Rotary electrical machine and method for manufacturing rotary electrical machine

Abstract

The present invention provides a method for manufacturing a rotary electrical machine comprising a stator (1) formed by providing a winding (5) on an iron core (4) obtained by stacking a plurality of iron plates (6), a rotor (2) disposed on the inner side of the stator with an air gap in between, and an outer shell (3) accommodating the stator and the rotor, the method comprising a stacking step for stacking the iron plates to form the iron core and an aligning step for aligning the stator and the rotor. In the aligning step, with the rotor disposed on the inner side of the stator, each of the iron plates is rotated with one point of the iron plate acting as a fulcrum such that an inner circumferential part (6h) of the rotated iron plate contacts the rotor, causing the rotor to move in the direction of the central axis position of the stator or causing the stator to move in the direction of the central axis position of the rotor and thus be aligned; after alignment, the iron plates are returned to the pre-rotation state, and the stator and rotor in the aligned state are secured to the outer shell. This makes it possible to provide a method for manufacturing a rotary electrical machine in which the method comprises an aligning step for performing alignment directly using a mechanical mechanism, without involving voltage.

Description

Rotating electric machine and method of manufacturing the same

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

[0002] Rotating electric machines such as electric motors and generators are mainly composed of a shaft, bearings, rotor, stator, windings, and an outer casing. There is a small gap between the rotor and stator. Rotating electric machines are widely used in ventilation and air conditioning equipment.

[0003] A rotating electric machine generates a rotating or alternating magnetic field in the stator and transmits the magnetic flux to the rotor via air or other fluid, thereby driving the rotor. For example, when magnetic flux flows from the stator to the air to the rotor, the shorter the length of the air gap between the stator and rotor is, the more efficient the rotating electric machine will be. Also, the more uniform the length of the air gap is around the circumference, the less uneven the flow of magnetic flux will be, and the less abnormal noise and vibration will occur. Generally, the opposing surfaces of the stator and rotor are cylindrical, and when assembling a rotating electric machine, the air gap is made uniform by adjusting the axes of the two cylinders, the stator and the rotor.

[0004] Patent Document 1 discloses a method for adjusting the axis of a rotating electric machine, in which the voltage of each coil of the stator winding is measured and the relative positions of the stator and rotor are adjusted so that each voltage is uniform.

[0005] Patent No. 4461568 Public Relations

[0006] The axis alignment method described in Patent Document 1 requires separate voltage measurement components such as a coil voltage measuring device and multiple terminals for axis alignment, which creates a problem of complex axis alignment mechanisms.

[0007] The present disclosure has been made to solve the above-mentioned problems, and aims to provide a manufacturing method for a rotating electric machine that includes an alignment process in which alignment is performed directly using a mechanical mechanism without using voltage.

[0008] The manufacturing method of a rotating electric machine according to the present disclosure is a manufacturing method of a rotating electric machine including a stator formed by providing a winding on an iron core formed by stacking a plurality of iron plates, a rotor arranged inside the stator with a gap therebetween, and an outer casing that houses the stator and the rotor, and the manufacturing method of the rotating electric machine includes a lamination process of stacking the iron plates to form the iron core, and an alignment process of aligning the stator and the rotor, in which, with the rotor arranged inside the stator, each of the iron plates is rotated around a certain point on the iron plate as a fulcrum, and the inner periphery of the rotated iron plate comes into contact with the rotor, thereby moving the rotor toward the central axis position of the stator or the stator moving toward the central axis position of the rotor and being aligned, and after alignment, the iron plates are returned to their state before rotation, and the aligned stator and rotor are fixed to the outer casing.

[0009] According to the manufacturing method of a rotating electric machine according to the present disclosure, it is possible to provide a manufacturing method of a rotating electric machine that includes an alignment step in which alignment is performed directly using a mechanical mechanism without using a voltage.

[0010] 1 is a schematic cross-sectional view of a rotating electric machine according to a first embodiment. FIG. 2 is a perspective view of a stator and a rotor of the rotating electric machine according to the first embodiment. FIG. 3 is a top view of an iron plate of the rotating electric machine according to the first embodiment. FIG. 4 is a perspective view of a stator of the rotating electric machine according to the first embodiment. FIG. 5 is a side view of the stator of the rotating electric machine according to the first embodiment. FIG. 6 is a perspective view of the stator of the rotating electric machine according to the first embodiment. FIG. 7 is a side view of the stator of the rotating electric machine according to the first embodiment. FIG. 8 is a top view of the stator and rotor of the rotating electric machine according to the first embodiment. FIG. 9 is a top view of the stator and rotor of the rotating electric machine according to the first embodiment. FIG. 10 is a schematic cross-sectional view of the rotating electric machine according to the first embodiment. FIG. 11 is a schematic cross-sectional view of the rotating electric machine according to the first embodiment. FIG. 12 is a schematic cross-sectional view of the rotating electric machine according to the first embodiment. FIG. 13 is a schematic top view of the stator and rotor of the rotating electric machine according to the first embodiment. FIG. 14 is a schematic cross-sectional view of the rotating electric machine according to the first embodiment. 1 is a schematic top view of an iron plate of a rotating electric machine according to embodiment 1. FIG. 2 is a schematic top view of an iron plate of a rotating electric machine according to embodiment 1. FIG. 3 is a schematic top view of an iron plate of a rotating electric machine according to embodiment 1. FIG. 4 is a schematic top view of an iron plate of a rotating electric machine according to embodiment 1. FIG. 5 is a schematic top view of an iron plate of a rotating electric machine according to embodiment 1. FIG. 6 is a schematic top view of an iron plate of a rotating electric machine according to embodiment 2. FIG. 7 is a perspective view of a stator and a rotor of a rotating electric machine according to embodiment 2. FIG. 8 is a perspective view of a stator and a rotor of a rotating electric machine according to embodiment 2.

[0011] Embodiment 1 A rotating electric machine 100 according to embodiment 1 will be described below with reference to the drawings. Fig. 1 is a cross-sectional view of the rotating electric machine 100 according to embodiment 1. In this embodiment, an inner rotor type induction motor will be described as an example of the rotating electric machine 100.

