JP4045038B2

JP4045038B2 - Stator for rotating electrical machine and method for manufacturing stator

Info

Publication number: JP4045038B2
Application number: JP37375998A
Authority: JP
Inventors: 敏一佐藤; 豊信山田; 勉川村; 資康望月
Original assignee: Toshiba Corp
Current assignee: Toshiba Corp
Priority date: 1998-09-02
Filing date: 1998-12-28
Publication date: 2008-02-13
Anticipated expiration: 2018-12-28
Also published as: JP2000152525A

Description

【０００１】
【発明の属する技術分野】
本発明は、帯状コアを環状化してなるステータコアを有する回転電機のステータおよびステータの製造方法に関する。
【０００２】
【発明が解決しようとする課題】
回転電機には、複数の単位コアが連結された形態の帯状コアを環状に折曲げることに基づいてステータコアが形成された構成のものがある。この構成の場合、各単位コアの周方向端面（＝分割面）が平面状に形成されており、平面状の分割面が周方向に隣接する平面状の分割面に接合されている。このため、分割面相互間で磁束の損失が生じ、磁気効率が低下する虞れがある。
【０００３】
本発明は上記事情に鑑みてなされたものであり、その目的は、磁気効率の低下を抑えることができる回転電機のステータおよびステータの製造方法を提供することにある。
【０００４】
【課題を解決するための手段】
請求項１記載の回転電機のステータは、複数の単位コアが連結された形態の帯状コアを環状化してなるステータコアと、前記各単位コアの周方向両端部に設けられ前記ステータコアの磁極ティースに対して一方向へ傾斜する第１の傾斜面および第１の傾斜面と同一方向へ傾斜する第２の傾斜面を交互に有する櫛歯部とを備え、前記各櫛歯部が周方向に隣接する櫛歯部に噛合して周方向にラップし、前記各櫛歯部の先端部に切落部が形成されているところに特徴を有している。
請求項４記載の回転電機のステータは、複数の単位コアが連結された形態の帯状コアを環状化してなるステータコアと、前記各単位コアの周方向両端部に設けられ前記ステータコアの磁極ティースに対して一方向へ傾斜する第１の傾斜面および第１の傾斜面と同一方向へ傾斜する第２の傾斜面を交互に有する櫛歯部とを備え、前記各櫛歯部が周方向に隣接する櫛歯部に噛合して周方向にラップし、前記各櫛歯部の先端部に切落部が形成され、前記単位ヨーク間の連結部分に円弧部が設けられているところに特徴を有している。
請求項１および４記載のそれぞれの手段によれば、櫛歯部が周方向に隣接する櫛歯部に噛合し、周方向にラップしている。このため、周方向に隣接する単位コア間での磁束の損失量が少なくなるので、磁気的な効率が向上する。しかも、磁極ティースにマグネットワイヤを巻装するにあたって、マグネットワイヤが櫛歯部の先端部に引掛かって傷付くことが防止される。特に請求項４記載の手段によれば、帯状コアの折曲時に単位ヨーク間の連結部分に応力が分散して作用するので、連結部分に亀裂等が生じることが防止される。
【０００５】
請求項２記載の回転電機のステータは、複数の単位コアが連結された形態の帯状コアを環状化してなるステータコアと、前記各単位コアの周方向両端部に設けられ前記ステータコアの磁極ティースに略平行な平行面および磁極ティースに対して傾斜する傾斜面を交互に有する櫛歯部とを備え、前記各櫛歯部が周方向に隣接する櫛歯部に噛合して周方向にラップし、前記各櫛歯部の先端部に切落部が形成されているところに特徴を有している。
請求項５記載の回転電機のステータは、複数の単位コアが連結された形態の帯状コアを環状化してなるステータコアと、前記各単位コアの周方向両端部に設けられ前記ステータコアの磁極ティースに略平行な平行面および磁極ティースに対して傾斜する傾斜面を交互に有する櫛歯部とを備え、前記各櫛歯部が周方向に隣接する櫛歯部に噛合して周方向にラップし、前記各櫛歯部の先端部に切落部が形成され、前記単位ヨーク間の連結部分に円弧部が設けられているところに特徴を有している。
請求項２および５記載のそれぞれの手段によれば、櫛歯部が周方向に隣接する櫛歯部に噛合し、周方向にラップしている。このため、周方向に隣接する単位コア間での磁束の損失量が少なくなるので、磁気的な効率が向上する。しかも、櫛歯部の端面が平行面および傾斜面から構成されているので、請求項１記載の手段に比べて櫛歯部間の周方向のラップ量が増える。このため、単位コア間での磁束の損失量が一層少なくなるので、磁気的な効率が一層向上する。しかも、磁極ティースにマグネットワイヤを巻装するにあたって、マグネットワイヤが櫛歯部の先端部に引掛かって傷付くことが防止される。特に請求項５記載の手段によれば、帯状コアの折曲時に単位ヨーク間の連結部分に応力が分散して作用するので、連結部分に亀裂等が生じることが防止される。
【０００６】
請求項３記載の回転電機のステータは、複数の単位コアが連結された形態の帯状コアを環状化してなるステータコアと、前記各単位コアの周方向両端部に設けられ前記ステータコアの磁極ティースに対して一方向へ傾斜する第１の傾斜面および第１の傾斜面と反対方向へ傾斜する第２の傾斜面を交互に有する櫛歯部とを備え、前記各櫛歯部が周方向に隣接する櫛歯部に噛合して周方向にラップし、前記各櫛歯部の先端部に切落部が形成されているところに特徴を有している。
請求項６記載の回転電機のステータは、複数の単位コアが連結された形態の帯状コアを環状化してなるステータコアと、前記各単位コアの周方向両端部に設けられ前記ステータコアの磁極ティースに対して一方向へ傾斜する第１の傾斜面および第１の傾斜面と反対方向へ傾斜する第２の傾斜面を交互に有する櫛歯部とを備え、前記各櫛歯部が周方向に隣接する櫛歯部に噛合して周方向にラップし、前記各櫛歯部の先端部に切落部が形成され、前記単位ヨーク間の連結部分に円弧部が設けられているところに特徴を有している。
請求項３および６記載のそれぞれの手段によれば、櫛歯部が周方向に隣接する櫛歯部に噛合し、周方向にラップしている。このため、周方向に隣接する単位コア間での磁束の損失量が少なくなるので、磁気的な効率が向上する。しかも、櫛歯部の端面が異方向へ傾斜する第１の傾斜面および第２の傾斜面から構成されているので、請求項１記載の手段および請求項２記載の手段に比べて櫛歯部間の周方向のラップ量が増える。このため、単位コア間での磁束の損失量が一層少なくなるので、磁気的な効率が一層向上する。しかも、磁極ティースにマグネットワイヤを巻装するにあたって、マグネットワイヤが櫛歯部の先端部に引掛かって傷付くことが防止される。特に請求項６記載の手段によれば、帯状コアの折曲時に単位ヨーク間の連結部分に応力が分散して作用するので、連結部分に亀裂等が生じることが防止される。
【０００７】
請求項７記載の回転電機のステータは、ステータコアのうちの帯状コアの両端部に軸方向へ延びる切欠部が形成され、ステータコアが切欠部の内面に沿って高エネルギー加工を施すことに基づいて環状に保持されているところに特徴を有している。
上記手段によれば、ステータコアの高エネルギー加工範囲が増えるので、ステータコアの強度が高まる。しかも、高エネルギー加工が施された盛上がり部分がステータコアの表面から突出することが防止される。
【０００９】
請求項８記載の回転電機のステータは、複数枚の磁性板を積層することに基づいて形成された帯状コアを備え、前記帯状コアに軸方向へ延びる切欠部が形成され、前記帯状コアが前記切欠部の内面に沿って高エネルギー加工を施すことに基づいて積層状態に保持されているところに特徴を有している。
上記手段によれば、帯状コアの高エネルギー加工範囲が増えるので、帯状コアの強度が高まる。しかも、高エネルギー加工が施された盛上がり部分が帯状コアの表面から突出することが防止される。
【００１０】
請求項９記載の回転電機のステータは、第１の傾斜面に第１の突部が設けられ、周方向に隣接する第１の突部に接触する第２の突部が第２の傾斜面に設けられているところに特徴を有している。
上記手段によれば、帯状コアを環状化する際に単位ヨーク間の連結部分が延びるが、第１の傾斜面の第１の突部が第２の傾斜面の第２の突部に接触することに基づいてステータコアが極力真円に成形される。しかも、第１の傾斜面が第１の突部および第２の突部を介して第２の傾斜面に確実に接触するので、磁気的な損失が低減される。
【００１１】
請求項１０記載の回転電機のステータは、平行面に第１の突部が設けられ、周方向に隣接する第１の突部に接触する第２の突部が傾斜面に設けられているところに特徴を有している。
上記手段によれば、帯状コアを環状化する際に単位ヨーク間の連結部分が延びるが、平行面の第１の突部が傾斜面の第２の突部に接触することに基づいてステータコアが極力真円に成形される。しかも、平行面が第１の突部および第２の突部を介して傾斜面に確実に接触するので、磁気的な損失が低減される。
【００１３】
請求項１１記載の回転電機のステータは、複数枚の磁性板を積層することに基づいて形成された帯状コアを備え、前記帯状コアの両端部に第１の傾斜面および第２の傾斜面を１枚ずつ交互に有する櫛歯部が形成され、前記帯状コアの残りの部分に第１の傾斜面および第２の傾斜面を複数枚ずつ交互に有する櫛歯部が形成されているところに特徴を有している。
上記手段によれば、帯状コアを環状に成形する際に両端部の櫛歯部が相手側に引掛かることなく円滑に噛合される。このとき、残りの櫛歯部は軸方向の噛合代が大きく設定されているので、隣接する櫛歯部に円滑に噛合される。
【００１４】
請求項１２記載の回転電機のステータは、複数枚の磁性板を積層することに基づいて形成された帯状コアを備え、前記帯状コアの両端部に平行面および傾斜面を１枚ずつ交互に有する櫛歯部が形成され、前記帯状コアの残りの部分に平行面および傾斜面を複数枚ずつ交互に有する櫛歯部が形成されているところに特徴を有している。
上記手段によれば、帯状コアを環状に成形する際に両端部の櫛歯部が相手側に引掛かることなく円滑に噛合される。このとき、残りの櫛歯部は軸方向の噛合代が大きく設定されているので、隣接する櫛歯部に円滑に噛合される。
【００１５】
請求項１３記載の回転電機のステータの製造方法は、請求項１ないし３のいずれかに記載の回転電機のステータを製造する方法において、輪郭形状が相違する第１の磁性板および第２の磁性板を順送りして打抜く工程と、前記第１の磁性板および前記第２の磁性板を重ねることに基づいて複数の櫛歯部を有する帯状コアを形成する工程と、前記帯状コアを環状化することに基づいて前記櫛歯部を周方向に隣接する櫛歯部に噛合させる工程とを備え、前記第１の磁性板および前記第２の磁性板を打抜くにあたって、第１のポンチによって打抜いた部分を第２のポンチによって打抜くことに基づいて両ポンチとは異形状の打抜部を形成するところに特徴を有する。
【００１６】
上記手段によれば、第１の磁性板および第２の磁性板を順送りして打抜いている。このため、第１の磁性板および第２の磁性板を別個のプレス機によって打抜く必要がなくなるので、装置が小形化される。しかも、第１のポンチによって打抜いた部分を第２のポンチによって打抜くことに基づいて両ポンチとは異形状の打抜部を形成しているので、ポンチの数が少なくて済む。
【００１７】
請求項１４記載の回転電機のステータの製造方法は、請求項１ないし３のいずれかに記載の回転電機のステータを製造する方法において、磁性板の向きを反転して磁性板に重ねることに基づいて複数の櫛歯部を有する帯状コアを形成する工程と、前記帯状コアを環状化することに基づいて前記櫛歯部を周方向に隣接する櫛歯部に噛合させる工程とを備えたところに特徴を有している。
上記手段によれば、輪郭形状が異なる複数種の磁性板を別個のプレス機によって打抜く必要がなくなるので、装置が小形化される。
【００１８】
請求項１５記載の回転電機のステータの製造方法は、請求項１ないし３のいずれかに記載の回転電機のステータを製造する方法において、磁性板を裏返して磁性板に重ねることに基づいて複数の櫛歯部を有する帯状コアを形成する工程と、前記帯状コアを環状化することに基づいて前記櫛歯部を周方向に隣接する櫛歯部に噛合させる工程とを備えたところに特徴を有している。
上記手段によれば、輪郭形状が異なる複数種の磁性板を別個のプレス機によって打抜く必要がなくなるので、装置が小形化される。
【００１９】
請求項１６記載の回転電機のステータの製造方法は、帯状コアのうち単位ヨーク間の連結部分の少なくとも一方側に磁性板の積層方向に沿って高エネルギー加工を施す工程を備え、前記工程が前記帯状コアの折曲前に行われるところに特徴を有している。
上記手段によれば、帯状コアを環状に折曲げる際に単位ヨーク間の連結部分に応力が集中し、磁性板に軸方向への外力が作用する。しかしながら、磁性板の軸方向への膨みが高エネルギー加工によって抑えられるので、磁性板相互間の密着度が高まり、振動や騒音の発生が抑止される。
【００２０】
請求項１７記載の回転電機のステータの製造方法は、帯状コアのうち単位ヨーク間の連結部分の一方側に磁性板の積層方向に沿って高エネルギー加工を施す第１の工程と、前記帯状コアのうち前記連結部分の他方側に前記積層方向に沿って高エネルギー加工を施す第２の工程とを備え、前記第１の工程が前記帯状コアの折曲前に行われ、前記第２の工程が前記帯状コアの折曲後に行われるところに特徴を有している。
上記手段によれば、帯状コアを環状に折曲げる際に磁性板の軸方向への膨みが折曲前の高エネルギー加工によって抑えられる。このとき、磁性板が軸方向へ動く余地が若干残されているので、櫛歯部が周方向に隣接する櫛歯部に突合されることなく円滑に噛合される。しかも、磁性板相互間の密着度が折曲後の高エネルギー加工によって大幅に高まるので、振動や騒音が大幅に抑えられる。
【００２１】
【発明の実施の形態】
以下、本発明の第１実施例を図１ないし図１４に基づいて説明する。尚、本実施例は、本発明をインナーロータ形の３相ＤＣブラシレスモータに適用したものである。まず、図１の（ａ）において、ヘリカル鉄心１は単位コア１Ａ〜１Ｆを繋ぎ桟２によって連結した帯状をなすものであり（但し、単位コア１Ａおよび１Ｆ間は分断されている）、単位コア１Ａ〜１Ｆは円弧状の単位ヨーク３と直状の磁極ティース４と磁極片５とから構成されている。尚、ヘリカル鉄心１は帯状コアに相当するものである。
【００２２】
単位コア１Ａ〜１Ｆは、図１の（ｂ）に示すように、磁性板に相当する第１の鋼板６および第２の鋼板７を軸方向へ１枚おきに交互に積層することに基づいて形成されている。これら第１の鋼板６および第２の鋼板７は、図２の（ａ）に示すように、帯状鋼板８の短手方向に沿って２列に打抜かれ、且つ、帯状鋼板８の長手方向に沿って交互に打抜かれたものであり、軸方向に積層された第１の鋼板６および第２の鋼板７はレーザー溶接を施すことに基づいて機械的に連結されている。
