Stator of rotary electric machine, rotary electric machine, and method for manufacturing stator of rotary electric machine

Abstract

When assembling divided iron cores, there was a problem in that multiple positioning steps were required, which led to an increased number of steps and more complex facilities, thereby causing an increase in processing costs.　According to the present invention, when joining a first divided iron core and a second divided iron core together, a first protrusion of the first divided iron core and a second recess of the second divided iron core are brought close to each other in the circumferential direction and and made to contact each other in a state of having the first divided iron core and the second divided iron core be offset in the height direction, after which one or both of the first protrusion and the second recess are slid in the height direction, whereby a first groove portion of the first divided iron core and a second tenon portion of the second divided iron core are engaged with each other, and a first tenon portion of the first divided iron core and a second groove portion of the second divided iron core are engaged with each other.

Description

Rotating electric machine stator, rotating electric machine, and method of manufacturing a rotating electric machine stator

[0001] The present disclosure relates to a stator for a rotating electric machine, a rotating electric machine, and a method for manufacturing a stator for a rotating electric machine.

[0002] For example, Patent Document 1 discloses the following stator structure. In a stator in which a plurality of split cores, each having a back yoke portion connected in a circular pattern and teeth protruding radially from the back yoke portion, are connected in a circular pattern, the split cores are: (1) a set of a predetermined number of first core blanks, each having a first convex portion formed on one of the left and right connecting surfaces of the back yoke portion and a first concave portion formed on the other, into which the first convex portion can be inserted from the stacking direction; (2) a set of a predetermined number of second core blanks, each having a second convex portion formed on one of the left and right connecting surfaces of the back yoke portion, which can be inserted into the first concave portion of the first core blank from the stacking direction and the circumferential direction, and a second concave portion formed on the other, into which both the first convex portion and the second convex portion of the first core blank can be inserted from the stacking direction and the circumferential direction; and each set of first core blanks and second core blanks is alternately stacked in the stacking direction, and the stator is configured by fitting the first convex portion of the first core blank of adjacent split cores with the first concave portion of the first core blank.

[0003] Patent No. 561339

[0004] In the stator described in Patent Document 1, when combining the split cores, the second protrusions are first fitted into the first recesses, and the second recesses are fitted into the first protrusions or second protrusions from the circumferential direction. At this time, if the radial positional relationship between each recess and protrusion is not adjusted, the recesses and protrusions will not fit together, making assembly impossible.

[0005] Furthermore, when the second protrusions are fitted into the first recesses, and the second recesses are fitted into the first protrusions or the second protrusions, gaps are provided between the recesses and the protrusions, so when fitting the first protrusions into the first recesses from the stacking direction, it is necessary to adjust the radial positional relationship between them again. As such, the stator described in Patent Document 1 requires multiple positioning processes when assembling the core segments, which increases the number of steps, complicates the equipment, and increases processing costs.

[0006] The present disclosure has been made to solve the problems described above, and aims to provide a stator for a rotating electric machine that eliminates the need for multiple positioning steps when combining adjacent core segments, thereby reducing processing costs.

[0007] The stator of the rotating electric machine of the present disclosure is configured by arranging a plurality of core segments in an annular shape, each segment consisting of a back yoke section formed by dividing a ring in the circumferential direction and teeth projecting from the back yoke section, and the stator has a first joint section formed on both end portions of the back yoke section and joining surfaces that join adjacent core segments, the first joint section having at least a first groove section, a first protrusion section, and a first tenon section in the height direction of one joint surface, and a second joint section having a second tenon section, a first recess section, and a second groove section in the height direction of the other joint surface, and the first groove The first tenon engages with the second tenon of the adjacent split core, the first convex contacts with the first concave of the adjacent split core, the first tenon engages with the second groove of the adjacent split core, the first and second tenon are configured to be insertable into the first and second grooves only from the height direction, the first convex is configured to be insertable into the first concave from either the height direction or the circumferential direction, and the first and second tenon are larger in shape than the first convex in both the radial and circumferential directions.

[0008] According to the stator of the rotating electric machine disclosed herein, radial and circumferential positioning is performed by bringing the first convex portion and the first concave portion into contact, thereby eliminating the need for multiple positioning steps and reducing processing costs.

[0009] 5 is a perspective view showing a core segment according to embodiment 1. FIG. 5 is a perspective view of a stator according to embodiment 1. FIG. 5 is a perspective view of a rotating electric machine in which a stator and a rotor according to embodiment 1 are combined. FIG. 5 is an explanatory view of side surfaces where core segments according to embodiment 1 come into contact with each other. FIG. 5 is an explanatory view of assembly of a stator using a core segment according to embodiment 1. FIG. 5 is a cross-sectional view taken along A-A in FIG. 5. FIG. 5 is a cross-sectional view taken along B-B in FIG. 5. FIG. 5 is a cross-sectional view taken along C-C in FIG. 5. FIG. 5 is a cross-sectional view taken along D-D in FIG. 5. FIG. 5 is a cross-sectional view taken along E-E in FIG. 5. FIG. 5 is a perspective view of a core segment according to embodiment 2. FIG. 5 is an explanatory view of assembly of a stator using a core segment according to embodiment 2. FIG. 5 is an explanatory view of assembly of a stator using a core segment according to embodiment 2. FIG. 5 is an explanatory view of assembly of a stator using a core segment according to embodiment 3. FIG. 5 is a plan view of a core segment according to embodiment 3. FIG. 5 is a perspective view of a core segment according to embodiment 4. FIG. 5 is a plan view of a core segment according to embodiment 4. FIG. 5 is an explanatory view of a core segment according to embodiment 5. FIG. 5 is a perspective view of a coupled core according to embodiment 6. FIG. 5 is a perspective view of a coupled core according to embodiment 6. FIG. 5 is an explanatory view of assembly of a stator using a core segment according to embodiment 7. FIG. 5 is an explanatory view of assembly of a stator using a core segment according to embodiment 7.