[0012] As shown in Fig. 1, the rotating electric machine 100 is composed of a stator 1, a rotor 2 arranged inside the stator 1 with a gap therebetween, and an outer casing 3 that houses the stator 1 and the rotor 2. The rotor 2 has a bearing 2a and a shaft 2b. The bearing 2a rotatably supports the shaft 2b of the rotor 2. The rotor 2 is held by the outer casing 3 at the bearing 2a. The central axis of the stator 1 is designated as axis O.

[0013] The stator 1 has an iron core 4 and a winding 5 having a coil wound around the iron core 4 .

[0014] FIG. 2 is a perspective view showing the stator 1 having the iron core 4 and windings 5, and the rotor 2. As shown in FIG. 2, the iron core 4 is formed by stacking multiple iron plates 6. The iron core 4 is also composed of an annular portion 4a, teeth 4b that protrude radially inward from the annular portion 4a and are arranged at predetermined intervals around the circumference of the annular portion 4a, and slots 4c between the teeth 4b. In this embodiment, an example will be described in which there are eight teeth 4b and eight slots 4c. As shown in FIG. 2, it is preferable to provide protrusions 4d that protrude radially outward from the annular portion 4a. Two protrusions 4d are provided for each iron plate 6, and each protrusion preferably has a through-hole 4e.

[0015] 2, the winding 5 has a coil wound around each of the teeth 4b of the iron core 4. In this embodiment, since there are eight teeth 4b, there are eight coils. Also, a slight gap is provided between the teeth 4b and the inner circumferential portion 5a of the winding 5 so as not to interfere with the operation of the axis alignment adjustment mechanism of the present invention. The operation of the axis alignment mechanism will be described later.

[0016] The iron core 4 is made of a material primarily composed of iron, which has good magnetic properties, and the rotating electric machine 100 generally uses coil material made of rolled metal sheets with a thickness of 0.2 to 0.65 mm. However, flat, plate-shaped sketch material may also be used instead of coil material. In addition to the iron core 4, the shaft 2b and bearings 2a of the rotor 2 are often made of a material primarily composed of iron. The conductor portion of the stator 1 and the windings 5 ​​are made of copper, aluminum, or similar conductive materials.

[0017] FIG. 3 is a top view showing an example of the iron plate 6 forming the iron core 4. The iron plate 6 is composed of an annular portion 6a, teeth 6b, and slots 6c, corresponding to the annular portion 4a, teeth 4b, and slots 4c of the iron core 4. As described above, the protrusions 4d are provided in two locations, referred to as the first protrusion 6d and the second protrusion 6e. The through hole provided in the first protrusion 6d is referred to as the first through hole 6f, and the through hole provided in the second protrusion 6e is referred to as the second through hole 6g. The first protrusion 6d and the first through hole 6f are preferably provided on the opposite side of the annular portion 6a from the teeth 6b. The second protrusions 6e and the second through holes 6g are preferably provided on the opposite side of the annular portion 6a from the slots 6c. It is also preferable to form the second through-hole 6g at a position spaced apart from the first through-hole 6f, and more preferably, the second through-hole 6g is offset by 157.5 (=180-22.5) degrees.

[0018] FIG. 2 shows an example in which 30 iron plates 6 are stacked. As shown in FIG. 2, each time a new iron plate 6 is stacked, it is preferably rotated 45 degrees clockwise around the axis O so that the first through holes 6f and the second through holes 6g are distributed in eight locations. The rotation direction during stacking of the iron plates 6 may also be counterclockwise. As described above, the second through holes 6g are offset by 157.5° relative to the first through holes 6f. Therefore, when viewing the iron core 4 from the axis O, the first protrusions 6d and the first through holes 6f, and the second protrusions 6e and the second through holes 6g are alternately and evenly spaced around the circumferential direction of the iron core 4. The iron plate 6 described above is used as part of an axial alignment mechanism, which will be described later.

[0019] Fig. 4 is a perspective view of the stator 1 showing two jigs in addition to the iron core 4 shown in Fig. 2, and Fig. 5 is a side view of the same. Note that in this figure, the windings 5 ​​of the stator 1 are omitted. As shown in Fig. 4, it is desirable to use two jigs, a rotating jig 7 and a fixing jig 8.

[0020] An example of the shape of the jig will be described. The rotating jig 7 has an annular portion 7a provided on a plane parallel to the upper surface of the iron core 4 with a certain gap therebetween, and multiple insertion portions 7b extending perpendicularly from the annular portion 7a in the lamination direction of the stator 1. The central axis of the annular portion 7a coincides with the central axis O of the stator 1. The insertion portions 7b are provided at positions corresponding to one of the through holes in the iron plate 6 and are inserted into that through hole. Here, the through hole into which the insertion portions 7b of the rotating jig 7 are inserted is referred to as a second through hole 6g and as a rotation hole 6g. The fixing jig 8 has an annular portion 8a provided on a plane parallel to the lower surface of the iron core 4 with a certain gap therebetween, and multiple insertion portions 8b extending perpendicularly from the annular portion 8a in the lamination direction of the stator 1. The central axis of the annular portion 8a coincides with the central axis O of the stator 1. In other words, the central axis of the annular portion 7a of the rotating jig 7 and the central axis of the annular portion 8a of the fixing jig 8 are both coaxial. In the following, the center of the annular portion 7a of the rotating jig 7 will be simply referred to as the center of the rotating jig 7, and the center of the annular portion 8a of the fixing jig 8 will be simply referred to as the center of the fixing jig 8. The insertion portion 8b is provided at a position corresponding to one of the through holes in the iron plate 6, and is inserted into that through hole. Here, the through hole into which the insertion portion 8b of the fixing jig 8 is inserted will be referred to as the first through hole 6f and as the fixing hole 6f.

[0021] The tip of the insertion portion 7b of the rotating jig 7 is not in contact with the annular portion 8a of the fixing jig 8. Similarly, the tip of the insertion portion 8b of the fixing jig 8 is not in contact with the annular portion 7a of the rotating jig 7.

