insulating material is inserted into slots provided between the teeth portions is disclosed as an example of such a stator (for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2016-171652 A Summary of the Invention [Problem to be solved by the invention]

[0004] Generally, in a method for manufacturing a stator, a laminated core is formed by stacking electromagnetic steel sheets, and then insulating paper is inserted axially into the slots of the laminated core. The electromagnetic steel sheets are formed by, for example, press forming. The electromagnetic steel sheets punched out by press forming have protrusions formed on their ends.

[0005] Therefore, when inserting insulating paper axially into the slots of the laminated core in which the electromagnetic steel sheets are stacked, there is a possibility that the insulating paper may get caught on the protrusions. Thus, there is a need for a method of manufacturing a stator that allows insulating paper to be more easily inserted into the slots of the laminated core.

[0006] An object of the present invention is to provide a method for manufacturing a stator that allows for easier insertion of insulating paper into the slots of a laminated core. [Means for solving the problem]

[0007] A method for manufacturing a stator according to an exemplary embodiment of the present invention is a method for manufacturing a stator including a laminated core obtained by spirally winding a plate-shaped core piece forming portion having a band-shaped back yoke forming portion and a plurality of teeth protruding from the back yoke forming portion in one width direction of the back yoke forming portion while deforming the plate-shaped core piece forming portion in one width direction, and insulating paper inserted into slots located between the teeth portions. The stator manufacturing method includes a pressing step of punching out the core piece forming portion from a steel plate by press forming, an attachment step of attaching the insulating paper onto a plurality of protrusions that are aligned in the circumferential direction on an outer circumferential surface of a cylindrical roll member that rotates around a central axis and extend along the central axis, and a lamination step of rotating the roll member with the protrusions and the insulating paper inserted into the slots to deform the core piece forming portion in one width direction and wind it spirally around the outer circumferential surface of the roll member, thereby laminating the core piece forming portions in their thickness direction.

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

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

[0010] According to the present invention, it is possible to provide a method for manufacturing a stator that allows insulating paper to be more easily inserted into slots of a laminated core. [Brief description of the drawings]

[0011] [Figure 1] FIG. 1 is a perspective view showing a schematic configuration of a stator according to the first embodiment. [Diagram 2] FIG. 2 is a plan view showing a schematic configuration of a laminated core. [Diagram 3] FIG. 3 is a cross-sectional view that illustrates a schematic shape of an end portion of a belt-shaped member. [Figure 4A] FIG. 4A is a diagram illustrating punching by a press. [Figure 4B] FIG. 4B is a diagram illustrating the shape of the end of the material punched out by the press. [Diagram 5] FIG. 5 is a perspective view that illustrates a schematic configuration of a roll member. [Figure 6] FIG. 6 is a plan view of the roll member. [Figure 7] FIG. 7 is a flowchart showing a method for manufacturing the stator according to the first embodiment. [Figure 8] FIG. 8 is a diagram of a punched steel plate. [Figure 9] FIG. 9 is a cross-sectional view that illustrates a schematic shape of an end portion of a steel plate. [Figure 10] FIG. 10 is a plan view showing a state in which insulating paper is attached to the roll member. [Figure 11] FIG. 11 is a plan view showing a schematic configuration of a laminated core according to the second embodiment. [Figure 12] FIG. 12 is a cross-sectional view of a laminated core. [Figure 13] FIG. 13 is a diagram of a punched steel plate. [Figure 14] FIG. 14 is a plan view of the core piece forming portion punched out from the steel plate. [Figure 15] FIG. 15 is a diagram for explaining a state in which one surfaces in the thickness direction of two core piece forming portions are opposed to each other. [Figure 16]FIG. 16 is a cross-sectional view that typically shows a state in which two core piece forming portions are overlapped. [Figure 17] FIG. 17 is a diagram for explaining how the core piece forming portion is wound around the roll member. [Figure 18] FIG. 18 is a diagram for explaining a state in which the core piece forming portion moves in the axial direction relative to the roll member. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the drawings. Note that the same or corresponding parts in the drawings are given the same reference numerals and their description will not be repeated. Furthermore, the dimensions of the components in each drawing do not faithfully represent the actual dimensions of the components and the dimensional ratios of each component.

[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 perpendicular 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 the following description, the terms "fix," "connect," and "attach" include not only cases where members are directly fixed to each other, but also cases where members are fixed to each other via other members. In other words, in the following description, the terms "fix," "connect," and "attach" include the meanings of direct and indirect fixation between members.

