Segment-core coupled body for rotating electric machine armature
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Solution Overview
Problem
The existing method of manufacturing armature cores with segmented structures for rotating electric machines requires relief portions for punch stiffness, leading to reduced output and decreased productivity due to increased material complexity in the pressing step.
Innovation Solution
A segment-core coupled body design with a posture holding portion and thin coupling portions that project radially outward, allowing for increased distance between core backs and reducing the need for relief portions, thereby minimizing material yield loss and maintaining output while improving productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If relief portions are provided to ensure punch stiffness during stamping, then manufacturing precision is improved, but output of the rotating electric machine is reduced
Solution Approach 1:
The invention moves the punch support function from the radial dimension (relief portions) to the axial dimension (back support portions extending in the axial direction). This dimensional transition allows the punch to be supported by the back support portions during stamping without requiring relief portions that would reduce output.
2Power
If multiple segments are arranged in circumferential direction to improve space factor, then output is improved, but the number of magnetic sheet components increases and productivity in pressing step is degraded
Solution Approach 1:
The invention merges multiple segment cores into a single integrated core-piece that includes all segment cores and coupling portions formed from one continuous magnetic sheet. This merging reduces the number of components to be stamped and assembled, thereby improving productivity in the pressing step while maintaining the multi-segment structure for high output.
3Productivity
If coupling portions are formed by stamping slit portions between opposed circumferential side surfaces, then the number of components is reduced and productivity is improved, but relief portions are required that reduce output
Solution Approach 1:
The invention transitions the coupling mechanism from radial coupling (slit portions between side surfaces requiring relief portions) to axial coupling (back support portions extending in the axial direction). This allows coupling portions to be formed without relief portions, maintaining both productivity and output.
4Productivity
If segment cores are coupled by thin coupling portions, then assembly is simplified and productivity is improved, but the distance between core backs must be minimized increasing material complexity
Solution Approach 1:
The invention extends the coupling portions in the axial direction rather than minimizing the distance between core backs in the radial direction. This axial extension provides sufficient structural support and stiffness without requiring minimal spacing, thereby simplifying assembly while reducing material complexity.
Data Source
AI summary
Provided is a segment-core coupled body, including a plurality of segment cores each including a core back and a tooth; and a plurality of coupling portions configured to couple the core backs to one another, wherein the plurality of segment cores and the plurality of coupling portions are each a laminated body of magnetic sheets, wherein the plurality of coupling portions each include: a posture holding portion adjacent to a gap defined between adjacent core backs; a first thin portion configured to couple one corner portion of the adjacent core backs and the posture holding portion; and a second thin portion configured to couple another corner portion of the adjacent core backs and the posture holding portion, and wherein, the posture holding portion projects toward a radially outer side with respect to the adjacent core backs.