Armature and armature production method

Abstract

To provide an armature and an armature production method in which the increase of core loss in a core block can be suppressed.SOLUTION: In an armature 5, a core block 6 is formed by layering a plurality of magnetic plates 63. A tooth insulation part 71 of an insulation sheet 7 is disposed between a tooth part 62 of the core block 6 and a coil part. The tooth insulation part 71 surrounds the tooth part 62 with one or more insulation mounting parts 711 arranged around the tooth part 62 and with a first end 711a and a second end 711b overlapping each other. In the tooth insulation part 71, the overlapping first end 711a and second end 711b are bonded together, whereby a bonded part 712 is formed. The tooth insulation part 71 surrounds the tooth part 62, whereby the plurality of magnetic plates 63 are integrated.SELECTED DRAWING: Figure 6

Description

[Technical Field]

[0001] The present disclosure relates to armatures and methods of manufacturing armatures. [Background technology]

[0002] Patent Document 1 discloses a rotating electric machine having a stator core made of a plurality of split cores connected in a ring 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 welds. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2017-169296 Summary of the Invention [Problem to be solved by the invention]

[0004] In the conventional rotating electric machine disclosed in Patent Document 1, the core sheets in the split core are electrically connected to each other by welds, which increases eddy currents generated in the split core and increases iron loss in the split core.

[0005] The present disclosure is intended to solve the above-mentioned problems, and has an object to provide an armature that can suppress an increase in iron loss in the core block, and a method for manufacturing the armature. [Means for solving the problem]

[0006] The armature according to the present disclosure comprises a plurality of armature blocks, each of which has an iron core block, an insulating sheet, and a coil portion, and the iron core block is constructed by stacking a plurality of magnetic plates, the iron core block having a yoke portion and a tooth portion protruding from the yoke portion, the coil portion being provided on the tooth portion, the insulating sheet having a tooth insulating portion interposed between the coil portion and the tooth portion, the tooth insulating portion having one or more insulating mounting portions having a first end and a second end, the one or more insulating mounting portions being arranged around the tooth portion so as to surround the tooth portion with the first end and the second end overlapping each other, and a joint portion being formed in the tooth insulating portion by joining the overlapping first end and second end to each other, and the tooth insulating portion integrating the plurality of magnetic plates by surrounding the tooth portion. In addition, the manufacturing method of an armature according to the present disclosure includes a lamination process in which a core block having a yoke portion and a tooth portion protruding from the yoke portion is produced by stacking a plurality of magnetic plates; an insulation assembly process in which the plurality of magnetic plates are integrated by surrounding the tooth portion with a tooth insulating portion of an insulating sheet; and after the insulation assembly process, a winding process in which a coil portion is provided on the tooth portion via the tooth insulating portion, the tooth insulating portion having one or more insulating attachment portions with first and second ends, and in the insulation assembly process, the one or more insulating attachment portions are arranged around the tooth portion to overlap the first end and the second end with each other, and the overlapping first end and second end are joined to each other to form a joint in the tooth insulating portion. [Effects of the Invention]

[0007] According to the present disclosure, an increase in iron loss in the core block can be suppressed. [Brief explanation of the drawings]

[0008] [Figure 1] 1 is a partial cross-sectional view showing an electrical device according to a first embodiment. [Figure 2] FIG. 2 is a perspective view showing the armature of FIG. [Figure 3]FIG. 3 is a side view showing the core block of FIG. 2. [Figure 4] FIG. 4 is a perspective view showing the magnetic plate of FIG. 3. [Figure 5] FIG. 3 is an exploded perspective view showing a main part of the armature block of FIG. 2. [Figure 6] 6 is a schematic diagram showing the state of the teeth, insulating sheet, and bobbin in FIG. 5 when viewed along the protruding direction of the teeth. FIG. [Figure 7] FIG. 6 is a perspective view showing an insulating mounting portion, a yoke insulating portion, and a tip insulating portion of FIG. 5. [Figure 8] FIG. 4 is a perspective view showing the guide member of FIG. 3. [Figure 9] 5 is a flowchart showing a method for manufacturing the armature according to the first embodiment. [Figure 10] 10 is a side view showing a state in which a plurality of magnetic plates are stacked in the stacking step S1 of FIG. 9. FIG. [Figure 11] 10 is a side view showing a state in which the core block is being pressed in the pressing step S2 of FIG. 9. FIG. [Figure 12] 10 is a schematic front view showing a state before the tooth insulating portions surround the teeth in the insulation assembly step S3 of FIG. 9. FIG. [Figure 13] 13 is a schematic front view showing a state in which the tooth insulating portion of FIG. 12 surrounds the tooth portion. FIG. [Figure 14] 10 is a diagram showing the state when winding of the conductor of the coil portion starts around the teeth portion of the iron core block to which the insulating sheet and the bobbin are attached in the insulation assembly step S3 of FIG. 9. FIG. [Figure 15] 15 is a diagram showing the configuration when the winding of the conductor of the coil portion around the teeth portion of FIG. 14 is completed. FIG. [Figure 16] FIG. 10 is a front view showing another example of the joint portion in the armature according to the first embodiment. [Figure 17] 10 is a schematic diagram showing the state of the teeth, insulating sheet, and bobbin of the armature according to the second embodiment when viewed along the protruding direction of the teeth. FIG. [Figure 18] FIG. 18 is a schematic diagram showing the state before the insulating sheet of FIG. 17 is attached to the iron core block. [Figure 19] FIG. 19 is a schematic diagram showing the state when the insulating sheet of FIG. 18 is attached to the iron core block. [Figure 20] FIG. 11 is an exploded perspective view showing a main portion of an armature block in an armature according to a third embodiment. [Figure 21] 21 is a schematic diagram showing the state of the teeth, insulating sheet, and bobbin in FIG. 20 when viewed along the protruding direction of the teeth. FIG. [Figure 22] 22 is a schematic diagram showing the state before the insulating sheet of FIG. 21 is attached to the iron core block and the bobbin. FIG. [Figure 23] 23 is a schematic diagram showing a state when an insulating sheet is attached to the core block and bobbin of FIG. 22. FIG. [Figure 24] FIG. 11 is a front view showing another example of the joint portion in the armature according to the third embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0009] The following describes embodiments of the subject matter of the present disclosure with reference to the accompanying drawings. In each drawing, identical or corresponding parts are designated by the same reference numerals, and redundant explanations are appropriately simplified or omitted. Note that the subject matter of the present disclosure is not limited to the following embodiments, and any component of the embodiments may be modified or omitted within the scope of the gist of the present disclosure.