[0010] Hereinafter, preferred embodiments of a stator for a rotating electric machine according to the present disclosure will be described with reference to the drawings. The same components and corresponding parts are designated by the same reference numerals, and detailed descriptions thereof will be omitted. Similarly, in the following embodiments, redundant descriptions of components designated by the same reference numerals will be omitted.

[0011] Embodiment 1. Fig. 1 is a perspective view showing a core segment 1a constituting a stator according to embodiment 1. Fig. 2 is a perspective view of a stator 2 formed by combining a plurality of core segments 1a according to embodiment 1 in an annular shape. Fig. 3 is a perspective view showing a rotating electric machine 2B in which the stator 2 and a rotor 2A are combined.

[0012] The core segments 1a are constructed by cutting electromagnetic steel sheets into a predetermined shape using a press, wire processing machine, laser processing machine, or the like, and then stacking multiple cut electromagnetic steel sheets in order to a predetermined height. The surface corresponding to the circular surface of the stator 2 in Figure 2 that is visible in Figures 1 and 2 is defined as the top surface of the core segment 1a, the surface opposite the top surface that is not visible in Figures 1 and 2 is defined as the bottom surface of the core segment 1a, and the surface on which the striped laminated electromagnetic steel sheets can be seen is defined as the side surface. The core segments 1a are divided into a back yoke portion 3 on the outer diameter side of the stator 2 and teeth portions 4 on the inner diameter side.

[0013] The back yoke portion 3 is the portion that forms a circular ring when multiple core segments 1a are combined, and has a shape that divides the ring equally in the circumferential direction. The core segments 1a come into contact with each other on two circumferential ends, each with a different shape. The shape of these ends will be described in detail.

[0014] 1, of the two ends where the core segments 1a come into contact, one end 5a1 has three different shapes formed thereon, which, from the top surface side, are a dovetail groove portion (hereinafter referred to as a groove portion) 6a1, a L-shaped protrusion portion (hereinafter referred to as a protrusion portion) 7a1, and a dovetail tenon portion (hereinafter referred to as a tenon portion) 8a1. The shapes are adjacent to each other in the stacking direction (also referred to as the height direction, the same applies hereinafter), and the size in the stacking direction of the protrusion portion 7a1 is the largest, while the sizes of the groove portion 6a1 and the tenon portion 8a1 in the stacking direction are the same, but the shape is formed to be one size smaller than the protrusion portion 7a1.

[0015] The groove 6a1 is recessed in a trapezoidal shape in the circumferential direction of the one end 5a1, and the shape becomes smaller in the circumferential direction as it approaches the end. That is, the radial gap is smallest at the open end of the groove, and conversely, the bottom of the groove, which corresponds to the lower side of the recessed trapezoid, is configured as a dovetail groove where the radial gap is largest.

[0016] The convex portion 7a1 has a triangular shape that protrudes in the circumferential direction, and the shape is configured such that the radial size becomes smaller as it approaches the end in the circumferential direction.

[0017] The tenon portion 8a1 has a trapezoidal shape that protrudes circumferentially from one end 5a1, and is configured as a dovetail shape in which the radial size of the part of the circumferential end that corresponds to the lower side of the protruding trapezoid is the largest, and the radial size of the base part on the opposite side to the end that corresponds to the upper side of the protruding trapezoid is the smallest.

[0018] The other end 5a2 shown on the right side of Figure 1 also has three different shapes, which are, from the top, a dovetail portion (hereafter referred to as "tenon portion") 8a2, a V-shaped recess (hereafter referred to as "recess") 7a2, and a dovetail groove portion (hereafter referred to as "groove") 6a2. The shapes are adjacent to each other in the stacking direction, and the recess 7a2 is the largest in size in the stacking direction. The tenon portion 8a2 and the groove portion 6a2 are the same size in the stacking direction, but are formed to be one size smaller than the recess 7a2.

[0019] Furthermore, the grooves 6a1 and tenons 8a2, the protrusions 7a1 and recesses 7a2, and the tenons 8a1 and grooves 6a2 are all configured to be the same size in the stacking direction. Note that there may be gaps between the grooves 6a1 and the protrusions 7a1, and between the protrusions 7a1 and the tenons 8a1. The grooves 6a1 and 6a2 have the same shape, and the tenons 8a1 and 8a2 also have the same shape, so a description thereof will be omitted.

[0020] The recess 7a2 has a triangular recessed shape in the circumferential direction, and its shape is configured so that the radial gap becomes smaller as it approaches the bottom of the recess. The recessed shape of the grooves 6a1, 6a2 in the circumferential direction and the protruding shape of the tenon portions 8a1, 8a2 in the circumferential direction match, so that when the grooves 6a1, 6a2 and the tenon portions 8a2, 8a1 are combined, there is no gap.

