Rotating electric machine core, electromagnetic steel sheet, rotating electric machine stator, and rotating electric machine

Abstract

To provide a manufacturing technique for a rotating electrical machine core that can reduce the amount of electromagnetic steel sheets used.SOLUTION: A rotating electric machine core 10 is formed by stacking multiple electromagnetic steel sheets 1 by crimping, and the electromagnetic steel sheet 1 includes a crimp joint portion 2 for crimping, and the crimp joint portion 2 consists of a press-fit convex portion 3 provided on one side of the electromagnetic steel sheets 1 and a receiving concave portion 5 provided on the opposite side, and as a crimp joint structure consisting of the press-fit convex portion 3 of one electromagnetic steel sheet 1 being pressed into the receiving concave portion 5 of another electromagnetic steel sheet 1, one or more crimp joint structures having a gap 7 are formed between the end face 4 of the press-fit convex portion 3 and the bottom face 6 of the receiving concave portion 5, and as a result, there are locations where gaps 8 are formed between the electromagnetic steel sheets 1-1.SELECTED DRAWING: Figure 1-2

Description

[Technical Field]

[0001] The present invention relates to a rotating electric machine core, an electromagnetic steel sheet, a rotating electric machine stator, and a rotating electric machine, and more particularly to a rotating electric machine core etc. that can reduce the amount of electromagnetic steel sheet used in the manufacturing process. [Background technology]

[0002] Fig. 8 is a perspective view showing an example of a conventional rotating electric core in which electromagnetic steel sheets are laminated by crimping. Fig. 9 is an enlarged view of a main part of the rotating electric core shown in Fig. 8. As shown in these figures, in a conventional rotating electric core 810, a plurality of electromagnetic steel sheets 81 are laminated without gaps to ensure the amount of magnetic flux that can flow in. The laminated electromagnetic steel sheets 81 are fixed to each other by crimping, and the crimped joint portion 82 used for this is a so-called dowel, consisting of a press-fit protrusion 83 and a receiving recess 85 formed on the back side thereof.

[0003] The joining and fixing of the two electromagnetic steel sheets 81, 81 by the crimp joint portion 82, i.e., the dowel, is achieved by press-fitting the press-fit convex portion 83 of the lower electromagnetic steel sheet 81 into the receiving concave portion 85 of the upper electromagnetic steel sheet 81, thereby forming a laminated structure. An end face 84 of the press-fit convex portion 83 is completely pressed into the bottom face 86 of the receiving concave portion 85 into which it is press-fit, forming a crimped joint structure with no gaps between them, i.e., the dowel is completely crimped, so that the required number of electromagnetic steel sheets 81, 81, ... are stacked without any gaps.

[0004] Many patent applications have been filed for rotating electrical machine cores. For example, Patent Document 1, listed below, discloses a rust prevention technology for the inside of a core, in which a resin layer is provided to cover the winding, insulator, and winding connection in a stator that is made up of a stator core, an insulator attached to the stator core, a winding wound around the stator core via the insulator, a winding connection electrically connected to the winding, and terminals. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2021-128175 A "Stator" Summary of the Invention [Problem to be solved by the invention]

[0006] In the conventional rotating electrical core shown in Figure 8, the dowels, which are the press-fit convex parts of the crimped joint structure, are completely press-fit into the corresponding receiving concave parts, and the electromagnetic steel sheets are therefore stacked without any gaps, resulting in a large number of sheets and correspondingly high costs. Reducing the amount of electromagnetic steel sheets used will lead to cost reductions.

[0007] Therefore, the problem to be solved by the present invention is to provide a manufacturing technique for a rotating electrical machine core that can reduce the amount of electromagnetic steel sheets used, taking into account the state of the prior art. [Means for solving the problem]

[0008] After studying the above-mentioned problems, the inventors of the present application came up with the idea that it would be possible to reduce the amount of electromagnetic steel sheets used by leaving gaps between the electromagnetic steel sheets when stacking them, rather than completely crimping the dowels as in the prior art, thereby reducing the stacking density. Furthermore, stacking with gaps reduces the cross-sectional area of ​​the electromagnetic steel sheets, increasing magnetic resistance. The inventors also came up with the idea that this could be reduced by tilting the end faces of the core. Based on these findings, the invention claimed in this application, or at least the invention disclosed therein, as a means for solving the above-mentioned problems, is as follows:

[0009] [1] A core for a rotating electric machine formed by stacking multiple electromagnetic steel sheets by crimping, wherein the electromagnetic steel sheets have a crimp joint portion for the crimp joint, and the crimp joint portion comprises a press-fit convex portion provided on one side of the electromagnetic steel sheets and a receiving concave portion provided on the opposite side thereof, and as a crimp joint structure formed by pressing the press-fit convex portion of one electromagnetic steel sheet into the receiving concave portion of another electromagnetic steel sheet, one or more crimp joint structures having a gap between the end face of the press-fit convex portion and the bottom surface of the receiving concave portion are formed, thereby forming a gap between the electromagnetic steel sheets in some locations. [2] A rotating electric core according to [1], characterized in that all of the crimped joint portions are formed to the same specifications, the press-fit convex portion is press-fitted only partway without abutting against the bottom surface of the receiving concave portion, and the gap is formed between all of the electromagnetic steel sheets. [3] The rotating electric core according to [1], characterized in that the crimped joint portion has two or more specifications with different heights of the press-fit convex portion, thereby providing an abutment and gap portion where the press-fit convex portion abuts against the bottom surface of the receiving concave portion and where the gap is formed between the electromagnetic steel sheets participating in the crimped joint structure. [4] A rotating electric core according to [3], characterized in that, between the electromagnetic steel sheets other than the abutment and gap locations, the press-fit convex portion is pressed in only partway without abutting against the bottom surface of the receiving concave portion, thereby forming the gap between all of the electromagnetic steel sheets.

[0010] [5] The rotating electric core according to any one of [1], [2], [3], and [4], characterized in that the electromagnetic steel sheets have eave-shaped inclined portions that cover at least a portion of the gaps. [6] At least a part of the gap is <z>A rotating electrical core according to any one of [1], [2], [3], and [4], characterized in that it is filled with any one of the insulating materials described above. <z>Insulation material or resin plate made by insulating coating using resin powder [7] At least a part of the gap is <z>The rotating electrical core according to [5], characterized in that it is filled with any one of the insulating materials described above. <z>Insulation material or resin plate made by insulating coating using resin powder [8] An electromagnetic steel sheet for forming a rotating electric core by lamination, the electromagnetic steel sheet having a crimp joint portion for crimp joint, the crimp joint portion consisting of a press-fit convex portion provided on one side of the electromagnetic steel sheet and a receiving concave portion provided on the opposite side, and characterized in that an eave-shaped inclined portion is provided at the end. [9] The electromagnetic steel sheet according to [8], characterized in that it is used to form a rotating electrical core in which at least a part of the gap is covered, as described in [5].

[0011]

[10] A rotating electric machine stator, characterized by comprising the rotating electric machine core according to any one of [1], [2], [3], [4], and [7].

[11] A rotating electric machine stator, comprising the rotating electric machine core according to [5].

[12] A rotating electric machine stator, comprising the rotating electric machine core according to [6].

[13] A rotating electric machine stator according to

[10] , comprising: <ra>A rotating electric machine characterized by any one of the above. <ra>Resolver or rotating electrical machine other than resolver

[14] A rotating electric machine stator according to any one of

[11] and

[12] , <ra>A rotating electric machine characterized by any one of the above. <ra>Resolver or rotating electrical machine other than resolver [Effects of the Invention]

[0012] The rotating electric core, electromagnetic steel sheets, rotating electric stator, and rotating electric machine of the present invention are configured as described above, and therefore, the amount of electromagnetic steel sheets used can be reduced, thereby reducing costs. Furthermore, the presence of gaps in the crimped joint structure reduces the opposing surface area with the opposing magnetic material, increasing the magnetic resistance between the electromagnetic steel sheets, but this can also reduce the generation of eddy currents.