[0022] Furthermore, in this embodiment, the annular portion 7a of the rotating jig 7 is formed on the upper surface of the iron core 4, and the annular portion 8a of the fixing jig 8 is formed on the lower surface of the iron core 4, but the annular portion 7a of the rotating jig 7 may be formed on the lower surface of the iron core 4, and the annular portion 8a of the fixing jig 8 may be formed on the upper surface of the iron core 4.

[0023] Furthermore, it is expected that the insertion portions of the rotating jig 7 and the fixing jig 8 will come into contact with the iron plate 6 and rub against it when the axis alignment mechanism is in operation. Therefore, from the viewpoint of lifespan and precision, it is preferable that the insertion portions be made of metal or high-strength resin. It is desirable that the above-mentioned jigs be used as part of the axis alignment mechanism described below.

[0024] It is also preferable that the fixing hole 6f into which the inserting portion 8b of the fixing jig 8 of the iron plate 6 is inserted is circular, and the rotation hole 6g into which the inserting portion 7b of the rotation jig 7 is inserted is an elongated hole.

[0025] The rotating electric machine 100 of this embodiment is configured as described above. As described above, the stator 1 preferably includes the iron plate 6 having two protrusions and a through hole, the rotating jig 7, and the fixing jig 8. In this embodiment, a case will be described in which the stator 1 having the above configuration functions as an axial alignment mechanism. Next, the alignment operation of the axial alignment mechanism will be described with reference to FIGS. 4 to 7. Note that the changes before the mechanism operation shown in FIGS. 4 and 6 and after the mechanism operation shown in FIGS. 5 and 7 are exaggerated more than the actual changes for ease of understanding.

[0026] First, the operation of the axis alignment mechanism will be described with reference to Figures 4 to 7. Figures 4 and 5 show the state before the mechanism operates, and Figures 6 and 7 show the state after the mechanism operates.

[0027] First, the rotating jig 7 is rotated counterclockwise around axis O. At this time, the fixing jig 8 is not rotated. By rotating the rotating jig 7 counterclockwise, each of the iron plates 6 through which the rotating jig 7 passes rotates counterclockwise. At this time, because the fixing jig 8 does not rotate, each of the iron plates 6 rotates from the rotation hole 6g through which the rotating jig 7 is inserted, around the fixing hole 6f through which the fixing jig 8 is inserted. In other words, when each of the iron plates 6 rotates during alignment, the fixing hole 6f functions as a fulcrum, and the rotation hole 6g functions as a point of force. Then, the central axis of the inner diameter of the iron plate 6 moves away from the original axis O. In the case of the eight slots in this example, each of the iron plates 6 moves radially in eight directions away from the original axis O in a spiral orbit at equal 45-degree intervals.

[0028] Next, an alignment method for the rotating electric machine 100 using the axis alignment mechanism will be described with reference to FIGS. 8 and 9 . The rotating jig 7 and the fixing jig 8 are omitted in FIGS. 8 and 9 . Here, the tips of the teeth 6 b are located at the inner periphery 6 h of the iron plate 6. FIG. 8 shows the state before the stator 1 and the rotor 2 are aligned before the mechanism is activated, and FIG. 9 shows the state after the mechanism is activated and the stator 1 and the rotor 2 are aligned. With the rotor 2 positioned inside the stator 1, the rotating jig 7 is rotated counterclockwise relative to the fixing jig 8, causing each iron plate 6 to rotate counterclockwise with the fixing hole 6 f as a fulcrum and the rotation hole 6 g as a force point. As a result, the inner periphery 6 h of the iron plate 6 comes into contact with the rotor 2 and moves in a pushing motion toward the rotor 2, as shown in FIG. 9 . The rotor 2 moves toward the central axis position of the inner periphery of the stator 1, or the stator 1 moves toward the central axis position of the rotor 2, thereby aligning the stator 1 and the rotor 2. The alignment method will be described in detail later.

[0029] Note that alignment can be achieved in the same way by rotating the rotating jig 7 clockwise. Note that it is preferable to have a larger number of stacked iron plates 6. This increases the contact surface between the rotor 2 and the inner periphery 6h of the iron plate 6 that moves the rotor 2, making it easier to stabilize alignment accuracy.

[0030] 10 is a cross-sectional view showing the rotating electric machine 100 after the mechanism is operated. As shown in FIG. 10, when the mechanism is operated, the stacking of the iron plates 6, which had been stacked straight in the axial direction, becomes misaligned, and the iron core 4 takes on a spiral staircase-like shape.

[0031] Next, an example of a method for assembling the rotating electric machine 100 in the first embodiment will be described with reference to Figures 11 to 14. While Figure 1 illustrates an integrated outer casing 3, Figure 11 illustrates an outer casing 3 divided into three parts: an upper bracket 20 having a bearing 2a holder, a lower bracket 21, and a frame 22 that protects the cylindrical or rectangular shaped iron core 4. The assembly method for the rotating electric machine 100 mainly comprises a lamination process for laminating the iron plates 6 and an alignment process for aligning the stator 1 and the rotor 2.

[0032] In the lamination process, as described above, the iron plates 6 shown in Fig. 3 are laminated as shown in Fig. 2 to form the iron core 4. Next, a fixing jig 8 is inserted into the fixing hole 6f of the iron plate 6, and a rotating jig 7 is inserted into the rotating hole 6g, to form the stator 1 shown in Fig. 4.

[0033] Next, in the alignment process, the axis alignment mechanism is operated with the rotor 2 placed inside the stator 1 as shown in Figure 8. After operation, the stator 1 and rotor 2 are aligned as shown in Figure 7. Here, due to the nature of the axis alignment mechanism, if the mechanism is released, there will be no structure to hold the rotor 2. Therefore, in order to prevent interference with the operation of the mechanism, the housing 20a of the upper bracket 20 and the housing 21a of the lower bracket 21 are placed over the upper and lower bearings 2a of the rotor 2, respectively.

[0034] Next, while holding the shaft 2b portion of the rotor 2 etc. so that the relative position with the stator 1 does not shift, the rotating jig 7 is rotated in the reverse direction to return the iron plate 6 to the state before rotation, and the stator 1 and rotor 2 are maintained in an aligned state.