[0021] As described above, the grooves 6a1 and 6a2 are configured such that the radial gap becomes smaller in the circumferential direction as they approach the groove opening end, and conversely, the radial gap becomes larger as they approach the groove bottom. Furthermore, the tenon portions 8a1 and 8a2 are configured such that the radial size becomes larger in the circumferential direction as they approach the tenon tip, and conversely, the radial size becomes smaller as they approach the tenon base. Therefore, it is impossible to insert the tenon portions 8a1 and 8a2 into the grooves 6a1 and 6a2 from the circumferential direction, and it is also impossible to separate the combined grooves 6a1 and 6a2 and the tenon portions 8a2 and 8a1 by moving them circumferentially relative to each other.

[0022] The only combination possible is when the tenon portions 8a2, 8a1 are inserted into the groove portions 6a1, 6a2 in the stacking direction. The triangular protruding shape of the convex portion 7a1 in the circumferential direction and the triangular recessed shape of the concave portion 7a2 in the circumferential direction match, so there is no gap when the convex portion 7a1 and the concave portion 7a2 are combined. However, there may be a gap as long as the magnetic resistance does not become too large.

[0023] The recessed portion 7a2 can be combined with the protruding portion 7a1 in either the circumferential direction or the stacking direction. The protruding portions of the tenon portions 8a1 and 8a2 are larger than the protruding portion of the protruding portion 7a1 in both the radial and circumferential directions. Details will be explained using Figure 4. Figure 4 is a top view of the protruding portion 7a1 superimposed on the tenon portions 8a1 and 8a2. The area of ​​the protruding portion 7a1 is clearly indicated by diagonal lines. The entire area of ​​the diagonal lines representing the protruding portion 7a1 is contained within the area of ​​the tenon portions 8a1 and 8a2. In this way, the protruding portions of the tenon portions 8a1 and 8a2 are not simply larger than the protruding portion 7a1, but are configured to encompass the protruding portion 7a1.

[0024] The teeth portion 4 shown in Figure 1 is a portion that extends from near the circumferential center of the back yoke portion 3 toward the inner diameter direction of the stator 2. The side surface on the inner diameter side is arc-shaped, and both circumferential side surfaces are configured to be parallel to each other. At the point closest to the inner diameter, shoes 10 are provided on both sides, protruding in the circumferential direction from the parallel surfaces. The size of the shoes 10 is set so that when the split cores 1a are combined, there is a gap between the shoes 10 of adjacent split cores 1a.

[0025] Next, a method for manufacturing the core segments 1a will be described. The core segments 1a are formed by stacking three different types of electromagnetic steel sheets. The first type is a first electromagnetic steel sheet having grooves 6a1 and tenon portions 8a2, the second type is a second electromagnetic steel sheet having protrusions 7a1 and recesses 7a2, and the third type is a third electromagnetic steel sheet having tenon portions 8a1 and grooves 6a2. These sheets are stacked in order to reach the required height in the stacking direction. In this case, three types of punching dies are required for the three types of electromagnetic steel sheets. For example, the first electromagnetic steel sheet having grooves 6a1 and tenon portions 8a2 and the third electromagnetic steel sheet having tenon portions 8a1 and grooves 6a2 are line-symmetrical, so the third electromagnetic steel sheet can be substituted by flipping the first electromagnetic steel sheet. In this case, only two types of punching dies are required, thereby reducing processing costs.

[0026] Next, a method for assembling the stator 2 by combining the core segments 1a will be described with reference to Figures 5 to 10. Figure 5 shows the state in which the core segments 1b and 1c are pressed against each other in the circumferential direction while shifted in the lamination direction. Although the core segments 1b and 1c have the same shape as the core segment 1a, for ease of explanation, they will be referred to as core segments 1b and 1c. Figures 6 to 10 are cross-sectional views taken along lines A-A to E-E shown in Figure 5. One end 5b1 of the core segment 1b and one end 5c2 of the core segment 1c are brought into contact in the circumferential direction while shifted in the lamination direction. The direction and amount of shift must satisfy the following conditions (1) to (3). (1) As shown in the B-B cross section of Figure 7, the groove 6b1 of the core segment 1b contacts the recess 7c2 of the core segment 1c. (2) As shown in the CC cross section in Figure 8 and the D-D cross section in Figure 9, the convex portion 7b1 of the core segment 1b comes into contact with the concave portion 7c2 and groove portion 6c2 of the core segment 1c. At this time, because they press against each other from the circumferential direction, a component force is generated in the direction that aligns the radial positions of the core segments 1b and 1c at the V-shaped tapered portion, completing radial positioning. (3) As shown in the A-A cross section in Figure 6 and the E-E cross section in Figure 10, the tenon portion 8b1 of the core segment 1b and the tenon portion 8c2 of the core segment 1c do not come into contact with any other parts.

[0027] From this state, while maintaining their circumferential pressing, the core segments are moved in the opposite direction of the shift in the stacking direction, inserting the groove 6b1 of core segment 1b into the tenon portion 8c2 of core segment 1c, and the tenon portion 8b1 of core segment 1b into the groove 6c2 of core segment 1c, completing the assembly of core segment 1b and core segment 1c. When one or both of core segments 1b and 1c are slid in the stacking direction to fit the groove 6b1 into the tenon portion 8c2 and the groove 6c2 into the tenon portion 8b1, the radial positioning is already complete, and this state is maintained by the fit of the protrusion 7b1 and the recess 7c2. Therefore, the grooves 6b1, 6c2 and the tenon portions 8c2, 8b1 can be moved in the stacking direction without interference and can be fitted together as is. By repeating these steps with adjacent core segments, the stator 2 shown in Figure 2 can be assembled. 3 can be assembled by disposing the rotor 2A on the stator 2. Note that in the second to fifth embodiments, the rotor 2A is disposed on the stator to assemble the rotating electric machine in the same manner.

