Stator manufacturing method, electric motor manufacturing method

Abstract

To provide a manufacturing method of stator in which assembly work of an insulation component is simplified and work time can be reduced.SOLUTION: A manufacturing method of stator includes steps of: forming a stator core 1, in which a plurality of t-shaped core blocks 6 having yoke part 11 and tooth part 12 are arranged in a linear array, and connected to each other by a thin linking part 7; forming a connection upper insulation component 20, in which a plurality of upper insulation components 2 are arranged at the same intervals as the core blocks 6, and are connected by upper runners 4 and forming a connection lower insulation component 30, in which a plurality of lower insulation components 3 are arranged at the same intervals as the core blocks 6, and are connected by lower runners 5; insulating an area around the tooth part 12, by inserting the connection upper insulation component 20 and the connection lower insulation component 30 from both sides of a stator core 1 in lamination direction of a steel sheet; and cutting the upper runner 4 of the connection upper insulation component 20 and cutting the lower runner 5 of the connection lower insulation component 30.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] The present disclosure relates to a method for manufacturing a stator of an electric motor, a method for manufacturing an electric motor, and a connecting insulating component. [Background technology]

[0002] Conventionally, electric motor stators are manufactured as follows: A pair of insulators is attached via insulating film from above and below a T-shaped, multi-layered split core having teeth and a yoke that forms a magnetic path on the outer periphery of the teeth, and after windings are wound around the teeth via the insulators, the multiple split cores are joined circumferentially and wedges are inserted (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 3099001 Summary of the Invention [Problem to be solved by the invention]

[0004] In Patent Document 1, when assembling an insulator to a stator core of an electric motor, insulating parts are attached to each T-shaped section one by one, which is a time-consuming process. Furthermore, when automating assembly, a process of aligning the insulating parts to make them easier to assemble and a process of assembling the insulating parts to the stator core are required, which poses the issues of increased equipment size and securing installation space.

[0005] The present disclosure has been made in view of the above, and an object of the present disclosure is to provide a method for manufacturing a stator that simplifies the assembly work of insulating components and reduces the work time. [Means for solving the problem]

[0006] In order to solve the above-mentioned problems and achieve the object, the method of manufacturing a stator of the present disclosure includes the steps of: forming a stator core in which a plurality of T-shaped core blocks formed from laminated steel plates are linearly arranged and connected to each other by thin-walled connecting portions of the yoke portions, the core blocks having a yoke portion that forms an outer peripheral magnetic path and teeth that protrude inward from the yoke portion and form magnetic poles; forming a first linking insulating part in which a plurality of insulating parts are arranged at the same intervals as the plurality of core blocks and connected by first runners; and forming a second linking insulating part in which a plurality of insulating parts are arranged at the same intervals as the plurality of core blocks and connected by second runners; inserting the first linking insulating part and the second linking insulating part into the stator core from both sides in the stacking direction of the steel plates to insulate the periphery of the teeth; and cutting the first runner of the first linking insulating part and the second runner of the second linking insulating part. After cutting the first and second runners, The method includes a step of winding a winding around the teeth via an insulating part, and a step of bending the stator core at the thin-walled connecting portion to form a ring shape. [Effects of the Invention]

