WO2013084614A1

WO2013084614A1 - Rotating electric machine and method for manufacturing rotating electric machine

Info

Publication number: WO2013084614A1
Application number: PCT/JP2012/077590
Authority: WO
Inventors: 大毅梶田; 中須　信昭
Original assignee: 株式会社日立製作所
Priority date: 2011-12-07
Filing date: 2012-10-25
Publication date: 2013-06-13
Also published as: JP2013121226A; CN103975504A; CN103975504B; JP5859297B2

Abstract

Provided is a rotating electric machine comprising an iron core having a structure that requires neither deformation nor bonding and can be manufactured with small iron loss and high efficiency and at low cost. A rotating electric machine comprising a stator and a rotor, wherein a stator tooth that constitutes the stator is provided with an iron core (31), an electric wire disposed around the iron core (31), and an insulator disposed between the iron core (31) and the electric wire, and the iron core (31) is configured by laminating rectangular flat plate-shaped thin plates (2) each formed by cutting thin-plate shaped soft magnetic materials (1) into a predetermined width (B) one by one or every small number of sheets.

Description

Rotating electric machine and method of manufacturing rotating electric machine

The present invention relates to a structure and a manufacturing method of a stator among rotating electrical machines.

A rotating electrical machine such as a motor or an alternator is composed of a rotor, a stator, a housing that covers them, and the like. Of the members constituting the rotating electrical machine, the stator is composed of an iron core made of a soft magnetic material, an electric wire wound around the iron core, an insulator that insulates the iron core from the electric wire, and the like.
Loss generated in the stator is roughly divided into iron loss and copper loss. Iron loss is determined by the characteristics of the soft magnetic material that forms the iron core and the shape of the iron core, and copper loss is determined by the characteristics and shape of the wire. High efficiency can be achieved by reducing the loss, but since low-loss soft magnetic materials and wire materials are expensive, there is a need for a rotating electrical machine that achieves both higher efficiency and lower costs. .
As the soft magnetic material, an electromagnetic steel plate or an amorphous metal is used. Both have small iron loss characteristics, and a high-efficiency rotating electrical machine can be realized by using it as an iron core.

However, since magnetic steel sheets are manufactured by rolling, they are formed into thin plates, and amorphous metals are formed into thin foils by forming an amorphous body by rapid cooling. It was a problem that I could not.
As a method for solving the above problem, Patent Document 1 discloses an example in which thin plate-shaped core pieces punched into a shape provided with caulking projections are stacked and formed into a block shape. Patent Document 1 relates to a rotating electrical machine in which iron core pieces are aligned and stacked using caulking protrusions and formed into a block shape to form an iron core, and a thin plate-like iron core piece can be used as an iron core.

In addition, by winding the amorphous metal in the foil strip into a hollow circle with an insulating resin material in between, the laminated core is solidified with resin and then cut in the normal direction to form a block shape An example in which the film is formed into a thin film is disclosed in Patent Document 2.
That is, in Patent Document 2, an amorphous metal iron core is formed by winding and cutting, and a plurality of stator teeth formed by winding an electric wire around the iron core are arranged in the rotating direction of the rotating electrical machine. The foil-shaped amorphous metal can be used as an iron core.

JP 53-4803 A JP 2010-115069 A

However, in the methods of

Patent Documents

1 and 2, an increase in iron loss due to deformation of the soft magnetic material becomes a problem. In general, when a soft magnetic material is deformed, the iron loss increases as the residual stress generated in the material increases.
That is, as shown in Patent Document 1, in iron core pieces stacked by caulking or amorphous metal wound and formed as shown in Patent Document 2, iron remains due to residual stress generated during caulking and winding. This increases the loss and hinders the high efficiency of the rotating electrical machine. Furthermore, in Patent Document 2, since amorphous metal is a difficult-to-cut material, it occurs when cutting individual amorphous metal foil strips when cutting in the normal direction while being laminated in a hollow circular shape with an insulating resin material in between. Since the stress to act on the adjacent amorphous metal foil strip, very high residual stress accumulates at the end of cutting.

An annealing treatment is generally performed as a method of relieving residual stress generated in a deformed soft magnetic material. The annealed soft magnetic material loses elasticity and becomes brittle, and the internal residual stress is relaxed. However, even if annealing is performed, the internal residual stress cannot be completely relieved, and the small iron loss characteristics of the soft magnetic material using a ferromagnetic material as a base material cannot be fully utilized. In addition, a special annealing furnace capable of generating a magnetic field is required for the annealing treatment, which increases the manufacturing cost.