[0015] (Embodiment 1) A method for manufacturing a stator 1 according to a first exemplary embodiment of the present invention will be described with reference to Fig. 1 to Fig. 10. The stator 1 is a stator for a motor. The stator 1 is manufactured using roll members 9. First, the stator 1 manufactured in this embodiment will be briefly described with reference to Figs. 1 to 3.

[0016] (Stator configuration) As shown in Fig. 1, the stator 1 has a laminated core 10 and insulating paper 20. The laminated core 10 is cylindrical and extends along a central axis P. In this embodiment, the laminated core 10 is a laminate in which strip plate members 11 extending spirally about the central axis P are laminated in the thickness direction.

[0017] The laminated core 10 has a cylindrical core back portion 12 and a plurality of teeth portions 13 extending radially inward from the radial inner periphery side of the core back portion 12 .

[0018] When viewed from the axial direction of the laminated core 10, slots 14 that extend in the axial direction and open radially inward are located between adjacent teeth portions 13. Insulating paper 20 is housed within the slots 14. A coil wire (not shown) is inserted inside the insulating paper 20.

[0019] 2 is an exploded plan view of laminated core 10. Strip member 11 is obtained by spirally winding core piece forming portions 71 punched out by a press.

[0020] As shown in Fig. 3, the band plate member 11 has a first surface 11a which is one surface in the thickness direction, and a second surface 11b which is the other surface in the thickness direction. The first surface 11a of the band plate member 11 has a curved surface portion 111 at an end. The second surface 11b of the band plate member 11 has a protrusion portion 112 at an end. The curved surface portion 111 and the protrusion portion 112 are formed by punching a steel plate with a press.

[0021] 4A and 4B are diagrams for explaining punching by a general press. As shown in Fig. 4A, in punching by a press, a punch X1 is moved downward relative to a die X2 to punch out a 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] As a result, as shown in Fig. 4B, a curved surface portion W1 is formed at an end of one surface Wa in the thickness direction of the punched material W. A protrusion portion W2 is formed at an end of the other surface Wb in the thickness direction of the material W. In this manner, in punching by press, a curved surface portion W1 is formed at a rear end of the surface in the thickness direction of the material W in the direction in which the punch X1 moves relative to the die X2. A protrusion portion W2 is formed at a front end of the surface in the direction in which the punch X1 moves relative to the die X2.

[0023] As shown in Fig. 1, the insulating paper 20 is housed in the slot 14. More specifically, the insulating paper 20 is positioned between the inner surface of the slot 14 and a coil wire (not shown) that is inserted into the slot 14. The insulating paper 20 has a rectangular shape that is long in the axial direction of the laminated core 10. A longitudinal end 21 of the insulating paper 20 protrudes from the slot 14 in the axial direction.

[0024] (Structure of Roll Member) Next, roll members 9 used when manufacturing stator 1 will be briefly described with reference to FIGS.

[0025] As shown in Fig. 5, the roll member 9 is cylindrical. The roll member 9 has a main body portion 91 and a protruding portion 92. As shown in Fig. 5, the core piece forming portion 71 is wound around the outer circumferential surface of the roll member 9.

[0026] The main body 91 of the roll 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 circumferential surface of the main body 91 is equal to the diameter of the inner periphery of the laminated core 10 that is formed by the radially inner end faces of the multiple teeth 13 of the laminated core 10.

[0027] As shown in Figures 5 and 6, the protrusions 92 protrude outward from the outer peripheral surface of the main body portion 91. The protrusions 92 are plate-shaped and extend along the central axis Q of the main body portion 91. The thickness direction of the protrusions 92 is the circumferential direction of the main body portion 91. In this embodiment, the axial length of the protrusions 92 is equal to the axial length of the main body portion 91. The protrusions 92 are arranged in the circumferential direction of the main body portion 91. The protrusions 92 have a shape and size that allows them to be inserted into the slots 14 in the laminated core 10.

[0028] The roll member 9 has protrusions 92 in the same number as the slots 14 of the laminated core 10. The protrusions 92 are inserted between a plurality of tooth forming portions 73 of the core piece forming portion 71 that is wound onto the outer circumferential surface of the main body portion 91.

[0029] The roll member 9 is rotated about a central axis Q by a driving device (not shown). As the roll member 9 rotates, the protrusions 92 move in the rotational direction of the roll member 9. As a result, the teeth forming portions 73 move in the rotational direction by the protrusions 92. Thus, the core piece forming portions 71 are wound around the outer circumferential surface of the main body portion 91.

[0030] (Manufacturing method of stator) Next, an exemplary method for manufacturing the stator 1 will be described with reference to FIGS. 1, 3, 5, and 7 to 10. FIG.