[0013] However, an excessive increase in magnetic resistance may result in a decrease in magnetic flux transmission efficiency and affect the characteristics of the rotating electric machine, but this can be solved by using a canopy-shaped inclined portion that covers at least a portion of the gap.With this configuration, the present invention can provide a stacking method that reduces the amount of electromagnetic steel sheet used and does not significantly change the characteristics of the rotating electric machine. [Brief explanation of the drawings]

[0014] [Figure 1] 1 is a perspective view illustrating an example of a basic configuration of a rotating electrical machine core according to the present invention; [Figure 1-2] 2 is a perspective explanatory view showing a cross section of a main part of the basic configuration example shown in FIG. 1. FIG. [Figure 2] 2 is a perspective explanatory view showing the main part of the basic configuration example shown in FIG. 1 from the axial center side. FIG. [Figure 3] 1 is a perspective explanatory view showing an example of an electromagnetic steel sheet for forming a rotating electric core of the present invention having two or more specifications of a caulking joint portion; FIG. [Figure 4x] 4 is a perspective explanatory view showing a cross section of a main part of the rotating electric core of the present invention formed from the electromagnetic steel sheets shown in FIG. 3, taken along the line xx' in FIG. [Figure 4y] 4 is a perspective explanatory view showing a cross section of a main part of the rotating electric core of the present invention formed from the electromagnetic steel sheets shown in FIG. 3, taken along the line yy' in FIG. [Figure 5] 1 is a perspective explanatory view showing a cross section of a main part of an example of a configuration of a rotating electric core according to the present invention, in which an electromagnetic steel plate has an eave-shaped inclined portion; [Figure 6] 6 is a perspective explanatory view showing the main part of the configuration example shown in FIG. 5 from the axial center side. FIG. [Figure 7] 6 is an explanatory perspective view showing the entire configuration example of the rotating electrical machine core of the present invention shown in FIG. 5. [Figure 8] 1 is a perspective view showing an example of a conventional rotating electrical core in which electromagnetic steel sheets are laminated by caulking. [Figure 9] FIG. 9 is an enlarged view of a main part of the rotating electrical machine core shown in FIG. 8. DETAILED DESCRIPTION OF THE INVENTION

[0015] The present invention will be described in detail below with reference to the drawings. FIG. 1 is a perspective view illustrating an example of the basic configuration of a rotating electrical machine core according to the present invention. FIG. 1-2 is a perspective explanatory view showing a cross section of a main part of the basic configuration example shown in FIG. 1; Fig. 2 is an explanatory perspective view showing the main parts of the basic configuration example shown in Fig. 1 from the axial side. As shown in Fig. 2, this rotating electric core 10 is a rotating electric core formed by stacking multiple electromagnetic steel sheets 1 by crimping. The electromagnetic steel sheets 1 have crimp joint portions 2 for crimping. The crimp joint portions 2 consist of press-fit convex portions 3 provided on one side of the electromagnetic steel sheets 1 and receiving concave portions 5 provided on the opposite side. The crimp joint structure, in which the press-fit convex portion 3 of one electromagnetic steel sheet 1 is press-fitted into the receiving concave portion 5 of another electromagnetic steel sheet 1, has one or more crimp joint structures with gaps 7 between the end faces 4 of the press-fit convex portions 3 and the bottom faces 6 of the receiving concave portions 5, thereby forming gaps 8 between the electromagnetic steel sheets 1-1. The gaps 8 can be formed when the dowels are not completely crimped.

[0016] In the present rotating electrical core 10 having such a configuration, a plurality of electromagnetic steel sheets 1 are laminated by crimping, but at least one location between the electromagnetic steel sheets 1 is not in close contact with one another, forming a gap 8, which reduces the number of electromagnetic steel sheets used compared to the conventional type, which uses closely laminated electromagnetic steel sheets. Therefore, a cost reduction effect can be obtained according to the degree to which the number of electromagnetic steel sheets used is reduced.

[0017] The number of gaps 8 formed is not limited, but can be provided between all of the electromagnetic steel sheets 1-1, as shown in Figures 1, 1-2, and 2. In other words, in this case, if the number of electromagnetic steel sheets 1 used is n, the number of gaps 8 formed is n-1. In the example shown in each figure, the number of laminated sheets = 6 and the number of gaps = 5. In the example of the prior art shown in Figure 8 above, the number of laminated sheets = 10 (number of gaps = 0), which is a 40% reduction in the number of electromagnetic steel sheets used.