[0010] Embodiment 1 1 is a partial cross-sectional view showing an electric device according to embodiment 1. A rotating electric machine 1 as an electric device has a housing 2, a rotating shaft 3, a rotor 4, and an armature 5.

[0011] The housing 2 has a frame 21 and an end plate 22. The frame 21 is a case in which an opening 211 is formed. The end plate 22 is a lid 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.

[0012] The frame 21 and the end plate 22 each have a through hole through which the rotating shaft 3 passes. A bearing 23 is 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 each bearing 23.

[0013] The rotor 4 is fixed as a mover to the rotating shaft 3 inside the housing 2. This allows the rotor 4 to rotate integrally with the rotating shaft 3 relative to the housing 2.

[0014] The rotor 4 has 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 has a cylindrical shape. The rotor core 41 is disposed coaxially with the rotating shaft 3.

[0015] A plurality of permanent magnets 42 are provided on the rotor core 41. The plurality of permanent magnets 42 are arranged at intervals in the circumferential direction of the rotor 4. As a result, a plurality of magnetic poles are formed on the outer periphery of the rotor 4.

[0016] Note that a squirrel-cage rotor, a wound rotor, or the like may also be used as the rotor 4. A squirrel-cage rotor is a rotor in which a plurality of uninsulated rotor conductors are provided on a rotor core 41, and a pair of short-circuit rings arranged at both ends of the rotor core 41 are short-circuited by each rotor conductor. A wound rotor is a rotor in which a rotor winding that is electrically insulated from the rotor core 41 is provided on the rotor core 41.

[0017] The armature 5 is fixed inside the housing 2 while being fitted onto the inner peripheral surface of the frame 21. The armature 5 is annular in shape. The armature 5 surrounds the outer peripheral portion of the rotor 4. As a result, the inner peripheral portion of the armature 5 faces the outer peripheral portion of the rotor 4 via a gap. The armature 5 is arranged coaxially with the rotating shaft 3.

[0018] 2 is a perspective view showing the armature 5 of FIG. 1. The armature 5 has a plurality of armature blocks 51. The plurality of armature blocks 51 are connected continuously in an annular shape in the circumferential direction of the armature 5. The circumferential direction of the armature 5 is a direction along the circumference of a circle whose center is the axis of the armature 5. Each of the plurality of armature blocks 51 has a core block 6, an insulating sheet 7, a bobbin 8, and a coil portion 9.

[0019] The core block 6 has a yoke portion 61 and teeth portions 62. The yoke portion 61 is arranged along the circumferential direction of the armature 5. The teeth portions 62 protrude from the center of the yoke portion 61 toward the inside 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.

[0020] Here, FIG. 3 is a side view showing the core block 6 of FIG. 2. The core block 6 is configured 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 in 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 a direction perpendicular to both the circumferential direction and the radial direction of the armature 5. The plurality of magnetic plates 63 are stacked without being joined to each other.

[0021] Fig. 4 is a perspective view showing the magnetic plates 63 of Fig. 3. Each magnetic plate 63 has a yoke constituent plate portion 63a and a tooth constituent plate portion 63b. The tooth constituent plate portion 63b protrudes from the yoke constituent plate portion 63a on the same plane as the yoke constituent plate portion 63a. The yoke portion 61 is formed by stacking the yoke constituent plate portions 63a. The tooth portion 62 is formed by stacking the tooth constituent plate portions 63b.

[0022] 2, the coil portions 9 are provided on the tooth portions 62. When the armature block 51 is viewed along the direction in which the tooth portions 62 protrude from the yoke portion 61, i.e., along the tooth protruding direction, the coil portions 9 surround the tooth portions 62.

[0023] The coil portion 9 is composed of a conductor wire wound around the tooth portion 62. The conductor wire of the coil portion 9 is a conductor wire covered with an insulating coating having electrical insulation properties. The conductor wire of the coil portion 9 is made of copper wire, aluminum wire, or the like.

[0024] FIG. 5 is an exploded perspective view showing the main parts of the armature block 51 of FIG. 2. The coil section 9 is not shown in FIG. 5. The insulating sheet 7 is attached to the core block 6. The insulating sheet 7 is made of an insulating material that has electrical insulation properties. The insulating sheet 7 is interposed between the coil section 9 and the core block 6. As a result, the insulating sheet 7 ensures electrical insulation between the coil section 9 and the core block 6. Examples of insulating materials that can be used to make the insulating sheet 7 include polyphenylene sulfide (PPS) resin and polyethylene terephthalate (PTE) resin.

[0025] The insulating sheet 7 has a tooth insulating portion 71 , a pair of yoke insulating portions 72 , and a pair of tip insulating portions 73 .

[0026] The tooth insulating portions 71 are interposed between the tooth portions 62 and the coil portions 9. Therefore, the coil portions 9 are provided on the tooth portions 62 via the tooth insulating portions 71. The tooth insulating portions 71 ensure electrical insulation between the tooth portions 62 and the coil portions 9.