In Patent Document 2, in order to fix the iron core pieces and the amorphous metals, it is necessary to provide an fixing process such as providing an adhesive layer between the amorphous metals or covering the whole with a resin or an adhesive. Thus, in the case of an iron core having a resin, an adhesive, etc., the manufacturing cost and the manufacturing time are increased, and further, the ratio of the soft magnetic material to the volume of the entire stator teeth is reduced, so that the efficiency of the rotating electrical machine is reduced. To suppress this, if the resin or adhesive layer is made thin, it will not spread evenly between amorphous metals, and peeling will occur during cutting, etc., making it impossible to use it as a stator tooth, resulting in poor yield. End up.

Therefore, the present invention has been made in view of such circumstances, and it is possible to configure a block-shaped iron core without deforming the soft magnetic material and without inclusions between the layers of the soft magnetic material. If possible, paying attention to the fact that it is possible to obtain a rotating electrical machine that takes advantage of the iron loss characteristics of a soft magnetic material, without the need for deformation or adhesion, the structure of a stator of a rotating electrical machine that uses a soft magnetic material as an iron core It aims at providing the manufacturing method of a stator.

In order to solve the above-mentioned problems, the following technical means have been taken in the rotating electrical machine of the present invention. That is,
(1) In a rotating electrical machine having a stator and a rotor, stator teeth constituting the stator are arranged between an iron core, an electric wire arranged around the iron core, and the iron core and the electric wire. The iron core is configured by laminating thin plate-shaped thin sheets of soft magnetic material formed in different widths for each sheet or a plurality of sheets.

(2) In the above rotating electric machine, the rectangular flat thin plates have the same length.

(3) In the above rotating electric machine, the insulator is constituted by an insulating coating coated on the electric wire.

(4) In the above rotating electric machine, one block is formed by laminating a plurality of the thin plates having the same width, and the iron core is constructed by laminating a plurality of the blocks having different widths.

(5) In the above rotating electrical machine, the soft magnetic material is made of an electromagnetic steel plate or amorphous metal whose base material is iron, cobalt, or nickel.

(6) In the above rotating electric machine, the thin plate or the block is stacked at an angle of 90 degrees with the axial direction of the rotor.

(7) In the above rotating electric machine, the thin plate or the block is laminated in a direction different from a radial direction of the shaft of the rotor.

(8) In the above rotating electric machine, the thin plate or the block includes a thin plate or block whose width is larger than the width of the iron core in the circumferential direction of the rotation axis.

(9) In the above rotating electric machine, the iron core is provided with a substantially R shape at a corner portion by varying the width of the thin plate or the block.

(10) In the above rotating electric machine, the iron core is adjusted such that the thickness of the thin plate or block at the upper and lower portions in the stacking direction is larger than the thickness of the block at the middle portion in the stacking direction by adjusting the width of the thin plate or the block. I tried to make it smaller.

(11) The insulator has a thin and concave cross-sectional shape, and an angle formed between a side surface and a bottom surface of the concave portion is 90 degrees or more.

(12) The insulator is composed of a thin lower insulator having a concave cross-sectional shape matched to the outer peripheral shape of the iron core, and a thin plate-like upper insulator.

(13) The insulator is a thin-walled insulator having a hollow portion on the inside that matches the outer peripheral shape of the iron core.

Moreover, in the manufacturing method of the rotary electric machine of this invention, the following technical means were taken. That is,
(14) A method of manufacturing a rotating electrical machine having stator teeth, wherein a thin plate-like soft magnetic material is formed with a predetermined width for each sheet or a small number of sheets to create a rectangular plate-like thin plate. A second step of laminating the thin plate or a block formed by laminating a plurality of the thin plates of the same width, and a third step of winding an electric wire around the laminated thin plate or the block through an insulator. In the second step, the width of the thin plate or the block was laminated in the laminating direction in accordance with the iron core shape of the stator teeth.

(15) In the second step, the thin plate or the block is installed and laminated inside a mold in which insulating paper is laid.

(16) After the second step, a fourth step of pressing the uppermost part of the laminated thin plate or the block with a pressing plate, and gripping from above and below the thin plate or the block in the stacking direction using a gripping tool And a sixth step of inserting the grasped thin plate or the block into a hollow insulator, and the third step is performed after the sixth step.

(17) After the second step, a fourth step of pressing the uppermost part of the laminated thin plate or block with a pressing plate, and gripping from above and below the thin plate or the block in the stacking direction using a gripping tool And a sixth step of inserting the gripped thin plate or block into a hollow insulator, and the third step is performed before the fourth step or the fourth step. This step was performed in parallel with the fifth step.

(18) After the second step, a fourth step of pressing the uppermost part of the laminated thin plate or the block with a pressing plate, and gripping from above and below the thin plate or the block in the stacking direction using a gripping tool And in the third step, the electric wire on which the insulating coating is formed is wound.