[0007] The stator manufacturing method of the present disclosure has the effect of simplifying the work of assembling insulating components and reducing the work time. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a top view showing a state in which the stator of the first embodiment is linearly expanded; [Figure 2] FIG. 10 is a top view showing the state of the stator according to the first embodiment after being formed into an annular shape. [Figure 3] FIG. 1 is an enlarged perspective view showing the configuration of one core block of the stator according to the first embodiment; [Figure 4] FIG. 1 is an exploded perspective view showing the configuration of a stator according to a first embodiment; [Figure 5] FIG. 1 is a top view showing a partial configuration of a stator according to a first embodiment when linearly expanded; [Figure 6] FIG. 10 is a top view showing a partial configuration of the stator according to the first embodiment after being formed into an annular shape. [Figure 7] 1 is a cross-sectional view showing an electric motor incorporating a stator according to a first embodiment; [Figure 8]1 is a flowchart showing the steps of a method for manufacturing a stator according to a first embodiment. [Figure 9] FIG. 1 is a top view showing a state in which the stator core of the first embodiment is linearly expanded; [Figure 10] FIG. 1 is a top view showing the configuration of the connecting insulating part of the first embodiment. [Figure 11] FIG. 1 is a top view showing the configuration of a lower connecting insulating part according to the first embodiment; [Figure 12] FIG. 1 is a top view showing a configuration in which an upper coupling insulating part and a lower coupling insulating part are assembled to a stator core according to a first embodiment. [Figure 13] FIG. 1 is a side view showing a state before an upper coupling insulating part and a lower coupling insulating part are assembled to a stator core according to a first embodiment. [Figure 14] FIG. 10 is a side view showing a state after an upper coupling insulating part and a lower coupling insulating part are assembled to the stator core of the first embodiment. [Figure 15] FIG. 10 is a top view showing a configuration in which the upper runner and the lower runner are cut off in a state in which the upper insulating part and the lower insulating part are attached to the stator core of the first embodiment. [Figure 16] FIG. 10 is a cross-sectional view showing a configuration in which the upper runner and the lower runner are cut off in a state in which the upper insulating part and the lower insulating part are attached to the stator core of the first embodiment. [Figure 17] FIG. 1 is a top view showing a state in which a winding is wound around a stator core according to a first embodiment. [Figure 18] FIG. 1 is a top view showing a state after the stator core of the first embodiment has been formed into a ring shape. [Figure 19] 10 is a flowchart showing the steps of a method for manufacturing an electric motor according to a second embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0009] Hereinafter, a method for manufacturing a stator, a method for manufacturing an electric motor, and a connecting insulating part according to embodiments will be described in detail with reference to the drawings.

[0010] Embodiment 1 FIG. 1 is a top view showing the state of the stator of embodiment 1 when linearly developed. FIG. 2 is a top view showing the state of the stator of embodiment 1 after being formed into a ring. FIG. 3 is an enlarged perspective view showing the configuration of one core block of the stator of embodiment 1. FIG. 4 is an exploded perspective view showing the configuration of the stator of embodiment 1. FIG. 5 is a top view showing a partial configuration of the stator of embodiment 1 when linearly developed. FIG. 6 is a top view showing a partial configuration of the stator of embodiment 1 after being formed into a ring. FIG. 7 is a cross-sectional view showing an electric motor incorporating the stator of embodiment 1.

[0011] FIG. 4 shows a linear stator core 1 with an upper connecting insulating part 20 (first connecting insulating part) arranged on the upper side and a lower connecting insulating part 30 (second connecting insulating part) arranged on the lower side. The stator core 1 has multiple core blocks 6 connected by thin-walled connecting portions 7. The upper connecting insulating part 20 includes multiple upper insulating parts 2 and an upper runner 4 (first runner), with the multiple upper insulating parts 2 connected by the upper runner 4. The lower connecting insulating part 30 includes multiple lower insulating parts 3 and a lower runner 5 (second runner), with the multiple lower insulating parts 3 connected by the lower runner 5. FIG. 1 shows a linear stator 9 with the upper insulating part 2 fitted on the upper side of the stator core 1. FIG. 2 shows the stator 9 with a winding 8 wound thereon after annular forming. FIG. 3 shows one core block 6 with the upper insulating part 2 and the lower insulating part 3 fitted therein.

[0012] As shown in FIG. 4, the stator 9 of the first embodiment includes a stator core 1 in which N approximately T-shaped core blocks 6 are connected by thin-walled connecting portions 7 and linearly expanded. In the first embodiment, N=12, but N is arbitrary. The stator core 1 is formed from a laminated steel plate in which multiple steel plates are stacked together. The core block 6 has a yoke portion 11 that forms the outer peripheral magnetic path of the stator core 1, teeth 12 that protrude inward from the center of the yoke portion 11 and form magnetic poles, and an inner peripheral portion 13 that protrudes circumferentially from the teeth 12.