[0035] Next, with the stator 1 and rotor 2 aligned, the brackets and jigs are joined, respectively. The upper bracket 20 is joined to the rotating jig 7, and similarly, the lower bracket 21 is joined to the fixing jig 8. In other words, the stator 1 and rotor 2 are fixed to the outer casing 3. As shown in FIG. 11 , the joint between the upper bracket 20 and the rotating jig 7 is designated as joint 20b, and the joint between the lower bracket 21 and the fixing jig 8 is designated as joint 21b. Note that if the bracket and the jig are made of metal, they are preferably joined by welding, and if they are made of resin, they are preferably joined by welding or adhesive. Furthermore, since the rotating electric machine 100 in the first embodiment is intended to be attached to a blower such as a ventilation fan, it is appropriate to provide holes, positioning pins, and the like for attaching the rotating electric machine 100 in the upper bracket 20 and the lower bracket 21, which are coaxial with the rotational axis of the rotor 2.

[0036] Next, the upper bracket 20 and the lower bracket 21 are held together, and the frame 22 is formed using resin or the like to fill the gaps around the outer periphery of the stator 1. Figure 12 shows the state after the frame 22 has been formed in Figure 11. The rotating electric machine 100 of this embodiment is completed through the above-described steps.

[0037] As described above, the two brackets are covered before the axis alignment mechanism is operated, but if there are no equipment constraints, they may be covered immediately before joining the brackets and the jig. In the case of a single-shaft rotating electric machine 100 such as that shown in Figure 11, the upper bracket 20 through which the shaft 2b passes may be covered before the axis alignment mechanism is operated, and the lower bracket 21 through which the shaft 2b does not pass may be covered immediately before joining the bracket and the jig.

[0038] As described above, the brackets are joined using jigs. However, as shown in FIG. 13 , the fixing jig 8 and the rotating jig 7 may be removed after the alignment process, and the upper bracket 20 and the lower bracket 21 may be directly joined to the cores 4 without the jigs. The assembly method for the rotating electric machine 100 may also include a jig removal process for removing the fixing jig and the rotating jig after the alignment process. When a metal frame 22 is used, the cores 4 are fastened together by press-fitting them into the cylindrical frame 22. When a resin frame 22 is used, the frame 22 is molded by integral molding, and anti-rotation grooves are provided in the cores 4 to fasten them together. Alternatively, as shown in FIG. 14 , a structure without the frame 22 may be used. When the frame 22 is eliminated, it is desirable to ensure the joining strength between the cores 4 by welding, bolting, adhesive, or the like.

[0039] Furthermore, in the assembly method described above, when returning the iron plate 6 to its pre-rotation state in the alignment step, the rotor 2 is held to maintain the relative positions of the stator 1 and the rotor 2. However, an assembly method in which the rotor 2 does not need to be held in the alignment step will be described using Figures 15 and 16. For simplification, Figure 15 is a schematic top view showing only the inner and outer peripheries of the iron core 4 of the stator 1 and the shaft 2b of the rotor 2. Figure 15 shows the state in which the stator 1 and the rotor 2 are aligned. For simplification, Figure 16 is a schematic cross-sectional view of a rotating electric machine 100 in which the rotor 2 is shown with only the bearing 2a and the shaft 2b.

[0040] First, the axis alignment mechanism is activated to align the stator 1 and the rotor 2. Next, as shown in Fig. 15 , with the stator 1 and the rotor 2 aligned, the position of the shaft 2b of the rotor 2 from the outer periphery of the iron core 4 of the stator 1 is measured, for example. Next, as shown in Fig. 16 , based on the measured position of the shaft 2b, rotor bearing press-fit hole positions 3b are machined in the outer casing 3 relative to the stator insertion portion 3a of the outer casing 3, and the bearing 2a is press-fitted. By housing the stator 1 and the rotor 2 within the formed outer casing 3, the central axes of the stator 1 and the rotor 2 can be aligned without holding the rotor 2, and the stator 1 and the rotor 2 can be aligned.

[0041] As described above, in the manufacturing method of the rotating electric machine 100 of this embodiment, in the alignment step, the stator 1 and the rotor 2 are brought into contact with each other using the iron plate 6 with protrusions and through holes, the fixing jig 8, and the rotating jig 7 as an axial alignment adjustment mechanism, thereby directly aligning the stator 1 and the rotor 2. In conventional manufacturing methods of rotating electric machines, in the alignment step, voltage is measured to measure the eccentricity, and the measured value is fed back to move the stator 1 and adjust the relative position of the stator 1 and the rotor 2, thereby indirectly aligning the stator 1 and the rotor 2. If a disturbance occurs during eccentricity measurement, the alignment accuracy is reduced because the disturbed measured value is fed back for alignment. Furthermore, because the alignment is performed indirectly, the relative position of the stator 1 and the rotor 2 must be adjusted carefully and with high precision. In contrast, the manufacturing method of the rotating electric machine 100 of this embodiment includes an alignment step in which the stator 1 and the rotor 2 are directly aligned using a mechanical axial alignment mechanism without using voltage, thereby improving alignment accuracy. Furthermore, since direct alignment is possible, the relative positions of the stator 1 and the rotor 2 can be adjusted relatively easily.

[0042] Furthermore, in the alignment process of the first embodiment, it is possible to improve the alignment accuracy by devising a method for laminating the iron plates 6. Because the lamination method has a high degree of freedom, it can be easily adopted in rotating electrical machines that have facility and design constraints, and the range of application is wide.

[0043] Furthermore, in the alignment process of embodiment 1, the inner peripheral portion 6h of the iron plate 6 is brought into contact with the rotor 2 to align it, so that it is possible to correct both the horizontal misalignment between the rotor 2 and the stator 1 and the axial misalignment in which the central axis of the rotor 2 is misaligned with respect to the central axis of the stator 1 at the same time.

[0044] Next, an example of a product installation of the rotating electric machine 100 according to this embodiment will be described with reference to FIG. 17 . FIG. 17 shows a pressurized ventilation fan 200 as an example of a product installation. The pressurized ventilation fan 200 includes a housing 201, the rotating electric machine 100, and blades 202 that rotate when driven by the rotating electric machine 100. The pressurized ventilation fan 200 is installed so as to be embedded in a wall or ceiling. Note that the rotating electric machine 100 is omitted from the illustration.