[0027] The tooth insulating portions 71 surround the tooth portions 62, passing around both outsides of the tooth portions 62 in the magnetic plate lamination direction. As a result, when the core block 6 is viewed along the tooth protrusion direction, the tooth insulating portions 71 surround the tooth portions 62. The tooth insulating portions 71 overlap the outer peripheral surfaces of the tooth portions 62 without loosening. By surrounding the tooth portions 62, the tooth insulating portions 71 integrate the multiple magnetic plates 63. Therefore, even if the core block 6 is subjected to a force in a direction that moves the multiple magnetic plates 63 away from each other, the tooth insulating portions 71 maintain the stacked state of the multiple magnetic plates 63.

[0028] The tooth insulating portion 71 has one or more insulating attachment portions 711. In this embodiment, the tooth insulating portion 71 has two insulating attachment portions 711. Each insulating attachment portion 711 is a separate member. The two insulating attachment portions 711 surround the tooth portion 62, sandwiching the tooth portion 62 from both outer sides in the width direction of the tooth portion 62. The width direction of the tooth portion 62 is perpendicular to both the magnetic plate lamination direction and the tooth protruding direction.

[0029] Each insulating attachment portion 711 is strip-shaped. One end of each insulating attachment portion 711 in the longitudinal direction is a first end 711a, and the other end is a second end 711b. That is, each insulating attachment portion 711 has a first end 711a and a second end 711b.

[0030] 6 is a schematic diagram showing the teeth 62, insulating sheet 7, and bobbin 8 of FIG. 5 when viewed along the tooth protruding direction. The tooth insulating portion 71 surrounds the teeth 62 with two insulation attachment portions 711 arranged around the teeth 62, with a first end 711a and a second end 711b overlapping each other. In the tooth insulating portion 71, the first end 711a of one insulation attachment portion 711 overlaps the second end 711b of the other insulation attachment portion 711, and the second end 711b of one insulation attachment portion 711 overlaps the first end 711a of the other insulation attachment portion 711.

[0031] In the tooth insulating portion 71, a joint portion 712 is formed by joining the overlapping first end portion 711a and the second end portion 711b to each other. As a result, the two insulation attachment portions 711 are continuously connected in an endless manner. The number of joint portions 712 formed in the tooth insulating portion 71 is the same as the number of insulation attachment portions 711. Therefore, one or more joint portions 712 are formed in the tooth insulating portion 71. In this embodiment, two joint portions 712 are formed in the tooth insulating portion 71.

[0032] In this embodiment, a joint portion 712 is located on each of the outer sides of the tooth portion 62 in the magnetic plate lamination direction. Also, in this embodiment, of both end faces of the tooth portion 62 in the magnetic plate lamination direction, one joint portion 712 overlaps one end face, and the other joint portion 712 overlaps the other end face. Furthermore, in this embodiment, the first end portion 711a and the second end portion 711b of each joint portion 712 are joined to each other with an adhesive 713.

[0033] 5, a pair of yoke insulating parts 72 are provided at the end of the tooth insulating part 71 on the yoke part 61 side. Of the pair of yoke insulating parts 72, one yoke insulating part 72 is provided on one insulating mounting part 711, and the other yoke insulating part 72 is provided on the other insulating mounting part 711. The pair of yoke insulating parts 72 are interposed between the yoke part 61 and the coil part 9. As a result, each yoke insulating part 72 ensures electrical insulation between the yoke part 61 and the coil part 9.

[0034] A pair of tip insulating portions 73 are provided on the end of the tooth insulating portion 71 opposite the yoke portion 61 side. Of the pair of tip insulating portions 73, one tip insulating portion 73 is provided on one insulating attachment portion 711, and the other tip insulating portion 73 is provided on the other insulating attachment portion 711. The pair of tip insulating portions 73 are interposed between the tip portions of the tooth portion 62 and the coil portion 9. As a result, each tip insulating portion 73 ensures electrical insulation between the tip portions of the tooth portion 62 and the coil portion 9.

[0035] 7 is a perspective view showing the insulation mounting portion 711, the yoke insulating portion 72, and the tip insulating portion 73 of FIG. 5. The yoke insulating portion 72 and the tip insulating portion 73 are provided on the insulation mounting portion 711, avoiding the first end portion 711a and the second end portion 711b. The coil portion 9 shown in FIG. 2 is disposed between the yoke insulating portion 72 and the tip insulating portion 73.

[0036] 2, the bobbin 8 is disposed between the core block 6 and the coil portion 9. The bobbin 8 is made of an insulating material having electrical insulating properties.

[0037] 5 and 6, the bobbin 8 has a pair of guide members 81. Each guide member 81 is attached to the core block 6 with a fitting portion (not shown) fitted into the core block 6. The pair of guide members 81 are arranged on either side of the core block 6 in the magnetic plate lamination direction. The pair of guide members 81 are attached to the core block 6 in a state where they individually overlap each other on both end faces of the core block 6 in the magnetic plate lamination direction, with tooth insulating portions 71 interposed between them.

[0038] Of the two joints 712 in the tooth insulating portion 71, one joint 712 is interposed between the tooth portion 62 and one guide member 81, and the other joint 712 is interposed between the tooth portion 62 and the other guide member 81.

[0039] 8 is a perspective view showing a guide member 81 of FIG. 3. Each guide member 81 has a winding drum 82, a first restricting wall 83, and a second restricting wall 84. The winding drum 82 overlaps the end face of the core block 6 in the tooth protruding direction, with the tooth insulating portion 71 interposed between them. The first restricting wall 83 is provided at the end of the winding drum 82 on the yoke portion 61 side. The second restricting wall 84 is provided at the end of the winding drum 82 opposite the yoke portion 61 side. As a result, the first restricting wall 83 and the second restricting wall 84 face each other in the longitudinal direction of the winding drum 82.