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

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

[0033] Fig. 8 is an example of a punched view of a steel plate 70. In Fig. 8, a region R where the steel plate 70 is punched is marked with diagonal lines. In the press process S1, the region R of the steel plate 70 is punched out with a punch. This forms a plate-shaped core piece forming portion 71 having a band-shaped back yoke forming portion 72 and a plurality of teeth forming portions 73 that protrude to one side in the width direction of the back yoke forming portion 72. A slot 14 of the laminated core 10 is formed between adjacent tooth forming portions 73 among the plurality of tooth forming portions 73 in the arrangement direction.

[0034] As described above, the core piece forming portion 71 formed by press forming has the curved portion 111 and the protrusion 112 at its end. Fig. 9 shows a schematic diagram of the shape of the end of the core piece forming portion 71 formed by press forming. The surface of the core piece forming portion 71 having the curved portion 111 at its end becomes the first surface 11a of the strip member 11 of the laminated core 10. The surface of the core piece forming portion 71 having the protrusion 112 at its end becomes the second surface 11b of the strip member 11 of the laminated core 10.

[0035] 10, in the mounting step S2, one sheet of insulating paper 20 is mounted on each of the multiple protruding portions 92 of the roll member 9. Specifically, the insulating paper 20 is folded at the center portion in the width direction. The insulating paper 20 is mounted on the protruding portion 92 in a position in which the folded portion is located at the tip end of the protruding portion 92 in the protruding direction, and both ends in the width direction are located at the base end of the protruding portion 92. In this embodiment, as shown in FIG. 5, the longitudinal length of the insulating paper 20 and the axial length of the protruding portion 92 are equal.

[0036] As described above, the protruding portions 92 are inserted between the multiple tooth forming portions 73 of the core piece forming portion 71. Therefore, the insulating paper 20 attached to the protruding portions 92 is inserted into the slots 14 when the core piece forming portion 71 is wound around the roll member 9 in the lamination process S3 described below.

[0037] 5, in the lamination process S3, the core piece forming portion 71 is wound spirally to laminate the core piece forming portion 71 in the thickness direction. More specifically, the protrusions 92 and insulating paper 20 are inserted into the slots 14 formed between adjacent tooth forming portions 73 in the core piece forming portion 71 formed in the press process S1. Next, the roll member 9 is rotated. As the roll member 9 rotates, the core piece forming portion 71 is wound spirally around the outer circumferential surface of the roll member 9 while being deformed in one direction in the width direction.

[0038] The portion of the core piece forming portion 71 to be newly wound onto the outer peripheral surface of the roll member 9 pushes the core piece forming portion 71 that is already wound spirally onto the outer peripheral surface of the roll member 9 toward the winding start side. As a result, the core piece forming portions 71 are stacked in the thickness direction to form the laminated core 10. The back yoke forming portions 72 stacked in the thickness direction become the core back portion 12 of the laminated core 10. The tooth forming portions 73 stacked in the thickness direction become the teeth portions 13 of the laminated core 10.

[0039] Thereafter, the laminated core 10 and the insulating paper 20 are removed from the axial end of the roll member 9. In this way, the stator 1 is manufactured, which includes the laminated core 10 and the insulating paper 20. The laminated core 10 of the stator 1 has a cylindrical core back portion 12 and a plurality of teeth portions 13 extending radially inward from the radial inner periphery side of the core back portion 12, and the strip plate members 11 are laminated in the thickness direction. The insulating paper 20 is accommodated in slots 14 located between the teeth portions 13.

[0040] The exemplary stator manufacturing method according to the present embodiment described above is a method for manufacturing a stator 1 including a laminated core 10 obtained by spirally winding a plate-shaped core piece forming portion 71 having a band-shaped back yoke forming portion 72 and a plurality of teeth forming portions 73 protruding from the back yoke forming portion 72 in one width direction of the back yoke forming portion 72 while deforming the plate-shaped core piece forming portion 71 in one width direction, and insulating paper 20 inserted into slots 14 located between the tooth forming portions 73. The manufacturing method of the stator 1 includes a pressing process S1 in which core piece forming portions 71 are punched out from a steel plate 70 by press forming, an attachment process S2 in which insulating paper 20 is attached onto a plurality of protrusions 92 that are lined up in the circumferential direction on the outer peripheral surface of a cylindrical roll member 9 that rotates about a central axis Q and extend along the central axis Q, and a lamination process S3 in which the roll member 9 is rotated with the protrusions 92 and the insulating paper 20 inserted into the slots 14, thereby deforming the core piece forming portions 71 in one direction in the width direction and winding them spirally around the outer peripheral surface of the roll member 9, thereby laminating the core piece forming portions 71 in their thickness direction.