【００２３】
第１の鋼板６には第１の打抜部９が５個形成されている。これら各第１の打抜部９は、図２の（ｂ）に示すように、中心線ＣＬに平行な直線状の平行面１０および中心線ＣＬに対して一方向へθ°傾斜する直線状の傾斜面１１によって画定されたものであり、第１の鋼板６の矢印Ａ方向端部は、図２の（ｄ）に示すように、平行面１０から構成され、反矢印Ａ方向端部は、図２の（ｅ）に示すように、傾斜面１１から構成されている。尚、中心線ＣＬは磁極ティース４に平行な直線を称するものである。
【００２４】
第２の鋼板７には、図２の（ａ）に示すように、第２の打抜部１２が５個形成されている。これら各第２の打抜部１２は、図２の（ｃ）に示すように、中心線ＣＬに対して傾斜面１１とは反対方向へθ°傾斜する直線状の傾斜面１３および中心線ＣＬに平行な直線状の平行面１０によって画定されたものであり、第２の鋼板７の矢印Ａ方向端部は、図２の（ｅ）に示すように、傾斜面１３から構成され、反矢印Ａ方向端部は、図２の（ｄ）に示すように、平行面１０から構成されている。
【００２５】
単位コア１Ａ〜１Ｆには、図１の（ａ）に示すように、単位ヨーク３の矢印Ａ方向端部に位置してラップ部１４が形成されている。これら各ラップ部１４は軸方向視が三角形状をなすものであり、第１の鋼板６の平行面１０と第２の鋼板７の傾斜面１３とを１枚ずつ交互に有する櫛歯状をなしている。
【００２６】
単位コア１Ａ〜１Ｆには、単位ヨーク３の反矢印Ａ方向端部に位置してラップ部１４が形成されている。これら各ラップ部１４は軸方向視が三角形状をなすものであり、第１の鋼板６の傾斜面１１と第２の鋼板７の平行面１０とを１枚ずつ交互に有する櫛歯状をなしている。尚、ラップ部１４は櫛歯部に相当するものである。
【００２７】
図３のステータコア１５はヘリカル鉄心１を複数の繋ぎ桟２から円環状に折曲げてなるものであり、各ラップ部１４は周方向に隣接するラップ部１４に軸方向から噛合し、周方向に沿ってラップしている。このうち単位コア１Ａの一方のラップ部１４と単位コア１Ｆの一方のラップ部１４との間には軸方向へ延びる切欠部１６が形成されており、単位コア１Ａおよび単位コア１Ｆ間は切欠部１６の内面に沿ってレーザー溶接を施すことに基づいて連結されている。
【００２８】
ステータコア１５には、図４の（ａ）に示すように、各磁極ティース４に対応して合成樹脂製のモールド層１７が形成されている。これら各モールド層１７は、図４の（ｂ）に示すように、磁極ティース４の表面を覆う角筒状のコイル巻装部１８と、コイル巻装部１８の内周部に位置する鍔部１９と、単位ヨーク３の軸方向上端面を覆う円弧状の端板部２０と、単位ヨーク２の軸方向下端面を覆う円弧状の端板部２１とから構成されたものであり、ステータコア１５を成形型（図示せず）内に収納して溶融樹脂を注入するインサート成形に基づいて形成されている。
【００２９】
各磁極ティース４には、コイル巻装部１８の上からコイル２２が装着されている。これら各コイル２２はヘリカル鉄心１を円環状に折曲げる前に磁極ティース４に巻装されたものであり、図４の（ａ）に示すように、巻回方向を外周側から内周側および内周側から外周側へ層毎に反転させながら略階段状に巻回されている。
【００３０】
次に帯状鋼板８から第１の鋼板６および第２の鋼板７を打抜く順送り型のクランクプレス装置３０について説明する。まず、図５の（ａ）において、上型ホルダ３１はクランク機構（図示せず）を介してプレスモータ３２（図６参照）に連結されたものであり、プレスモータ３２が作動すると、上型ホルダ３１が上死点および下死点間で繰返し移動する。
【００３１】
上型ホルダ３１の下方にはテーブル３３が配設されている。このテーブル３３の上面には帯状鋼板８がセットされており、搬送機構３４（図６参照）が作動すると、帯状鋼板８がテーブル３３の上面に沿って矢印Ａ方向へ搬送される。尚、搬送機構３４は搬送モータ３５（図６参照）を駆動源とするものである。
【００３２】
上型ホルダ３１の下面には、図５の（ａ）に示すように、バッキングプレート３６が装着されている。このバッキングプレート３６の下面にはポンチプレート３７が装着されており、ポンチプレート３７には、図７の（ｂ）に示すように、反矢印Ａ方向から順に一対の第１の打抜ポンチ３８，一対の第２の打抜ポンチ３９，一対の切断ポンチ４０が装着されている。尚、第１の打抜ポンチ３８および第２の打抜ポンチ３９は、第１のポンチおよび第２のポンチに相当するものである。
【００３３】
各ポンチ３８〜４０は、図５の（ａ）に示すように、ポンチプレート３７の貫通孔４１内に上下動可能に挿入されたものであり、各第１の打抜ポンチ３８は、図７の（ｂ）に示すように、第１の鋼板６の第１の打抜部９と同一傾斜角度の三角形状をなし、各第２の打抜ポンチ３９は第２の鋼板７の第２の打抜部１２と同一傾斜角度の三角形状をなしている。
【００３４】
ポンチプレート３７には、図５の（ａ）に示すように、空間部４２が形成されており、空間部４２内には、図７の（ａ）に示すように、各ポンチ３８〜４０に対応してカム４３〜４５が収納されている。これら各カム４３〜４５は、図５の（ａ）に示すように、薄肉部４６および厚肉部４７を有するものであり、各カム４３〜４５には、図５の（ｂ）に示すように、薄肉部４６および厚肉部４７を跨ぐ横長い貫通孔４８が形成されている。
【００３５】
上型ホルダ３１には、図５の（ａ）に示すように、各貫通孔４８に対応して貫通状のねじ孔４９が形成されており、各ねじ孔４９内にはピン５０の上端部が上下動可能に挿入されている。また、バッキングプレート３６には、各ピン５０に対応して貫通孔５１が形成されており、各カム４３〜４５の貫通孔４８内には、バッキングプレート３６の貫通孔５１を通してピン５０の下端部が挿入されている。
【００３６】
各ねじ孔４９内には止めねじ５２が螺合されており、各止めねじ５２とピン５０との間には圧縮コイルスプリング５３が介在されている。これら各スプリング５３はピン５０を下方へ付勢するものであり、各ポンチ３８〜４０の頭部はピン５０の下端部によって下方へ押えられている。
【００３７】
各組のカム４３〜４５は、図６に示すように、エアーシリンダ５４〜５６のロッドに連結されている。これらシリンダ５４〜５６は各組のカム４３〜４５を図７の（ａ）の矢印Ａ方向および反矢印Ａ方向へスライドさせるものであり、各カム４３〜４５がスライドし、図５の（ａ）に実線で示すように、各ポンチ３８〜４０の頭部にカム４３〜４５の薄肉部４６が対向すると、両者の間に隙間が形成され、図５の（ａ）に二点鎖線で示すように、各ポンチ３８〜４０の頭部にカム４３〜４５の厚肉部４７が対向すると、両者が略接触する。
【００３８】
各ポンチ３８〜４０の頭部とカム４３〜４５の薄肉部４６とが対向した状態でポンチプレート３７が下降した場合には、各ポンチ３８〜４０が帯状鋼板８に接触した時点でスプリング５３が収縮し、各ポンチ３８〜４０が上昇する。このため、各ポンチ３８〜４０によるプレス動作が実行されない（ポンチ３８〜４０の無効状態）。
【００３９】
各ポンチ３８〜４０の頭部とカム４３〜４５の厚肉部４７とが対向した状態でポンチプレート３７が下降した場合には、各ポンチ３８〜４０が帯状鋼板８に接触しても上昇できず、ポンチプレート３７と一体的に下死点まで下降する。このため、各ポンチ３８〜４０による帯状鋼板８のプレス動作が実行される（ポンチ３８〜４０の有効状態）。
【００４０】
ポンチプレート３７には、図７の（ｂ）に示すように、反矢印Ａ方向から順に一対の打抜ポンチ５７，一対の打抜ポンチ５８，一対の打抜ポンチ５９が固定されており、ポンチプレート３７が下降すると、一対の打抜ポンチ５７〜５９がポンチプレート３７と一体的に下死点まで下降し、一対の打抜ポンチ５７〜５９による帯状鋼板８のプレス動作が実行される。
【００４１】
プレスモータ３２および搬送モータ３５は、図６に示すように、モータ駆動回路６０および６１を介して制御装置６２に電気的に接続されている。この制御装置６２はマイクロコンピュータを主体に構成されたものであり、モータ駆動回路６１を通して搬送モータ３５を駆動制御することに基づいて帯状鋼板８を断続的に搬送し、モータ駆動回路６０を通してプレスモータ３２を駆動制御することに基づいて上型ホルダ３１を上死点および下死点間で連続的に移動させる。
【００４２】
シリンダ５４〜５６の配管経路にはソレノイドバルブ６３〜６５が介在されている。これらバルブ６３〜６５はバルブ駆動回路６６〜６８を介して制御装置６２に電気的に接続されており、制御装置６２はバルブ駆動回路６６〜６８を通してバルブ６３〜６５を駆動制御することに基づいてカム４３〜４５をスライドさせ、ポンチ３８〜４０の状態を切換える。
【００４３】
マイクロスイッチ６９はポンチプレート３７が下死点に到達することに基づいてオンされるものであり、制御装置６２はスイッチ６９からのオン信号に基づいてポンチカウンタ「Ｎｐ」をカウントアップし、カウンタ「Ｎｐ」の値に基づいてバルブ６３〜６５の制御タイミングを得る。
【００４４】
次にプレス装置３０の動作内容について説明する。尚、下記動作は制御装置６２がＲＯＭに予め記憶された制御プログラムに基づいてプレスモータ３２，搬送モータ３５，バルブ６３〜６５を駆動制御することに基づいて実行されるものである。
【００４５】
制御装置６２は、図７の（ａ）に示すように、バルブ６３を駆動制御することに基づいて各カム４３の厚肉部４７を打抜ポンチ３８に対向させ、各打抜ポンチ３８を有効化する。これと共に、バルブ６４および６５を駆動制御することに基づいて各カム４４の薄肉部４６および各カム４５の薄肉部４６を打抜ポンチ３９および切断ポンチ４０に対向させ、各打抜ポンチ３９および各切断ポンチ４０を無効化する。尚、図７の（ｂ）は有効状態にあるポンチ３８および５７〜５９を実線で示し、無効状態にあるポンチ３９および４０を二点鎖線で示している。
【００４６】
制御装置６２は、上述の動作を終えると、ポンチプレート３７を連続的に上下動させながら、帯状鋼板８を設定ピッチで矢印Ａ方向へ４回搬送する。すると、図７の（ｃ）〜（ｆ）に示すように、一対の打抜ポンチ３８による帯状鋼板８の打抜き動作が４回実行され、帯状鋼板８に一対の第１の打抜部９が４組形成される。
【００４７】
このとき、図１の（ｅ）〜（ｆ）に示すように、一対の打抜ポンチ５７による帯状鋼板８の打抜き動作が２回実行され、帯状鋼板８に一対の菱形孔７０が２組形成される。これと共に、図１の（ｆ）に示すように、一対の打抜ポンチ５８および一対の打抜ポンチ５９による帯状鋼板８の打抜き動作が１回ずつ実行され、帯状鋼板８に一対の切欠部７１および一対の孔７２が１組ずつ形成される。尚、符号７３はパイロット孔を示している。
【００４８】
制御装置６２は、上述の動作を終えると、バルブ６５の状態を切換える。そして、図８の（ａ）に示すように、各カム４５の厚肉部４７を切断ポンチ４０に対向させ、各切断ポンチ４０を有効化した後、帯状鋼板８を設定ピッチで搬送する。すると、図８の（ｃ）に示すように、一対の切断ポンチ４０によって帯状鋼板８が切断され、一対の平行面１０が形成される。このとき、一対の打抜ポンチ３８，一対の打抜ポンチ５７，一対の打抜ポンチ５８，一対の打抜ポンチ５９によって新たな一対の第１の打抜部９，一対の菱形孔７０，一対の切欠部７１，一対の孔７２が一組ずつ形成される。
【００４９】
制御装置６２は、上述の動作を終えると、バルブ６５の状態を切換える。そして、図９の（ａ）に示すように、各カム４５の薄肉部４６を切断ポンチ４０に対向させ、各切断ポンチ４０を無効化する。この後、帯状鋼板８を設定ピッチで２回搬送し、図９の（ｃ）および（ｄ）に示すように、帯状鋼板８に新たな一対の第１の打抜部９，一対の菱形孔７０，一対の切欠部７１，一対の孔７２を２組ずつ形成する。
【００５０】
制御装置６２は、上述の動作を終えると、バルブ６３および６４の状態を切換える。そして、図１０の（ａ）に示すように、各カム４３の薄肉部４６を打抜ポンチ３８に対向させ、各打抜ポンチ３８を無効化する。これと共に、各カム４４の厚肉部４７を打抜ポンチ３９に対向させ、各打抜ポンチ３９を有効化する。
【００５１】
制御装置６２は、打抜ポンチ３８および３９の状態を切換えると、帯状鋼板８を設定ピッチで搬送する。すると、図１０の（ｃ）に示すように、図９の（ｄ）で第１の打抜ポンチ３８によって打抜かれた部分が第２の打抜ポンチ３９によって打抜かれ、第１の打抜部９および第２の打抜部１２とは形状が異なる第３の打抜部７４が形成される。
【００５２】
制御装置６２は、上述の動作を終えると、図１０の（ｄ）および（ｅ）に示すように、帯状鋼板８を設定ピッチで２回搬送し、一対の打抜ポンチ３９によって帯状鋼板８に一対の第２の打抜部１２を２組形成する。このとき、一対の打抜ポンチ５７，一対の打抜ポンチ５８，一対の打抜ポンチ５９によって帯状鋼板８が打抜かれ、新たな一対の菱形孔７０，一対の切欠部７１，一対の孔７２が２組ずつ形成される。
【００５３】
制御装置６２は、上述の動作を終えると、バルブ６５の状態を切換える。そして、図１１の（ａ）に示すように、各カム４５の厚肉部４７を切断ポンチ４０に対向させ、各切断ポンチ４０を有効化した後、帯状鋼板８を設定ピッチで搬送する。すると、図１１の（ｃ）に示すように、一対の切断ポンチ４０によって帯状鋼板８が第３の打抜部７４から切断され、５個の第１の打抜部９，平行面１０，傾斜面１１を有する第１の鋼板６が形成され、帯状鋼板８の矢印Ａ方向端部に一対の傾斜面１３が形成される。
【００５４】
このとき、一対の打抜ポンチ３９，一対の打抜ポンチ５７，一対の打抜ポンチ５８，一対の打抜ポンチ５９によって帯状鋼板８に新たな一対の第２の打抜部１２，一対の菱形孔７０，一対の切欠部７１，一対の孔７２が１組ずつ形成される。これと共に、図１１の（ｄ）に示すように、一対の切断ポンチ４０によって傾斜面１１および１３に中心線ＣＬに対して平行な平行面７５が形成される。
【００５５】
制御装置６２は、上述の動作を終えると、バルブ６５の状態を切換える。そして、図１２の（ａ）に示すように、各カム４５の薄肉部４６を切断ポンチ４０に対向させ、各切断ポンチ４０を無効化した後、帯状鋼板８を設定ピッチで２回搬送する。すると、図１２の（ｃ）および（ｄ）に示すように、一対の打抜ポンチ３９，一対の打抜ポンチ５７，一対の打抜ポンチ５８，一対の打抜ポンチ５９によって帯状鋼板８に新たな一対の第２の打抜部１２，一対の菱形孔７０，一対の切欠部７１，一対の孔７２が２組ずつ形成される。
【００５６】
制御装置６２は、上述の動作を終えると、バルブ６３および６４の状態を切換える。そして、図１３の（ａ）に示すように、各カム４３の厚肉部４７を打抜ポンチ３８に対向させ、各打抜ポンチ３８を有効化する。これと共に、各カム４４の薄肉部４６を打抜ポンチ３９に対向させ、各打抜ポンチ３９を無効化する。
【００５７】