[0013] As shown in FIG. 4 , the connecting upper insulating part 20 has 12 upper insulating parts 2, the same number as the core blocks 6 of the stator core 1. The upper insulating parts 2 are connected by upper runners 4 via runner connectors 24. The spacing between the upper insulating parts 2 is mold-designed to the same dimension as the spacing between the core blocks 6. The connecting lower insulating part 30 has 12 lower insulating parts 3, the same number as the core blocks 6 of the stator core 1. The lower insulating parts 3 are connected by lower runners 5 via runner connectors 34. The spacing between the lower insulating parts 3 is mold-designed to the same dimension as the spacing between the core blocks 6. The upper insulating parts 2 and lower insulating parts 3 are attached to the stator core 1 from above and below so as to cover the teeth 12 of the stator core 1.

[0014] As shown in FIG. 5, when the yoke portion 11 of the stator core 1 is linearly developed, it has tapered surfaces 11a that open from top to bottom at an angle θ from the tooth portion 12, sandwiching the thin-walled connecting portion 7. When the number of poles is N, θ = 360° / 2N. When the number of poles is 12, θ = 15°. By forming it in this manner, when the stator core 1 is formed into an annular shape, adjacent tapered surfaces 11a come into contact as shown in FIG. 6, which reduces the magnetic resistance of the magnetic flux passing through the yoke portion 11.

[0015] As shown in Figure 7, the electric motor 100 of embodiment 1 includes a front casing 102 and a rear casing 103 that hold a stator 9, a rotor 104 arranged within the annular stator 9, and a rotating shaft 106 that is supported by a pair of bearings 105 held in the center of the front casing 102 and the rear casing 103 and that supports the rotor 104 within the stator 9.

[0016] In the stator 9 of the first embodiment, after the upper connecting insulating part 20 is injection molded, the upper insulating part 2 is inserted into the stator core 1 while holding the upper runner 4, and then the upper runner 4 is cut. Because the lower insulating part 3 has a similar structure, after the lower connecting insulating part 30 is injection molded, the lower insulating part 3 is inserted into the stator core 1 while holding the lower runner 5, and then the lower runner 5 is cut. Thereafter, the winding 8 is wound around the stator core 1. Thereafter, as shown in FIG. 2, the stator 9 is formed into an annular shape, and the stator 9 of the electric motor is completed.

[0017] In a typical method of attaching insulating parts to the stator core 1, the insulating parts are temporarily stored after injection molding and then assembled one by one to the stator core 1. For a 12-pole system, this requires 24 assembly steps. While automated assembly is considered to improve workability, this requires equipment for aligning the individually separated upper insulating part 2 and lower insulating part 3 for easy assembly and for assembling them to the stator core 1, which requires equipment costs and installation space. According to the first embodiment, the insulating parts are the connecting upper insulating part 20 and the connecting lower insulating part 30, which have runner parts that are discarded during molding. This simplifies the assembly process and reduces work time. Furthermore, automated assembly eliminates the need for the process of aligning the insulating parts for easy assembly and the process of assembling the insulating parts to the stator core 1, thereby reducing equipment costs and resolving the problem of securing installation space.