[0045] The blades 202 have a plurality of blades, and convey a fluid such as air by rotating in a manner suited to the shape of the blades.

[0046] The housing 201 is a base that supports the rotating electric machine 100 and the blades 202, and is provided with legs 201a that are strong enough to support them. The housing also has a hole 201b in the center that does not impede the rotational movement of the blades 202 and serves as an air passage for the pressurized ventilation fan 200.

[0047] Furthermore, a lead wire 203 connected to a commercial power source is routed along a leg 201a of the product housing and connected to a power supply circuit of the rotating electric machine 100. However, the commercial power source and the power supply circuit are not shown in FIG.

[0048] By using the rotating electric machine 100 of this embodiment, which can align the stator and rotor and achieve low vibration and low noise, it is possible to provide an inexpensive, high-performance, and high-quality positive pressure ventilation fan 200. Furthermore, similar effects can be obtained with other air conditioning, ventilation, and air blowing equipment similar to positive pressure ventilation fans.

[0049] Next, a description will be given of a modification of the first embodiment. In addition, a method for aligning the stator 1 and the rotor 2 using the axis alignment mechanism will be described in more detail together with the modification.

[0050] A method for aligning the stator 1 and rotor 2 using an axial alignment mechanism will be described using Figures 18 to 24. For ease of explanation, Figures 18 to 24 only show the iron plate 6, rotating jig 7, and fixing jig 8. The iron plate 6 shown in Figures 18 to 24 is a schematic diagram, omitting the slots 6c and showing the inner peripheral portions 6h, which are the tips of the teeth 6b, connected by a circle. In Figures 18 to 24, the two jigs are shown with dashed lines, and the central axis O of the two jigs is indicated by the intersection of a dot-dash line. Here, the hole formed by connecting the inner peripheral portions 6h by a circle is referred to as the inner peripheral hole. Although the rotor 2 is omitted from Figures 18 to 24, the rotor 2 is positioned inside the inner peripheral hole. The iron plate 6 shown in Figures 18 and 19 is referred to as iron plate 6A, and the iron plate 6 shown in Figures 20 and 21 is referred to as iron plate 6B. For ease of understanding, the rotation angle of the iron plate 6 rotated by the rotating jig 7 is exaggerated and shown larger than the actual rotation angle of the iron plate 6 that rotates the rotating jig 7 .

[0051] FIG. 18 shows the iron plate 6A before the rotating jig 7 is rotated, and FIG. 19 shows the iron plate 6A after the rotating jig 7 is rotated. In FIG. 18, the iron plate 6A is shown with the first protrusion 6d and the fixing hole 6f located at the bottom and the second protrusion 6e and the rotation hole 6g located at the top. As shown in FIG. 18, before rotation, the central axes of the two jigs and the iron plate 6A are aligned. When the rotating jig 7 is rotated relative to the fixing jig 8, the iron plate 6A rotates with the fixing hole 6f as the fulcrum and the rotation hole 6g as the force point, so that the rotation hole 6g moves along a curve 30, as shown in FIG. 19. At this time, the central axis of the inner peripheral hole of the iron plate 6A moves to the left of the central axis O of the two jigs.

[0052] Next, Figures 20 and 21 show an iron plate 6B placed so that the first protrusion 6d and the fixing hole 6f are positioned in dyad symmetry with respect to the iron plate 6A shown in Figures 18 and 19. Figure 20 shows the iron plate 6B before the rotating jig 7 is rotated, and Figure 21 shows the iron plate 6B after the rotating jig 7 is rotated. When the rotating jig 7 is rotated, the iron plate 6B also rotates in the same direction and by the same amount as the iron plate 6A. Note that the central axis position of the inner peripheral hole of the iron plate 6B moves to the right of the central axis position of the rotating jig 7.

[0053] As shown in Figures 18 and 21, when the iron plate 6 rotates, the rotation hole 6g moves radially outward away from the central axis of the rotation jig 7. In other words, the insertion portion 7b of the rotation jig 7 moves toward the central axis of the iron plate 6 within the rotation hole 6g. Therefore, it is preferable that the rotation hole 6g has an elongated hole shape extending in the direction of the central axis of the iron plate 6, and the rotation jig 7 is rotated in a state in which the rotation hole 6g has a margin in the radial direction of the iron plate 6 relative to the insertion portion 7b of the rotation jig 7. It is also possible to narrow the insertion portion 7b of the rotation jig 7 so that there is a margin in the radial direction of the iron plate 6 within the rotation hole 6g. Furthermore, because the fixing hole 6f functions as a fulcrum when the iron plate 6 is rotated, it is preferable that the fixing hole 6f does not have a margin in the radial direction of the iron plate 6 relative to the insertion portion 8b of the fixing jig 8 so that the fixing hole 6f functions as a fulcrum.

[0054] Furthermore, it is preferable that the rotation hole 6g be formed away from the fixing hole 6f. When rotating the iron plate 6 with the fixing hole 6f as the fulcrum and the rotation hole 6g as the force point, the required movement amount during rotation can be large, minimizing the influence of errors during position control. Furthermore, the torque is increased, making it easier to rotate the iron plate 6. However, if the rotation hole 6g is formed at a position offset by 180° circumferentially from the fixing hole 6f, when the iron plate 6B is stacked in a position with two-fold symmetry, the rotation hole 6g of the iron plate 6A and the fixing hole 6f of the iron plate 6B will overlap, which may result in incorrect insertion of the two jigs. Therefore, it is desirable to set a large angle between the rotation hole 6g and the fixing hole 6f within a range that does not overlap. Furthermore, when stacking the iron plates 6 with a 45° offset for each stacked iron plate 6, as shown in Figure 5, it is desirable to position the rotation hole 6g 360° × (7 / 16) away from the fixing hole 6f so that the rotation hole 6g is located between adjacent fixing holes 6f.

[0055] Fig. 22 is a diagram in which the iron plate 6A before rotation shown in Fig. 18 and the iron plate 6B before rotation shown in Fig. 20 are overlapped. Fig. 23 is a diagram in which the iron plate 6A after rotation shown in Fig. 19 and the iron plate 6B after rotation shown in Fig. 21 are overlapped.