制御装置６２は、打抜ポンチ３８および３９の状態を切換えると、帯状鋼板８を設定ピッチで３回搬送する。すると、図１３の（ｃ）〜（ｅ）に示すように、一対の打抜ポンチ３８，一対の打抜ポンチ５７，一対の打抜ポンチ５８，一対の打抜ポンチ５９によって帯状鋼板８に新たな一対の第１の打抜部９，一対の菱形孔７０，一対の切欠部７１，一対の孔７２が３組ずつ形成される。
【００５８】
制御装置６２は、上述の動作を終えると、バルブ６５の状態を切換える。そして、図１４の（ａ）に示すように、各カム４５の厚肉部４７を切断ポンチ４０に対向させ、各切断ポンチ４０を有効化した後、帯状鋼板８を設定ピッチで搬送する。すると、図１４の（ｃ）および（ｄ）に示すように、各切断ポンチ４０によって帯状鋼板８が切断され、５個の第２の打抜部１２，平行面１０，傾斜面１３，平行面７５を有する第２の鋼板７が形成される。
【００５９】
上記実施例によれば、単位コア１Ａ〜１Ｆの周方向両端部にラップ部１４を形成し、各ラップ部１４を周方向に隣接するラップ部１４に軸方向から噛合させ、周方向にラップさせた。このため、単位コア１Ａ〜１Ｆから周方向に隣接する単位コア１Ａ〜１Ｆに流れる磁束の損失量が少なくなるので、磁気的な効率が向上する。
【００６０】
また、単位コア１Ａ〜１Ｆの矢印Ａ方向側のラップ部１４の端面を第１の鋼板６の平行面１０および第２の鋼板７の傾斜面１３から構成し、反矢印Ａ方向側のラップ部１４の端面を第１の鋼板６の傾斜面１１および第２の鋼板７の平行面１０から構成した。このため、ラップ部１４相互間の周方向のラップ量が増えるので、単位コア１Ａ〜１Ｆから周方向に隣接する単位コア１Ａ〜１Ｆに流れる磁束の損失量が一層少なくなり、磁気的な効率が一層向上する。
【００６１】
また、断面長方形状の切断ポンチ４０によって第１の鋼板６および第２の鋼板７を切断することに基づいて平行面７５を形成した。このため、第１に、先が尖った鋭利な切断ポンチを用いて両者を切断する場合に比べ、両者の切断端部に「ばり」が生じ難くなる。このため、ヘリカル鉄心１を環状化する際に「ばり」同士が接触する虞れが少なくなるので、ステータコア１５の真円度が高まる。
【００６２】
第２に、ヘリカル鉄心１を円環状に折曲げ、単位コア１Ａの切断端部のラップ部１４および単位コア１Ｆの切断端部のラップ部１４を噛合させると、図３に示すように、外周側へ開口するレーザー溶接用の切欠部１６が形成される。このため、ステータコア１５のレーザー溶接範囲が増えるので、ステータコア１５の溶接強度が高まる。しかも、レーザー溶接の盛上がり部分がステータコア１５の外周面から突出することが防止されるので、ステータコア１５の外周面をフレームの内周面に装着し易くなる。
【００６３】
また、輪郭形状が相違する第１の鋼板６および第２の鋼板７を順送りして打抜いた。このため、第１の鋼板６を形成するプレス機および第２の鋼板７を形成するプレス機を個別に用いる必要がなくなるので、装置が小形化される。しかも、第１の打抜ポンチ３８によって打抜いた部分を第２の打抜ポンチ３９によって打抜くことに基づいて両ポンチ３８および３９とは異形状の打抜部７４を形成したので、ポンチの数が少なくて済む。このため、ポンチプレート３７の矢印Ａ方向の長さ寸法が小さくなるので、装置が一層小形化される。
【００６４】
次に本発明の第２実施例を図１５に基づいて説明する。尚、上記第１実施例と同一の部材については同一の符号を付して説明を省略し、以下、異なる部材についてのみ説明を行う。ヘリカル鉄心１には、図１５の（ａ）に示すように、各ラップ部１４の先端部に位置して切落部７６が形成されている。これら各切落部７６は中心線ＣＬに対して垂直な平面状をなすものであり、図１５の（ｂ）に示すように、中心線ＣＬに対して垂直な打抜部７７が形成された第１の鋼板６および第２の鋼板７を１枚ずつ交互に積層することに基づいて形成されている。
【００６５】
上記実施例によれば、ラップ部１４に切落部７６を形成した。このため、磁極ティース４にコイル巻装部１８の上からコイル２２を巻装するにあたって、マグネットワイヤがラップ部１４の先端部に引掛かって傷付くことが防止される。尚、上記第２実施例においては、打抜部７７を有する第１の鋼板６および第２の鋼板７を積層することに基づいて切落部７６を形成したが、これに限定されるものではなく、例えば第１の鋼板６および第２の鋼板７を積層することに基づいてヘリカル鉄心１を形成した後、各ラップ部１４の先端部を切断することに基づいて切落部７６を形成しても良い。
【００６６】
次に本発明の第３実施例を図１６に基づいて説明する。尚、上記第１実施例と同一の部材については同一の符号を付して説明を省略し、以下、異なる部材についてのみ説明を行う。ヘリカル鉄心１には、各単位ヨーク３の周方向中央部に位置して半円形状の切欠部７８が形成され、各磁極片５の周方向中央部に位置して半円形状の切欠部７９が形成されている。これら各切欠部７８および７９は軸方向へ延びるものであり、前者の各切欠部７８は外周側へ開口し、後者の各切欠部７９は内周側へ開口している。
【００６７】
各切欠部７８および７９は切欠状の打抜部を有する第１の鋼板６および第２の鋼板７を１枚ずつ交互に積層することに基づいて形成されたものであり、各切欠部７８および７９の内面にはレーザー溶接が施され、第１の鋼板６および第２の鋼板７は、各切欠部７８および７９の内面に施されたレーザー溶接によって積層状態に保持されている。
【００６８】
上記実施例によれば、ヘリカル鉄心１に切欠部７８および７９を形成し、切欠部７８および７０の内面に沿ってレーザー溶接を施した。このため、ヘリカル鉄心１の溶接範囲が増えるので、ヘリカル鉄心１の強度が高まる。しかも、レーザー溶接の盛上がり部分がヘリカル鉄心１の表面から突出することが防止されるので、ステータコア１５の外周面をフレームの内周面に挿入し易くなる上、ステータコア１５の内周面とロータの外周面との間のエアギャップが均一化される。
【００６９】
尚、上記第３実施例においては、打抜部を有する第１の鋼板６および第２の鋼板７を積層することに基づいて切欠部７８および７９を形成したが、これに限定されるものではなく、例えば第１の鋼板６および第２の鋼板７を積層することに基づいてヘリカル鉄心１を形成した後、ヘリカル鉄心１に切欠部７８および７９を形成しても良い。
【００７０】
また、上記第３実施例においては、６個の単位コア１Ａ〜１Ｆに切欠部７８および７９を各々形成したが、これに限定されるものではなく、単位コア１Ａ〜１Ｆのうち１個以上の所定のものに切欠部７８および７９を形成しても良い。この場合、両端部の単位コア１Ａおよび１Ｆには切欠部７８および７９を形成することが好ましい。
【００７１】
また、上記第３実施例においては、切欠部７８および７９の内面にレーザー溶接を施したが、これに限定されるものではなく、例えばアーク溶接，ビーム溶接，ＴＩＧ溶接，ＹＡＧ溶接等の高エネルギー加工を施しても良い。
【００７２】
また、上記第１ないし第３実施例においては、断面長方形状の切断ポンチ４０を用いて帯状鋼板８を切断したが、これに限定されるものではない。図１７は切断ポンチ４０に換えて別の切断ポンチ８０を用いた本発明の第４実施例を示すものである。以下、本発明の第４実施例を図１７に基づいて説明する。
【００７３】
切断ポンチ８０は、図１７の（ａ）に示すように、三角部８１および四角部８２から構成されたものであり、第１の鋼板６の矢印Ａ方向端部および第２の鋼板７の反矢印Ａ方向端部間を切断する場合には、図１７の（ｂ）に示すように、第１の鋼板６および第２の鋼板７に三角部８１によって傾斜面８３および８４が形成され、四角部８２によって上述の平行面７５が形成される。また、第１の鋼板６の反矢印Ａ方向端部および第２の鋼板７の矢印Ａ方向端部間を切断する場合には、図１７の（ｃ）に示すように、第１の鋼板６および第２の鋼板７に四角部８２によって平行面７５が形成され、三角部８１は切断動作を行わない。
【００７４】
次に本発明の第５実施例を図１８に基づいて説明する。尚、上記第１実施例と同一の部材については同一の符号を付して説明を省略し、以下、異なる部材についてのみ説明を行う。第１の鋼板６には、図１８の（ａ）に示すように、５個の第１の打抜部８５が形成されている。これら各第１の打抜部８５は中心線ＣＬに対して一方向へθ1 °（＞θ°）傾斜する第１の傾斜面８６と、傾斜面８６と同一方向へθ2 °（＜θ1 °）傾斜する第２の傾斜面８７とによって画定されたものであり、第１の鋼板６の矢印Ａ方向端部は傾斜面８６から構成され、反矢印Ａ方向端部は傾斜面８７から構成されている。
【００７５】
第２の鋼板７には５個の第２の打抜部８８が形成されている。これら各第２の打抜部８８は中心線ＣＬに対して傾斜面８６および８７とは反対方向へθ2 °傾斜する第２の傾斜面８９と、傾斜面８９と同一方向へθ1 °傾斜する第１の傾斜面９０とによって画定されたものであり、第２の鋼板７の矢印Ａ方向端部は傾斜面８９から構成され、反矢印Ａ方向端部は傾斜面９０から構成されている。尚、「θ1 °−θ2 °＝θ°」に設定されている。
【００７６】
第１の打抜部８５は第１の打抜ポンチ３８に換えて第１の打抜部８５に対応する形状の第１の打抜ポンチ（図示せず）を使用することに基づいて形成されたものである。また、第２の打抜部８８は第２の打抜ポンチ３９に換えて第２の打抜部８８に対応する形状の第２の打抜ポンチ（図示せず）を使用することに基づいて形成されたものである。
【００７７】
単位コア１Ａ〜１Ｆには、図１８の（ｂ）に示すように、単位ヨーク３の矢印Ａ方向端部に位置してラップ部９１が形成されている。これら各ラップ部９１は軸方向視が三角形状をなすものであり、各ラップ部９１の周方向端面は第１の鋼板６の第１の傾斜面８６と第２の鋼板７の第２の傾斜面８９とを１枚ずつ交互に有する櫛歯状をなしている。
【００７８】
単位コア１Ａ〜１Ｆには、図１８の（ｂ）に示すように、単位ヨーク３の反矢印Ａ方向端部に位置してラップ部９１が形成されている。これら各ラップ部９１は軸方向視が三角形状をなすものであり、各ラップ部９１の周方向端面は第１の鋼板６の第２の傾斜面８７と第２の鋼板７の第１の傾斜面９０とを１枚ずつ交互に有する櫛歯状をなしている。
【００７９】
ヘリカル鉄心１は複数の繋ぎ桟２から円環状に折曲げられており、各ラップ部９１は、図１８の（ｃ）に示すように、周方向に隣接するラップ部９１に軸方向から噛合し、周方向にラップしている。尚、ラップ部９１は櫛歯部に相当するものである。
【００８０】
上記実施例によれば、各ラップ部９１を周方向に隣接するラップ部９１に軸方向から噛合させ、周方向にラップさせたので、磁束の損失量が少なくなり、磁気的な効率が向上する。しかも、単位ヨーク３の矢印Ａ方向側に位置するラップ部９１の端面を中心線ＣＬに対して異方向へ傾斜する第１の傾斜面８６および第２の傾斜面８９から構成し、単位ヨーク３の反矢印Ａ方向側に位置するラップ部９１の端面を中心線ＣＬに対して異方向へ傾斜する第２の傾斜面８７および第１の傾斜面９０から構成した。このため、ラップ部９１間の周方向のラップ量が第１実施例のラップ部１４に比べて増えるので、磁束の損失量が一層少なくなり、磁気的な効率が一層向上する。
【００８１】
次に本発明の第６実施例を図１９に基づいて説明する。尚、上記第１実施例と同一の部材については同一の符号を付して説明を省略し、以下、異なる部材についてのみ説明を行う。第１の鋼板６には、図１９の（ａ）に示すように、５個の第１の打抜部９２が形成されている。これら各第１の打抜部９２は中心線ＣＬに対して一方向へθ3 °（＜θ°）傾斜する第１の傾斜面９３と、傾斜面９３とは反対方向へθ4 °（＞θ3 °）傾斜する第２の傾斜面９４とによって画定されたものであり、第１の鋼板６の矢印Ａ方向端部は傾斜面９３から構成され、反矢印Ａ方向端部は傾斜面９４から構成されている。
【００８２】
第２の鋼板７には５個の第２の打抜部９５が形成されている。これら各第２の打抜部９５は中心線ＣＬに対して一方向へθ4 °傾斜する第２の傾斜面９６と、傾斜面９６とは反対方向へθ3 °傾斜する第１の傾斜面９７とによって画定されたものであり、第２の鋼板７の矢印Ａ方向端部は傾斜面９６から構成され、反矢印Ａ方向端部は傾斜面９７から構成されている。尚、「θ3 °＋θ4 °＝θ°」に設定されている。
【００８３】
第１の打抜部９２は第１の打抜ポンチ３８に換えて第１の打抜部９２に対応する形状の第１の打抜ポンチ（図示せず）を使用することに基づいて形成されたものである。また、第２の打抜部９５は第２の打抜ポンチ３９に換えて第２の打抜部９５に対応する形状の第２の打抜ポンチ（図示せず）を使用することに基づいて形成されたものである。
【００８４】
単位コア１Ａ〜１Ｆには、図１９の（ｂ）に示すように、単位ヨーク３の矢印Ａ方向端部に位置してラップ部９８が形成されている。これら各ラップ部９８は軸方向視が三角形状をなすものであり、各ラップ部９８の周方向端面は第１の鋼板６の第１の傾斜面９３と第２の鋼板７の第２の傾斜面９６とを１枚ずつ交互に有する櫛歯状をなしている。
【００８５】
単位コア１Ａ〜１Ｆには、単位ヨーク３の反矢印Ａ方向端部に位置してラップ部９８が形成されている。これら各ラップ部９８は軸方向視が三角形状をなすものであり、第１の鋼板６の第２の傾斜面９４と第２の鋼板７の第１の傾斜面９７とを１枚ずつ交互に有する櫛歯状をなしている。
【００８６】
ヘリカル鉄心１は複数の繋ぎ桟２から円環状に折曲げられており、各ラップ部９８は、図１９の（ｃ）に示すように、周方向に隣接するラップ部９８に軸方向から噛合し、周方向にラップしている。尚、ラップ部９８は櫛歯部に相当するものである。
【００８７】
上記実施例によれば、各ラップ部９８を周方向に隣接するラップ部９８に軸方向から噛合させ、周方向にラップさせた。このため、単位コア１Ａ〜１Ｆから周方向に隣接する単位コア１Ａ〜１Ｆに流れる磁束の損失量が少なくなるので、磁気的な効率が向上する。しかも、単位ヨーク３の矢印Ａ方向側に位置するラップ部９８の端面を中心線ＣＬに対して同一方向へ傾斜する第１の傾斜面９３および第２の傾斜面９６から構成し、単位ヨーク３の反矢印Ａ方向側に位置するラップ部９８の端面を中心線ＣＬに対して同一方向へ傾斜する第２の傾斜面９４および第１の傾斜面９７から構成した。このため、ラップ部９８間の周方向のラップ量は少なくなるものの、ラップ部９８間を噛合させる際にラップ部９８の端面間がぶつかり難くなるので、ヘリカル鉄心１を円環状に折曲げ易くなる。
【００８８】
次に本発明の第７実施例を図２０および図２１に基づいて説明する。尚、上記第１実施例と同一の部材については同一の符号を付して説明を省略し、以下、異なる部材についてのみ説明を行う。ヘリカル鉄心１には、図２１の（ｃ）に示すように、各繋ぎ桟２の内面に位置して円弧部９９が形成されている。
【００８９】
各円弧部９９は、図２０の（ａ）に示すように、円弧部９９を有する第１の鋼板６および円弧部９９を有する第２の鋼板７を１枚ずつ交互に積層することに基づいて形成されたものであり、図２１の（ｃ）に示すように、ヘリカル鉄心１を各繋ぎ桟２を中心に円環状に折曲げる際に繋ぎ桟２に応力が分散して作用するので、繋ぎ桟２に亀裂等が生じることが防止される。