[0041] Generally, core piece forming portion 71 formed by press molding has protrusions 112 formed by press molding at its ends. Therefore, when insulating paper 20 is inserted axially into slots 14 of laminated core 10 obtained by spirally winding core piece forming portion 71 while deforming it in one width direction, there is a possibility that insulating paper 20 will get caught on protrusions 112.

[0042] In contrast, with the above-described method, the insulating paper 20 can be inserted into the slots 14 when the core piece forming portions 71 formed by press molding are wound spirally while being deformed in one width direction. This allows the insulating paper 20 to be easily inserted into the slots 14 without being affected by the protrusions 112 of the core piece forming portions 71. This makes it possible to provide a manufacturing method for the stator 1 that allows the insulating paper 20 to be more easily inserted into the slots 14 of the laminated core 10.

[0043] (Embodiment 2) A method for manufacturing a stator according to the second exemplary embodiment of the present invention will be described with reference to Fig. 11 to Fig. 18. A laminated core 110 of a stator manufactured in this embodiment has two strip plate members 121, 122. In the following, the same components as those in the first embodiment are denoted by the same reference numerals, and description thereof will be omitted.

[0044] (Stator configuration) The stator manufactured in this embodiment has a laminated core 110 and insulating paper 20. The laminated core 110 is a laminate in which two strip plate members 121, 122 extending spirally about a central axis P are laminated in the thickness direction. As in the first embodiment, the laminated core 110 has a cylindrical core back portion 12, a plurality of teeth portions 13, and a plurality of slots 14. FIG. 11 is an exploded plan view showing the laminated core 110.

[0045] The band plate members 121 and 122 have the same configuration as the band plate member 11 of the first embodiment. That is, as shown in Fig. 12, the band plate members 121 and 122 have a first surface 11a which is one surface in the thickness direction and a second surface 11b which is the other surface in the thickness direction. The first surface 11a of the band plate members 121 and 122 has a curved surface portion 111 at an end portion. The second surface 11b of the band plate members 121 and 122 has a protrusion portion 112 at an end portion.

[0046] 12, in cross section, laminated core 110 has band plate members 121 and band plate members 122 stacked alternately in the thickness direction. Band plate member 121 has a first surface 11a located on one side in the stacking direction. Band plate member 122 has a second surface 11b located on the same side in the stacking direction.

[0047] That is, in this embodiment, one of the two strip plate members, strip plate member 121, has a first surface 11a located on one side in the stacking direction. The other of the two strip plate members, strip plate member 122, has a second surface 11b located on one side in the stacking direction. Thus, in laminated core 110, the surfaces of strip plate members 121, 122 are not aligned in one direction in the stacking direction. In this specification, the phrase "the surfaces of the strip plate members are not aligned in one direction in the stacking direction" refers to a state in which a surface of a strip-shaped member having a curved portion at an end and a surface of a strip-shaped member having a protrusion at an end are located on the same side in the stacking direction.

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

[0049] In the press step S11 of this embodiment, a plurality of band-shaped core piece forming portions 71 are lined up and punched out from a steel plate 70, which is a magnetic material, by press molding. In this embodiment, a case will be described in which two core piece forming portions 71 are lined up and punched out in the press step S11. The two core piece forming portions 71 become the band plate members 121, 122 in the laminated core 110.

[0050] Fig. 13 is an example of a punched view of a steel plate 70. As shown in Fig. 13, the back yoke forming portions 72 of the two core piece forming portions 71 extend in the longitudinal direction of the steel plate 70. The teeth forming portions 73 of one of the two core piece forming portions 71 protrude toward the back yoke forming portion 72 of the other core piece forming portion 71. The teeth forming portions 73 of the other of the two core piece forming portions 71 protrude toward the back yoke forming portion 72 of the one core piece forming portion 71.

[0051] Furthermore, the tooth forming portions 73 of one core piece forming portion 71 are located between adjacent tooth forming portions 73 in the longitudinal direction of the other core piece forming portion 71. In this way, the two core piece forming portions 71 have the multiple tooth forming portions 73 protruding in opposite directions. Therefore, by punching out region R, two opposing core piece forming portions 71 are formed. Figure 14 shows two core piece forming portions 71 punched out from steel plate 70.

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

[0053] The mounting step S12 of this embodiment is similar to the mounting step S2 of the first embodiment, and therefore a description thereof will be omitted.

[0054] In the lamination step S13 of this embodiment, as shown in FIGS. 15 and 16, two core piece forming portions 71 are stacked in the thickness direction with their first surfaces 11a facing each other.