[0056] As shown in Figure 23, after rotation, the centers of the iron plates 6A and 6B move in opposite directions relative to the center of the rotating jig 7. Therefore, the elliptical inner hole formed by the overlap of the inner holes of the iron plates 6A and 6B narrows in the left-right direction. Here, the diameter of the inner holes of the iron plates 6A and 6B before the mechanism operates is defined as D, and the linear distance by which the center positions of the inner holes of the iron plates 6A and 6B change before and after the mechanism operates is defined as X. Note that the gap between the iron plate 6 and the rotor 2 is small, and X is equal to the gap distance. Depending on the motor output size, low-power motors have gaps of only about 0.2 to 0.4 mm, so the rotation angle of the rotating jig 7 during actual shaft alignment is only a few degrees. Therefore, X / D is often less than 1 / 80, but for clarity, it is exaggerated in Figure 23 to show X / D approximately 1 / 6. 19 and 21 described above and FIG. 24 described later are also illustrated with emphasis, similar to FIG.

[0057] Figure 24 shows the state in which four iron plates 6A, 6B, 6C, and 6D are stacked so that the first protrusions 6d and the fixing holes 6f are arranged in quadrilaterally symmetrical positions, and each iron plate 6 is rotated by a rotation jig 7. As shown in Figure 24, the inner peripheral holes of the iron plates 6 are narrowed in the vertical and horizontal directions. Note that in Figure 24, for example, the fixing hole 6f of iron plate 6A is shown to overlap with the fixing hole 6f of iron plate 6D, but as described above, the rotation angle of each iron plate 6 is exaggerated, so in reality, the fixing hole 6f of one iron plate 6 does not overlap with the other iron plates 6.

[0058] From the above results, when viewed from the direction of axis O, the iron plates 6 are rotated and stacked so that the first protrusions 6 d of one iron plate 6 do not completely overlap with the first protrusions 6 d of another iron plate 6, that is, so that the positions of at least the fixing holes 6 f of the first protrusions 6 d are dispersed, and then the stacked iron plates 6 are rotated around the fixing holes 6 f as fulcrums, thereby forming an inner circumferential hole that is narrower than the inner circumferential hole before rotation. When the inner circumferential hole of the stator 1 narrows to a position where it contacts the cylindrical outer periphery of the rotor 2, the rotor 2 moves toward the central axis position of the inner circumferential hole of the stator 1, or the stator 1 moves toward the central axis position of the rotor 2, thereby aligning the stator 1 and the rotor 2.

[0059] Furthermore, when the stacked iron plates 6 are viewed from the direction of the axis O, the alignment accuracy can be further improved by stacking the iron plates 6 so that the first protrusions 6d and the fixing holes 6f are evenly arranged in the circumferential direction of the iron core 4, that is, so that at least the fixing holes 6f of the first protrusions 6d are arranged in positions with N-fold symmetry. Also, the alignment accuracy can be further improved as the number N in "the fixing holes 6f are arranged in positions with N-fold symmetry" increases. The reason for this will be explained below.

[0060] As shown in the first embodiment, the case where eight or more iron plates 6 are stacked so that the fixing holes 6f are arranged at positions with eight-fold symmetry will be described. After the mechanism is activated, the inner peripheral hole of the iron plate 6 becomes a pseudo-circle of D-2X. This inner peripheral hole narrows to the outer periphery of the rotor 2, thereby aligning the stator 1 and the rotor 2. To be precise, the inner peripheral hole after the mechanism is activated becomes an octagon with eight sides formed by an arc of diameter D, and therefore does not become a perfect circle of D-2X. However, since the gap distance between the inner peripheral portion 6h of the iron plate 6 and the rotor 2 is small and X is equal to the gap distance, the word "pseudo-circular" is used to indicate that the hole is nearly a circle. In other words, by increasing the number N in "the fixing holes 6f are arranged at positions with N-fold symmetry" as in the first embodiment, the inner peripheral hole of the iron plate 6 can be made closer to a perfect circle. Therefore, the inner peripheral hole of the iron plate 6 can be narrowed all around the outer periphery of the rotor 2, thereby further improving alignment accuracy. The iron plates 6 may be stacked so that the first protrusions 6d and the fixing holes 6f are arranged at positions that are symmetrical with at least three symmetries. In other words, the iron plates 6 may be stacked so that the first protrusions 6d and the fixing holes 6f are evenly arranged in at least three locations in the circumferential direction of the iron core 4 when viewed from the direction of the axis O. Even in this case, the inner peripheral holes of the iron plates 6 can be narrowed from the three directions of the Y toward the outer periphery of the rotor 2, further improving the alignment accuracy.

[0061] As described above, stacking the iron plates 6 with the positions of the fixing holes 6f dispersed makes it possible to vary the narrowing of the inner peripheral holes of the iron plates 6. In other words, the alignment accuracy can be improved by devising how to stack the iron plates 6 having the protrusions and through holes formed therein.

[0062] As described above, it is preferable to stack the iron plates 6 by rotating them around the axis O so that the fixing holes 6f are arranged at N-fold symmetry positions. That is, if the fixing hole 6f of the first plate is at an angle of 0°, the fixing hole 6f of the second plate is arranged at an angle of 360° × (1 / N), the fixing hole 6f of the third plate is arranged at an angle of 360° × (2 / N), and so on, with N plates forming a group, returning to the original angle (0°). Therefore, the first protrusions 6d are arranged spirally in the stacking direction of the iron plates 6. Note that N is preferably set to the same number of slots in the iron plates 6. In this case, when viewed from the axis O, the fixing holes 6f of every N plates overlap. That is, the fixing hole 6f of the first plate overlaps with the fixing hole 6f of the (N × M + 1)th plate. Similarly, the fixing hole 6f of the second plate overlaps with the fixing hole 6f of the (N × M + 2)th plate. M is any natural number.