【００９０】
ヘリカル鉄心１の各ラップ部１４には、図２１の（ｂ）に示すように、第１の突部１００が設けられている。これら各突部１００は、図２１の（ａ）に示すように、第１の鋼板６の平行面１０および第２の鋼板７の平行面１０に形成されたものであり、各突部１００の端面は、図２０の（ａ）に示すように、平行面１０に対して平行な直線状をなし、各突部１００の平行面１０に対する突出量（幅寸法）は「Ｗ／２」に設定されている。
【００９１】
ヘリカル鉄心１の各ラップ部１４には、図２１の（ｂ）に示すように、第２の突部１０１が設けられている。これら各突部１０１は、図２１の（ａ）に示すように、第１の鋼板６の傾斜面１１および第２の鋼板７の傾斜面１３に形成されたものであり、各突部１０１の端面は、図２０の（ａ）に示すように、傾斜面１１あるいは１３に対して平行な直線状をなし、各突部１０１の傾斜面１１あるいは１３に対する突出量は「Ｗ／２」に設定されている。
【００９２】
第１の突部１００の幅寸法「Ｗ／２」および第２の突部１０１の幅寸法「Ｗ／２」は、ヘリカル鉄心１の折曲時の繋ぎ桟２の延び量「Ｗ」を考慮して決められたものである。ヘリカル鉄心１を円環状に折曲げる際に複数の繋ぎ桟２は延びるが、図２０の（ｂ）に示すように、第１の突部１００が第２の突部１０１に面接触することに基づいてステータコア１５が極力真円に成形される。このため、平行面１０が第１の突部１００および第２の突部１０１を介して傾斜面１１あるいは１３に確実に接触するので、磁気的な損失が低減される。しかも、ラップ部１４相互間の周方向の重なり量が確実に増えるので、総じて、モータの回転特性および磁気的特性が向上する。
【００９３】
尚、上記第７実施例においては、ラップ部１４の平行面１０に第１の突部１００を形成し、傾斜面１１および１３に第２の突部１０１を形成したが、これに限定されるものではなく、例えば下記のように構成しても良い。これら各構成の場合でも、ヘリカル鉄心１が繋ぎ桟２の延びに影響されずに極力真円に曲げられるので、磁気的な特性が向上する。
【００９４】
図１８の第１の傾斜面８６および９０に幅寸法「Ｗ／２」の第１の突部を形成する。そして、第２の傾斜面８７および８９に幅寸法「Ｗ／２」の第２の突部を形成し、ヘリカル鉄心１を複数の繋ぎ桟２から円環状に折曲げることに基づいて各第１の突部を周方向に隣接する第２の突部に面接触させる。
【００９５】
図１９の第１の傾斜面９３および９７に幅寸法「Ｗ／２」の第１の突部を形成する。そして、第２の傾斜面９４および９６に幅寸法「Ｗ／２」の第２の突部を形成し、ヘリカル鉄心１を複数の繋ぎ桟２から円環状に折曲げることに基づいて第１の突部を周方向に隣接する第２の突部に面接触させる。
【００９６】
また、上記第１ないし第７実施例においては、第１の鋼板６および第７の鋼板７を積層することに基づいてヘリカル鉄心１を形成したが、これに限定されるものではなく、例えば鋼材に切削加工等を施すことに基づいてヘリカル鉄心１を形成しても良い。
【００９７】
次に本発明の第８実施例を図２２に基づいて説明する。尚、上記第１実施例と同一の部材については同一の符号を付して説明を省略し、以下、異なる部材についてのみ説明を行う。プレス装置３０のポンチプレート３７には一対の第１の打抜ポンチ３８が固定されており、ポンチプレート３７を連続的に上下動させながら帯状鋼板８を設定ピッチで断続的に搬送することに基づいて帯状鋼板８から第１の鋼板６を複数列（例えば２列）に打抜く。
【００９８】
帯状鋼板８から第１の鋼板６を打抜いたら、二点鎖線で示すように、上列の第１の鋼板６を裏返して第２の鋼板７と同一の輪郭形状にする。そして、上列の第１の鋼板６を下列の第１の鋼板６に重ね、ヘリカル鉄心１を形成する。この場合、第１の鋼板６を形成するプレス機および第２の鋼板７を形成するプレス機を個別に用いる必要がなくなるので、装置が小形化される。
【００９９】
尚、上記第８実施例においては、上列の第１の鋼板６を裏返して下列の第１の鋼板６に重ねたが、これに限定されるものではなく、例えば、下列の第１の鋼板６を裏返して上列の第１の鋼板６に重ねても良い。
【０１００】
また、上記第８実施例においては、帯状鋼板８から第１の鋼板６を打抜いたが、これに限定されるものではなく、例えば第２の鋼板７を打抜いても良い。この場合、上列の第２の鋼板７を裏返して第１の鋼板６と同一輪郭形状にした後に下列の第２の鋼板７に重ねたり、下列の第２の鋼板７を裏返して第１の鋼板６と同一輪郭形状にした後に上列の第２の鋼板７に重ねると良い。
【０１０１】
次に本発明の第９実施例を図２３に基づいて説明する。尚、上記第１実施例と同一の部材については同一の符号を付して説明を省略し、以下、異なる部材についてのみ説明を行う。プレス装置３０のポンチプレート３７には一対の第１の打抜ポンチ３８が固定されており、ポンチプレート３７を連続的に上下動させながら帯状鋼板８を設定ピッチで断続的に搬送することに基づいて帯状鋼板８から第１の鋼板６を対向状態で複数列（例えば２列）に打抜く。
【０１０２】
帯状鋼板８から第１の鋼板６を打抜いたら、二点鎖線で示すように、下列の第１の鋼板６の向きを１８０°変更して第２の鋼板７と同一の輪郭形状にする。そして、下列の第１の鋼板６を上列の第１の鋼板６に重ね、ヘリカル鉄心１を形成する。この場合、第１の鋼板６を形成するプレス機および第２の鋼板７を形成するプレス機を個別に用いる必要がなくなるので、装置が小形化される。
【０１０３】
尚、上記第９実施例においては、下列の第１の鋼板６の向きを１８０°変更して上列の第１の鋼板６に重ねたが、これに限定されるものではなく、例えば上列の第１の鋼板６の向きを１８０°変更して下列の第１の鋼板６に重ねても良い。
また、上記第９実施例においては、帯状鋼板８から第１の鋼板６を打抜いたが、これに限定されるものではなく、例えば第２の鋼板７を打抜いても良い。この場合、上列の第２の鋼板７の向きを１８０°変更して第１の鋼板６と同一輪郭形状にした後に下列の第２の鋼板７に重ねたり、下列の第２の鋼板７の向きを１８０°変更して第１の鋼板６と同一輪郭形状にした後に上列の第２の鋼板７に重ねると良い。
【０１０４】
また、上記第８および第９実施例においては、帯状鋼板８から第１実施例の第１の鋼板６を打抜いたが、これに限定されるものではなく、例えば第２ないし第７実施例のいずれかに記載の第１の鋼板６あるいは第２の鋼板７を打抜いて積層しても良い。
【０１０５】
また、上記第８および９実施例においては、一対の打抜ポンチ３８を上下動させながら帯状鋼板８を設定ピッチで断続的に搬送することに基づいて一対の第１の鋼板６を打抜いたが、これに限定されるものではなく、例えば一対の打抜ポンチ３８をＮ組用い（但し、Ｎは２以上の自然数）、Ｎ組の打抜ポンチ３８を上下動させながら帯状鋼板８を「設定ピッチ×Ｎ」で断続的に搬送することに基づいて一対の第１の鋼板６を打抜いても良い。
【０１０６】
また、上記第１ないし第９実施例においては、第１の鋼板６および第２の鋼板７を１枚ずつ交互に積層したが、これに限定されるものではなく、例えば本発明の第１０実施例を示す図２４のように、複数枚（例えば２枚）ずつ交互に積層しても良い。
【０１０７】
次に本発明の第１１実施例を図２５ないし図２７に基づいて説明する。尚、上記第１実施例と同一の部材については同一の符号を付して説明を省略し、以下、異なる部材についてのみ説明を行う。第３の鋼板１０２は、図２６の（ｃ）に示すように、５個の第１の打抜部９を有するものであり、第３の鋼板１０２の矢印Ａ方向端部には傾斜面１３および平行面７５が形成され、反矢印Ａ方向端部には平行面１０が形成されている。
【０１０８】
第４の鋼板１０３は、図２６の（ｂ）に示すように、５個の第２の打抜部１２を有するものであり、第４の鋼板１０３の矢印Ａ方向端部には平行面１０が形成され、反矢印Ａ方向端部には傾斜面１１および平行面７５が形成されている。尚、第３の鋼板１０２および第４の鋼板１０３は帯状鋼板８から打抜かれたものである。
【０１０９】
ヘリカル鉄心１は、図２５の（ｂ）に示すように、第１の鋼板６，第３の鋼板１０２，第４の鋼板１０３，第２の鋼板７を下から上に該順序で繰返し積層することに基づいて形成されたものであり、ヘリカル鉄心１には、図２５の（ａ）に示すように、単位コア１Ａ〜１Ｆの両端部に位置してラップ部１４が形成されている。
【０１１０】
単位コア１Ｂ〜１Ｆの矢印Ａ方向端部のラップ部１４は傾斜面１３および平行面１０を２枚ずつ交互に有し、単位コア１Ａ〜１Ｅの反矢印Ａ方向端部のラップ部１４は平行面１０および傾斜面１１を２枚ずつ交互に有している。これら各ラップ部１４は繋ぎ桟２を介して別のラップ部１４に連結されているので、動き難い。しかも、図２７の（ａ）に示すように、軸方向の噛合代１０４（空間の幅寸法）が大きいので、ヘリカル鉄心１を円環状に成形する際に隣接するラップ部１４の噛合代１０４内に容易に噛合される。
【０１１１】
単位コア１Ａの矢印Ａ方向端部のラップ部１４は、図２５の（ａ）に示すように、平行面１０および傾斜面１３を１枚ずつ交互に有し、単位コア１Ｆの反矢印Ａ方向端部のラップ部１４は傾斜面１１および平行面１０を１枚ずつ交互に有している。これら各ラップ部１４は動き易く、ヘリカル鉄心１を円環状に成形する際に相手側のラップ部１４に引掛かる可能性があるが、弾性変形して相手側のラップ部１４を逃げるので、相手側のラップ部１４の噛合代１０５（図２７のｂ参照）内に容易に噛合される。
【０１１２】
尚、上記第１１実施例においては、単位コア１Ａ〜１Ｅの反矢印Ａ方向端部に平行面１０および傾斜面１１を３枚以上の所定単位で交互に有するラップ部１４を形成し、単位コア１Ｂ〜１Ｆの矢印Ａ方向端部に傾斜面１３および平行面１０を３枚以上の所定単位で交互に有するラップ部１４を形成しても良い。
【０１１３】
次に本発明の第１２実施例を図２８に基づいて説明する。尚、上記第５実施例と同一の部材については同一の符号を付して説明を省略し、以下、異なる部材についてのみ説明を行う。第３の鋼板１０６は、図２８の（ａ）に示すように、５個の第１の打抜部８５を有するものであり、第３の鋼板１０６の矢印Ａ方向端部には第２の傾斜面８９が形成され、第３の鋼板１０６の反矢印Ａ方向端部には第１の傾斜面９０が形成されている。
【０１１４】
第４の鋼板１０７は、図２８の（ｄ）に示すように、５個の第２の打抜部８８を有するものであり、第４の鋼板１０７の矢印Ａ方向端部には第１の傾斜面８６が形成され、第４の鋼板１０７の反矢印Ａ方向端部には第２の傾斜面８７が形成されている。尚、第３の鋼板１０６および第４の鋼板１０７は帯状鋼板８から打抜かれたものである。
【０１１５】
ヘリカル鉄心１は第１の鋼板６，第３の鋼板１０６，第４の鋼板１０７，第２の鋼板７を下から上に該順序で繰返し積層することに基づいて形成されたものであり、ヘリカル鉄心１には、図２８の（ｅ）に示すように、単位ヨーク１Ａ〜１Ｆの両端部に位置してラップ部９１が形成されている。
【０１１６】
単位コア１Ｂ〜１Ｆの矢印Ａ方向端部のラップ部９１は第１の傾斜面８６および第２の傾斜面８９を２枚ずつ交互に有し、単位コア１Ａ〜１Ｅの反矢印Ａ方向端部のラップ部９１は第２の傾斜面８７および第１の傾斜面９０を２枚ずつ交互に有している。これら各ラップ部９１は軸方向の噛合代が大きく設定されているので、ヘリカル鉄心１を円環状に成形する際に隣接するラップ部９１に容易に噛合される。
【０１１７】
単位コア１Ａの矢印Ａ方向端部のラップ部９１は第１の傾斜面８６および第２の傾斜面８９を１枚ずつ交互に有し、単位コア１Ｆの反矢印Ａ方向端部のラップ部１４は第２の傾斜面８７および第１の傾斜面９０を１枚ずつ交互に有している。これら各ラップ部９１はヘリカル鉄心１を円環状に成形する際に相手側のラップ部９１に突合わされた時点で弾性変形するので、相手側のラップ部９１に容易に噛合される。
【０１１８】
尚、上記第１２実施例においては、単位コア１Ｂ〜１Ｆの矢印Ａ方向端部に第１の傾斜面８６および第２の傾斜面８９を３枚以上の所定単位で交互に有するラップ部９１を形成し、単位コア１Ａ〜１Ｅの反矢印Ａ方向端部に第１の傾斜面９０および第２の傾斜面８７を３枚以上の所定単位で交互に有するラップ部９１を形成しても良い。
【０１１９】
次に本発明の第１３実施例を図２９に基づいて説明する。尚、上記第６実施例と同一の部材については同一の符号を付して説明を省略し、以下、異なる部材についてのみ説明を行う。第３の鋼板１０８は、図２９の（ａ）に示すように、５個の第１の打抜部９２を有するものであり、第３の鋼板１０８の矢印Ａ方向端部には第２の傾斜面９６が形成され、第３の鋼板１０８の反矢印Ａ方向端部には第１の傾斜面９７が形成されている。
【０１２０】
第４の鋼板１０９は、図２９の（ｄ）に示すように、５個の第２の打抜部９５を有するものであり、第４の鋼板１０９の矢印Ａ方向端部には第１の傾斜面９３が形成され、第４の鋼板１０９の反矢印Ａ方向端部には第２の傾斜面９４が形成されている。尚、第３の鋼板１０８および第４の鋼板１０９は帯状鋼板８から打抜かれたものである。
【０１２１】
ヘリカル鉄心１は第１の鋼板６，第３の鋼板１０８，第４の鋼板１０９，第２の鋼板７を下から上に該順序で繰返し積層することに基づいて形成されたものであり、ヘリカル鉄心１には、図２９の（ｅ）に示すように、単位コア１Ａ〜１Ｆの両端部に位置してラップ部９８が形成されている。
【０１２２】
単位コア１Ｂ〜１Ｆの矢印Ａ方向端部のラップ部９８は第１の傾斜面９３および第２の傾斜面９６を２枚ずつ交互に有し、単位コア１Ａ〜１Ｅの反矢印Ａ方向端部のラップ部９８は第２の傾斜面９４および第１の傾斜面９７を２枚ずつ交互に有している。これら各ラップ部９８は軸方向の噛合代が大きいので、ヘリカル鉄心１を円環状に成形する際に隣接するラップ部９８に容易に噛合される。
【０１２３】
単位コア１Ａの矢印Ａ方向端部のラップ部９８は第１の傾斜面９３および第２の傾斜面９６を１枚ずつ交互に有し、単位コア１Ｆの反矢印Ａ方向端部のラップ部９８は第２の傾斜面９４および第１の傾斜面９７を１枚ずつ交互に有している。これら各ラップ部９８はヘリカル鉄心１を円環状に成形する際に相手側のラップ部９８に突合わされた時点で弾性変形し、相手側のラップ部９８に容易に噛合される。
【０１２４】
尚、上記第１３実施例においては、単位コア１Ｂ〜１Ｆの矢印Ａ方向端部に第１の傾斜面９３および第２の傾斜面９６を３枚以上の所定単位で交互に有するラップ部９８を形成し単位コア１Ａ〜１Ｅの反矢印Ａ方向端部に第１の傾斜面９７および第２の傾斜面９４を３枚以上の所定単位で交互に有するラップ部９８を形成しても良い。
【０１２５】
また、上記第１ないし第１３実施例においては、ヘリカル鉄心１にレーザー溶接を施すことに基づいてヘリカル鉄心１を積層状態に保持したが、これに限定されるものではなく、例えばアーク溶接，ビーム溶接，ＴＩＧ溶接，ＹＡＧ溶接等の高エネルギー加工を施すことに基づいて積層状態に保持したり、かしめやリベット止めすることに基づいて積層状態に保持しても良い。
【０１２６】