[0028] This eliminates the need for a positioning process when combining adjacent core segments or the need to provide a positioning mechanism on the assembly equipment side, thereby suppressing increases in processing costs. Furthermore, because the grooves 6b1, 6c2 and the tenon portions 8c2, 8b1, and the protrusions 7b1 and the recesses 7c2 fit snugly together, no gaps occur between the core segments, preventing a decrease in the efficiency of the rotating electric machine. While snug fit between the protrusions 7b1 and the recesses 7c2 is desirable for suppressing increases in magnetic resistance, a gap between the protrusions 7b1 and the recesses 7c2 is acceptable as long as the increase in magnetic resistance is within an acceptable range.

[0029] According to the above configuration, when the core segments 1b and 1c are assembled, the convex portions 7b1 of the core segments 1b and the concave portions 7c2 of the core segments 1c come into contact when they are first pressed together circumferentially while shifted in the stacking direction. Therefore, even if the positional relationship between the core segments 1b and 1c is shifted radially, a component force is generated between the convex portions 7b1 and the concave portions 7c2 in a direction that eliminates the radial shift, allowing them to be positioned radially without an additional positioning step. Furthermore, since the positioning in both the circumferential and radial directions is completed when the core segments 1b and 1c are pressed together circumferentially, simply shifting them in the stacking direction will allow the grooves 6b1 of the core segments 1b and the tenon portions 8c2 of the core segments 1c to fit together, and the tenon portions 8b1 of the core segments 1b and the grooves 6c2 of the core segments 1c to fit together. Therefore, a positioning mechanism is not required here either. In this way, when combining the core segments, no positioning mechanism is required, simplifying assembly equipment and reducing processing costs. Furthermore, when the core segments 1b and 1c are combined, the grooves 6b1 and tenons 8c2, the protrusions 7b1 and recesses 7c2, and the tenons 8b1 and grooves 6c2 fit together without any gaps, resulting in no gaps at the joints. This prevents an increase in magnetic resistance and suppresses a decrease in the efficiency of the rotating electric machine. However, as mentioned above, a gap may exist between the protrusions 7b1 and recesses 7c2 as long as the increase in magnetic resistance is within an acceptable range.

[0030] Embodiment 2. Fig. 11 is a perspective view showing a core segment 1d according to embodiment 2, and Figs. 12 and 13 are schematic diagrams of combining multiple core segments 1d into a circular ring. When assembling a stator from the core segments 1a of embodiment 1, if the core segments 1a are combined one by one, when the last one is combined to form a circular ring, the core segments will interfere with each other, making the assembly more difficult. To avoid this, a configuration like the core segment 1d shown in Fig. 11 can be used.

[0031] Core segment 1d differs from core segment 1a in the arrangement of three different shapes at both ends. One end 5d1 of core segment 1d has, from the top surface, a dovetail groove portion (hereinafter referred to as groove) 6d1, a V-shaped protrusion (hereinafter referred to as protrusion) 7d1, and a dovetail portion (hereinafter referred to as tenon portion) 8d1, while the opposite end 5d2 has, from the top surface, a dovetail groove portion (hereinafter referred to as groove) 6d2, a V-shaped recess (hereinafter referred to as recess) 7d2, and a dovetail portion (hereinafter referred to as tenon portion) 8d2. A stator can be assembled by combining core segment 1d with core segment 1e, which has a structure opposite to that of core segment 1d.

[0032] 11 to form core segment 1e, the groove 6d1 and tenon 8d1 at one end 5d1 of core segment 1d are interchanged, and the tenon 8e1, protrusion 7e1, and groove 6e1 are configured in this order from the top surface of end 5e1. Also, the groove 6d2 and tenon 8d2 at the opposite end 5d2 are interchanged, and the tenon 8e2, recess 7e2, and groove 8e1 are configured in this order from the top surface of end 5e2.

[0033] If the stator is made up of an even number of core segments, the stator can be assembled without interference by alternately combining core segments 1d and 1e as shown in Fig. 12. Also, if the stator is made up of an odd number of core segments, the stator can be assembled smoothly without the core segments interfering with each other by incorporating only one core segment 1a in embodiment 1 and combining the rest with core segments 1d and 1e in embodiment 2 in the same way as when there is an even number of core segments, as shown in Fig. 13.

[0034] Embodiment 3. Figure 14 is a perspective view showing a core segment 1f according to embodiment 3, and Figure 15 is a plan view showing a core segment 1f according to embodiment 3. In embodiments 1 and 2, the components include a V-shaped convex portion and a V-shaped concave portion, but this is not limited to a V-shape. Any shape may be used as long as a component force is generated in a direction that reduces the radial misalignment between the core segments at the contact points when the core segments are pressed against each other. For example, as shown in Figures 14 and 15, circular convex portions 11 and circular concave portions 12 may be used. With this shape, a component force is generated in a direction that reduces the radial misalignment between the core segments at the contact points when the core segments are pressed against each other.