[0018] 1, 1-2, and 2, when multiple gaps 8 are formed, the spacing (height size) between the gaps is not particularly limited, and even if the spacing is different, it is within the scope of the present invention. However, it is more desirable to set all gaps 8 at the same spacing as shown in the drawings, in terms of simplifying the manufacturing process, standardizing the product, maintaining the characteristics of the rotating electrical machine, etc.

[0019] As shown in Figures 1, 1-2, and 2, the rotating electric core 10 of the present invention has all crimped joint portions 2 formed to the same specifications, the press-fit convex portion 3 is pressed in only partway and does not abut against the bottom surface 6 of the receiving concave portion 5, i.e., the dowel is not completely crimped, and gaps 8 are formed between all of the electromagnetic steel sheets 1-1.

[0020] FIG. 3 is a perspective explanatory view showing an example of an electromagnetic steel sheet for forming a rotating electrical core of the present invention having two or more specifications for the caulked joint portion. Fig. 4x is an explanatory perspective view showing a cross section of a main part of the rotating electric core of the present invention formed from the electromagnetic steel sheets shown in Fig. 3, taken along the x-x' cross section in Fig. 3, and Fig. 4y is an explanatory perspective view showing a cross section of a main part of the rotating electric core of the present invention formed from the electromagnetic steel sheets shown in Fig. 3, taken along the y-y' cross section in Fig. 3. As shown in these figures, the rotating electric core 310 has two or more caulking joints with different heights of the press-fit convex portions. That is, as follows:

[0021] First specification: Crimped joint area 32R It consists of a press-fitting protrusion 33R and a receiving recess 35R provided on the opposite surface thereof. Second specification: Crimped joint part 32B It consists of a press-fitting protrusion 33B and a receiving recess 35B provided on the opposite surface thereof. The press-fitting projection 32R is formed higher, and the press-fitting projection 32B is formed lower.

[0022] The arrangement of the first specification (crimped joint portion 32R) and the second specification (crimped joint portion 32B) in one electromagnetic steel sheet 31 is preferably alternated as shown in Figure 3. Alternatively, even if they are not alternated, an arrangement that provides good balance around the center of gravity and is point-symmetrical about the axis is preferable. In the example shown in the figure, there are 11 crimped joint portions, which is somewhat unbalanced, but a well-balanced arrangement can be easily achieved by using an even number of crimped joint portions.

[0023] Figure 4x shows the core portion from x' as a part of the x-x' cross section in Figure 3. Here, in the overall configuration made up of six electromagnetic steel sheets 31, first specification (crimped joint portion 32R) and second specification (crimped joint portion 32B) are alternately stacked from the bottom, and the crimped joint portion of the uppermost sheet is the second specification (crimped joint portion 32B). The crimped joint portion of the lowermost sheet is the first specification (crimped joint portion 32R), and its press-fit protrusion 33R is press-fitted in a state where its end face 34R abuts against the bottom face 36B of the receiving recess 35B that constitutes the crimped joint portion 32B of the sheet above, i.e., in a completely crimped state without any gaps, forming a crimped joint structure, and a gap 38 is formed between the electromagnetic steel sheets 31-31 participating in the crimped joint structure. This portion is called the "abutment and gap portion."

[0024] The crimped joint portion 32B, which is completely pressed in without any gaps by the press-fit protrusion 33R of the crimped joint portion 32R relating to the lowest sheet, does not abut against the bottom surface 36R of the receiving recess 35R that constitutes the crimped joint portion 32R of the sheet above it because the height of the press-fit protrusion 33B is low, forming a gap 37; in other words, the crimped joint structure is formed by being pressed in in a partially crimped state rather than being completely crimped, and a gap 38 is formed between the electromagnetic steel sheets 31-31 that participate in the crimped joint structure.

[0025] In this way, by alternately stacking the first specification and the second specification, which have different heights of press-fit convex portions, crimped joint structures that form abutment and gap areas and intermediate crimped joint structures in which the crimped joint is only partially formed are formed alternately, and in both cases gaps 38 are formed, and gaps 38 are formed between all of the electromagnetic steel sheets 31-31. The present invention is not limited to a configuration in which there are gaps between all of the electromagnetic steel sheets, but as mentioned above, such a configuration is more desirable.