[0040] The coil portion 9 surrounds the tooth portion 62, the tooth insulating portion 71, and the bobbin 8. In each guide member 81, the coil portion 9 overlaps the winding drum portion 82. In each guide member 81, as shown in FIG. 2, the coil portion 9 is passed between a first restricting wall 83 and a second restricting wall 84. In this way, the coil portion 9 is held by the tooth portion 62.

[0041] The multiple armature blocks 51 are connected in a ring shape by connecting adjacent yoke portions 61 to each other. In the armature 5, the core blocks 6 are connected in a ring shape to form an armature core. In the armature core, the multiple yoke portions 61 are connected in a ring shape, and multiple tooth portions 62 are arranged at intervals in the circumferential direction of the armature 5. In the armature 5, the coil portions 9 of the multiple armature blocks 51 are electrically connected to form an armature winding. A rotating magnetic field is generated in the armature 5 when current is applied to the armature winding. The generated rotating magnetic field causes the rotor 4 to rotate integrally with the rotating shaft 3 relative to the armature 5 and the housing 2.

[0042] Next, a method for manufacturing the armature 5 will be described. Fig. 9 is a flowchart showing a method for manufacturing the armature according to the first embodiment. The method for manufacturing the armature includes a lamination step S1, a pressing step S2, an insulation assembly step S3, and a winding step S4. When manufacturing the armature 5, the lamination step S1, the pressing step S2, the insulation assembly step S3, and the winding step S4 are carried out in this order.

[0043] <Lamination process S1> A lamination step S1 is performed when manufacturing the armature 5. In the lamination step S1, a plurality of magnetic plates 63 are laminated to form the core block 6.

[0044] Fig. 10 is a side view showing a state when multiple magnetic plates 63 are stacked in the stacking step S1 of Fig. 9. Each magnetic plate 63 is prepared in advance by punching it out from a raw material plate made of a magnetic material. In the stacking step S1, the multiple magnetic plates 63 are stacked by stacking the yoke constituent plate portions 63a of the magnetic plates 63 on each other and stacking the tooth constituent plate portions 63b of the magnetic plates 63 on each other.

[0045] In the stacking process S1, in order to absorb the thickness deviation that occurs within a single magnetic plate 63, multiple magnetic plates 63 may be stacked by alternately flipping each magnetic plate 63 punched out from the raw material plate, or multiple magnetic plates 63 punched out from the raw material plate with different shapes may be mixed and stacked.

[0046] When multiple magnetic plates 63 are stacked in the stacking step S1, the portion where the yoke constituent plate portions 63a are stacked becomes the yoke portion 61, and the portion where the tooth constituent plate portions 63b are stacked becomes the tooth portion 62. This produces the core block 6. In the stacking step S1, multiple magnetic plates 63 are stacked without joining the individual magnetic plates 63 to each other.

[0047] <Pressure step S2> After the lamination step S1, a pressure application step S2 is performed. In the pressure application step S2, the core block 6 is pressed in a direction in which the magnetic plates 63 are pressed against each other. That is, in the pressure application step S2, the core block 6 is pressed in the magnetic plate lamination direction.

[0048] 11 is a side view showing the state in which the core block 6 is being pressed in the pressing step S2 of FIG. 9. In the pressing step S2, the core block 6 is pressed by a pressing device having a plurality of pressing members 10. The pressing device presses the core block 6 by pressing the pressing members 10 against the core block 6 from both outsides of the core block 6 in the magnetic plate lamination direction. In this embodiment, the pressing members 10 press the tips of the teeth portions 62 and the yoke portion 61. This reduces gaps between the plurality of magnetic plates 63, which may occur due to warping of each magnetic plate 63, and increases the space factor of the magnetic material in the core block 6.

[0049] <Insulation assembly process S3> After the pressing step S2, the insulating assembly step S3 is carried out. In the insulating assembly step S3, the insulating sheet 7 is attached to the core block 6 while the core block 6 is being pressed, thereby integrating the multiple magnetic plates 63. Specifically, in the insulating assembly step S3, the teeth portions 62 are surrounded by the tooth insulating portions 71 of the insulating sheet 7 while the core block 6 is being pressed, thereby integrating the multiple magnetic plates 63.

[0050] FIG. 12 is a schematic front view showing the state before the tooth insulating portions 71 surround the teeth 62 in the insulation assembly process S3 of FIG. 9. FIG. 13 is a schematic front view showing the state in which the tooth insulating portions 71 surround the teeth 62 in FIG. 12. In the insulation assembly process S3, the two insulation attachment portions 711 sandwich the teeth 62 from both outer sides in the width direction of the teeth 62, thereby arranging the two insulation attachment portions 711 around the teeth 62. At this time, the first end 711a and the second end 711b are overlapped on both outer sides of the teeth 62 in the magnetic plate lamination direction. In this way, in the insulation assembly process S3, the two insulation attachment portions 711 are arranged around the teeth 62, and the first end 711a and the second end 711b are overlapped on each other. At this time, the pair of yoke insulating portions 72 provided on the tooth insulating portion 71 overlap the yoke portion 61. At this time, the pair of tip insulating portions 73 provided on the tooth insulating portion 71 overlap the tip portions of the tooth portion 62 .