[0018] Next, the details of the method for manufacturing the stator 9 will be described. FIG. 8 is a flowchart showing the steps of the method for manufacturing the stator 9 according to the first embodiment. FIG. 9 is a top view showing the state of the stator core 1 according to the first embodiment when linearly developed. FIG. 10 is a top view showing the configuration of the upper connecting insulating part 20 according to the first embodiment. FIG. 11 is a top view showing the configuration of the lower connecting insulating part 30 according to the first embodiment. FIG. 12 is a top view showing the configuration in which the upper connecting insulating part 20 and the lower connecting insulating part 30 are assembled to the stator core 1 according to the first embodiment. FIG. 13 is a side view showing the state before the upper connecting insulating part 20 and the lower connecting insulating part 30 are assembled to the stator core 1 according to the first embodiment. FIG. 14 is a side view showing the state after the upper connecting insulating part 20 and the lower connecting insulating part 30 are assembled to the stator core 1 according to the first embodiment. FIG. 15 is a top view showing the configuration in which the upper connecting insulating part 20 and the lower connecting insulating part 30 are assembled to the stator core 1 according to the first embodiment and the upper runner 4 and the lower runner 5 are cut. Fig. 16 is a cross-sectional view showing a configuration in which upper runner 4 and lower runner 5 are cut off in a state in which upper connecting insulating part 20 and lower connecting insulating part 30 are assembled to stator core 1 of embodiment 1. Fig. 17 is a top view showing a state in which winding 8 is wound around stator core 1 of embodiment 1. Fig. 18 is a top view showing a state after stator core 1 of embodiment 1 has been formed into a ring.

[0019] The method for manufacturing a stator will be described using the flowchart in Fig. 8. The stator forming process S10 includes a stator core forming process S11, a linked insulating component molding process S12, a linked insulating component inserting process S13, a connecting portion cutting process S14, a winding process S15, and a ring core forming process S16.

[0020] In the stator core forming step S11, a stator core 1 as shown in Fig. 9 is formed. As described above, the stator core 1 is formed from laminated steel sheets, and a plurality of roughly T-shaped core blocks 6 are arranged linearly at equal intervals P1. Each core block 6 has a yoke portion 11 that forms an outer peripheral magnetic path and teeth 12 that protrude inward from the yoke portion 11 and form magnetic poles. The core blocks 6 are connected to each other by thin-walled connecting portions 7 of the yoke portion 11. An inner peripheral portion 13 is provided at the tip of the teeth 12.

[0021] In the connecting insulating part molding process S12, an upper connecting insulating part 20 shown in Fig. 10 and a lower connecting insulating part 30 shown in Fig. 11 are injection molded. As shown in Fig. 10, the upper connecting insulating part 20 has multiple upper insulating parts 2 linearly arranged at equal intervals P2. The multiple upper insulating parts 2 are connected to the upper runner 4 by runner connection parts 24. The intervals P2 and P1 are the same length. The upper insulating parts 2 cover the upper surfaces of the tooth portions 12 of the stator core 1, both side surfaces of the tooth portions 12, the inner peripheral surface of the yoke portion 11, and the upper portion of the outer peripheral surface of the inner peripheral portion 13.

[0022] As shown in Figure 11, the connecting lower insulating part 30 has multiple lower insulating parts 3 arranged in a line at equal intervals P3. The multiple lower insulating parts 3 are connected to the lower runner 5 by runner connection parts 34. The intervals P3 and P1 are the same length. The lower insulating parts 3 cover the lower surfaces of the tooth parts 12 of the stator core 1, both side surfaces of the tooth parts 12, the inner peripheral surface of the yoke part 11, and the lower part of the outer peripheral surface of the inner peripheral part 13.

[0023] In the connecting insulating part insertion step S13, as shown in Figures 12 to 14, the upper connecting insulating part 20 and the lower connecting insulating part 30 are inserted into the stator core 1 from both sides in the lamination direction of the stator core 1. During insertion, the upper runner 4 of the upper connecting insulating part 20 and the lower runner 5 of the lower connecting insulating part 30 are gripped. Since Figure 12 is a top view, only the upper connecting insulating part 20 is shown. For convenience, the upper runner 4 and the lower runner 5 are omitted from Figures 13 and 14. By inserting the upper connecting insulating part 20 and the lower connecting insulating part 30 from above and below the stator core 1, the periphery of the slot, which is the area surrounded by the tooth portion 12, the yoke portion 11, and the inner periphery 13, is insulated.

[0024] In the connecting insulating component insertion process S13, the upper insulating components 2 are connected by upper runners 4 and the lower insulating components 3 are connected by lower runners 5 so that the multiple iron core blocks 6, upper insulating components 2, and lower insulating components 3 are arranged at equal intervals, so that the upper insulating components 2 and lower insulating components 3 can be easily inserted into the iron core blocks 6.