[0055] Next, as shown in Fig. 17, the two core piece forming parts 71 are stacked in the thickness direction and are spirally wound around the outer circumferential surface of the roll member 9 while being deformed in one direction in the width direction by the rotation of the roll member 9. When the roll member 9 rotates, as shown in Fig. 18, the two core piece forming parts 71 to be newly wound around the outer circumferential surface of the roll member 9 push the core piece forming parts 71 that are already spirally wound around the outer circumferential surface of the roll member 9 toward the winding start side. As a result, the core piece forming parts 71 are stacked in the thickness direction.

[0056] As shown in FIG. 18, the first surfaces 11a of the two core piece forming portions 71 face each other. That is, the second surfaces 11b on the outer sides in the thickness direction of the two core piece forming portions 71 face the second surfaces 11b of the core piece forming portions 71a adjacent to each other in the stacking direction of the two core piece forming portions 71. Therefore, the two core piece forming portions 71 move in the thickness direction due to the rotation of the roll member 9, so that the second surfaces 11b of the core piece forming portions 71 come into contact with the second surfaces 11b of the core piece forming portions 71a. As a result, the protrusions 112 of the core piece forming portions 71 come into contact with the protrusions 112 of the core piece forming portions 71a, and the two protrusions 112 protrude in a direction intersecting the thickness direction of the two core piece forming portions 71. This makes it difficult for the insulating paper 20 to come out of the slot 14.

[0057] In this embodiment, the two core piece forming portions 71 are stacked in the thickness direction with their first surfaces 11a facing each other. However, the two core piece forming portions may be stacked in the thickness direction with their second surfaces 11b facing each other. The two core piece forming portions 71 may be stacked in the thickness direction with the first surface 11a of one core piece forming portion 71 facing the second surface 11b of the other core piece forming portion 71.

[0058] In the pressing step S11 of the exemplary stator manufacturing method according to the present embodiment described above, two core piece forming portions 71 are punched out side by side from a steel plate 70. In the lamination step S13, the two core piece forming portions 71, while stacked in the thickness direction, are spirally wound around the outer circumferential surface of the roll member 9 while being deformed in one of the width directions by the rotation of the roll member 9, thereby stacking the two core piece forming portions 71 in their thickness direction.

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

[0060] Furthermore, when forming the laminated core 110 by spirally winding the two core piece forming portions 71, the insulating paper 20 can be inserted into the slots 14. This allows the insulating paper 20 to be easily inserted into the slots 14 without being affected by the protrusions 112 of the two core piece forming portions 71.

[0061] In addition, in the stacking process S13 of this embodiment, the two core piece forming portions 71 are stacked in the thickness direction with their second surfaces 11b, which are the surfaces on one side of the thickness direction having the protrusion portions 112 formed on their ends by the press process S11, facing each other, or with their first surfaces 11a, which are the surfaces on the other side of the thickness direction having the curved portions 111 formed on their ends by the press process S11, facing each other, and then the two core piece forming portions 71 are deformed in one direction in the width direction by rotating the roll member 9 and spirally wound around the outer peripheral surface of the roll member 9, thereby stacking the two core piece forming portions 71 in their thickness direction.

[0062] As a result, the two core piece forming portions 71 punched out from the steel plate 70 are stacked in the thickness direction with their second faces 11b having the protrusions 112 formed at their ends by the press process S11 facing each other, or with their first faces 11a having the curved portions 111 formed at their ends by the press process S11 facing each other, and then spirally wound around the roll member 9. As a result, in the formed laminated core 110, the protrusions 112 are positioned opposite each other in the two core piece forming portions 71. This makes it easy for the insulating paper 20 to get caught on the protrusions 112 when the insulating paper 20 is inserted into the slot 14 in the axial direction of the laminated core 110.

[0063] In response to this, when the two core piece forming portions 71 are spirally wound around the roll member 9, the insulating paper 20 is inserted into the slot 14. This allows the insulating paper 20 to be easily inserted into the slot 14 without being affected by the protrusions 112 of the two core piece forming portions 71.

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

[0065] The laminated core 110 of this embodiment can be formed by laminating the strip plate members 121, 122, which are formed by punching using a press, without aligning the surfaces in one direction of the lamination direction. This makes it possible to realize the laminated core 110 that can be easily manufactured.

[0066] Moreover, the faces located on one side in the stacking direction of the strip plate members 121, 122 constituting the laminated core 110 include a first face 11a having a curved portion 111 at an end formed by punching with a press, and a second face 11b having a protrusion 112 at an end formed by punching with a press. Therefore, compared to a case in which all of the faces located on one side in the stacking direction of the strip plate members 121, 122 constituting the laminated core 110 are first faces 11a having curved portions 111, the insulating paper 20 accommodated in the slot 14 is less likely to slip out to one side in the stacking direction. This makes it possible to realize a configuration that can hold the insulating paper 20 more reliably in the slot 14.