[0051] After this, in the insulation assembly process S3, as shown in FIG. 13, the overlapping first end 711a and second end 711b are joined together with adhesive 713. As a result, a joint 712 is formed in the tooth insulating portion 71. At this time, the first end 711a and second end 711b are joined together while the core block 6 is pressed. The pressed state of the core block 6 is maintained until the adhesive 713 hardens. As a result, the two insulation mounting portions 711 are connected endlessly. The stacked magnetic plates 63 are integrated as the tooth portions 62 are surrounded by the endless tooth insulating portion 71.

[0052] In the insulation assembly process S3, the insulating sheet 7 is attached to the core block 6, and then the bobbin 8 is attached to the core block 6. At this time, the bobbin 8 may be attached to the core block 6 after it has been removed from the pressure device, or the bobbin 8 may be attached to the core block 6 while the core block 6 is being pressed by the pressure device.

[0053] When attaching the bobbin 8, a pair of guide members 81 are attached individually to both end surfaces of the core block 6 in the magnetic plate lamination direction, as shown in Fig. 6. At this time, each guide member 81 overlaps the tooth portion 62 with the tooth insulating portion 71 interposed therebetween.

[0054] <Winding process S4> After the insulation assembly process S3, the winding process S4 is carried out. In the winding process S4, the coil portion 9 is provided on the tooth portion 62 via the tooth insulating portion 71. In the winding process S4, the conductor of the coil portion 9 is wound around the tooth portion 62 and the bobbin 8 together, thereby providing the coil portion 9 on the tooth portion 62.

[0055] 14 is a diagram showing the state when winding of the conductor of the coil portion 9 starts around the teeth 62 of the core block 6 to which the insulating sheet 7 and bobbin 8 are attached in the insulation assembly step S3 of FIG. 9. FIG. 15 is a diagram showing the state when winding of the conductor of the coil portion 9 finishes around the teeth 62 of FIG. 14. In the winding step S4, the coil portion 9 is provided on the teeth 62 by a winding machine 11. The winding machine 11 has a core holding part 111 and a nozzle part 112. The core holding part 111 holds the core block 6. The nozzle part 112 is movable around the core holding part 111 as it delivers the conductor of the coil portion 9.

[0056] In the winding process S4, as shown in Fig. 14, the core block 6 to which the insulating sheet 7 and bobbin 8 are attached is held by the core holding part 111, and the conductor wire of the coil part 9 extending from the nozzle part 112 is hung on the core block 6. Thereafter, in the winding process S4, the nozzle part 112 moves on a circumference centered on the core holding part 111 while the conductor wire of the coil part 9 extends from the nozzle part 112. As a result, as shown in Fig. 15, the conductor wire is wound around the teeth part 62, and the coil part 9 is provided on the teeth part 62 via the insulating sheet 7 and bobbin 8. In this manner, the armature block 51 is produced.

[0057] After the winding step S4, the armature blocks 51 are connected in an annular shape, and the coil portions 9 are electrically connected together. In this manner, the armature 5 is manufactured.

[0058] In this armature 5, the core block 6 is formed by stacking multiple magnetic plates 63. The tooth insulating portions 71 surround the teeth 62 with the first end 711a and the second end 711b overlapping each other, and the two insulation mounting portions 711 are arranged around the teeth 62. The overlapping first end 711a and the second end 711b are joined to form joint portions 712 in the tooth insulating portions 71. The tooth insulating portions 71 integrate the multiple magnetic plates 63 by surrounding the teeth 62. Therefore, the endless tooth insulating portions 71 can easily integrate the multiple magnetic plates 63 without joining the multiple magnetic plates 63 to each other by welding, crimping, or the like. This prevents the multiple magnetic plates 63 from being electrically connected to each other, thereby suppressing an increase in eddy currents generated in the core block 6. Therefore, an increase in iron loss in the core block 6 can be suppressed. Furthermore, the work of attaching the insulating sheet 7 to the core block 6 and the work of integrating the multiple magnetic plates 63 can be performed simultaneously. This reduces the amount of work required to manufacture the armature 5, and improves the productivity of the armature 5. Furthermore, because the first end 711a and the second end 711b of the insulation mounting portion 711 arranged around the tooth portion 62 can be overlapped and joined to each other, the tooth portion 62 can be easily surrounded by the tooth insulating portion 71. This further improves the productivity of the armatures 5.

[0059] Furthermore, the joints 712 are located on both outer sides of the teeth 62 in the magnetic plate lamination direction. Therefore, the joints 712 can be arranged to avoid the slots formed between the teeth 62. This increases the space factor of the coil 9 in the slots formed between the teeth 62, and increases the torque generated by energizing the armature 5.

[0060] Furthermore, the first end 711a and the second end 711b at the joint 712 are joined to each other by adhesive 713. Therefore, the overlapping first end 711a and second end 711b can be easily joined to each other.

[0061] In this armature manufacturing method, in the insulation assembly process S3, two insulation mounting portions 711 are arranged around the teeth 62, and the first end 711a and the second end 711b are overlapped with each other. In the insulation assembly process S3, the overlapping first end 711a and the second end 711b are joined to form a joint 712 in the tooth insulating portion 71. Therefore, the magnetic plates 63 can be easily integrated with the endless tooth insulating portion 71 without joining the magnetic plates 63 with each other by welding, crimping, or the like. This reduces iron loss in the core block 6. Furthermore, the work of attaching the insulating sheet 7 to the core block 6 and the work of integrating the magnetic plates 63 can be performed simultaneously. This reduces the labor required for manufacturing the armature 5 and improves productivity of the armature 5. Furthermore, the teeth 62 can be easily surrounded by the tooth insulating portion 71. This further improves productivity of the armature 5.

[0062] Furthermore, after the lamination step S1 and before the insulation assembly step S3, a pressurizing step S2 is performed in which the core block 6 is pressurized in a direction in which the multiple magnetic plates 63 are pressed against each other. In the insulation assembly step S3, the teeth portions 62 are surrounded by the tooth insulating portions 71 while the core block 6 is pressed. This reduces the gaps between the multiple magnetic plates 63, thereby increasing the space factor of the magnetic material in the core block 6. This increases the torque generated by energizing the armature 5.