According to the present invention, a plurality of soft magnetic materials cut into a rectangular flat plate are laminated to form an iron core, and the periphery thereof is covered with an insulator and an electric wire, so that the stator teeth can be formed without requiring deformation or adhesion. Thus, a highly efficient stator structure with small iron loss can be obtained at low cost.

FIG. 1 is a diagram showing a configuration of an axial gap type rotating electrical machine according to the first embodiment of the present invention. FIG. 2 is a diagram illustrating the configuration of the stator teeth of the axial gap type rotating electrical machine according to the first embodiment of the present invention. FIG. 3 is a diagram showing a configuration of an iron core using a rectangular flat soft magnetic material according to the first embodiment of the present invention. FIG. 4 is a reference diagram of an iron core fixed by caulking for comparison with Example 1 of the present invention. FIG. 5A is a structural diagram in the case where soft magnetic materials are stacked in a direction perpendicular to an upper base and a lower base in Example 1 of the present invention. FIG. 5B is a structural diagram in the case where soft magnetic materials are stacked in a direction parallel to the upper and lower bases in Example 1 of the present invention. FIG. 5C is a structural diagram when the soft magnetic material is laminated in a direction parallel to the hypotenuse of the trapezoid in Embodiment 1 of the present invention. FIG. 6A is a structural diagram in the case where lamination is performed so that the corners of the iron core have acute angles in Example 1 of the present invention. 6B is a structural diagram in the case where the corners of the iron core are stacked so as to have an R shape in Example 1 of the present invention. FIG. FIG. 7 is a diagram showing a configuration of an iron core using a rectangular flat soft magnetic material according to Example 1 of the present invention. FIG. 8 is a diagram illustrating a configuration of a stator tooth of an axial gap type rotating electrical machine according to the second embodiment of the present invention. FIG. 9 is a diagram illustrating a configuration of a stator tooth of an axial gap type rotating electrical machine according to the third embodiment of the present invention. FIG. 10 is a diagram illustrating a method for manufacturing the stator teeth of the rotating electrical machine according to the first and second embodiments of the present invention. FIG. 11 is a diagram illustrating a method for manufacturing the stator teeth of the rotating electrical machine according to the third embodiment of the present invention. FIG. 12 is a diagram illustrating another method for manufacturing the stator teeth of the rotating electrical machine according to the third embodiment of the present invention. FIG. 13 is a diagram showing a configuration of an iron core using a rectangular flat soft magnetic material according to Example 4 of the present invention. FIG. 14A is a structural diagram in the case where lamination is performed so that the corners of the iron core have acute angles in Example 4 of the present invention. FIG. 14B is a structural diagram in a case where the corners of the iron core are stacked so as to have an R shape in the fourth embodiment of the present invention. FIG. 15 is a diagram illustrating a method for manufacturing the stator teeth of the rotating electrical machine according to the fourth embodiment of the present invention.

Hereinafter, an example of an embodiment of the present invention will be described by taking an axial gap type rotating electrical machine as an example with reference to the drawings. However, a rotating electrical machine using an iron core formed by stacking rectangular flat soft magnetic materials is used. If so, the present invention is not limited to the axial gap type, but can be applied to a radial gap type or the like.

[Example 1]
An example of the structure of the iron core and stator teeth using the soft magnetic material of the present invention will be described with reference to FIGS. FIG. 4 is a reference diagram for comparison with the present embodiment.
FIG. 1 is a view for explaining the structure of an axial gap type rotating electrical machine using a soft magnetic material according to the present invention. The axial gap type rotating electrical machine 10 includes a rotor 50 in which a plurality of permanent magnets 20 are arranged in a circumferential direction on a disk-shaped member 21 and a stator tooth 30 including an iron core 31 in the circumferential direction. A plurality of stators 60, a rotating shaft 70 for concentrically arranging the rotor 50 and the stator 60, and a housing 80 for storing them are provided.
In addition, it is not limited to the permanent magnet 20, and any magnet that generates a magnetic force may be used, and it may be replaced with another magnetic body or an electromagnet.

As shown in FIG. 2, the stator teeth 30 are excited by energizing an electric wire 33 wound around the outer periphery of the stator teeth 30 to generate attractive forces between the permanent magnets 20 and the stator teeth 30, thereby different stator teeth. Rotating motion is developed between the rotor 50 and the stator 60 by continuously exciting 30. Since the stator 60 is composed of a plurality of stator teeth 30, each stator tooth 30 is provided with a block-shaped iron core 31 individually.