[0067] In this embodiment, the strip members 121, 122 are members that extend spirally about an axis and can be laminated in the thickness direction. In this embodiment, the laminated core 110 is a laminate in which the strip members 121, 122 are laminated in the thickness direction. This makes it possible to realize the laminated core 110 that can be easily formed. As a result, a stator that can improve productivity is obtained.

[0068] In this embodiment, the laminated core 110 is a laminate in which two strip plate members 121, 122 are stacked in the thickness direction and laminated together.

[0069] In the laminated core 110 of this embodiment, too, the two core piece forming portions 71 formed by punching with a press are laminated in the thickness direction while overlapping each other, without aligning the faces of the two core piece forming portions 71 in one direction of the lamination direction, to form the laminated core 110. This makes it possible to realize a laminated core 110 that can be formed more easily. This makes it possible to obtain a stator that can further improve productivity.

[0070] Furthermore, the insulating paper 20 inserted into the slot 14 is less likely to slip out to one side in the stacking direction than if all of the faces located on one side in the stacking direction of the strip plate members 121, 122 that make up the laminated core 110 were first faces 11a having curved portions 111. This makes it possible to realize a configuration that can more reliably hold the insulating paper 20 in the slot 14.

[0071] (Other embodiments) Although the embodiment of the present invention has been described above, the above-mentioned embodiment is merely an example for carrying out the present invention. Therefore, the present invention is not limited to the above-mentioned embodiment, and it is possible to carry out the above-mentioned embodiment by appropriately modifying it within the scope of the gist of the present invention.

[0072] In each of the above-described embodiments, the central axis Q of the roll member 9 extends in the vertical direction. However, the central axis of the roll member may extend in the horizontal direction. The central axis of the roll member may extend in a direction inclined with respect to the vertical direction or in a direction inclined with respect to the horizontal direction.

[0073] In each of the above-described 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 each of the above-described embodiments, the longitudinal length of the insulating paper 20 is equal to the axial length of the protrusion 92. However, the longitudinal length of the insulating paper may be shorter than the axial length of the protrusion. The longitudinal length of the insulating paper may be longer than the axial length of the protrusion.

[0075] In each of the above embodiments, in the lamination direction of the laminated cores 10, 110, the ends 21 of the insulating paper 20 protrude from the slots 14 of the laminated cores 10, 110 in the lamination direction. However, the ends of the insulating paper in the lamination direction do not have to protrude from the slots in the lamination direction. The insulating paper 20 may protrude from the slots 14 in the lamination direction immediately after the laminated cores 10, 110 are manufactured in the lamination steps S3, S13, and then the portions protruding from the slots may be cut off.

[0076] In each of the above-described embodiments, the end 21 in the lamination direction of the insulating paper 20 protrudes in the axial direction from the slot 14 of the laminated core 10, 110. However, the end 21 in the lamination direction of the insulating paper 20 may be bent outward from the slot when the stator is viewed in the lamination direction.

[0077] This allows the end 21 of the insulating paper 20 in the lamination direction to easily catch on the end in the lamination direction of the laminated cores 10, 110. This makes it difficult for the insulating paper 20 to slip out of the slots 14 of the laminated cores 10, 110 in the lamination direction.

[0078] Furthermore, end portions 21 of the insulating paper 20 in the stacking direction may be bent toward the inside of the slots 14 when the stator is viewed in the stacking direction. This makes it possible to easily attach the insulating paper 20 to the roll member 9 when manufacturing the stator.

[0079] In the mounting steps S2 and S12 in each of the above embodiments, the insulating paper 20 having a length equal to the axial length of the protrusion 92 is mounted on the protrusion 92. That is, when the insulating paper 20 is mounted on the protrusion 92, the longitudinal end 21 of the insulating paper 20 is located at the axial end of the protrusion 92. However, in the mounting step, the insulating paper 20 having a length longer than the axial length of the protrusion 92 may be mounted on the protrusion 92. In this case, the portion of the insulating paper located at the axial end of the central axis Q of the roll member may be mounted on the protrusion in a state where it is folded outward, opposite the protrusion side.

[0080] As a result, the insulating paper inserted into the slot has the folded portion of the axial end caught on the laminated core, making it difficult for the insulating paper to come loose in the axial direction from the laminated core.