[0063] In the first embodiment, the first end 711a and the second end 711b at the joint 712 are joined to each other by adhesive 713. However, the method for joining the first end 711a and the second end 711b at the joint 712 is not limited to this. For example, the first end 711a and the second end 711b at the joint 712 may be joined to each other by fusing the first end 711a and the second end 711b. In this case, in the insulation assembly step S3, as shown in FIG. 16 , the first end 711a and the second end 711b are fused to each other by a fusion splicer 714 to form a fused portion 715. At the joint 712, the first end 711a and the second end 711b are joined to each other via the fused portion 715. An ultrasonic horn or the like is used as the fusion splicer 714.

[0064] Embodiment 2 In the first embodiment, tooth insulating portion 71 includes two insulation attachment portions 711. However, tooth insulating portion 71 may include only one insulation attachment portion 711.

[0065] 17 is a schematic diagram showing the tooth portion 62, insulating sheet 7, and bobbin 8 of the armature according to embodiment 2 when viewed along the tooth protruding direction. Note that FIG. 17 corresponds to FIG. 6 in embodiment 1. In this embodiment, the tooth insulating portion 71 has one insulation attachment portion 711. One insulation attachment portion 711 is arranged around the tooth portion 62 in a state surrounding the tooth portion 62. A first end portion 711a and a second end portion 711b of one insulation attachment portion 711 overlap each other.

[0066] 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 number of joint portions 712 formed in the tooth insulating portion 71 is one. The joint portion 712 is located only on one of the two outer sides of the tooth portion 62 in the magnetic plate lamination direction. The other configurations are the same as those in the first embodiment.

[0067] FIG. 18 is a schematic diagram showing the state before the insulating sheet 7 of FIG. 17 is attached to the core block 6. FIG. 19 is a schematic diagram showing the state when the insulating sheet 7 of FIG. 18 is attached to the core block 6. When manufacturing the armature block 51, in the insulation assembly process S3, the teeth 62 are inserted into the insulating attachment portion 711 while bending the insulation attachment portion 711 to widen the gap between the first end 711a and the second end 711b. Then, the first end 711a and the second end 711b are brought close to each other and overlap each other. As a result, the insulation attachment portion 711 is arranged around the teeth 62, surrounding the teeth 62, with the first end 711a and the second end 711b overlapping each other.

[0068] Thereafter, in an insulating assembly process S3, the first end 711a and the second end 711b are joined together to attach the insulating sheet 7 to the core block 6. With the insulating sheet 7 attached to the core block 6, the endless tooth insulating portion 71 surrounds the tooth portion 62, thereby integrating the multiple magnetic plates 63. The other processes in the armature manufacturing method are the same as those in embodiment 1.

[0069] In this way, even if the tooth insulating portion 71 includes only one insulation mounting portion 711, the tooth insulating portion 71 can easily surround the multiple magnetic plates 63. This allows the multiple magnetic plates 63 to be integrated without joining the multiple magnetic plates 63 to each other by welding, crimping, or the like. This makes it possible to suppress an increase in iron loss in the core block 6. Furthermore, the number of points where the first end 711a and the second end 711b are joined to each other can be reduced, further improving the productivity of the armature 5.

[0070] In the second embodiment, the first end 711a and the second end 711b at the joint 712 are joined to each other by adhesive 713. However, the first end 711a and the second end 711b at the joint 712 may be joined to each other by fusing the first end 711a and the second end 711b. In this case, in the insulating assembly step S3, the first end 711a and the second end 711b are joined to each other in the same manner as in FIG.

[0071] Embodiment 3 FIG. 20 is an exploded perspective view showing a main part of an armature block 51 in an armature according to embodiment 3. FIG. 21 is a schematic diagram showing the state of the tooth portion 62, insulating sheet 7, and bobbin 8 of FIG. 20 when viewed along the tooth protruding direction. Note that FIG. 20 corresponds to FIG. 5 in embodiment 1, and FIG. 21 corresponds to FIG. 6 in embodiment 1. A pair of guide members 81 in the bobbin 8 are arranged to sandwich the core block 6 in the magnetic plate lamination direction. The pair of guide members 81 individually overlap both end faces of the core block 6 in the magnetic plate lamination direction. In this embodiment, each guide member 81 is not provided with a fitting portion that fits into the core block 6.

[0072] The two joint portions 712 of the tooth insulating portion 71 are arranged on both outer sides of the tooth portion 62 in the magnetic plate lamination direction. Of the pair of guide members 81, one guide member 81 is interposed between one joint portion 712 and the tooth portion 62, and the other guide member 81 is interposed between the other joint portion 712 and the tooth portion 62. In this way, the tooth insulating portion 71 surrounds the tooth portion 62 and the bobbin 8 together. Each joint portion 712 overlaps the winding drum portion 82 of the guide member 81.

[0073] The bobbin 8 and the multiple 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 multiple magnetic plates 63 by surrounding the teeth 62 and the bobbin 8 together. The other configurations are the same as those in the first embodiment.

[0074] Fig. 22 is a schematic diagram showing the state before the insulating sheet 7 in Fig. 21 is attached to the core block 6 and bobbin 8. Fig. 23 is a schematic diagram showing the state when the insulating sheet 7 is attached to the core block 6 and bobbin 8 in Fig. 22. When manufacturing the armature block 51, in the insulation assembly step S3, as shown in Fig. 22, a pair of guide members 81 on the bobbin 8 are individually placed on both end faces of the core block 6 in the magnetic plate lamination direction. At this time, the core block 6 is kept pressed.