次に本発明の第１４実施例を図３０に基づいて説明する。尚、上記第１実施例と同一の部材については同一の符号を付して説明を省略し、以下、異なる部材についてのみ説明を行う。ヘリカル鉄心１には各繋ぎ桟２の一方側に位置してレーザー溶接１１０が施され、単位ヨーク１Ａの端部に位置してレーザー溶接１１１が施されている。これら各レーザー溶接１１０および１１１は第１の鋼板６および第２の鋼板７の積層方向に沿って施されたものであり、ヘリカル鉄心１を積層状態に保持している。
【０１２７】
各繋ぎ桟２にはヘリカル鉄心１の折曲時に応力が集中し、積層方向への膨らみ力が作用する。しかしながら、各繋ぎ桟２がレーザー溶接１１０によって補強され、積層方向への膨らみが抑えられているので、第１の鋼板６および第２の鋼板７間の密着度が高まり、振動や騒音が抑えられる。しかも、ヘリカル鉄心１の折曲時に第１の鋼板６および第２の鋼板７が積層方向へ撓む余地が若干残されているので、ラップ部１４が周方向に隣接するラップ部１４に引掛かることなく円滑に噛合される。
【０１２８】
尚、上記第１４実施例においては、第１実施例のヘリカル鉄心１に複数のレーザー溶接１１０を施したが、これに限定されるものではなく、第２ないし第１３実施例のいずれかに記載のヘリカル鉄心１に複数のレーザー溶接１１０を施しても良い。
【０１２９】
また、上記第１４実施例においては、ヘリカル鉄心１の折曲前に各繋ぎ桟２の一方側に積層方向に沿ってレーザー溶接１１０を施したが、これに限定されるものではなく、例えば各繋ぎ桟２の両側に積層方向に沿ってレーザー溶接１１０を施しても良い。
【０１３０】
次に本発明の第１５実施例を図３１に基づいて説明する。尚、上記第１４実施例と同一の部材については同一の符号を付して説明を省略し、以下、異なる部材についてのみ説明を行う。ヘリカル鉄心１には各繋ぎ桟２の一方側に位置してレーザー溶接１１０が施され、単位ヨーク１Ａおよび１Ｆの端部に位置してレーザー溶接１１１が施されており、ヘリカル鉄心１はレーザー溶接１１０および１１１を施した後に円環状に折曲げられている。
【０１３１】
各繋ぎ桟２の他方側にはヘリカル鉄心１の積層方向に沿ってレーザー溶接１１２が施されている。これら各レーザー溶接１１２はヘリカル鉄心１の折曲後に施されたものであり、第１の鋼板６および第２の鋼板７間の密着度を一層高め、振動や騒音を大幅に抑えている。
尚、上記第１４および第１５実施例においては、レーザー溶接１１０〜１１２に換えてアーク溶接，ビーム溶接，ＴＩＧ溶接，ＹＡＧ溶接等の高エネルギー加工を施しても良い。
【０１３２】
また、上記第１ないし第１５実施例においては、切欠部１６の内面にレーザー溶接を施すことに基づいてヘリカル鉄心１を円環状に保持したが、これに限定されるものではなく、例えば切欠部１６の内面にアーク溶接，ビーム溶接，ＴＩＧ溶接，ＹＡＧ溶接等の高エネルギー加工を施すことに基づいてヘリカル鉄心１を円環状に保持しても良い。
【０１３３】
また、上記第１ないし第１５実施例においては、ステータコア１５にレーザー溶接用の切欠部１６を形成したが、これに限定されるものではなく、例えば切欠部１６を廃止しても良い。この場合、ヘリカル鉄心１の両端部をかしめたり、リベット止めすることに基づいて円環状に保持すると良い。
【０１３４】
また、上記第１ないし第１５実施例においては、本発明をインナロータ形モータのステータに適用したが、これに限定されるものではなく、例えばアウタロータ形モータのステータに適用しても良い。
【０１３５】
【発明の効果】
以上の説明から明らかなように、本発明の回転電機のステータおよびステータの製造方法は次の効果を奏する。
請求項１および４記載のそれぞれの手段によれば、櫛歯部を周方向に隣接する櫛歯部に噛合させ、周方向にラップさせた。このため、周方向に隣接する単位コア間での磁束の損失量が少なくなるので、磁気的な効率が向上する。しかも、櫛歯部の端面を同一方向へ傾斜する第１の傾斜面および第２の傾斜面から構成した。このため、櫛歯部間を噛合させる際に櫛歯部の端面間がぶつかり難くなるので、帯状コアを環状に折曲げ易くなる。しかも、櫛歯部の先端部に切落部を形成した。このため、磁極ティースにマグネットワイヤを巻装するにあたって、マグネットワイヤが櫛歯部の先端部に引掛かって傷付くことが防止される。特に請求項４記載の手段によれば、単位ヨーク間の連結部分に円弧部を設けた。このため、帯状コアの折曲時に連結部分に応力が分散して作用するので、連結部分に亀裂等が生じることが防止される。
【０１３６】
請求項２および５記載のそれぞれの手段によれば、櫛歯部を周方向に隣接する櫛歯部に噛合させ、周方向にラップさせたので、磁気的な効率が向上する。しかも、櫛歯部の端面を平行面および傾斜面から構成したので、請求項１記載の手段に比べて櫛歯部間の周方向のラップ量が増え、磁気的な効率が一層向上する。しかも、櫛歯部の先端部に切落部を形成した。このため、磁極ティースにマグネットワイヤを巻装するにあたって、マグネットワイヤが櫛歯部の先端部に引掛かって傷付くことが防止される。特に請求項５記載の手段によれば、単位ヨーク間の連結部分に円弧部を設けた。このため、帯状コアの折曲時に連結部分に応力が分散して作用するので、連結部分に亀裂等が生じることが防止される。
請求項３および６記載のそれぞれの手段によれば、櫛歯部を周方向に隣接する櫛歯部に噛合させ、周方向にラップさせたので、磁気的な効率が向上する。しかも、櫛歯部の端面を異方向へ傾斜する第１の傾斜面および第２の傾斜面から構成したので、請求項１記載の手段および請求項２記載の手段に比べて櫛歯部間の周方向のラップ量が増え、磁気的な効率が一層向上する。しかも、櫛歯部の先端部に切落部を形成した。このため、磁極ティースにマグネットワイヤを巻装するにあたって、マグネットワイヤが櫛歯部の先端部に引掛かって傷付くことが防止される。特に請求項６記載の手段によれば、単位ヨーク間の連結部分に円弧部を設けた。このため、帯状コアの折曲時に連結部分に応力が分散して作用するので、連結部分に亀裂等が生じることが防止される。
【０１３７】
請求項７記載の手段によれば、ステータコアに高エネルギー加工用の切欠部を設けた。このため、高エネルギー加工範囲が増えるので、ステータコアの強度が高まる。しかも、高エネルギー加工が施された盛上がり部分がステータコアの表面から突出することが防止される。
【０１３８】
請求項８記載の手段によれば、帯状コアに高エネルギー加工用の切欠部を形成した。このため、高エネルギー加工範囲が増えるので、帯状コアの強度が高まる。しかも、高エネルギー加工が施された盛上がり部分が帯状コアの表面から突出することが防止される。
請求項９記載の手段によれば、第１の傾斜面に第１の突部を設け、第２の傾斜面に第２の突部を設けたので、第１の突部が第２の突部に接触することに基づいてステータコアが極力真円に成形される。しかも、第１の傾斜面が第１の突部および第２の突部を介して第２の傾斜面に確実に接触するので、磁気的な損失が低減される。
【０１３９】
請求項１０記載の手段によれば、平行面に第１の突部を設け、傾斜面に第２の突部を設けたので、第１の突部が第２の突部に接触することに基づいてステータコアが極力真円に成形される。しかも、平行面が第１の突部および第２の突部を介して傾斜面に確実に接触するので、磁気的な損失が低減される。
【０１４０】
請求項１１記載の手段によれば、帯状コアの両端部に第１の傾斜面および第２の傾斜面を１枚ずつ交互に有する櫛歯部を形成し、残りの部分に第１の傾斜面および第２の傾斜面を複数枚ずつ交互に有する櫛歯部を形成した。このため、帯状コアの両端部および残りの部分において、櫛歯部を隣接する櫛歯部に噛合させ易くなるので、帯状コアの成形性が高まる。
請求項１２記載の手段によれば、帯状コアの両端部に平行面および傾斜面を１枚ずつ交互に有する櫛歯部を形成し、残りの部分に平行面および傾斜面を複数枚ずつ交互に有する櫛歯部を形成した。このため、帯状コアの両端部および残りの部分において、櫛歯部を隣接する櫛歯部に噛合させ易くなるので、帯状コアの成形性が高まる。
【０１４１】
請求項１３記載の手段によれば、輪郭形状が相違する第１の磁性板および第２の磁性板を順送りして打抜いた。このため、第１の磁性板および第２の磁性板を別個のプレス機によって打抜く必要がなくなるので、装置が小形化される。しかも、第１のポンチによって打抜いた部分を第２のポンチによって打抜くことに基づいて両ポンチとは形状が異なる打抜部を形成したので、ポンチの数が少なくて済む。
【０１４２】
請求項１４記載の手段によれば、磁性板の向きを反転して磁性板に重ねることに基づいて帯状コアを形成した。このため、輪郭形状が異なる複数種の磁性板を別個のプレス機によって打抜く必要がなくなるので、装置が小形化される。
請求項１５記載の手段によれば、磁性板を裏返して磁性板に重ねることに基づいて帯状コアを形成した。このため、輪郭形状が異なる複数種の磁性板を別個のプレス機によって打抜く必要がなくなるので、装置が小形化される。
【０１４３】
請求項１６記載の手段によれば、帯状コアの折曲前に単位ヨーク間の連結部分の少なくとも一方側に高エネルギー加工を施した。このため、磁性板相互間の密着度が高まるので、振動や騒音の発生が抑えられる。
請求項１７記載の手段によれば、帯状コアの折曲前に単位ヨーク間の連結部分の一方側に高エネルギー加工を施した。このため、磁性板相互間の密着度が高まる上、櫛歯部を周方向に隣接する櫛歯部に噛合させ易くなる。しかも、帯状コアの折曲後に単位ヨーク間の連結部分の他方側に高エネルギー加工を施したので、磁性板相互間の密着度が大幅に高まり、振動や騒音が大幅に抑えられる。
【図面の簡単な説明】
【図１】本発明の第１実施例を示す図（ａはヘリカル鉄心を示す平面図、ｂはＸ−Ｘ線に沿う断面図）
【図２】（ａ）は第１の鋼板および第２の鋼板の打抜き状態を示す平面図、（ｂ）はＸ1 部を拡大して示す図、（ｃ）はＸ2 部を拡大して示す図、（ｄ）はＸ3 部を拡大して示す図、（ｅ）はＸ4 部を拡大して示す図
【図３】ステータコアを示す平面図
【図４】（ａ）はステータコアをコイルの巻装状態で示す平面図、（ｂ）はＸ−Ｘ線に沿う断面図
【図５】（ａ）はプレス装置の要部を拡大して示す断面図、（ｂ）はＸ−Ｘ線に沿ってカムを示す図
【図６】プレス装置の構成を概略的に示すブロック図
【図７】（ａ）はプレス装置を概略的に示す図、（ｂ）はポンチのレイアウトを示す平面図，（ｃ）〜（ｆ）は帯状鋼板が打抜かれる様子を示す図
【図８】（ａ）はプレス装置を概略的に示す図、（ｂ）はポンチのレイアウトを示す平面図、（ｃ）は帯状鋼板が切断される様子を示す図
【図９】（ａ）はプレス装置を概略的に示す図、（ｂ）はポンチのレイアウトを示す平面図、（ｃ）〜（ｄ）は帯状鋼板が打抜かれる様子を示す図
【図１０】（ａ）はプレス装置を概略的に示す図、（ｂ）はポンチのレイアウトを示す平面図、（ｃ）〜（ｅ）は帯状鋼板が打抜かれる様子を示す図
【図１１】（ａ）はプレス装置を概略的に示す図、（ｂ）はポンチのレイアウトを示す平面図、（ｃ）は帯状鋼板が切断される様子を示す図、（ｄ）はＸ部を拡大して示す図
【図１２】（ａ）はプレス装置を概略的に示す図、（ｂ）はポンチのレイアウトを示す平面図、（ｃ）〜（ｄ）は帯状鋼板が打抜かれる様子を示す図
【図１３】（ａ）はプレス装置を概略的に示す図、（ｂ）はポンチのレイアウトを示す平面図、（ｃ）〜（ｅ）は帯状鋼板が打抜かれる様子を示す図
【図１４】（ａ）はプレス装置を概略的に示す図、（ｂ）はポンチのレイアウトを示す平面図、（ｃ）は帯状鋼板が切断される様子を示す図、（ｄ）はＸ部を拡大して示す図
【図１５】本発明の第２実施例を示す図（ａはヘリカル鉄心を示す平面図、ｂは第１の鋼板および第２の鋼板の一部を拡大して示す平面図）
【図１６】本発明の第３実施例を示す図（ヘリカル鉄心を示す平面図）
【図１７】本発明の第４実施例を示す図（ａは切断ポンチを示す平面図、ｂおよびｃは第１の鋼板および第２の鋼板の切断端部を示す平面図）
【図１８】本発明の第５実施例を示す図（ａは第１の鋼板および第２の鋼板を示す平面図、ｂはヘリカル鉄心を示す平面図、ｃはステータコアの一部を示す平面図）
【図１９】本発明の第６実施例を示す図（ａは第１の鋼板および第２の鋼板を示す平面図、ｂはヘリカル鉄心を示す平面図、ｃはステータコアの一部を示す平面図）
【図２０】本発明の第７実施例を示す図（ａは第１の鋼板の一部を非折曲状態で示す平面図、ｂは第１の鋼板の一部を折曲状態で示す平面図）
【図２１】（ａ）は第１の鋼板および第２の鋼板を示す平面図、（ｂ）はヘリカル鉄心を示す平面図、（ｃ）はステータコアの一部を示す平面図
【図２２】本発明の第８実施例を示す図（鋼板の打抜き状態を示す平面図）
【図２３】本発明の第９実施例を示す図（鋼板の打抜き状態を示す平面図）
【図２４】本発明の第１０実施例を示す図（鋼板の積層状態を示す断面図）
【図２５】本発明の第１１実施例を示す図（ａはヘリカル鉄心を示す平面図、ｂはＸ−Ｘ線に沿う断面図）
【図２６】（ａ）は第２の鋼板を示す平面図、（ｂ）は第４の鋼板を示す平面図、（ｃ）は第３の鋼板を示す平面図、（ｄ）は第１の鋼板を示す平面図
【図２７】（ａ）は傾斜面および平行面を２枚ずつ交互に有するラップ部を示す図、（ｂ）は傾斜面および平行面を１枚ずつ交互に有するラップ部を示す図
【図２８】本発明の第１２実施例を示す図（ａは第３の鋼板を示す平面図、ｂは第１の鋼板を示す平面図、ｃは第２の鋼板を示す平面図、ｄは第４の鋼板を示す平面図、ｅはヘリカル鉄心を示す平面図）
【図２９】本発明の第１３実施例を示す図（ａは第３の鋼板を示す平面図、ｂは第１の鋼板を示す平面図、ｃは第２の鋼板を示す平面図、ｄは第４の鋼板を示す平面図、ｅはヘリカル鉄心を示す平面図）
【図３０】本発明の第１４実施例を示す図（ヘリカル鉄心の外観を示す斜視図）
【図３１】本発明の第１５実施例を示す図（ヘリカル鉄心の外観を示す斜視図）
【符号の説明】
１はヘリカル鉄心（帯状コア）、１Ａ〜１Ｆは単位コア、４は磁極ティース、６は第１の鋼板（磁性板，第１の磁性板）、７は第２の鋼板（磁性板，第２の磁性板）、９は第１の打抜部、１０は平行面、１１は傾斜面、１２は第２の打抜部、１３は傾斜面、１４はラップ部（櫛歯部）、１５はステータコア、１６は切欠部、３８は第１の打抜ポンチ（第１のポンチ）、３９は第２の打抜ポンチ（第２のポンチ）、７４は第３の打抜部（打抜部）、７６は切落部、７８および７９は切欠部、８６および９０は第１の傾斜面、８７および８９は第２の傾斜面、９１はラップ部（櫛歯部）、９３および９７は第１の傾斜面、９４および９６は第２の傾斜面、９８はラップ部（櫛歯部）、９９は円弧部、１００は第１の突部、１０１は第２の突部を示す。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a stator for a rotating electrical machine having a stator core formed by annularly forming a belt-like core and a method for manufacturing the stator.