[0081] In the mounting step, the insulating paper may be mounted on the protruding portion in a state in which a portion of the insulating paper located at an end in the axial direction of the central axis Q of the roll member is bent toward the protruding portion. This makes it easy to mount the insulating paper on the roll member.

[0082] In the first embodiment, the laminated core 10 has one strip member 11. However, the laminated core may have two or more strip members. In this case, the faces of the multiple strip members do not need to be aligned in one direction.

[0083] In the second embodiment, the laminated core 110 has two strip members 121 and 122. However, the laminated core may have three or more strip members. In this case, the faces of the multiple strip members do not need to be aligned in one direction.

[0084] In the pressing step S11 of the second embodiment, two core piece forming portions 71 are lined up and punched out. However, in the pressing step, three or more core piece forming portions may be lined up and punched out. In this case, in the lamination step S13, the faces of the multiple core piece forming portions do not need to be aligned in one direction.

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

[0086] That is, the stator may be a stator including a laminated core having a cylindrical core back portion and a plurality of teeth extending radially inward from the radial inner periphery side of the core back portion, in which steel plates are laminated in the thickness direction, and insulating paper housed in slots located between the teeth. In this case, one surface in the thickness direction of the steel plate has a curved portion at an end, and the other surface in the thickness direction of the steel plate has a protrusion at an end. The one surface may be located on one side in the stacking direction of some of the steel plates constituting the laminated core, and the other surface may be located on one side in the stacking direction of other of the steel plates constituting the laminated core.

[0087] The steel plates to be laminated in the laminated core are formed by punching with a press. Thus, the steel plates have a curved portion on one side in the thickness direction and a protrusion on the other side. The above-mentioned laminated core can be formed by stacking the surfaces of the steel plates formed by punching with a press without aligning them in one direction of the lamination direction. Thus, a laminated core that can be easily manufactured can be realized.

[0088] Moreover, the surfaces located on one side in the stacking direction of the steel plates that make up the laminated core include one surface in the thickness direction that has a curved portion at its end formed by punching with a press, and the other surface in the thickness direction that has a protrusion at its end formed by punching with the press. Therefore, compared to a case in which all of the surfaces located on one side in the stacking direction of the steel plates that make up the laminated core are one surface in the thickness direction that has a curved portion, the insulating paper accommodated in the slot is less likely to come out to one side in the stacking direction. This makes it possible to realize a configuration that can more reliably hold the insulating paper in the slot.

[0089] (Configuration example) The present technology can also be configured as follows.

[0090] (1) A stator manufacturing apparatus includes a laminated core obtained by spirally winding a plate-shaped core piece forming portion, the plate-shaped core piece forming portion having a band-shaped back yoke forming portion and a plurality of teeth forming portions protruding from the back yoke forming portion in one width direction of the back yoke forming portion while deforming the plate-shaped core piece forming portion in one width direction, and insulating paper inserted into slots located between the teeth forming portions; The stator manufacturing method includes a pressing step of punching out the core piece forming portions from a steel plate by press forming, an attachment step of attaching the insulating paper onto a plurality of protrusions that are aligned in the circumferential direction on an outer circumferential surface of a cylindrical roll member that rotates about a central axis and extend along the central axis, and a lamination step of rotating the roll member with the protrusions and the insulating paper inserted into the slots, thereby winding the core piece forming portions spirally around the outer circumferential surface of the roll member while deforming them in one direction in the width direction, and laminating the core piece forming portions in a thickness direction.

[0091] (2) In the stator manufacturing method described in (1), in the pressing step, the core piece forming portions are aligned and punched out from the steel plate. In the lamination step, the core piece forming portions are spirally wound around the outer circumferential surface of the roll member while being deformed in one direction in the width direction by the rotation of the roll member, with the core piece forming portions stacked in the thickness direction, to stack the core piece forming portions in their thickness direction.

[0092] (3) In the stator manufacturing method described in (2), in the stacking process, the multiple core piece forming portions are stacked in the thickness direction with one side of the thickness direction having a protrusion portion formed on their end by the press process facing each other, or with the other side of the thickness direction having a curved portion formed on their end by the press process facing each other, and then the multiple core piece forming portions are deformed in one direction in the width direction by rotation of the roll member and spirally wound around the outer peripheral surface of the roll member, thereby stacking the multiple core piece forming portions in their thickness direction.

[0093] (4) In the stator manufacturing method described in any one of (1) to (3), in the mounting process, a portion of the insulating paper located at an axial end of the central axis is mounted on the protrusion in a state where it is folded outward, opposite the protrusion.