[0026] Figure 4y shows the core portion from y' as part of the y-y' cross section in Figure 3. Here, in the overall structure made up of six electromagnetic steel sheets 31, the second specification (crimped joint portion 32B) and the first specification (crimped joint portion 32R) are alternately stacked from the bottom, and the crimped joint portion of the topmost sheet is the first specification (crimped joint portion 32R). In contrast to (x), from the bottom, an intermediate crimped joint structure and a crimped joint structure that serves as a contact and gap portion are formed in this order, and gaps 38 are formed in both.

[0027] Note that the present invention does not exclude configurations in which three or more types of specifications are provided for the caulking joint portion. However, two types of specifications can provide sufficient effects that meet the intended purpose. Furthermore, the scope of the present invention also includes designing a specification pattern that differentiates the height (depth) of the receiving recesses 35R and 35B, rather than the height differentiation of the press-fitting protrusions 33R and 33B shown in the figures, or designing a specification pattern that differentiates the height (depth) of both the press-fitting protrusions 33R and 33B and the receiving recesses 35R and 35B.

[0028] 5 is a perspective explanatory view showing a cross section of a main part of an example of the configuration of a rotating electrical core of the present invention, in which an electromagnetic steel sheet has an eave-shaped inclined portion. Fig. 6 is an explanatory perspective view showing the essential parts of the example configuration shown in Fig. 5 from the axial center side, and Fig. 7 is an explanatory perspective view showing the entire example configuration of the rotating electric machine core of the present invention shown in Fig. 5. As shown in these figures, in addition to any of the configurations already explained in the respective figures, this rotating electric machine core 510 is characterized in that the electromagnetic steel sheets 51 are provided with eave-shaped inclined portions 59 that cover at least a part of the gaps 58.

[0029] The rotating electric core of the present invention not only reduces costs by forming gaps between the laminated electromagnetic steel sheets, but also reduces eddy current generation by increasing the magnetic resistance between the electromagnetic steel sheets. However, an excessive increase in magnetic resistance can lead to a decrease in magnetic flux transmission efficiency, which can degrade the characteristics of the rotating electric machine. As a countermeasure, as shown in the figure, an inclined portion 59 can be provided on the end face of the core, inclining it like a canopy.

[0030] As a result, at least a portion of gap 58 is covered by inclined portion 59 made of a magnetic material, and conditions regarding magnetic resistance can be improved compared to the basic configuration shown in Fig. 1 etc. Note that when multiple gaps 58 are formed, it is within the scope of the present invention as long as at least a portion of each gap is covered by inclined portion 59, but it is more desirable to have inclined portion 59 provided on each electromagnetic steel sheet 51 so that all gaps 58 are covered.

[0031] In the rotating electric core 10 etc. of the present invention described above, at least a portion of the gaps 8 etc. can be configured to be filled with an insulating material. For example, a resin plate having the same shape as the rotating electric core 10 etc. may be inserted into the gaps 8 etc., or an insulating coating using resin powder may be used. For the insulating coating, for example, a technique can be used in which epoxy resin powder is attached to the conductor by static electricity and then baked to harden.

[0032] 5 and the like is also within the scope of the present invention. That is, this electromagnetic steel sheet 51 is for forming a rotating electric machine core 510 by lamination, and is provided with a crimp joint portion 52 for crimping, where the crimp joint portion 52 is made up of a press-fit convex portion 53 provided on one surface of the electromagnetic steel sheet 51 and a receiving concave portion 55 provided on the opposite surface, and is provided with a canopy-shaped inclined portion 59 at the end. Using this electromagnetic steel sheet 51, it is possible to form a rotating electric machine core 510 having a gap 58 and at least a portion of which is covered.

[0033] Furthermore, a rotating electric machine stator equipped with a rotating electric machine core 10 having any of the configurations described above, and further, a rotating electric machine itself such as a resolver equipped with such a rotating electric machine stator, are also within the scope of the present invention. [Industrial Applicability]

[0034] The rotating electric machine core, electromagnetic steel sheet, rotating electric machine stator, and rotating electric machine of the present invention can reduce the amount of electromagnetic steel sheet used and reduce costs. Furthermore, a specific configuration of the present invention can provide a lamination method that reduces the amount of electromagnetic steel sheet used and has little impact on the characteristics of the rotating electric machine. Therefore, this invention has high industrial applicability in the field of rotating electric machine manufacturing such as resolvers, their use fields such as factory automation, and all related fields. [Explanation of symbols]