[0075] Thereafter, in the insulation assembly process S3, as shown in FIG. 23 , the two insulation attachment parts 711 are arranged around the teeth 62 and the bobbin 8 by sandwiching the teeth 62 between the two insulation attachment parts 711 from both outer sides in the width direction of the teeth 62. At this time, the first end 711a and the second end 711b are overlapped with each other on both outer sides of the teeth 62 and the bobbin 8 in the magnetic plate lamination direction. As a result, in this embodiment, the first end 711a and the second end 711b overlap with the winding drum 82 of each guide member 81. In this way, in the insulation assembly process S3, the two insulation attachment parts 711 are arranged around the teeth 62 and the bobbin 8, and the first end 711a and the second end 711b are overlapped with each other.

[0076] Thereafter, in the insulation assembly process S3, the overlapping first end portion 711a and second end portion 711b are joined together with adhesive 713. As a result, joint portions 712 are formed in tooth insulating portions 71. In the present embodiment, two joint portions 712 are formed in tooth insulating portions 71. Each joint portion 712 overlaps with the winding drum portion 82 of each guide member 81.

[0077] The two insulating mounting portions 711 are joined together to form an endless connection. The bobbin 8 and the multiple magnetic plates 63 are integrated by surrounding the bobbin 8 and the teeth 62 with the endless tooth insulating portion 71, as shown in Fig. 21. The other steps in the armature manufacturing method are the same as those in the first embodiment.

[0078] In this armature 5, the tooth insulating portions 71 surround the teeth 62 and the bobbin 8, thereby integrating the bobbin 8 and the multiple magnetic plates 63. Therefore, not only the multiple magnetic plates 63 but also the bobbin 8 can be easily integrated by the tooth insulating portions 71. This makes it possible to suppress an increase in iron loss in the core block 6 and improve the productivity of the armature 5. Furthermore, it is no longer necessary to provide fitting portions on each guide member 81 of the bobbin 8 for fitting into the core block 6, which simplifies the structure of each guide member 81. This makes it possible to reduce the cost of the bobbin 8.

[0079] Furthermore, in this manufacturing method of the armature 5, in the insulation assembly process S3, after the bobbin 8 is attached to the tooth portion 62, the bobbin 8 and the tooth portion 62 are collectively surrounded by the tooth insulating portion 71, thereby integrating the bobbin 8 and the multiple magnetic plates 63. This makes it possible to suppress an increase in iron loss in the core block 6. Also, since the work of attaching the coil portion 9 to the tooth portion 62 in the winding process S4 can be facilitated, the productivity of the armature 5 can be further improved. Furthermore, the structure of each guide member 81 in the bobbin 8 can be simplified, thereby reducing the cost of the bobbin 8.

[0080] In the third embodiment, the first end 711a and the second end 711b at the joint 712 are joined to each other with adhesive 713. However, the first end 711a and the second end 711b at the joint 712 may be joined to each other by fusing the first end 711a and the second end 711b. In this case, in the insulation assembly step S3, as shown in FIG. 24 , the first end 711a and the second end 711b are fused to each other by a fusion bonding machine 714 to form a fused portion 715. At the joint 712, the first end 711a and the second end 711b are joined to each other via the fused portion 715. An ultrasonic horn or the like is used as the fusion bonding machine 714.

[0081] 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 drum portion 82 of the guide member 81. In this case, the joint portion 712 may be joined to the bobbin 8 with an adhesive, or the joint portion 712 may be joined to the bobbin 8 by fusing the joint portion 712 and the bobbin 8 together.

[0082] Furthermore, in the third embodiment, the tooth insulating portion 71 includes two insulation attachment portions 711. However, as in the second embodiment, the tooth insulating portion 71 may include only one insulation attachment portion 711. In this case, one insulation attachment portion 711 is disposed around the tooth portion 62, surrounding the bobbin 8 and the tooth portion 62. In this case, the first end 711a and the second end 711b of one insulation attachment portion 711 overlap each other. Furthermore, in this case, one joint portion 712 is formed in the tooth insulating portion 71 by joining the overlapping first end 711a and second end 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 magnetic plate lamination direction. In this manner, the bobbin 8 and the multiple magnetic plates 63 can be integrated by the tooth insulating portion 71. This can suppress an increase in iron loss in the core block 6 and improve the productivity of the armature 5. 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.

[0083] In addition, in the first and third embodiments, the number of insulation attachment portions 711 included in the tooth insulating portion 71 is two. However, the number of insulation attachment portions 711 included in the tooth insulating portion 71 may be three or more. In this case, the first end portion 711a and the second end portion 711b are overlapped with each other to arrange three or more insulation attachment portions 711 around the tooth portion 62, thereby surrounding the tooth portion 62 with the tooth insulating portion 71.

[0084] In each of the above-described embodiments, the joints 712 are located on at least one of the two outer sides of the teeth 62 in the magnetic plate lamination direction. However, the positions of the joints 712 are not limited to this. Therefore, the joints 712 may be located anywhere around the teeth 62.

[0085] In each of the above-described embodiments, after the stacking step S1 and before the insulating assembly step S3, a pressurizing step S2 is performed to pressurize the core block 6. However, if the stacked state of the multiple magnetic plates 63 is maintained in the insulating assembly step S3, the pressurizing step S2 may be omitted.

[0086] In each of the above-described embodiments, the armature 5 formed by connecting a plurality of armature blocks 51 in a ring shape is used as the armature of a rotating electric machine, which is an electric device. However, the present invention is not limited to this. For example, the armature 5 formed by connecting a plurality of armature blocks 51 continuously in a straight line may be used as the armature of a linear motor, which is an electric device. In this case, the mover moves along the armature 5 due to movement of a magnetic field generated by energizing the armature winding of the armature 5.