[0063] Furthermore, as described above, when N iron plates 6 are stacked in a set to form a spiral, the rotation hole 6g is preferably located 360° × {(N-1) / 2N} away from the fixing hole 6f. Like the fixing holes 6f, the rotation holes 6g are also located at the same position every N iron plates when viewed from the axial direction. Furthermore, it is preferable to select the shape of the first protrusion 6d so that the first protrusion 6d and the rotation hole 6g do not overlap when the iron plates 6 are stacked in a spiral shape. It is also preferable to select the shape of the second protrusion 6e so that the second protrusion 6e and the fixing hole 6f do not overlap.

[0064] In the first embodiment, the iron plates 6 are rotated each time they are stacked. However, for example, the second iron plate 6 is stacked without being rotated relative to the first iron plate 6, and the third iron plate is rotated. Even in this case, the iron plates can be stacked so that the fixing holes 6f are dispersed when the iron core 4 is viewed from the direction of the axis O. In the present embodiment, the rotation angle relative to the first iron plate 6 is gradually increased each time each iron plate 6 is stacked. However, for example, the second iron plate 6 is stacked by rotating it 90 degrees relative to the first iron plate 6, and the third iron plate is stacked by rotating it 45 degrees. Even in this case, the iron core 4 can be stacked so that the fixing holes 6f are dispersed when viewed from the direction of the axis O.

[0065] 2, multiple iron plates 6 shown in FIG. 3 are used, and the iron core 4 is formed by rotating and stacking them so that the positions of the protrusions and through holes are dispersed. However, iron plates with different positions of the protrusions and through holes for each iron plate may be stacked to form the iron core 4 so that the positions of the fixing holes 6f are dispersed. However, in order to use the same mold for the iron plates in terms of equipment, it is preferable to standardize the arrangement of the protrusions and through holes for all iron plates.

[0066] In addition, in the first embodiment, the iron plates 6 are stacked so that the positions of the fixing holes 6f are dispersed, and each iron plate 6 is rotated in the same rotation direction by the rotating jig 7, thereby making it possible to vary the narrowing of the inner peripheral holes of the iron plates 6. However, the same effect can be obtained by stacking the iron plates so that the positions of the fixing holes 6f are the same and rotating each iron plate in the opposite direction to each other. In this case, it is preferable to stack iron plates in which the position of the rotation hole 6g is changed for each iron plate, or to stack iron plates in which two rotation holes 6g are provided on one iron plate.

[0067] Furthermore, in the first embodiment, the iron plate 6 having the protrusions 6d, 6e and the through holes 6f, 6g is used as the axis alignment mechanism. However, an iron plate without through holes in the protrusions may also be used. As described above, the axis alignment mechanism shown in the first embodiment rotates each iron plate with the fixing hole 6f as the fulcrum and the rotation hole 6g as the force point. However, without the through holes, each iron plate may be rotated with the first protrusion 6d functioning as the fulcrum and the second protrusion 6e functioning as the force point. Even in this case, the stator 1 and the rotor 2 can be aligned in the same manner. For example, one method is to grip the first protrusion 6d and the second protrusion 6e with a mechanism that clamps the protrusions, fix the first protrusion 6d side to function as the fulcrum, and rotate each iron plate with the second protrusion 6e side to function as the force point.

[0068] Furthermore, in the first embodiment, the axial alignment mechanism uses the iron plate 6 having the protrusions 6d, 6e and the through holes 6f, 6g, and two jigs, the rotating jig 7 and the fixing jig 8. However, an iron plate without protrusions or through holes may be used without using a jig. As described above, the axial alignment mechanism shown in the first embodiment can be achieved by using two jigs to rotate each iron plate with the fixing hole 6f as a fulcrum and the rotation hole 6g as a force point, thereby easily aligning the stator 1 and the rotor 2. In contrast, the stator 1 and the rotor 2 can be similarly aligned by using iron plates without protrusions or through holes without using a jig and rotating each iron plate around a single point on the iron plate as a fulcrum. In this case, one example is to fix a single point on each iron plate with a magnet or the like that secures each iron plate, and then rotate each iron plate around the fixed point as a fulcrum.

[0069] Embodiment 2. A manufacturing method for a rotating electric machine according to embodiment 2 will be described with reference to Figures 25 to 27. Figure 25 is a top view showing an iron plate 6 according to embodiment 2. Figure 26 is a perspective view showing a stator 1 having an iron core 4 and windings 5 ​​formed by stacking a plurality of iron plates 6 shown in Figure 25, and a rotor 2. Figure 27 shows the state in which all protrusions 4d of the iron core 4 shown in Figure 26 have been removed after the alignment process.

[0070] First, as shown in Figure 25, the iron plate 6 of embodiment 1 has large first and second protrusions 6d and 6e, and is shaped so that it becomes thicker as it approaches the annular portion 6a of the iron plate 6, which is the base of the first and second protrusions 6d and 6e. Therefore, this is suitable when the load applied when operating the axis alignment mechanism is large or when the iron plate 6 is thin and strength is a concern. Furthermore, if the outer shell 3 is formed using a resin integral molding method and hardened together with the protrusions 4d, the hardened protrusions 4d can firmly support the stator 1. Furthermore, the outer periphery of the iron core 4 can be relatively smooth, resulting in a structure with few stress concentration points.

[0071] On the other hand, as shown in Fig. 25, the iron plate 6 of the second embodiment has smaller first protrusions 6d and second protrusions 6e than the iron plate 6 of the first embodiment, and the bases of the first protrusions 6d and second protrusions 6e are narrowest. The reason for this will be explained below.

[0072] Examples of the outer casing 3 of a rotating electric machine include three types: resin, sheet metal, and casting. When the outer casing 3 is formed by a resin integral molding method, the shape of the iron plate 6 in the first embodiment can also be used, as described above. However, when the outer casing 3 is formed by sheet metal or casting, the iron core 4 and the outer casing 3 are fastened together by shrink fitting or press fitting, so it is desirable to remove the first protrusion 6d and the second protrusion 6e after alignment and process the iron plate into a cylindrical shape.