[0035] Embodiment 4. FIG. 16 is a perspective view showing a core segment 1g according to embodiment 4, and FIG. 17 is a plan view showing a core segment 1g according to embodiment 4. In embodiments 1 to 3, the components include dovetail grooves and dovetails, but this is not limited thereto. Any shape may be used as long as it is larger than the L-shaped and circular protrusions, cannot be assembled or disassembled in the circumferential direction, and can be assembled in the stacking direction. For example, as shown in FIG. 16, hook protrusions 13 and hook recesses 14 may extend in the circumferential direction and bend radially inward. Such shapes can be larger than the L-shaped and circular protrusions, cannot be assembled or disassembled in the circumferential direction, and can be assembled in the stacking direction.

[0036] Fifth Embodiment. Figure 18 is a perspective view showing a core segment 1h according to a fifth embodiment. While it has been described that the two ends of the back yoke portion of the core segment have three different shapes, four types are also acceptable. Specifically, one end 5h1 of the core segment 1h may have, from the top surface, a dovetail groove portion (hereinafter referred to as a groove portion) 6h1, a V-shaped recess portion (hereinafter referred to as a recess portion) 9h1, a V-shaped protrusion portion (hereinafter referred to as a protrusion portion) 7h1, and a dovetail portion (hereinafter referred to as a tenon portion) 8h1, while the opposite end 5h2 may have, from the top surface, a dovetail portion (hereinafter referred to as a tenon portion) 8h2, a V-shaped protrusion portion (hereinafter referred to as a protrusion portion) 7h2, a V-shaped recess portion (hereinafter referred to as a recess portion) 9h2, and a dovetail groove portion (hereinafter referred to as a groove portion) 6h2. In this state, when the split cores are pressed against each other circumferentially while being shifted in the stacking direction, they should be shifted in the stacking direction so as to satisfy the following conditions: dovetail groove portion 6h1 contacts convex portion 7h2, concave portion 9h1 contacts convex portion 7h2 and concave portion 9h2, convex portion 7h1 contacts concave portion 9h2 and groove portion 6h2, and tenon portions 8h1 and 8h2 are not in contact with any parts.

[0037] In this case, four types of punching dies are required to manufacture the core segments 1h. However, by using an electromagnetic steel sheet with a combination of dovetail grooves and dovetail tenon sections and an electromagnetic steel sheet with a combination of a V-shaped recess and a V-shaped protrusion, the number of punching dies required can be reduced to two, thereby reducing processing costs. Furthermore, because the protrusions 7h1 and 7h2 interfere with each other in the axial direction when moved in the opposite direction from the direction of lamination, the axial retention strength of the recess 9h1 and tenon section 8h2, and the recess 9h2 and tenon section 8h1, can be further strengthened. The first through fifth embodiments described above can be freely combined, and any combination that satisfies the conditions described in each embodiment and does not create gaps at the joints between the core segments is acceptable. However, as mentioned above, gaps at the joints are acceptable as long as the increase in magnetic reluctance is within an acceptable range. Among these, when embodiment 2 and embodiment 5 are combined, the combined split core has an axisymmetric structure, so there is no need to prepare split cores that are opposite in orientation, such as split core 1e for split core 1d in embodiment 2, resulting in the unique effect of being able to reduce the number of types of split cores.

[0038] Sixth Embodiment Figure 19 is a perspective view showing a linked core 1i according to a sixth embodiment. The connection of each core segment described in the first to fifth embodiments can also be used when connecting only both ends of a linked core having multiple connected teeth. For example, the linked core 1i in Figure 19 is connected by applying the structure of any of the first to fifth embodiments to only one segment 15a on the circumference. The remaining connected core portions are connected by a rotating portion 17.

[0039] As a structure for connecting the divided portions 15a, for example, as shown in Figure 1 of the first embodiment, one end of the divided portion 15a has three different shapes formed thereon, which are, from the top side, a groove, a protrusion, and a tenon. Similarly, the other end of the divided portion 15a has three different shapes formed thereon, which are, from the top side, a tenon, a recess, and a groove. The shapes are adjacent to each other in the stacking direction, and the sizes of the convex and recessed portions in the stacking direction are the largest, while the sizes of the groove and tenon portions in the stacking direction are equal and are slightly smaller than the convex and recessed portions.

[0040] With this configuration, as shown in Fig. 19, the connecting core 1i is elastically deformed, the divided portions 15a are pushed from the circumferential direction while being shifted in the axial direction (see Fig. 5), and then assembly can be completed simply by moving them in the opposite direction to the shifted axial direction. This reduces the number of steps required for assembly and reduces processing costs.

[0041] In addition, in addition to the connection by the rotating portion 17 of this embodiment, it is also possible to apply embodiments 1 to 5 to the dividing portion 15b and join them in the same way when the connection is by, for example, the thin-walled portion 16 shown in Figure 20, or by a member other than the iron core, such as an insulating member.

[0042] Furthermore, when the connecting core is deformed and twisted into place while being shifted in the axial direction, the amount of axial shift that can be achieved differs between the rotating connecting core shown in Fig. 19 and the thin-walled connecting core shown in Fig. 20 due to differences in connection structure. The thin-walled connecting core shown in Fig. 20 is connected by the core material, so there is no backlash and it is necessary to cause elastic deformation to allow for shifting. In contrast, in the rotating connecting core of Fig. 19, adjacent teeth are connected by a concave-convex shape, so it is possible to shift the teeth by the amount of backlash in the concave-convex parts, making it easier to twist-fit than the thin-walled connecting core.