FIG. 2 is a diagram illustrating the structure of the stator teeth 30. FIG. The stator tooth 30 includes an iron core 31, an insulator 32, and an electric wire 33. The insulator 32 is disposed around the iron core 31 in order to ensure insulation between the iron core 31 and the electric wire 33, and the electric wire 33 is wound around the insulator 32. The insulator 32 is made of one or a plurality of insulating papers or a thin plate-like resin material having a thickness of 1 mm or less, and the electric wire 33 has a substantially circular or substantially cross-sectional shape using copper or aluminum as a base material. A rectangular wire is used.

FIG. 3 is a diagram illustrating the structure of the iron core of the stator. The iron core 31 includes a laminated structure 1 made of a thin plate-like soft magnetic material whose base material is iron, cobalt, or nickel. The laminated structure 1 is made of a thin plate-like soft magnetic material having a length L and an arbitrary width B. In this embodiment, a plurality of rectangular thin plates having the same length L and width B are stacked to form a substantially rectangular parallelepiped soft piece. The magnetic material block 2 is formed by stacking a predetermined number of soft magnetic material blocks 2 having different widths B.
Individual rectangular flat thin plates are cut using a shearing machine, etc., one by one or multiple sheets so that deformation such as bending does not occur in the thin plate-shaped soft magnetic material. In addition, the number of sheets is limited according to the thickness of the soft magnetic material and the cutting machine used so that residual stress generated on the fractured surface due to cutting does not affect the iron loss.
Thus, by making the iron core 31 into the laminated structure 1 formed by laminating the soft magnetic material blocks 2 having different widths B, the soft magnetic material is not deformed when it is cut into individual rectangular flat thin plates. Any cross-sectional shape such as a substantially circular shape, a substantially polygonal shape, or a substantially elliptical shape can be used.

As described above, when the iron core 31 is excited by the magnetic flux generated when the electric wire 33 is energized, the eddy current generated inside the iron core 31 or the residual stress due to the distortion generated during the machining of the iron core 31 is caused. Excitation is hindered and lost, and the efficiency of the rotating electrical machine is reduced.
For example, as shown in the reference diagram of FIG. 4, in the case of the iron core 31 manufactured by caulking the iron core piece, distortion occurs in the caulked portion of the laminated structure 1 made of the soft magnetic material, and the loss increases.
On the other hand, when the iron core 31 obtained by laminating the substantially rectangular parallelepiped soft magnetic material blocks 2 in which a plurality of rectangular flat thin plates are stacked as in the present embodiment is processed into individual rectangular flat thin plates. Since the distortion generated on the fracture surface is small, it is possible to reduce the loss as compared with the iron core 31 manufactured by caulking.
Further, in the iron core having the caulking projection as shown in the reference example of FIG. 4, the soft magnetic material is formed by stamping, and many end materials are generated, whereas in the iron core of the present invention, the soft magnetic material is individually provided. In addition, since it is cut and formed into a rectangular flat plate shape, the amount of milling material is small, and the effects of reducing the amount of soft magnetic material used and reducing the cost of parts can be expected.

Note that the direction in which the soft magnetic material blocks 2 are laminated is not limited to one direction. In the axial gap type rotating electrical machine, as in this embodiment, the radial gap type is approximately 90 degrees with respect to the axial direction. In the rotating electrical machine, the stacking direction can be changed as long as the direction is approximately 90 degrees with the radial direction.
As an example, in the case of manufacturing an iron core having a substantially trapezoidal cross section in an axial gap type rotating electrical machine, the direction perpendicular to the upper and lower bases of the substantially trapezoidal cross section as shown in FIG. A direction parallel to the upper and lower bases of the shape or a direction parallel to the hypotenuse having a substantially trapezoidal cross section as shown in FIG.

6A and 6B are diagrams illustrating the structure of the stator teeth when a substantially R shape is provided at the corner of the iron core. 6A, when the corner portion 36 of the iron core 31 has an acute trapezoidal shape, when the corner portion 36 of the iron core 31 has an acute angle with respect to the allowable bending radius of the electric wire 33, the electric wire 33, the insulator 32, and the iron core. There may be a gap between 31 and 31. When the electric wire 33 is not bent along the corner portion 36, the gap between the electric wire 33, the insulator 32, and the iron core 31 reduces the ratio of the iron core 31 to the entire volume of the stator teeth 30, which may increase loss. There is.
Further, when the iron core 31 is covered with the insulator 32 made of insulating paper, the insulator 32 may be damaged because the corner portion 36 has an acute angle. At this time, by adjusting the thickness and width B of the soft magnetic material block 2 to be laminated, the load on the insulator 32 is reduced by laminating so that the corner portion 36 has a substantially R shape as shown in FIG. 6B. Thus, the electric wire 33 is bent along the corner portion 36, the gap between the electric wire 33, the insulator 32, and the iron core 31 is reduced, and the iron core is densely arranged to reduce the loss of the stator. Teeth 30 can be obtained.