[0035] 1, 31, 51...Electromagnetic steel plate 2, 32R, 32B, 52... Crimped joint area 3, 33R, 33B, 53...Press-fit convex part 4, 34R, 34B, 54...End face of press-fit convex part 5, 35R, 35B, 55... Receiving recess 6, 36R, 36B, 56...Bottom surface of receiving recess 7, 37, 57...Void 8, 38, 58...gaps 10, 310, 510... Rotating electric core 59...Eaves-shaped slope 81...Electromagnetic steel plate 82... Crimped joint area 83...Press-fit convex part 84...End face of press-fit convex part 85...receiving recess 86 Bottom surface of receiving recess 810...Conventional rotating electrical core< / ra> < / ra> < / ra> < / ra> < / z> < / z> < / z> < / z>

Claims

1. A core for a rotating electric machine formed by laminating a plurality of electromagnetic steel sheets by caulking, the electromagnetic steel sheet has a caulking joint portion for the caulking joint, the caulking joint portion comprises a press-fitting convex portion provided on one surface of the electromagnetic steel sheet and a receiving concave portion provided on the opposite surface thereof, As a caulking joining structure in which the press-fit convex portion of one electromagnetic steel sheet is press-fitted into the receiving concave portion of another electromagnetic steel sheet, one or more crimped joint structures having a gap between an end face of the press-fitting convex portion and a bottom face of the receiving concave portion are formed, As a result, there are some gaps between the electromagnetic steel sheets. A rotating electrical core characterized by:

2. All of the crimped joints are formed to the same specifications, the press-fitting projection is pressed in partway without coming into contact with the bottom surface of the receiving recess, The gap is formed between all of the electromagnetic steel sheets. The rotating electrical machine core according to claim 1 .

3. The caulking joint portion has two or more specifications in which the press-fitting protrusions have different heights, As a result, There is an abutment and gap portion where the press-fit convex portion abuts against the bottom surface of the receiving concave portion and the gap is formed between the electromagnetic steel sheets participating in the caulking joint structure. The rotating electrical machine core according to claim 1 .

4. Between the electromagnetic steel sheets other than the contact and gap portion, the press-fitting projection is pressed in partway without coming into contact with the bottom surface of the receiving recess, As a result, The gap is formed between all of the electromagnetic steel sheets. The rotating electrical machine core according to claim 3 .

5. 5. The rotating electrical core according to claim 1, wherein the electromagnetic steel sheets are provided with eaves-shaped inclined portions that cover at least a portion of the gap.

6. 5. The rotating electrical core according to claim 1, wherein at least a portion of the gap is filled with any one of the insulating materials set forth in <Z> below. <Z> Insulation material with insulating coating using resin powder, or resin plate

7. 6. The rotating electrical machine core according to claim 5, wherein at least a portion of the gap is filled with any one of the insulating materials set forth in <Z> below. <Z> Insulation material with insulating coating using resin powder, or resin plate

8. An electromagnetic steel sheet for forming a rotating electric machine core by lamination, It has a crimp joint area for crimp joints, the caulking joint portion comprises a press-fitting convex portion provided on one surface of the electromagnetic steel sheet and a receiving concave portion provided on the opposite surface thereof, There is a sloped, eaves-like section at the end. Electromagnetic steel sheet.

9. The electromagnetic steel sheet according to claim 8, which is used to form a rotating electrical core according to claim 5, in which at least a part of the gap is covered.

10. A rotating electrical machine stator comprising the rotating electrical machine core according to any one of claims 1 to 7.

11. A rotating electric machine stator comprising the rotating electric machine core according to claim 5.

12. A rotating electric machine stator comprising the rotating electric machine core according to claim 6.

13. A rotating electric machine comprising the rotating electric machine stator according to claim 10, and characterized in that the rotating electric machine is one of the following items <Ra>. <Ra> Resolver or rotating electrical machine other than resolver

14. A rotating electric machine comprising the rotating electric machine stator according to claim 11 or 12, and characterized in that it satisfies any one of the following conditions <Ra>. <Ra> Resolver or rotating electrical machine other than resolver

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