[0043] Seventh Embodiment. Figures 21 and 22 are diagrams illustrating the assembly of a stator by combining multiple block-shaped cores in a circular ring shape. Figure 21 shows the assembly of three-teeth block-shaped cores 1k. The arrangement of shapes formed on one end of block-shaped core 1k is different from the arrangement of cores 1i and 1j. That is, as described above, one end of the divided portions of cores 1i and 1j has grooves, protrusions, and tenons formed from the top, similar to Figure 1 of the first embodiment, while the other end of the divided portions has tenons, recesses, and grooves formed from the top. In contrast, one end of block-shaped core 1k has grooves, protrusions, and tenons formed from the top, and the opposite end has grooves, recesses, and tenons formed from the top. The respective shapes are adjacent in the stacking direction, and the size in the stacking direction of the convex and concave portions is the largest, while the size in the stacking direction of the groove and tenon portions is the same, and they are formed so that they are one size smaller than the convex and concave portions. Also, the three teeth that make up the block-shaped connecting core 1k are connected by rotational connections or thin-walled connections, as in Figures 19 and 20.

[0044] When assembling a stator using an even number of block-shaped linked cores, they can be assembled without interference by assembling every other block-shaped linked core 1k upside down as shown in Fig. 21. However, since interference occurs when there is an odd number of blocks, as explained in the second embodiment, by incorporating only one block-shaped linked core 1m having a structure opposite to that of the block-shaped linked core 1k as shown in Fig. 22, the stator can be assembled without the twist fit explained in the sixth embodiment.

[0045] Although various exemplary embodiments and examples are described in this disclosure, the various features, aspects, and functions described in one or more embodiments are not limited to the application of a particular embodiment, but may be applied to the embodiments alone or in various combinations. Therefore, countless variations not illustrated are anticipated within the scope of the technology disclosed herein. For example, this includes cases where at least one component is modified, added, or omitted, or where at least one component is extracted and combined with components of another embodiment.

[0046] Various aspects are summarized below as appendices.

[0047] (Note 1) In a stator for a rotating electric machine, the stator is configured by arranging a plurality of split cores in an annular shape, the split cores being made up of a back yoke portion shaped like a ring divided in the circumferential direction and teeth projecting from the back yoke portion, the stator having joint surfaces formed on both side ends of the back yoke portion and joining adjacent split cores, the joint surfaces having at least a first groove, a first protrusion, and a first tenon formed in the height direction of one joint surface, and a second joint surface having a second groove, a first recess, and a second tenon formed in the height direction of the other joint surface, the first groove and the second tenon of the adjacent split core engage with each other, the first protrusion and the first recess of the adjacent split core are in contact with each other without any gap, and the first tenon and the second groove of the adjacent split core engage with each other, A stator for a rotating electric machine, characterized in that the first tenon portion and the second tenon portion are configured to be insertable into the first and second groove portions only from the height direction, the first protrusion portion is configured to be insertable into the first recess portion from either the height direction or the circumferential direction, and the first tenon portion and the second tenon portion are larger than the first protrusion portion in both the radial direction and the circumferential direction. (Appendix 2) The stator for a rotating electric machine according to Appendix 1, characterized in that the first joint portion has a second recess portion connected to the first protrusion portion in the height direction, the second joint portion has a second protrusion portion connected to the first recess portion in the height direction, and the second recess portion of one core segment and the second protrusion portion of the adjacent core segment are in contact with each other without any gap. (Appendix 3) The stator for a rotating electric machine according to Appendix 1 or 2, characterized in that the first groove portion and the second groove portion are provided at opposite ends of the core segments in the height direction. (Supplementary Note 4) The stator of a rotating electric machine according to Supplementary Note 1 or 2, characterized in that the first groove and the second groove are provided at ends of the core segments on the same side in the height direction. (Supplementary Note 5) The stator of a rotating electric machine according to Supplementary Note 1 or 2, characterized in that it is configured by combining an odd number of core segments in which the first groove and the second groove are provided at ends on opposite sides in the height direction, and core segments in which the first groove and the second groove are provided at ends on the same side in the height direction.(Supplementary Note 6) The stator of a rotating electric machine according to any one of Supplementary Notes 1 to 5, wherein the first and second groove portions have a trapezoidal recessed shape with respect to the circumferential direction, the recessed shape being a dovetail shape configured so that the radial gap is smallest at an open end of the groove corresponding to an upper side of the recessed trapezoid and largest at a bottom of the groove corresponding to a lower side of the recessed trapezoid, and the tenon portion has a trapezoidal protruding shape with a radial size largest at a portion of the circumferential end corresponding to the lower side of the protruding trapezoid and a radial size smallest at a base portion corresponding to the upper side of the protruding trapezoid. (Supplementary Note 7) The stator of a rotating electric machine according to any one of Supplementary Notes 1 to 5, wherein the first and second groove portions are formed in a hook shape with respect to the circumferential direction, and the first and second tenon portions are also formed in a hook shape. (Supplementary Note 8) The stator of a rotating electric machine according to any one of Supplementary Notes 1 to 7, wherein the first convex portion protrudes in a triangular shape with respect to the circumferential direction, and the first concave portion is recessed in a triangular shape with the circumferential end portion as a base. (Supplementary Note 9) The stator of a rotating electric machine according to any one of Supplementary Notes 1 to 7, wherein the first convex portion protrudes in a circular shape with respect to the circumferential direction, and the first concave portion is recessed in a circular shape with the circumferential end portion as a base.(Supplementary Note 10) In a stator for a rotating electric machine, the stator is configured by arranging a plurality of split cores in an annular shape, the split cores being made of a back yoke portion circumferentially divided into a ring and teeth projecting from the back yoke portion, the stator having a first joint portion formed at an end of the back yoke portion of a first split core, the first joint portion having at least a first groove portion, a first protrusion portion, and a first tenon portion formed in a height direction of a joint surface that joins with an adjacent second split core, the second joint portion having a second groove portion, a first recess portion, and a second tenon portion formed on a joint surface that faces the first joint portion of the second split core, the first groove portion and the second tenon portion engaging with each other, the first protrusion portion and the first recess portion contacting each other without any gap, and the first tenon portion engaging with the second groove portion, and a rotor disposed opposite the stator via a gap, the rotor being rotatably disposed on the stator, the rotor being rotatably disposed on the stator via a gap ...(Supplementary Note 12) In a manufacturing method of a stator for a rotating electric machine in which split cores each consisting of a back yoke portion shaped by dividing a ring in the circumferential direction and teeth protruding from the back yoke portion are arranged in a circular shape, the back yoke portion has joint surfaces formed on both side ends thereof and joined to adjacent split cores, the joint surfaces having at least a first groove portion, a first protrusion portion, and a first tenon portion formed in the height direction of one joint surface, and a second joint surface having a second tenon portion, a first recess portion, and a second groove portion formed in the height direction of the other joint surface, and the adjacent first split cores and second split cores a first concave portion of the first core segment and a second concave portion of the second core segment that are brought into contact with each other from the circumferential direction while the first core segment and the second core segment are shifted in the height direction, and then one or both of the second concave portion and the first convex portion are slid in the height direction to engage the first groove portion of the first core segment with the second tenon portion of the second core segment, and to engage the first tenon portion of the first core segment with the second groove portion of the second core segment.