FIG. 7 is a diagram illustrating the structure of the stator teeth when the thickness of the soft magnetic material block 2 is changed. The thickness T of the soft magnetic material block 2 is changed by cutting soft magnetic materials having different thicknesses, by cutting a plurality of soft magnetic materials, or by laminating a plurality of cuts with the same width B. It is possible. When the soft magnetic material block 2 is laminated to form the iron core 31, the thickness T of the soft magnetic material block 2 is not necessarily constant.
As an example, in an iron core having a substantially trapezoidal cross section, a soft magnetic material block 2a having a thin thickness T only near the upper and lower bases of the substantially trapezoidal shape as shown in FIG. The contact surface between the substantially R shape of the formed corner 36 and the insulator 32 becomes smooth, and the load on the insulator 32 can be reduced to prevent breakage.
Further, by making the soft magnetic material block 2b having a thickness T other than the vicinity of the upper base and the lower base of the substantially trapezoidal shape, a large number of soft magnetic materials 1 having the same length and width are prepared, and the soft magnetic material block 2b is prepared. It can be molded and the manufacturing time can be shortened. Of course, when each soft magnetic material block 2 is formed, the width B of the laminated soft magnetic material to be laminated may be slightly changed for each sheet to form a smoother R shape.

[Example 2]
FIG. 8 is a diagram illustrating the structure of the stator teeth when an insulator having a recess is used.
The insulator 32 is made of a thin plate-like insulating material having a thickness of 1 mm or less, and seals the lower insulator 32a having a recess adapted to the outer peripheral shape of the iron core 31 and the upper end opening of the lower insulator 32a. The upper insulator 32b is stopped. Note that the lower insulator 32a and the upper insulator 32b are both formed of synthetic resin or the like.
When such an insulator 32 is used, the soft magnetic material block 2 obtained by stacking one or more rectangular flat soft magnetic materials 1 and cutting them to an arbitrary width B is placed inside the recess of the lower insulator 32a. The upper insulator 32b covers the upper portion of the iron core 31. At this time, the back surface of the upper insulator 32b is in close contact with the upper surface of the uppermost soft magnetic material block 2.
As described above, since the periphery of the iron core 31 is covered with the lower insulator 32a and the upper insulator 32b, the iron core 31 can be fixed without the need to bond the soft magnetic materials 1 to each other. It becomes easy to wind the electric wire 33. Further, by using the lower insulator 32a and the upper insulator 32b having an R shape outside the corner portion 37, the electric wire 33 is bent along the corner portion 37, and the electric wire 33 and the two

insulators

32a and 32b are The gap between them becomes small, the iron cores are densely arranged, and the stator teeth 30 with a small loss can be obtained.

[Example 3]
FIG. 9 is a diagram illustrating the structure of the stator teeth when the insulator 32 having a hollow portion having a substantially trapezoidal cross section that matches the outer peripheral shape of the iron core 31 is used.
When such an insulator 32 is used, the iron core 31 having an arbitrary cross-sectional shape in which the soft magnetic material blocks 2 cut to an arbitrary width B are stacked is inserted into the groove 98 at the upper and lower portions in the stacking direction. The iron core 31 is fixed by being gripped by a gripper made of a thin claw or a rod-like member and inserted into the insulator 32 in the hollow portion.
By using the insulator 32 having the hollow portion in this way, the iron core 31 is fixed and easy to handle, and the electric wire 33 can be easily wound, and the insulator 32 covering the iron core 31 is a single component. Since it is comprised, it also becomes possible to reduce member cost.

An embodiment of a method for manufacturing an iron core and a stator tooth using the soft magnetic material of the present invention will be described with reference to FIGS.
FIG. 10 is a flowchart showing a method for manufacturing the stator teeth having the structure described in FIGS. 7 and 8.
(Step 11)
According to the shape of the stator teeth 30, the insulator 32 is installed in a mold having a substantially trapezoidal concave portion with a short bottom side.
In this case, when insulating paper is used as the insulator 32, one or a plurality of insulating papers that can cover the entire circumference of the stator teeth 30 are laid along the concave portion of the mold. On the other hand, as shown in FIG. When using the insulator 32 made of a synthetic resin or the like having such a recess, it is only necessary to install it in accordance with the mold.
(Step 12)
A soft magnetic material block 2 formed by stacking one or more rectangular flat soft magnetic materials 1 and cutting them to an arbitrary width B is placed on an insulator 32 placed in a recess of the mold.
(Step 13)
The soft magnetic material blocks 2 having different widths B are stacked on the soft magnetic material block 2 installed on the insulator 32.
(Step 14)
It is determined whether a predetermined number of soft magnetic materials 1 are laminated.
If the number of stacked sheets is less than the predetermined number, step 13 is repeated until the predetermined number is reached, and the iron core 31 is formed.
(Step 15)
The upper part of the iron core 31 is covered with an insulator 32 and the iron core 31 is fixed.
Note that the iron core 31 is fixed when the insulator 32 is bonded using an adhesive tape or an adhesive, or when the insulator 32 made of a synthetic resin or the like having a recess as shown in FIG. 8 is used. It is obtained by joining both