[0002]
[Problems to be solved by the invention]
Some rotary electric machines have a configuration in which a stator core is formed based on a ring-shaped core in which a plurality of unit cores are connected to each other. In the case of this configuration, the circumferential end face (= divided surface) of each unit core is formed in a planar shape, and the planar divided surface is joined to the planar divided surface adjacent in the circumferential direction. For this reason, a loss of magnetic flux occurs between the divided surfaces, and the magnetic efficiency may be reduced.
[0003]
This invention is made | formed in view of the said situation, The objective is to provide the stator and the manufacturing method of a stator of a rotary electric machine which can suppress the fall of magnetic efficiency.
[0004]
[Means for Solving the Problems]
 The stator of the rotating electrical machine according to claim 1 is provided with respect to a stator core formed by annularly forming a band-shaped core in a form in which a plurality of unit cores are connected, and magnetic pole teeth of the stator core provided at both circumferential ends of each unit core. And a comb tooth portion alternately having a first inclined surface inclined in one direction and a second inclined surface inclined in the same direction as the first inclined surface, and the comb tooth portions are adjacent to each other in the circumferential direction. Mesh with the comb teeth and wrap in the circumferential directionA cut-off portion is formed at the tip of each comb tooth portion.It has a characteristic in that.
 The stator of the rotating electrical machine according to claim 4 is a stator core formed by annularizing a band-shaped core in a form in which a plurality of unit cores are connected, and magnetic pole teeth of the stator core provided at both circumferential ends of each unit core. And a comb tooth portion alternately having a first inclined surface inclined in one direction and a second inclined surface inclined in the same direction as the first inclined surface, and the comb tooth portions are adjacent to each other in the circumferential direction. It is characterized in that it is meshed with a comb tooth portion and wrapped in the circumferential direction, a cut-off portion is formed at the tip portion of each comb tooth portion, and an arc portion is provided at a connecting portion between the unit yokes. ing.
 Each of claims 1 and 4According to the means, the comb tooth portion meshes with the comb tooth portion adjacent in the circumferential direction, and is wrapped in the circumferential direction. For this reason, since the amount of loss of magnetic flux between the unit cores adjacent in the circumferential direction is reduced, the magnetic efficiency is improved.Moreover, when the magnet wire is wound around the magnetic pole teeth, the magnet wire is prevented from being caught and damaged by the tip of the comb tooth portion. In particular, according to the means described in claim 4, since stress is dispersed and acts on the connecting portion between the unit yokes when the strip-shaped core is bent, it is possible to prevent the connecting portion from being cracked.
[0005]
 The stator of the rotating electrical machine according to claim 2 is substantially similar to a stator core formed by annularly forming a band-shaped core in a form in which a plurality of unit cores are connected, and magnetic pole teeth of the stator core provided at both circumferential ends of each unit core. Comb teeth portions alternately having parallel parallel surfaces and inclined surfaces inclined with respect to the magnetic teeth, each comb teeth portion meshes with a comb tooth portion adjacent in the circumferential direction and wraps in the circumferential direction,A cut-off portion is formed at the tip of each comb tooth portion.It has a characteristic in that.
 The stator of the rotating electrical machine according to claim 5 is substantially similar to a stator core formed by annularly forming a band-shaped core in a form in which a plurality of unit cores are connected, and magnetic pole teeth of the stator core provided at both circumferential ends of each unit core. Comb teeth portions alternately having parallel parallel surfaces and inclined surfaces that are inclined with respect to the magnetic pole teeth, and each of the comb teeth portions meshes with a comb tooth portion adjacent in the circumferential direction and wraps in the circumferential direction, A characteristic feature is that a cut-off portion is formed at the tip of each comb-tooth portion, and a circular arc portion is provided at a connecting portion between the unit yokes.
 Each of claims 2 and 5According to the means, the comb tooth portion meshes with the comb tooth portion adjacent in the circumferential direction, and is wrapped in the circumferential direction. For this reason, since the amount of loss of magnetic flux between the unit cores adjacent in the circumferential direction is reduced, the magnetic efficiency is improved. And since the end surface of a comb-tooth part is comprised from the parallel surface and the inclined surface, compared with the means of Claim 1, the amount of circumferential wraps between comb-tooth parts increases. For this reason, the loss of magnetic flux between the unit cores is further reduced, so that the magnetic efficiency is further improved.Moreover, when the magnet wire is wound around the magnetic pole teeth, the magnet wire is prevented from being caught and damaged by the tip of the comb tooth portion. In particular, according to the means described in claim 5, since stress is dispersed and acts on the connecting portion between the unit yokes when the strip-shaped core is bent, it is possible to prevent the connecting portion from being cracked.
[0006]
 A stator for a rotating electrical machine according to claim 3 is provided with respect to a stator core formed by annularly forming a band-shaped core in a form in which a plurality of unit cores are connected, and magnetic pole teeth of the stator core provided at both circumferential ends of each unit core. Each having a first inclined surface inclined in one direction and a comb tooth portion alternately having a second inclined surface inclined in the opposite direction to the first inclined surface, wherein each of the comb tooth portions is adjacent in the circumferential direction. Mesh with the comb teeth and wrap in the circumferential directionA cut-off portion is formed at the tip of each comb tooth portion.It has a characteristic in that.
 The stator of the rotating electrical machine according to claim 6 is:A stator core formed by annularly forming a band-shaped core in a form in which a plurality of unit cores are connected, and a first inclined surface that is provided at both circumferential ends of each unit core and is inclined in one direction with respect to the magnetic pole teeth of the stator core And comb tooth portions alternately having second inclined surfaces inclined in the opposite direction to the first inclined surface, and each comb tooth portion meshes with a comb tooth portion adjacent in the circumferential direction to wrap in the circumferential direction. In addition, a feature is that a cut-off portion is formed at a tip portion of each comb tooth portion, and an arc portion is provided at a connecting portion between the unit yokes.
 Each of claims 3 and 6According to the means, the comb tooth portion meshes with the comb tooth portion adjacent in the circumferential direction, and is wrapped in the circumferential direction. For this reason, since the amount of loss of magnetic flux between the unit cores adjacent in the circumferential direction is reduced, the magnetic efficiency is improved. And since the end surface of the comb tooth part is comprised from the 1st inclined surface and 2nd inclined surface which incline in a different direction, compared with the means of Claim 1, and the means of Claim 2, the comb tooth part The amount of lap in the circumferential direction increases. For this reason, the loss of magnetic flux between the unit cores is further reduced, so that the magnetic efficiency is further improved.Moreover, when the magnet wire is wound around the magnetic pole teeth, the magnet wire is prevented from being caught and damaged by the tip of the comb tooth portion. In particular, according to the means described in claim 6, since the stress acts on the connecting portion between the unit yokes when the strip-shaped core is bent, it is possible to prevent the connecting portion from being cracked.
[0007]
 Claim7The stator of the described rotating electrical machine has a notch extending in the axial direction at both ends of the belt-like core of the stator core, and the stator core is held in an annular shape based on performing high energy processing along the inner surface of the notch. It has a characteristic in that.
 According to the above means, since the high energy processing range of the stator core is increased, the strength of the stator core is increased. In addition, it is possible to prevent the swelled portion subjected to high energy processing from protruding from the surface of the stator core.
[0009]
 Claim8The stator of the rotating electrical machine described above includes a belt-like core formed on the basis of stacking a plurality of magnetic plates, the belt-like core is formed with a cutout portion extending in the axial direction, and the belt-like core is formed of the cutout portion. It is characterized in that it is held in a laminated state based on applying high energy processing along the inner surface.
 According to the above means, the high energy processing range of the band-shaped core is increased, so that the strength of the band-shaped core is increased. Moreover, it is possible to prevent the swelled portion subjected to the high energy processing from protruding from the surface of the belt-like core.
[0010]
 Claim9In the stator of the rotating electrical machine described above, a first protrusion is provided on the first inclined surface, and a second protrusion that contacts the first protrusion adjacent in the circumferential direction is provided on the second inclined surface. It has a characteristic in that.
 According to the above means, the connecting portion between the unit yokes extends when the belt-shaped core is annularized, but the first protrusion of the first inclined surface contacts the second protrusion of the second inclined surface. Based on this, the stator core is formed into a perfect circle as much as possible. In addition, since the first inclined surface reliably contacts the second inclined surface via the first protrusion and the second protrusion, the magnetic loss is reduced.
[0011]
 Claim10The stator of the rotating electrical machine described above is characterized in that a first protrusion is provided on a parallel surface, and a second protrusion that contacts the first protrusion adjacent in the circumferential direction is provided on an inclined surface. Have.
 According to the above means, the connecting portion between the unit yokes extends when the belt-shaped core is formed into an annular shape, but the stator core is formed on the basis that the first protrusion on the parallel surface comes into contact with the second protrusion on the inclined surface. It is molded into a perfect circle as much as possible. Moreover, since the parallel surface reliably contacts the inclined surface via the first protrusion and the second protrusion, the magnetic loss is reduced.
[0013]
 Claim11The stator of the rotating electrical machine described above includes a band-shaped core formed by laminating a plurality of magnetic plates, and each of the first and second inclined surfaces is provided at both ends of the band-shaped core. It is characterized in that comb teeth portions having alternating ones are formed, and comb teeth portions having a plurality of first inclined surfaces and a plurality of second inclined surfaces alternately formed on the remaining portion of the band-shaped core. ing.
 According to the said means, when shape | molding a strip | belt-shaped core annularly, the comb-tooth part of both ends is meshed | engaged smoothly, without being caught on the other party. At this time, the remaining comb teeth are set to have a large engagement margin in the axial direction, so that they are smoothly engaged with the adjacent comb teeth.
[0014]
 Claim12The stator of the rotating electrical machine described above includes a band-shaped core formed on the basis of stacking a plurality of magnetic plates, and comb teeth having alternating parallel and inclined surfaces at both ends of the band-shaped core. And a comb tooth portion having a plurality of parallel surfaces and inclined surfaces alternately formed on the remaining portion of the band-shaped core.
 According to the said means, when shape | molding a strip | belt-shaped core annularly, the comb-tooth part of both ends is meshed | engaged smoothly, without being caught on the other party. At this time, the remaining comb teeth are set to have a large engagement margin in the axial direction, so that they are smoothly engaged with the adjacent comb teeth.
[0015]
 Claim13DescribedRotating electric machineA method for manufacturing a stator is described in any one of claims 1 to 3.Rotating electric machineIn a method of manufacturing a stator, based on a step of sequentially feeding and punching a first magnetic plate and a second magnetic plate having different contour shapes, and overlapping the first magnetic plate and the second magnetic plate. Forming a strip-shaped core having a plurality of comb-tooth portions, and engaging the comb-tooth portions with adjacent comb-tooth portions in the circumferential direction based on annularizing the strip-shaped core, When punching one magnetic plate and the second magnetic plate, a punched portion having a different shape from both punches is formed based on punching a portion punched by the first punch with the second punch. However, it has characteristics.
[0016]
According to the above means, the first magnetic plate and the second magnetic plate are sequentially fed and punched. For this reason, it is not necessary to punch out the first magnetic plate and the second magnetic plate by separate press machines, so that the apparatus is miniaturized. In addition, since the punched portion having a shape different from that of both punches is formed on the basis of punching the portion punched by the first punch with the second punch, the number of punches can be reduced.
[0017]
 Claim14DescribedRotating electric machineA method for manufacturing a stator is described in any one of claims 1 to 3.Rotating electric machineIn the method of manufacturing a stator, the step of forming a strip-shaped core having a plurality of comb-tooth portions based on reversing the direction of the magnetic plate and overlapping the magnetic plate, and And a step of engaging the comb-tooth portion with the comb-tooth portion adjacent in the circumferential direction.
 According to the above means, it is not necessary to punch out a plurality of types of magnetic plates having different contour shapes by separate press machines, so that the apparatus is miniaturized.
[0018]
 Claim15DescribedRotating electric machineA method for manufacturing a stator is described in any one of claims 1 to 3.Rotating electric machineIn a method of manufacturing a stator, a step of forming a band-shaped core having a plurality of comb-tooth portions based on turning over a magnetic plate and overlapping the magnetic plate, and the comb-tooth portion based on annularizing the band-shaped core And a step of meshing with a comb tooth portion adjacent in the circumferential direction.
 According to the above means, it is not necessary to punch out a plurality of types of magnetic plates having different contour shapes by separate press machines, so that the apparatus is miniaturized.
[0019]
 Claim16DescribedRotating electric machineThe stator manufacturing method includes a step of applying high energy processing along at least one side of the connecting portion between the unit yokes of the band-shaped core along the stacking direction of the magnetic plates, and the step is performed before the band-shaped core is bent. It has features in everywhere.
 According to the above means, stress is concentrated on the connecting portion between the unit yokes when the belt-shaped core is bent into an annular shape, and an external force in the axial direction acts on the magnetic plate. However, since the expansion of the magnetic plates in the axial direction is suppressed by high energy processing, the degree of adhesion between the magnetic plates is increased, and the generation of vibration and noise is suppressed.
[0020]
 Claim17DescribedRotating electric machineThe stator manufacturing method includes a first step in which high energy processing is performed on one side of the connecting portion between the unit yokes in the strip-shaped core along the stacking direction of the magnetic plates, and the other side of the connecting portion in the strip-shaped core. And a second step of performing high energy processing along the laminating direction, wherein the first step is performed before the band-shaped core is bent, and the second step is performed after the band-shaped core is bent. It has features where it is done.