[0048] 1a to 1h: split cores, 1i, 1j, 1k, 1m: connecting cores, 2: stator, 2A: rotor, 2B: rotating electric machine, 3: back yoke portion, 4: teeth portion, 6a1, 6a2, 6b1, 6c2, 6d1, 6d2, 6e1, 6h1, 6h2: groove portions, 7a1, 7b1, 7d1, 7e1, 7h1, 7h2: convex portions, 8a 1, 8a2, 8b1, 8c2, 8e1, 8e2, 8d1, 8d2, 8h1, 8h2: tenon portions, 7a2, 7d2, 7c2, 7e2, 9h1, 9h2: recesses, 10: shoe, 11: circular protrusions, 12: circular recesses, 13: hook protrusions, 14: hook recesses, 15a, 15b: dividing portions, 16: thin-walled portions, 17: rotating portions.

Claims

1. In a stator for a rotating electric machine, the stator is configured by arranging a plurality of split cores in an annular shape, the split cores being made up of a back yoke portion shaped like a ring divided in the circumferential direction and teeth protruding from the back yoke portion, the stator having joint surfaces formed on both side ends of the back yoke portion and joining adjacent split cores, the joint surfaces having at least a first groove, a first convex portion, and a first tenon portion formed in the height direction of one joint surface, and a second joint surface having a second groove, a first concave portion, and a second tenon portion formed in the height direction of the other joint surface, the first groove portion and the second tenon portion of the adjacent core split are engaged with each other, the first protrusion portion and the first recess portion of the adjacent core split are in contact with each other, and the first tenon portion and the second groove portion of the adjacent core split are engaged with each other, A stator for a rotating electric machine, characterized in that the first tenon portion and the second tenon portion are configured to be insertable into the first and second groove portions only from the height direction, the first convex portion is configured to be insertable into the first concave portion from either the height direction or the circumferential direction, and the first tenon portion has a shape that includes the first convex portion when viewed from the height direction.

2. 2. The stator of a rotating electric machine according to claim 1, characterized in that the first joint has a second recess that is continuous with the first convex portion in the height direction, the second joint has a second convex portion that is continuous with the first recess in the height direction, and the second recess of the split core and the second convex portion of the adjacent split core are in contact with each other.

3. 3. The stator for a rotating electric machine according to claim 1, wherein the first groove and the second groove are provided at ends of the core segments on opposite sides in a height direction.

4. 3. The stator for a rotating electric machine according to claim 1, wherein the first groove and the second groove are provided at ends of the core segments on the same side in a height direction.

5. 3. The stator of a rotating electric machine according to claim 1 or 2, characterized in that it is constructed by combining an odd number of split cores in which the first groove portion and the second groove portion are provided at ends on opposite sides in the height direction, and a split core in which the first groove portion and the second groove portion are provided at ends on the same side in the height direction.

6. 3. The stator of a rotating electric machine as described in claim 1 or 2, characterized in that the first and second groove portions have a trapezoidally recessed shape in the circumferential direction, the shape of which is a dovetail shape configured so that the radial gap is smallest at the opening end of the groove corresponding to the upper side of the recessed trapezoid and the radial gap is largest at the bottom of the groove corresponding to the lower side of the recessed trapezoid, and the tenon portion has a trapezoidal shape protruding in the circumferential direction, the radial size of the portion of the circumferential end portion corresponding to the lower side of the protruding trapezoid is largest, and the radial size of the root portion corresponding to the upper side of the protruding trapezoid is smallest.

7. 3. A stator for a rotating electric machine as described in claim 1 or 2, characterized in that the first and second groove portions are formed in a hook shape with respect to the circumferential direction, and the first and second tenon portions are also formed in a hook shape.