[0025] In the connecting portion cutting process S14, as shown in Figures 15 and 16, while the connecting upper insulating part 20 and the connecting lower insulating part 30 are inserted into the stator core 1, the runner connection part 24 of the connecting upper insulating part 20 is cut and the runner connection part 34 of the connecting lower insulating part 30 is cut.

[0026] In the winding step S15, as shown in FIG. 17, the winding 8 is wound around the slots of the stator core 1.

[0027] In the annular core forming step S16, as shown in FIG. 18, the stator core 1 is bent at the thin-walled connecting portions 7 toward the inner circumferential portion 13 to be formed into an annular shape.

[0028] Through the above steps, the stator 9 is completed.

[0029] As described above, according to the first embodiment, the use of an upper connecting insulating part 20 in which a plurality of upper insulating parts 2 are connected by upper runners 4 and a lower connecting insulating part 30 in which a plurality of lower insulating parts 3 are connected by lower runners 5 simplifies the work of assembling the insulating parts to the stator core 1, thereby reducing the work time. Furthermore, in the case of automated assembly, the process of aligning the insulating parts to make assembly easier and the process of assembling the stator core 1 and the insulating parts are not required, reducing equipment costs and resolving the problem of securing installation space.

[0030] Embodiment 2 In the second embodiment, a method for manufacturing an electric motor using the stator of the first embodiment will be described. Fig. 19 is a flowchart showing the steps of the method for manufacturing an electric motor of the second embodiment. The manufacturing process of the electric motor includes the stator forming step S10, the rotor forming step S20, and the assembly step S30 described above. In the assembly step S30, the stator 9 is held in the front casing 102 and the rear casing 103, the rotor 104 is placed on the inner periphery of the stator 9, and the rotating shaft 106 of the rotor 104 is held in the front casing 102 and the rear casing 103 via bearings 105 (see Fig. 7).

[0031] The configurations shown in the above embodiments are examples of the contents of the present disclosure, and may be combined with other known technologies, and parts of the configurations may be omitted or modified within the scope of the gist of the present disclosure. [Explanation of symbols]

[0032] 1 stator core, 2 upper insulating part, 3 lower insulating part, 4 upper runner, 5 lower runner, 6 core block, 7 thin-walled connecting part, 8 winding, 9 stator, 11 yoke part, 11a tapered surface, 12 teeth part, 13 inner circumference part, 20 connecting upper insulating part, 24, 34 runner connecting part, 30 connecting lower insulating part, 100 electric motor, 102 front casing, 103 rear casing, 104 rotor, 105 bearing, 106 rotating shaft.

Claims

1. forming a stator core in which a plurality of T-shaped core blocks formed from laminated steel plates, each having a yoke portion that forms an outer peripheral magnetic path and teeth that protrude inward from the yoke portion and form magnetic poles, are linearly arranged and connected to each other by thin-walled connecting portions of the yoke portion; forming a first connecting insulating component in which a plurality of insulating components are arranged at the same intervals as the plurality of iron core blocks and connected by first runners, and a second connecting insulating component in which a plurality of insulating components are arranged at the same intervals as the plurality of iron core blocks and connected by second runners; inserting the first connecting insulating component and the second connecting insulating component into the stator core from both sides in the lamination direction of the steel plates to insulate the periphery of the tooth portion; cutting the first runner of the first connecting insulating component and cutting the second runner of the second connecting insulating component; a step of winding a winding around the tooth portion via the insulating component after cutting the first runner and the second runner; bending the stator core at the thin-walled connecting portion to form an annular shape; A method for manufacturing a stator, comprising:

2. a process comprising a method for manufacturing a stator according to claim 1; retaining the stator in a casing; a step of disposing a rotor on an inner periphery of the stator and holding the rotor in the casing via a bearing; A method for manufacturing an electric motor, comprising:

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