[0094] (5) The stator includes a laminated core having a cylindrical core back portion and a plurality of teeth extending radially inward from the radial inner periphery of the core back portion, the laminated core being made of steel plates stacked in the thickness direction, and insulating paper housed in slots located between the teeth. One surface of the steel plate in the thickness direction has a curved portion at an end, and the other surface of the steel plate in the thickness direction has a protrusion at an end. The one surface is located on one side in the stacking direction of some of the steel plates constituting the laminated core, and the other surface is located on one side in the stacking direction of other of the steel plates constituting the laminated core.

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

[0096] (7) In the stator according to (5) or (6), the steel plates are strip members that extend in a spiral shape about an axis and can be laminated in a thickness direction. The laminated core is a laminate in which the steel plates are laminated in the thickness direction.

[0097] (8) In the stator described in (7), the laminated core is a laminate in which a plurality of the steel plates are stacked in the thickness direction and are overlapped in the thickness direction.

[0098] (9) A motor includes a stator according to any one of (5) to (8). [Industrial Applicability]

[0099] The present invention is applicable to a method for manufacturing a stator in which insulating paper is housed in slots. [Explanation of symbols]

[0100] 1 Stator 10, 110 Laminated core 11, 121, 122 Strip members 11a 1st page 11b Side 2 111 Curved surface part 112 Protrusion 12 Core back section 13 Teeth 14 Slots 20 Insulating paper 21 End 9 Roll member 91 Main body 92 Protrusion 70 steel plate 71, 71a Core piece forming section 72 Back yoke forming section 73 Teeth forming section

Claims

1. a laminated core obtained by spirally winding a plate-shaped core piece forming portion, the plate-shaped core piece forming portion having a band-shaped back yoke forming portion and a plurality of teeth forming portions protruding from the back yoke forming portion in one width direction of the back yoke forming portion while deforming the plate-shaped core piece forming portion in one width direction; an insulating paper inserted into a slot located between the teeth forming portions; A method for manufacturing a stator comprising: a pressing step of punching out the core piece forming portion from a steel plate by press forming; a mounting step of mounting the insulating paper onto a plurality of protrusions arranged in a circumferential direction on an outer circumferential surface of a cylindrical roll member that rotates about a central axis and that extends along the central axis; a lamination process in which, with the protrusions and the insulating paper inserted into the slots, the roll member is rotated to deform the core piece forming portions in one direction in the width direction while spirally winding the core piece forming portions around the outer circumferential surface of the roll member, thereby laminating the core piece forming portions in a thickness direction; having Stator manufacturing method.

2. 2. The method for manufacturing a stator according to claim 1, In the pressing step, a plurality of the core piece forming portions are punched out from the steel plate in a line, In the lamination process, the plurality of core piece forming parts are spirally wound around an outer circumferential surface of the roll member while being deformed in one direction in the width direction by rotation of the roll member in a state where the plurality of core piece forming parts are stacked in the thickness direction, thereby laminating the plurality of core piece forming parts in their thickness direction. Stator manufacturing method.

3. 3. The method for manufacturing a stator according to claim 2, In the lamination process, the plurality of core piece forming parts are stacked in the thickness direction with one side of the thickness direction having a protrusion formed at their end by the press process facing each other, or with the other side of the thickness direction having a curved portion formed at their end by the press process facing each other, and are then spirally wound around the outer circumferential surface of the roll member while being deformed in one direction in the width direction by rotation of the roll member, thereby laminating the plurality of core piece forming parts in their thickness direction. Stator manufacturing method.

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

5. a laminated core having a cylindrical core back portion and a plurality of teeth portions extending radially inward from a radially inner circumferential side of the core back portion, the laminated core being formed by laminating steel plates in a thickness direction; an insulating paper accommodated in a slot located between the teeth; A stator comprising: One surface of the steel plate in the thickness direction has a curved portion at an end, The other surface in the thickness direction of the steel plate has a protrusion at an end portion, The one surface is located on one side in a lamination direction of some of the steel plates constituting the laminated core, The other surface is located on one side in the lamination direction of another steel plate among the steel plates constituting the laminated core. stator.

6. 6. The stator according to claim 5, an end portion of the insulating paper in the lamination direction is bent toward the outside of the slot when the stator is viewed in the lamination direction; stator.

7. 6. The stator according to claim 5, The steel plate is a strip member that extends spirally around an axis and can be laminated in a thickness direction, The laminated core is a laminate in which the steel plates are laminated in the thickness direction. stator.

8. 8. The stator according to claim 7, The laminated core is a laminate in which a plurality of the steel plates are stacked in the thickness direction, stator.

9. A motor comprising the stator according to any one of claims 5 to 8.

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