8. 3. The stator of a rotating electric machine according to claim 1, wherein the first convex portion protrudes in a triangular shape in the circumferential direction, and the first concave portion is recessed in a triangular shape with the circumferential end portion as a base.

9. 3. The stator of claim 1, wherein the first convex portion protrudes in a circular shape in the circumferential direction, and the first concave portion is concave in a circular shape with the circumferential end portion as a base.

10. The stator of a rotating electric machine is configured by arranging a plurality of split cores in an annular shape, the split cores being made of a back yoke portion shaped like a ring divided in the circumferential direction and teeth protruding from the back yoke portion, the stator has a first joint portion formed at an end of the back yoke portion of a first split core, the first joint portion having at least a first groove portion, a first convex portion, and a first tenon portion formed in the height direction of a joint surface that joins with an adjacent second split core, the second joint portion having a second groove portion, a first concave portion, and a second tenon portion formed on a joint surface facing the first joint portion of the second split core, the first groove portion and the second tenon portion engage with each other, the first convex portion and the first concave portion come into contact with each other, and the first tenon portion and the second groove portion engage with each other, A stator for a rotating electric machine, characterized in that the first tenon portion and the second tenon portion are configured to be insertable into the first and second groove portions only from the height direction, the first convex portion is configured to be insertable into the first concave portion from either the height direction or the circumferential direction, and the first tenon portion has a shape that includes the first convex portion when viewed from the height direction.

11. A stator for a rotating electric machine is constructed by forming a coupled core by rotatably connecting a plurality of split cores, each of which is made up of a back yoke portion and teeth portions protruding from the back yoke portion by providing a rotating portion on the back yoke portion, and arranging the coupled cores, the stator having a first joint portion formed on one end of the coupled core and having at least a first groove portion, a first convex portion, and a first tenon portion formed in a height direction of a joint surface that joins with an adjacent coupled core, and a first joint portion formed on the other end of the coupled core and having at least a second groove portion, a first concave portion, and a first tenon portion formed in a height direction of a joint surface that joins with an adjacent coupled core. a second joint portion on which a second tenon portion is formed, the first groove portion and the second tenon portion are engaged, the first convex portion and the first concave portion are in contact, the first tenon portion and the second groove portion are engaged, the first tenon portion and the second tenon portion are configured to be insertable into the first and second groove portions only from the height direction, the first convex portion is configured to be insertable into the first concave portion from either the height direction or the circumferential direction, and the first tenon portion has a shape that includes the first convex portion when viewed from the height direction.

12. A stator for a rotating electric machine is constructed by arranging a plurality of split cores, each of which is made up of a back yoke portion and teeth portions protruding from the back yoke portion, and connecting the split cores to each other to form a connected core, the stator having a first joint portion formed at one end of the connected core and having at least a first groove portion, a first protrusion portion, and a first tenon portion formed in a height direction of a joint surface that joins with an adjacent connected core, and a first joint portion formed at the other end of the connected core and having at least a second groove portion, a first recess portion, a second recess portion, and a third joint portion formed in a height direction of a joint surface that joins with an adjacent connected core. a second joint portion on which a second tenon portion is formed, the first groove portion and the second tenon portion are engaged with each other, the first convex portion and the first concave portion are in contact with each other, the first tenon portion and the second groove portion are engaged with each other, the first tenon portion and the second tenon portion are configured to be insertable into the first and second groove portions only from the height direction, the first convex portion is configured to be insertable into the first concave portion from either the height direction or the circumferential direction, and the first tenon portion has a shape that includes the first convex portion when viewed from the height direction.

13. 13. A rotating electric machine comprising: a rotating electric machine stator according to claim 1; and a rotor rotatably disposed opposite the stator with a gap therebetween.

14. In a manufacturing method for a stator for a rotating electric machine, in which a back yoke portion having a shape obtained by dividing a circle in the circumferential direction and a split core consisting of teeth protruding from the back yoke portion are arranged in an annular shape, the back yoke portion has joint surfaces formed on both side ends thereof and joined to adjacent split cores, the joint surfaces having at least a first groove portion, a first protrusion portion, and a first tenon portion formed in the height direction of one joint surface, and a second tenon portion, a first recess portion, and a second groove portion formed in the height direction of the other joint surface, the first tenon portion having a shape that includes the first protrusion portion when viewed from the height direction, and the first tenon portion having a shape that includes the first protrusion portion when viewed from the height direction, the second tenon portion having a shape that includes the first protrusion portion when viewed from the height direction, and the second .... and a first core split having a first groove portion and a second core split having a first groove portion and a second core split having a first groove portion and a second core split having a first groove portion and a second core split having a first groove portion and a second core split having a first groove portion and a second core split having a first groove portion and a second core split having a second ... first groove portion and a second core split having a first groove portion and a second core split having a first groove portion and a second core split having a first groove portion and a second core split having a first groove portion and a second core split having a first groove portion and a second core split having a first groove portion and a second core split having a first groove portion and a second core split having a first groove portion and a second core split having a first groove portion and a second core split having a first groove portion and a second core split having a first groove portion and a second core split having a first groove portion and a second core split having a first groove portion and a second core split having a first groove portion and a first core split having a first groove portion and a second core split having a first groove portion and a first core split having a first groove portion and a second core split having a first groove portion and a first core split having a first groove portion and a second core split having a first groove portion and a first core split having a first groove portion and a second core split having a first groove portion and a first core split having a first groove portion and