insulators

32a and 32b by a method such as welding by soldering or TIG welding, or by joining with a fitting portion provided at the upper end of the lower insulator 32a and the lower end of the upper insulator 32b. .
(Step 16)
An electric wire 33 is wound around the insulator 32.
The stator teeth 30 using a rectangular flat soft magnetic material can be manufactured by the above steps.

FIG. 11 is a flowchart showing a method of manufacturing the stator teeth having the structure described in FIG.
(Step 21)
One or a plurality of rectangular flat soft magnetic materials 1 are stacked in an arbitrary width B in a substantially trapezoidal concave portion having a short lower bottom side and a concave portion of a mold having one or more grooves on the lower bottom side of the concave portion. A soft magnetic material block 2 formed by cutting is installed.
(Step 22)
The soft magnetic material blocks 2 having different widths B are stacked on the soft magnetic material block 2 installed on the insulator 32.
(Step 23)
It is determined whether a predetermined number of soft magnetic materials 1 are laminated.
(Step 24)
When the number of stacked layers is less than the predetermined number, the second step is repeated until the predetermined number is reached, and the iron core 31 is formed. Fourth, the upper part of the iron core 31 is pressed down by a pressing plate having one or more grooves on the lower surface.
(Step 25)
Fifth, a gripper made of a thin claw or a rod-like member is inserted into the groove of the mold and the pressing plate, and the iron core 31 is gripped.
(Step 26)
The iron core 31 is inserted into the hollow insulator 32 through the claw through the groove 98 provided in the hollow insulator 32.
(Step 27)
Seventh, the electric wire 33 is wound around the insulator 32.
The stator teeth 30 using a rectangular flat soft magnetic material can be manufactured by the above steps.

FIG. 12 is a flowchart showing another example of the manufacturing method of the iron core and the stator teeth having the structure described in FIG.
(Step 31)
One or a plurality of rectangular flat soft magnetic materials 1 are stacked in an arbitrary width B in a substantially trapezoidal concave portion having a short lower bottom side and a concave portion of a mold having one or more grooves on the lower bottom side of the concave portion. A soft magnetic material block 2 formed by cutting is installed.
(Step 37)
In parallel with step 31, the electric wire 33 is wound around the hollow insulator 32.
(Step 32)
The soft magnetic material blocks 2 having different widths B are laminated on the soft magnetic material block 2 installed on the mold.
(Step 33)
It is determined whether a predetermined number of soft magnetic materials 1 are laminated.
If the number of stacked layers is less than the predetermined number, step 32 is repeated until the predetermined number is reached, and the iron core 31 is formed.
(Step 34)
The upper part of the iron core 31 is pressed down with a pressing plate having one or more grooves on the lower surface.
(Step 35)
A gripper made of a thin claw or a rod-like member is inserted into the groove of the mold and the pressing plate to grip the iron core 31.
(Step 36)
The iron core 31 is inserted into the hollow insulator 32 through the claw through the groove 98 provided in the hollow insulator 32.
Thus, by manufacturing the stator teeth by the manufacturing method shown in FIG. 12, the iron core 31 and the wire 33 can be formed in parallel, and the manufacturing time can be shortened.

According to the embodiment described above, the iron core 31 is formed by stacking the soft magnetic material blocks 2 made of one or a plurality of soft magnetic materials 1 cut into a rectangular flat plate, so that deformation or adhesion is not required. Therefore, a stator having an iron core with a small iron loss can be obtained at low cost.

[Example 4]
An example of the structure of the iron core and the stator teeth using the soft magnetic material of the present invention will be described with reference to FIGS. 13, 14A and 14B.
FIG. 13 is a diagram illustrating the structure of the stator teeth of the present embodiment. In the stator teeth 30, the electric wire 33 on which the insulating coating 34 is formed is directly wound around the iron core 31 to be fixed. For the electric wire 33, a wire having a substantially circular cross section or a substantially rectangular cross section using copper or aluminum as a base material is used.