 According to the above means, when the belt-like core is bent into an annular shape, the swelling of the magnetic plate in the axial direction is suppressed by high energy processing before bending. At this time, since there is some room for the magnetic plate to move in the axial direction, the comb teeth are smoothly meshed with each other without being abutted against the adjacent comb teeth in the circumferential direction. In addition, since the degree of adhesion between the magnetic plates is greatly increased by the high energy processing after bending, vibration and noise are greatly suppressed.
[0021]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, a first embodiment of the present invention will be described with reference to FIGS. In this embodiment, the present invention is applied to an inner rotor type three-phase DC brushless motor. First, in FIG. 1 (a), the helical core 1 has a belt-like shape in which unit cores 1A to 1F are connected by connecting bars 2 (however, the unit cores 1A and 1F are separated). 1A to 1F are composed of an arc-shaped unit yoke 3, a straight magnetic teeth 4 and a magnetic pole piece 5. The helical iron core 1 corresponds to a strip-shaped core.
[0022]
As shown in FIG. 1B, the unit cores 1 A to 1 F are based on alternately laminating the first steel plate 6 and the second steel plate 7 corresponding to the magnetic plates every other piece in the axial direction. Is formed. The first steel plate 6 and the second steel plate 7 are punched in two rows along the short direction of the strip steel plate 8 as shown in FIG. The first steel plate 6 and the second steel plate 7 which are alternately punched along the axial direction and are laminated in the axial direction are mechanically connected based on performing laser welding.
[0023]
Five first punched portions 9 are formed in the first steel plate 6. As shown in FIG. 2B, each of these first punched portions 9 has a linear parallel surface 10 parallel to the center line CL and a linear shape inclined by θ ° in one direction with respect to the center line CL. The end of the first steel plate 6 in the direction of arrow A is composed of a parallel surface 10 as shown in FIG. 2 (d), and the end of the opposite direction of arrow A is As shown in FIG. 2 (e), it is composed of an inclined surface 11. The center line CL refers to a straight line parallel to the magnetic pole teeth 4.
[0024]
As shown in FIG. 2A, five second punched portions 12 are formed on the second steel plate 7. As shown in FIG. 2C, each of these second punched portions 12 includes a linear inclined surface 13 and a center line CL that are inclined by θ ° in the opposite direction to the inclined surface 11 with respect to the center line CL. The end of the second steel plate 7 in the direction of arrow A is composed of an inclined surface 13 as shown in FIG. The end portion in the A direction is composed of a parallel surface 10 as shown in FIG.
[0025]
In the unit cores 1A to 1F, as shown in FIG. 1A, a lap portion 14 is formed at the end of the unit yoke 3 in the arrow A direction. Each of the lap portions 14 has a triangular shape when viewed in the axial direction, and has a comb-teeth shape in which the parallel surfaces 10 of the first steel plates 6 and the inclined surfaces 13 of the second steel plates 7 are alternately arranged one by one. ing.
[0026]
The unit cores 1 A to 1 F are formed with wrap portions 14 located at the ends of the unit yoke 3 in the direction opposite to the arrow A. Each of these lap portions 14 has a triangular shape when viewed in the axial direction, and has a comb-teeth shape in which the inclined surfaces 11 of the first steel plates 6 and the parallel surfaces 10 of the second steel plates 7 are alternately arranged one by one. ing. Note that the wrap portion 14 corresponds to a comb tooth portion.
[0027]
The stator core 15 in FIG. 3 is formed by bending the helical iron core 1 into a ring shape from a plurality of connecting bars 2, and each lap portion 14 meshes with a lap portion 14 adjacent in the circumferential direction from the axial direction. Wrapping along. Among these, a notch 16 extending in the axial direction is formed between one lap portion 14 of the unit core 1A and one lap portion 14 of the unit core 1F, and a notch portion is formed between the unit core 1A and the unit core 1F. The connection is based on laser welding along the inner surface of 16.
[0028]
As shown in FIG. 4A, the stator core 15 is formed with a synthetic resin mold layer 17 corresponding to each magnetic pole tooth 4. As shown in FIG. 4B, each mold layer 17 includes a rectangular tube-shaped coil winding portion 18 that covers the surface of the magnetic pole teeth 4, and a collar portion that is located on the inner peripheral portion of the coil winding portion 18. 19, an arc-shaped end plate portion 20 covering the upper end surface in the axial direction of the unit yoke 3, and an arc-shaped end plate portion 21 covering the lower end surface in the axial direction of the unit yoke 2. Is formed on the basis of insert molding in which molten resin is poured into a mold (not shown).
[0029]
A coil 22 is mounted on each magnetic pole tooth 4 from above the coil winding portion 18. Each of these coils 22 is wound around the magnetic pole teeth 4 before the helical iron core 1 is bent into an annular shape, and the winding direction is changed from the outer peripheral side to the inner peripheral side as shown in FIG. It is wound in a substantially step-like manner while being reversed from layer to layer on the inner periphery side.
[0030]
Next, a progressive feed crank press device 30 for punching the first steel plate 6 and the second steel plate 7 from the strip steel plate 8 will be described. First, in FIG. 5A, the upper die holder 31 is connected to a press motor 32 (see FIG. 6) via a crank mechanism (not shown), and when the press motor 32 operates, The holder 31 repeatedly moves between the top dead center and the bottom dead center.
[0031]
A table 33 is disposed below the upper mold holder 31. The strip steel plate 8 is set on the upper surface of the table 33, and when the transport mechanism 34 (see FIG. 6) is operated, the strip steel plate 8 is transported along the upper surface of the table 33 in the direction of arrow A. The transport mechanism 34 uses a transport motor 35 (see FIG. 6) as a drive source.
[0032]
A backing plate 36 is attached to the lower surface of the upper mold holder 31 as shown in FIG. A punch plate 37 is attached to the lower surface of the backing plate 36. The punch plate 37 has a pair of first punching punches 38 in order from the direction of the opposite arrow A, as shown in FIG. A pair of second punching punches 39 and a pair of cutting punches 40 are mounted. The first punching punch 38 and the second punching punch 39 correspond to the first punch and the second punch.
[0033]
As shown in FIG. 5A, each punch 38 to 40 is inserted into the through hole 41 of the punch plate 37 so as to be movable up and down, and each first punching punch 38 is formed as shown in FIG. (B), the first punching portion 9 of the first steel plate 6 has a triangular shape with the same inclination angle, and each second punching punch 39 is the second punching plate of the second steel plate 7. It has a triangular shape with the same inclination angle as the punched portion 12.
[0034]
As shown in FIG. 5A, a space 42 is formed in the punch plate 37. In the space 42, as shown in FIG. Correspondingly, cams 43 to 45 are accommodated. Each of these cams 43 to 45 has a thin portion 46 and a thick portion 47 as shown in FIG. 5A, and each of the cams 43 to 45 has a configuration as shown in FIG. In addition, a horizontally long through hole 48 is formed so as to straddle the thin portion 46 and the thick portion 47.
[0035]
As shown in FIG. 5A, the upper mold holder 31 is formed with through screw holes 49 corresponding to the through holes 48, and the upper ends of the pins 50 are formed in the screw holes 49. Is inserted to move up and down. Further, the backing plate 36 has through holes 51 corresponding to the respective pins 50, and the lower ends of the pins 50 are inserted into the through holes 48 of the cams 43 to 45 through the through holes 51 of the backing plate 36. Has been inserted.
[0036]
A set screw 52 is screwed into each screw hole 49, and a compression coil spring 53 is interposed between each set screw 52 and the pin 50. Each of these springs 53 urges the pin 50 downward, and the heads of the punches 38 to 40 are pressed downward by the lower end of the pin 50.
[0037]
As shown in FIG. 6, each set of cams 43 to 45 is connected to rods of air cylinders 54 to 56. These cylinders 54 to 56 are used for sliding the cams 43 to 45 in the direction of the arrow A and the direction of the opposite arrow A in FIG. ), When the thin-walled portions 46 of the cams 43 to 45 face the heads of the punches 38 to 40, a gap is formed between them, and the two-dot chain line in FIG. Thus, when the thick part 47 of the cams 43-45 opposes the head of each punch 38-40, both will substantially contact.
[0038]
When the punch plate 37 is lowered in a state where the heads of the punches 38 to 40 and the thin portions 46 of the cams 43 to 45 face each other, the springs 53 are moved when the punches 38 to 40 come into contact with the strip steel plate 8. Shrink and each punch 38-40 rises. For this reason, the press operation by each punch 38-40 is not performed (invalid state of punch 38-40).
[0039]
When the punch plate 37 is lowered in a state where the heads of the punches 38 to 40 and the thick portions 47 of the cams 43 to 45 face each other, the punches 38 to 40 can be lifted even if they contact the strip steel plate 8. First, the punch plate 37 and the punch plate 37 are lowered to the bottom dead center. For this reason, the pressing operation of the strip steel plate 8 by the punches 38 to 40 is executed (effective state of the punches 38 to 40).
[0040]
As shown in FIG. 7B, a pair of punching punches 57, a pair of punching punches 58, and a pair of punching punches 59 are fixed to the punch plate 37 in order from the direction of the opposite arrow A. When the plate 37 is lowered, the pair of punching punches 57 to 59 are lowered integrally with the punch plate 37 to the bottom dead center, and the strip plate 8 is pressed by the pair of punching punches 57 to 59.
[0041]
As shown in FIG. 6, the press motor 32 and the transport motor 35 are electrically connected to the control device 62 via motor drive circuits 60 and 61. The control device 62 is mainly composed of a microcomputer, and intermittently transports the strip steel plate 8 based on driving control of the transport motor 35 through the motor drive circuit 61, and press motor through the motor drive circuit 60. The upper mold holder 31 is continuously moved between the top dead center and the bottom dead center based on the drive control of 32.
[0042]
Solenoid valves 63 to 65 are interposed in the piping paths of the cylinders 54 to 56. These valves 63 to 65 are electrically connected to the control device 62 via valve drive circuits 66 to 68, and the control device 62 controls driving of the valves 63 to 65 through the valve drive circuits 66 to 68. The cams 43 to 45 are slid to change the state of the punches 38 to 40.
[0043]
The micro switch 69 is turned on when the punch plate 37 reaches the bottom dead center. The control device 62 counts up the punch counter “Np” based on the ON signal from the switch 69, and the counter “ The control timing of the valves 63 to 65 is obtained based on the value of “Np”.
[0044]
Next, the operation content of the press apparatus 30 will be described. The following operation is executed based on the drive control of the press motor 32, the transport motor 35, and the valves 63 to 65 by the control device 62 based on a control program stored in advance in the ROM.
[0045]
As shown in FIG. 7A, the control device 62 controls the driving of the valve 63 so that the thick portion 47 of each cam 43 is opposed to the punching punch 38 and makes each punching punch 38 effective. Turn into. At the same time, the thin wall portion 46 of each cam 44 and the thin wall portion 46 of each cam 45 are made to face the punching punch 39 and the cutting punch 40 based on the drive control of the valves 64 and 65, respectively. The cutting punch 40 is invalidated. 7B, the punches 38 and 57 to 59 in the valid state are indicated by solid lines, and the punches 39 and 40 in the invalid state are indicated by two-dot chain lines.
[0046]
After finishing the above-mentioned operation, the control device 62 conveys the belt-shaped steel plate 8 four times in the direction of arrow A at a set pitch while continuously moving the punch plate 37 up and down. Then, as shown in (c) to (f) of FIG. 7, the punching operation of the strip steel plate 8 by the pair of punching punches 38 is executed four times, and the pair of first punching portions 9 are provided on the strip steel plate 8. Four sets are formed.
[0047]
At this time, as shown in (e) to (f) of FIG. 1, the punching operation of the strip steel plate 8 by the pair of punching punches 57 is executed twice, and two pairs of rhombic holes 70 are formed in the strip steel plate 8. Is done. At the same time, as shown in FIG. 1 (f), the punching operation of the strip steel plate 8 by the pair of punching punches 58 and the pair of punching punches 59 is performed once, and the pair of notch portions 71 is formed in the strip steel plate 8. A pair of holes 72 is formed one by one. Reference numeral 73 denotes a pilot hole.
[0048]
The control device 62 switches the state of the valve 65 after completing the above-described operation. And as shown to (a) of FIG. 8, after making the thick part 47 of each cam 45 oppose the cutting punch 40 and enabling each cutting punch 40, the strip | belt-shaped steel plate 8 is conveyed with a set pitch. Then, as shown in FIG. 8C, the strip-shaped steel plate 8 is cut by the pair of cutting punches 40, and a pair of parallel surfaces 10 is formed. At this time, the pair of punching punches 38, the pair of punching punches 57, the pair of punching punches 58, and the pair of punching punches 59 make a new pair of first punching portions 9, a pair of diamond-shaped holes 70, a pair of punching punches 58. A pair of notches 71 and a pair of holes 72 are formed.
[0049]
The control device 62 switches the state of the valve 65 after completing the above-described operation. And as shown to (a) of FIG. 9, the thin part 46 of each cam 45 is made to oppose the cutting punch 40, and each cutting punch 40 is invalidated. Thereafter, the belt-shaped steel plate 8 is conveyed twice at a set pitch, and as shown in FIGS. 9C and 9D, a new pair of first punched portions 9 and a pair of rhombic holes are formed in the strip-shaped steel plate 8. 70, a pair of notches 71, and a pair of holes 72 are formed in pairs.
[0050]
The control device 62 switches the state of the valves 63 and 64 after finishing the above-described operation. Then, as shown in FIG. 10A, the thin portion 46 of each cam 43 is made to face the punching punch 38, and each punching punch 38 is invalidated. At the same time, the thick portion 47 of each cam 44 is opposed to the punching punch 39, and each punching punch 39 is validated.
[0051]
When the state of the punching punches 38 and 39 is switched, the control device 62 conveys the strip steel plate 8 at a set pitch. Then, as shown in FIG. 10C, the portion punched by the first punching punch 38 in FIG. 9D is punched by the second punching punch 39, and the first punching portion A third punching portion 74 having a shape different from those of the ninth punching portion 12 and the second punching portion 12 is formed.
[0052]
When the control device 62 finishes the above-described operation, as shown in FIGS. 10D and 10E, the control device 62 conveys the strip steel plate 8 twice at a set pitch, and the pair of punching punches 39 forms the strip steel plate 8. Two pairs of second punching portions 12 are formed. At this time, the strip steel plate 8 is punched by the pair of punching punches 57, the pair of punching punches 58, and the pair of punching punches 59, and a new pair of rhombus holes 70, a pair of notch portions 71, and a pair of holes 72 are formed. Two sets are formed.
[0053]
The control device 62 switches the state of the valve 65 after completing the above-described operation. And as shown to (a) of FIG. 11, after making the thick part 47 of each cam 45 oppose the cutting punch 40 and enabling each cutting punch 40, the strip | belt-shaped steel plate 8 is conveyed with a set pitch. Then, as shown in FIG. 11 (c), the strip-shaped steel plate 8 is cut from the third punched portion 74 by the pair of cutting punches 40, and the five first punched portions 9, the parallel surface 10, and the inclined surface. The 1st steel plate 6 which has the surface 11 is formed, and a pair of inclined surface 13 is formed in the arrow A direction edge part of the strip | belt-shaped steel plate 8. FIG.
[0054]
At this time, the pair of punching punches 39, the pair of punching punches 57, the pair of punching punches 58, the pair of punching punches 59, and the pair of second punching portions 12 and the pair of rhombuses on the strip-shaped steel plate 8. One set of the hole 70, the pair of notches 71, and the pair of holes 72 is formed. At the same time, as shown in FIG. 11 (d), a parallel plane 75 parallel to the center line CL is formed on the inclined surfaces 11 and 13 by the pair of cutting punches 40.