[0073] Therefore, by making the first protrusion 6d and the second protrusion 6e small and making the bases of the first protrusion 6d and the second protrusion 6e narrowest as in the iron plate 6 of embodiment 2, the labor required to remove the protrusions from the iron plate can be reduced as shown in Fig. 27. However, if the protrusions of the iron plate are made too narrow, they may break or bend during operation of the mechanism, so it is desirable to form the protrusions with strength in mind.

[0074] The manufacturing method of a rotating electric machine in embodiment 2 includes forming the first protrusion 6d and the second protrusion 6e so that they are thinnest at their respective bases, and after the alignment process, includes a protrusion removal process in which the first protrusion 6d and the second protrusion 6e are removed.

[0075] As described above, in the manufacturing method of the rotating electric machine according to the second embodiment, when the outer shell is formed from sheet metal or casting, the protruding portions of each iron plate are removed after the alignment process, and the iron core and the outer shell can be fastened together by shrink fitting or press fitting.

[0076] The configurations shown in the above embodiments are merely examples of the contents of the present disclosure, and may be combined with other known technologies. Also, embodiments may be combined with each other. Furthermore, a portion of the configuration may be omitted or modified without departing from the gist of the present disclosure.

[0077] REFERENCE SIGNS LIST 1 stator, 2 rotor, 3 outer shell, 4 iron core, 5 winding, 5a winding inner periphery, 6 iron plate, 6b teeth, 6d first protrusion, 6e second protrusion, 6f first through hole, 6g second through hole, 6h inner periphery, 7 rotating jig, 8 fixing jig, 100 rotating electric machine

Claims

1. A stator formed by attaching a winding to an iron core made of multiple stacked iron plates, A rotor is positioned inside the stator with an air gap between them, In a method for manufacturing a rotating electric machine comprising an outer casing that houses the stator and the rotor, A lamination process in which the aforementioned iron plates are stacked to form an iron core, The system includes a centering step for centering the stator and the rotor, A method for manufacturing a rotating electric machine, comprising the centering step, in which, with the rotor positioned inside the stator, each of the iron plates is rotated around a point on the iron plate as a pivot point, and the inner circumference of the rotated iron plate comes into contact with the rotor, causing the rotor to move in the direction of the central axis of the stator or the stator to move in the direction of the central axis of the rotor, thereby centering the iron plate, and after centering, the iron plates are returned to their pre-rotation state, and the centered stator and rotor are fixed to the outer casing.

2. The aforementioned iron plate is provided with a first projection and a second projection on its outer circumference. A method for manufacturing a rotating electric machine according to claim 1, wherein in the centering step, the iron plate is rotated with the first protrusion as the fulcrum and the second protrusion as the point of force application.

3. The first projection is provided with a first through hole, The second projection is provided with a second through hole, A fixing jig is inserted into the first through hole of each of the stacked iron plates, and a rotating jig is inserted into the second through hole. The method for manufacturing a rotating electric machine according to claim 2, wherein, in the centering step, the second through-hole has a margin in the radial direction of the iron plate relative to the rotating jig, the rotating jig is rotated relative to the fixed jig, and the iron plate is rotated by the rotation of the rotating jig with the first through-hole as the fulcrum and the second through-hole as the point of force application.

4. The method for manufacturing a rotating electric machine according to claim 2 or 3, wherein, in the lamination step, the iron plates are laminated such that, when viewed from the axial direction, the first protrusion of one iron plate does not completely overlap with the first protrusion of another iron plate.

5. The method for manufacturing a rotating electric machine according to claim 4, wherein, in the lamination step, the iron plates are laminated such that, when viewed from the axial direction, the first protrusions are evenly arranged in the circumferential direction of the iron core.

6. The method for manufacturing a rotating electric machine according to claim 5, wherein, in the lamination step, the iron plates are laminated such that, when viewed from the axial direction, the first protrusions are evenly arranged at least three locations in the circumferential direction of the iron core.

7. The method for manufacturing a rotating electric machine according to claim 5, wherein in the lamination step, the iron plates are laminated such that, when viewed from the axial direction, the first protrusions and the second protrusions are alternately arranged in the circumferential direction of the iron core.

8. The method for manufacturing a rotating electric machine according to claim 7, wherein in the lamination step, the iron plates are laminated such that, when viewed from the axial direction, the first protrusion and the second protrusion are arranged at equal intervals in the circumferential direction of the iron core.

9. The method for manufacturing a rotating electric machine according to claim 2 or 3, wherein the first protrusion and the second protrusion are formed to be the thinnest at their respective bases.

10. A method for manufacturing a rotating electric machine according to claim 2 or 3, further comprising a protrusion removal step after the centering step, wherein the first protrusion and the second protrusion are removed.

11. A method for manufacturing a rotating electric machine according to claim 3, further comprising a jig removal step after the centering step, wherein the fixing jig and the rotating jig are removed.

12. A stator formed by attaching a winding to an iron core made of multiple stacked iron plates, A rotor is positioned with a gap between it and the inner circumference of the stator, A rotating electric machine comprising a stator and an outer casing that houses the rotor, A rotating electric machine having a first projection that functions as a fulcrum and a second projection that functions as a point of force application on the outer circumference of the iron plate when the iron plate rotates during centering.

13. The rotating electric machine according to claim 12, wherein the first projection is a first through-hole that functions as a fulcrum when the iron plate rotates during centering, and the second projection is a second through-hole that functions as a point of force application when the iron plate rotates during centering.

14. The rotating electric machine according to claim 12, wherein the iron core has a teeth portion around which a winding is wound, and a gap is provided between the teeth portion and the inner circumference of the winding.

15. A stator formed by providing a winding on an iron core made of multiple stacked iron plates, A rotor is positioned with a gap between it and the inner circumference of the stator, A rotating electric machine comprising a stator and an outer casing that houses the rotor, A protrusion is provided on the outer circumference of the aforementioned iron plate. A rotating electric machine in which the protrusions of the first iron plate and the protrusions of the second iron plate are provided in a circumferentially distributed manner when viewed from the axial direction.

16. The rotating electric machine according to claim 15, wherein the second iron plate is provided adjacent to the first iron plate in the stacking direction.

17. The rotating electric machine according to claim 15 or 16, wherein at least a portion of the protrusions of the plurality of iron plates are arranged in a helical shape in the stacking direction.