14A and 14B are diagrams illustrating the structure of the stator teeth when a substantially R shape is provided at the corner of the iron core.
As in Examples 1 to 3, the iron core 31 is made of a soft magnetic material made of iron, cobalt, or nickel as a base material, and a thin soft magnetic material having a length L is cut into a rectangular flat plate with an arbitrary width B. It is configured by laminating one or a plurality of soft magnetic material blocks 31 each having a substantially rectangular parallelepiped shape that is formed by stacking one or a plurality of them without causing deformation such as bending.
By stacking soft magnetic material blocks 31 having different widths B, the iron core 31 can have an arbitrary cross-sectional shape such as a substantially circular shape, a substantially polygonal shape, or a substantially elliptical shape without deforming the soft magnetic material. is there.

In the case of the present embodiment, the iron core 31 formed by stacking the soft magnetic material blocks 31 having different widths B is fixed by the electric wire 33 on which the insulating film 34 is formed. When the corner portion 36 of the iron core 31 has a substantially trapezoidal shape with an acute angle, the gap between the electric wire 33 and the iron core 31 is larger when the corner portion 36 of the iron core 31 has an acute angle than the allowable bending radius of the electric wire 33. Is likely to occur.
When the electric wire 33 is not bent along the corner portion 36, the gap between the electric wire 33 and the iron core 31 reduces the ratio of the iron core 31 with respect to the entire volume of the stator teeth 30, and the loss may increase. Further, since the corner portion 36 has an acute angle, the insulating coating 34 may be damaged.

Therefore, by adjusting the width B of the soft magnetic material block 2 to be stacked, the load on the insulating coating 34 is reduced by stacking so that the corner portion 36 has a substantially R shape as shown in FIG. 14B. To prevent the breakage and to bend the electric wire 33 along the corner portion 36, the gap between the electric wire 33 and the iron core 31 is reduced, and the iron core is densely arranged to obtain the stator teeth 30 with low loss. Can do.

FIG. 15 is a flowchart showing a method of manufacturing the stator teeth having the structure described in FIG.
(Step 41)
One or a plurality of rectangular flat soft magnetic materials 1 are stacked in an arbitrary width B in a substantially trapezoidal concave portion having a short lower bottom side and a concave portion of a mold having one or more grooves on the lower bottom side of the concave portion. A soft magnetic material block 2 formed by cutting is installed.
(Step 42)
The soft magnetic material blocks 2 having different widths B are stacked on the soft magnetic material block 2 installed on the insulator 32.
(Step 43)
Third, it is determined whether a predetermined number of soft magnetic materials 1 are laminated.
If the number of stacked sheets is less than the predetermined number, step 42 is repeated until the predetermined number is reached, and the iron core 31 is formed.
(Step 44)
The upper part of the iron core 31 is pressed down with a pressing plate having one or more grooves on the lower surface.
(Step 45)
A gripper made of a thin claw or a rod-like member is inserted into the groove portion of the mold and the pressing plate, and the pressing plate is removed while pressing and gripping so that the laminated state of the iron core 31 does not collapse, and the iron core 31 is extracted from the mold.
(Step 46)
In this state, the electric wire 33 is wound around the iron core 31, the iron core 31 is fixed, and then the cage is pulled out.
Thus, by manufacturing the stator teeth by the manufacturing method shown in FIG. 15, the stator teeth 30 using the rectangular flat soft magnetic material in which the iron core 31 is fixed by the electric wires 33 can be manufactured.
According to the embodiment described above, the iron core 31 is formed by stacking the soft magnetic material blocks 2 made of one or a plurality of soft magnetic materials 1 cut into a rectangular flat plate, so that deformation or adhesion is not required. Therefore, a stator having an iron core with a small iron loss can be obtained at low cost.

As described above, the present invention has been specifically described based on the embodiment. However, several kinds of individually described inventions can be used in combination. Further, although the description has been given using the example of the axial gap type rotating electrical machine, since the cross-sectional shape of the iron core can be arbitrarily changed, the same effect can be obtained also in the radial gap type rotating electrical machine. That is, the present invention is not limited to the embodiment of the present invention, and can be changed without departing from the gist of the rotating electric machine having a stator tooth formed by stacking rectangular flat soft magnetic materials and forming an iron core. Needless to say.

As described above, according to the rotating electrical machine of the present invention, the iron core of the stator teeth is a rectangular flat plate formed by cutting a thin plate-like soft magnetic material into a predetermined width every sheet or every few sheets. Because it is composed by laminating thin thin plates, it is widely adopted as a low-cost and high-efficiency rotating electrical machine and manufacturing method without giving deformation to the soft magnetic material or requiring an adhesive. Can be expected.