[0087] The configurations described in the above embodiments are merely examples of the contents of the present disclosure. The embodiments can be combined with other known technologies. Part of the configuration of the embodiments can be omitted or modified without departing from the gist of the present disclosure.

[0088] Examples of aspects that may be included in the present disclosure are set forth below as appendices. (Appendix 1) Multiple Armature Blocks Equipped with Each of the plurality of armature blocks includes an iron core block, an insulating sheet, and a coil portion, The core block is configured by stacking a plurality of magnetic plates, the core block has a yoke portion and teeth portions protruding from the yoke portion, 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 having a first end and a second end; the tooth insulating portion surrounds the tooth portion with the one or more insulation attachment portions disposed around the tooth portion and the first end portion and the second end portion overlapping each other; a joint portion is formed in the tooth insulating portion by joining the overlapping first end portion and the overlapping second end portion to each other, The tooth insulating portion surrounds the tooth portion to integrate the plurality of magnetic plates into an armature. (Appendix 2) 2. The armature according to claim 1, wherein the joint 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. (Appendix 3) 3. The armature according to claim 1, wherein the first end and the second end at the joint are joined to each other with an adhesive. (Appendix 4) 3. The armature according to claim 1, wherein the first end and the second end at the joint are joined to each other by fusing the first end and the second end. (Appendix 5) Each of the plurality of armature blocks has a bobbin, 5. The armature according to claim 1, wherein the tooth insulating portion surrounds the tooth portion and the bobbin, thereby integrating the bobbin and the plurality of magnetic plates. (Appendix 6) a lamination step of laminating a plurality of magnetic plates to form an iron core block having a yoke portion and teeth protruding from the yoke portion; an insulating assembly process of integrating the plurality of magnetic plates by surrounding the teeth with a tooth insulating portion of an insulating sheet; a winding process for providing a coil portion on the tooth portion via the tooth insulating portion after the insulation assembly process; Equipped with the tooth insulating portion has one or more insulating mounting portions having a first end and a second end; In the insulation assembly process, the one or more insulation attachment portions are arranged around the tooth portion to overlap the first end portion and the second end portion, and the overlapping first end portion and the second end portion are joined together to form a joint portion in the tooth insulation portion. (Appendix 7) a pressurizing step of pressing the core block in a direction in which the plurality of magnetic plates are pressed against each other after the lamination step and before the insulating assembly step; 7. The method for manufacturing an armature according to claim 6, wherein in the insulation assembly step, the teeth are surrounded by the tooth insulating portions while the core block is pressed. (Appendix 8) The method for manufacturing an armature according to claim 6 or 7, wherein in the insulating assembly process, a bobbin is provided on the tooth portion, and then the bobbin and the tooth portion are collectively surrounded by the tooth insulating portion, thereby integrating the bobbin and the plurality of magnetic plates. [Explanation of symbols]

[0089] 1 Rotating electric machine (electrical equipment), 6 Core block, 7 Insulation sheet, 8 Bobbin, 9 Coil portion, 61 Yoke portion, 62 Teeth portion, 63 Magnetic plate, 71 Teeth insulating portion, 711 Insulation mounting portion, 711a First end portion, 711b Second end portion, 712 Joint portion, 713 Adhesive.

Claims

1. Multiple Armature Blocks Equipped with Each of the plurality of armature blocks includes an iron core block, an insulating sheet, and a coil portion, The core block is configured by stacking a plurality of magnetic plates, the core block has a yoke portion and teeth portions protruding from the yoke portion, 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 having a first end and a second end; the tooth insulating portion surrounds the tooth portion with the one or more insulation attachment portions disposed around the tooth portion and the first end portion and the second end portion overlapping each other; a joint portion is formed in the tooth insulating portion by joining the first end portion and the second end portion, which are overlapped with each other, The tooth insulating portion surrounds the tooth portion to integrate the plurality of magnetic plates into an armature.

2. The armature according to claim 1 , wherein the joint 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. 3. The armature according to claim 1, wherein the first end and the second end of the joint are joined to each other with an adhesive.

4. 3. The armature according to claim 1, wherein the first end and the second end at the joint are joined to each other by fusing the first end and the second end.

5. Each of the plurality of armature blocks has a bobbin, 3. The armature according to claim 1, wherein the tooth insulating portion surrounds the teeth and the bobbin, thereby integrating the bobbin and the plurality of magnetic plates.

6. a lamination step of laminating a plurality of magnetic plates to form an iron core block having a yoke portion and teeth protruding from the yoke portion; an insulating assembly process of integrating the plurality of magnetic plates by surrounding the teeth with a tooth insulating portion of an insulating sheet; a winding process for providing a coil portion on the tooth portion via the tooth insulating portion after the insulation assembly process; Equipped with the tooth insulating portion has one or more insulating mounting portions having a first end and a second end; In the insulation assembly process, the one or more insulation mounting portions are arranged around the tooth portion to overlap the first end portion and the second end portion, and the overlapping first end portion and the second end portion are joined to each other to form a joint portion in the tooth insulation portion.

7. a pressurizing step of pressing the core block in a direction in which the plurality of magnetic plates are pressed against each other after the lamination step and before the insulating assembly step; The method for manufacturing an armature according to claim 6, wherein in the insulating assembling step, the teeth are surrounded by the tooth insulating portions while the core block is being pressed.

8. 8. The method for manufacturing an armature according to claim 6 or claim 7, wherein in the insulating assembly process, after a bobbin is provided on the tooth portion, the bobbin and the tooth portion are collectively surrounded by the tooth insulating portion, thereby integrating the bobbin and the plurality of magnetic plates.

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