DESCRIPTION OF SYMBOLS 1 ... Soft magnetic material 2 ... Soft magnetic material block 10 ... Axial gap type rotary electric machine 20 ... Magnet 21 ... Disk-shaped member 30 ... Stator teeth 50 ... Rotor 60 ... Stator 70 ... Rotating shaft 80 ... Housing 98 ... Insulator groove 31 ... Stator tooth core 32 ... Stator tooth insulator 33 ... Electric wire 34 of stator teeth ... Insulating coating 36 of electric wires ... Corner portion 37 of stator teeth core ... Corner portion L of insulator of stator teeth ... Soft magnetic material and soft magnetism Material block length B: Soft magnetic material and soft magnetic material block width T: Soft magnetic material and soft magnetic material block thickness

Claims

In a rotating electrical machine having a stator and a rotor,
The stator teeth constituting the stator include an iron core, an electric wire arranged around the iron core, and an insulator arranged between the iron core and the electric wire,
The said iron core is comprised by laminating | stacking the thin plate-shaped thin magnetic plate formed from the thin plate-shaped soft-magnetic material in the width | variety which differs for every sheet or every several sheets.
The rotating electric machine according to claim 1, wherein the rectangular flat thin plates have the same length.
The rotating electrical machine according to claim 1, wherein the insulator is an insulating coating coated on the electric wire.
A single block is formed by laminating a plurality of the thin plates having the same width,
The rotating electrical machine according to claim 1, wherein the iron core is configured by stacking a plurality of the blocks having different widths.
2. The rotating electrical machine according to claim 1, wherein the soft magnetic material is made of an electromagnetic steel plate or amorphous metal whose base material is iron, cobalt, or nickel.
The rotating electrical machine according to claim 1, wherein the thin plates are laminated at an angle of 90 degrees with the axial direction of the rotor.
The rotating electrical machine according to claim 1, wherein the thin plates are stacked in a direction different from a radial direction of the shaft of the rotor.
The rotating electrical machine according to claim 7, wherein the thin plate includes a thin plate having a width larger than a width of the iron core in a circumferential direction of the rotation axis.
The rotating electric machine according to claim 1, wherein the iron core is provided with a substantially R shape at a corner portion due to a difference in width of the thin plate.
2. The rotating electrical machine according to claim 1, wherein the iron core is configured such that a thickness of the upper and lower thin plates in the stacking direction is smaller than a thickness of the middle portion in the stacking direction by adjusting a width of the thin plate.
The rotating electrical machine according to claim 1, wherein the insulator has a thin and concave cross-sectional shape, and an angle formed between a side surface and a bottom surface of the concave portion is 90 degrees or more.
The insulator is composed of a thin lower insulator having a concave cross-sectional shape matched to the outer peripheral shape of the iron core, and a thin plate-like upper insulator,
The rotating electrical machine according to claim 11, wherein the iron core is covered with the lower insulator and the upper insulator.
2. The rotating electrical machine according to claim 1, wherein the insulator is a thin-walled insulator having a hollow portion matched with an outer peripheral shape of the iron core inside.
A method of manufacturing a rotating electrical machine having stator teeth,
A first step of forming a thin plate of a rectangular flat plate by forming a thin plate-like soft magnetic material with a predetermined width every one or a small number of sheets;
A second step of laminating a block formed by laminating a plurality of the thin plates or the same width of the thin plates;
A third step of winding an electric wire through an insulator around the laminated thin plate or the block;
In the second step, the width of the thin plate or the block is stacked in the stacking direction in accordance with the iron core shape of the stator teeth.
15. The method of manufacturing a rotating electrical machine according to claim 14, wherein, in the second step, the thin plate or the block is installed and laminated inside a mold in which insulating paper is laid.
After the second step, a fourth step of pressing the top of the laminated thin plate or the block with a pressing plate;
A fifth step of gripping the thin plate or the block from above and below using a gripping tool;
A sixth step of inserting the gripped thin plate or the block into a hollow insulator;
The method for manufacturing a rotating electrical machine according to claim 14, wherein the third step is performed after the sixth step.
After the second step, a fourth step of pressing the top of the laminated thin plate or the block with a pressing plate;
A fifth step of gripping the thin plate or the block from above and below using a gripping tool;
A sixth step of inserting the gripped thin plate or the block into a hollow insulator;
15. The method of manufacturing a rotating electrical machine according to claim 14, wherein the third step is performed before the fourth step or in parallel with the fourth step and the fifth step.
After the second step, a fourth step of pressing the top of the laminated thin plate or the block with a pressing plate;
A fifth step of gripping the thin plate or the block from above and below using a gripping tool,
The method of manufacturing a rotating electrical machine according to claim 14, wherein in the third step, an electric wire on which an insulating coating is formed is wound.