[0055]
The control device 62 switches the state of the valve 65 after completing the above-described operation. And as shown to (a) of FIG. 12, after making the thin part 46 of each cam 45 oppose the cutting punch 40 and invalidating each cutting punch 40, the strip | belt-shaped steel plate 8 is conveyed twice with a set pitch. Then, as shown in FIGS. 12C and 12D, the strip-shaped steel plate 8 is newly added by the pair of punching punches 39, the pair of punching punches 57, the pair of punching punches 58, and the pair of punching punches 59. A pair of second punching portions 12, a pair of rhombus holes 70, a pair of notches 71, and a pair of holes 72 are formed in pairs.
[0056]
The control device 62 switches the state of the valves 63 and 64 after finishing the above-described operation. And as shown to (a) of FIG. 13, the thick part 47 of each cam 43 is made to oppose the punching punch 38, and each punching punch 38 is validated. At the same time, the thin portion 46 of each cam 44 is opposed to the punching punch 39 to invalidate each punching punch 39.
[0057]
When the state of the punching punches 38 and 39 is switched, the control device 62 conveys the strip steel plate 8 three times at a set pitch. Then, as shown in FIGS. 13C to 13E, the strip-shaped steel plate 8 is newly added by the pair of punching punches 38, the pair of punching punches 57, the pair of punching punches 58, and the pair of punching punches 59. Three pairs of first punched portions 9, a pair of rhombus holes 70, a pair of cutout portions 71, and a pair of holes 72 are formed.
[0058]
The control device 62 switches the state of the valve 65 after completing the above-described operation. And as shown to (a) of FIG. 14, after making the thick part 47 of each cam 45 oppose the cutting punch 40 and enabling each cutting punch 40, the strip | belt-shaped steel plate 8 is conveyed with a set pitch. Then, as shown in FIGS. 14C and 14D, the strip steel plate 8 is cut by each cutting punch 40, and the five second punched portions 12, the parallel surface 10, the inclined surface 13, and the parallel surfaces are cut. A second steel plate 7 having 75 is formed.
[0059]
According to the said Example, the lap | wrap part 14 is formed in the circumferential direction both ends of unit core 1A-1F, each lap | wrap part 14 is meshed | engaged from the axial direction to the lap | wrap part 14 adjacent to the circumferential direction, and is made to wrap in the circumferential direction. It was. For this reason, the loss of magnetic flux flowing from the unit cores 1A to 1F to the unit cores 1A to 1F adjacent in the circumferential direction is reduced, so that the magnetic efficiency is improved.
[0060]
Moreover, the end surface of the lap | wrap part 14 by the side of the arrow A of unit core 1A-1F is comprised from the parallel surface 10 of the 1st steel plate 6, and the inclined surface 13 of the 2nd steel plate 7, and the lap | wrap part by the opposite arrow A direction side 14 end faces were constituted by the inclined surface 11 of the first steel plate 6 and the parallel surface 10 of the second steel plate 7. For this reason, since the circumferential wrap amount between the wrap parts 14 increases, the loss amount of the magnetic flux flowing from the unit cores 1A to 1F to the unit cores 1A to 1F adjacent in the circumferential direction is further reduced, and the magnetic efficiency is increased. Further improvement.
[0061]
Moreover, the parallel surface 75 was formed based on cut | disconnecting the 1st steel plate 6 and the 2nd steel plate 7 with the cutting punch 40 of rectangular cross section. For this reason, first, compared to a case where both are cut using a sharp cutting punch having a sharp point, “burrs” are less likely to be generated at the cut ends of both. For this reason, when the helical iron core 1 is annularized, there is less possibility of “burrs” coming into contact with each other, and the roundness of the stator core 15 is increased.
[0062]
Second, when the helical iron core 1 is bent into an annular shape and the lap portion 14 at the cut end of the unit core 1A and the lap portion 14 at the cut end of the unit core 1F are engaged with each other, as shown in FIG. A notch 16 for laser welding that opens to the side is formed. For this reason, since the laser welding range of the stator core 15 increases, the welding strength of the stator core 15 increases. In addition, since the swelled portion of laser welding is prevented from protruding from the outer peripheral surface of the stator core 15, the outer peripheral surface of the stator core 15 can be easily attached to the inner peripheral surface of the frame.
[0063]
Moreover, the 1st steel plate 6 and the 2nd steel plate 7 from which a contour shape differs are fed forward and punched. For this reason, it is not necessary to use the press machine which forms the 1st steel plate 6, and the press machine which forms the 2nd steel plate 7, and an apparatus is reduced in size. In addition, the punched portion 74 having a shape different from that of the punches 38 and 39 is formed on the basis of punching the portion punched by the first punching punch 38 by the second punching punch 39. The number is small. For this reason, since the length dimension of the punch plate 37 in the arrow A direction is reduced, the apparatus is further miniaturized.
[0064]
Next, a second embodiment of the present invention will be described with reference to FIG. The same members as those in the first embodiment are denoted by the same reference numerals, and the description thereof is omitted. Hereinafter, only different members will be described. As shown in FIG. 15A, the helical iron core 1 has a cut-off portion 76 located at the tip of each lap portion 14. Each of these cut-out portions 76 has a planar shape perpendicular to the center line CL, and as shown in FIG. 15B, a punched portion 77 perpendicular to the center line CL is formed. The first steel plate 6 and the second steel plate 7 are formed by alternately laminating one by one.
[0065]
According to the above embodiment, the cut-off portion 76 is formed in the lap portion 14. Therefore, when the coil 22 is wound on the magnetic pole tooth 4 from above the coil winding portion 18, the magnet wire is prevented from being caught by the tip end portion of the wrap portion 14 and being damaged. In addition, in the said 2nd Example, although the cut-off part 76 was formed based on laminating | stacking the 1st steel plate 6 and the 2nd steel plate 7 which have the punching part 77, it is not limited to this For example, after forming the helical iron core 1 based on laminating the first steel plate 6 and the second steel plate 7, the cut-off portion 76 is formed based on cutting the front end portion of each lap portion 14. May be.
[0066]
Next, a third embodiment of the present invention will be described with reference to FIG. The same members as those in the first embodiment are denoted by the same reference numerals, and the description thereof is omitted. Hereinafter, only different members will be described. In the helical core 1, a semicircular cutout 78 is formed at the circumferential center of each unit yoke 3, and the semicircular cutout 79 is located at the circumferential central portion of each pole piece 5. Is formed. These notches 78 and 79 extend in the axial direction. The former notches 78 open to the outer peripheral side, and the latter notches 79 open to the inner peripheral side.
[0067]
Each of the notches 78 and 79 is formed on the basis of alternately laminating the first steel plate 6 and the second steel plate 7 each having a notch-shaped punched portion. Laser welding is applied to the inner surface of 79, and the first steel plate 6 and the second steel plate 7 are held in a laminated state by laser welding applied to the inner surfaces of the notches 78 and 79.
[0068]
According to the above embodiment, the notches 78 and 79 were formed in the helical iron core 1, and laser welding was performed along the inner surfaces of the notches 78 and 70. For this reason, since the welding range of the helical core 1 increases, the strength of the helical core 1 increases. In addition, since the swelled portion of laser welding is prevented from protruding from the surface of the helical core 1, the outer peripheral surface of the stator core 15 can be easily inserted into the inner peripheral surface of the frame, and the inner peripheral surface of the stator core 15 and the rotor The air gap between the outer peripheral surface is made uniform.
[0069]
In the third embodiment, the notches 78 and 79 are formed on the basis of the lamination of the first steel plate 6 and the second steel plate 7 having the punched portions. However, the present invention is not limited to this. For example, after forming the helical iron core 1 based on laminating the first steel plate 6 and the second steel plate 7, the notches 78 and 79 may be formed in the helical iron core 1.
[0070]
Moreover, in the said 3rd Example, although the notch parts 78 and 79 were each formed in the six unit cores 1A-1F, it is not limited to this, One or more of the unit cores 1A-1F Notches 78 and 79 may be formed in a predetermined one. In this case, it is preferable to form notches 78 and 79 in the unit cores 1A and 1F at both ends.
[0071]
In the third embodiment, the inner surfaces of the notches 78 and 79 are laser welded. However, the present invention is not limited to this. For example, high energy such as arc welding, beam welding, TIG welding, YAG welding, etc. Processing may be performed.
[0072]
Moreover, in the said 1st thru | or 3rd Example, although the strip | belt-shaped steel plate 8 was cut | disconnected using the cutting punch 40 with a rectangular cross section, it is not limited to this. FIG. 17 shows a fourth embodiment of the present invention in which another cutting punch 80 is used instead of the cutting punch 40. Hereinafter, a fourth embodiment of the present invention will be described with reference to FIG.
[0073]
As shown in FIG. 17A, the cutting punch 80 is composed of a triangular portion 81 and a square portion 82, and the end portion in the arrow A direction of the first steel plate 6 and the second steel plate 7 are opposite to each other. When cutting between the end portions in the direction of arrow A, as shown in FIG. 17B, inclined surfaces 83 and 84 are formed on the first steel plate 6 and the second steel plate 7 by the triangular portion 81, and the squares are formed. The parallel plane 75 described above is formed by the portion 82. Further, when cutting between the opposite end of the first steel plate 6 in the direction of arrow A and the end of the second steel plate 7 in the direction of arrow A, as shown in FIG. And the parallel surface 75 is formed in the 2nd steel plate 7 by the square part 82, and the triangular part 81 does not perform cutting | disconnection operation | movement.
[0074]
Next, a fifth embodiment of the present invention will be described with reference to FIG. The same members as those in the first embodiment are denoted by the same reference numerals, and the description thereof is omitted. Hereinafter, only different members will be described. As shown in FIG. 18A, five first punched portions 85 are formed in the first steel plate 6. Each of these first punched portions 85 has a first inclined surface 86 inclined by θ1 ° (> θ °) in one direction with respect to the center line CL, and θ2 ° (<θ1 °) in the same direction as the inclined surface 86. It is defined by the inclined second inclined surface 87, and the end portion in the arrow A direction of the first steel plate 6 is constituted by the inclined surface 86, and the opposite end portion in the arrow A direction is constituted by the inclined surface 87. Yes.
[0075]
Five second punched portions 88 are formed in the second steel plate 7. Each of these second punched portions 88 has a second inclined surface 89 inclined by θ2 ° in the direction opposite to the inclined surfaces 86 and 87 with respect to the center line CL, and a second inclined surface 89 inclined by θ1 ° in the same direction as the inclined surface 89. The end of the second steel plate 7 in the direction of arrow A is composed of an inclined surface 89, and the end of the opposite direction of arrow A is composed of the inclined surface 90. Note that “θ1 ° −θ2 ° = θ °” is set.
[0076]
The first punching portion 85 is formed on the basis of using a first punching punch (not shown) having a shape corresponding to the first punching portion 85 in place of the first punching punch 38. It is a thing. Further, the second punching portion 88 is based on using a second punching punch (not shown) having a shape corresponding to the second punching portion 88 instead of the second punching punch 39. It is formed.
[0077]
In the unit cores 1A to 1F, a lap portion 91 is formed at the end of the unit yoke 3 in the arrow A direction, as shown in FIG. Each of these lap portions 91 has a triangular shape when viewed in the axial direction, and the circumferential end surface of each lap portion 91 has a first inclined surface 86 of the first steel plate 6 and a second inclined surface of the second steel plate 7. It has a comb-like shape having the surfaces 89 alternately one by one.
[0078]
In the unit cores 1A to 1F, as shown in FIG. 18 (b), a lap portion 91 is formed at the end of the unit yoke 3 in the direction opposite to the arrow A. Each of these lap portions 91 has a triangular shape when viewed in the axial direction, and the circumferential end surface of each lap portion 91 is the second inclined surface 87 of the first steel plate 6 and the first inclined surface of the second steel plate 7. It has a comb-like shape having the surfaces 90 alternately one by one.
[0079]
The helical iron core 1 is bent into an annular shape from a plurality of connecting bars 2, and each lap portion 91 meshes with the lap portion 91 adjacent in the circumferential direction from the axial direction as shown in FIG. Wrapping in the circumferential direction. The wrap portion 91 corresponds to a comb tooth portion.
[0080]
According to the above embodiment, each lap portion 91 is engaged with the lap portion 91 adjacent in the circumferential direction from the axial direction and wrapped in the circumferential direction, so that the loss of magnetic flux is reduced and the magnetic efficiency is improved. . In addition, the end surface of the lap portion 91 located on the arrow A direction side of the unit yoke 3 is composed of a first inclined surface 86 and a second inclined surface 89 that are inclined in different directions with respect to the center line CL. The end surface of the lap portion 91 located on the side opposite to the arrow A is composed of a second inclined surface 87 and a first inclined surface 90 that are inclined in different directions with respect to the center line CL. For this reason, since the amount of laps in the circumferential direction between the wrap portions 91 is increased as compared with the wrap portion 14 of the first embodiment, the loss of magnetic flux is further reduced and the magnetic efficiency is further improved.
[0081]
Next, a sixth embodiment of the present invention will be described with reference to FIG. The same members as those in the first embodiment are denoted by the same reference numerals, and the description thereof is omitted. Hereinafter, only different members will be described. As shown in FIG. 19A, five first punched portions 92 are formed in the first steel plate 6. Each of these first punched portions 92 has a first inclined surface 93 inclined by θ3 ° (<θ °) in one direction with respect to the center line CL, and θ4 ° (> θ3 ° in the opposite direction of the inclined surface 93). ) Is defined by the inclined second inclined surface 94, and the end of the first steel plate 6 in the direction of arrow A is formed by the inclined surface 93, and the end of the opposite arrow A direction is formed by the inclined surface 94. ing.
[0082]
Five second punched portions 95 are formed in the second steel plate 7. Each of these second punched portions 95 has a second inclined surface 96 inclined by θ4 ° in one direction with respect to the center line CL, and a first inclined surface 97 inclined by θ3 ° in the opposite direction to the inclined surface 96. The end of the second steel plate 7 in the direction of arrow A is composed of an inclined surface 96, and the end of the counter arrow A direction is composed of an inclined surface 97. Note that “θ3 ° + θ4 ° = θ °” is set.
[0083]
The first punching portion 92 is formed on the basis of using a first punching punch (not shown) having a shape corresponding to the first punching portion 92 instead of the first punching punch 38. It is a thing. Further, the second punching portion 95 is based on using a second punching punch (not shown) having a shape corresponding to the second punching portion 95 instead of the second punching punch 39. It is formed.
[0084]
In the unit cores 1A to 1F, as shown in FIG. 19B, a wrap portion 98 is formed at the end of the unit yoke 3 in the arrow A direction. Each of these lap portions 98 has a triangular shape when viewed in the axial direction, and the circumferential end surface of each lap portion 98 has a first inclined surface 93 of the first steel plate 6 and a second inclined surface of the second steel plate 7. It has a comb-like shape having the surfaces 96 alternately one by one.
[0085]
In the unit cores 1A to 1F, a wrap portion 98 is formed at the end of the unit yoke 3 in the direction opposite to the arrow A. Each of these lap portions 98 has a triangular shape when viewed in the axial direction, and the second inclined surface 94 of the first steel plate 6 and the first inclined surface 97 of the second steel plate 7 are alternately placed one by one. It has a comb-like shape.
[0086]
The helical iron core 1 is bent into an annular shape from a plurality of connecting bars 2, and each lap portion 98 meshes with the lap portion 98 adjacent in the circumferential direction from the axial direction as shown in FIG. Wrapping in the circumferential direction. Note that the wrap portion 98 corresponds to a comb tooth portion.
[0087]
According to the said Example, each lap | wrap part 98 was meshed | engaged from the axial direction with the lap | wrap part 98 adjacent to the circumferential direction, and was wrapped in the circumferential direction. For this reason, the loss of magnetic flux flowing from the unit cores 1A to 1F to the unit cores 1A to 1F adjacent in the circumferential direction is reduced, so that the magnetic efficiency is improved. In addition, the end surface of the lap portion 98 located on the arrow A direction side of the unit yoke 3 is composed of a first inclined surface 93 and a second inclined surface 96 that are inclined in the same direction with respect to the center line CL. The end surface of the lap portion 98 located on the opposite side of the arrow A is composed of a second inclined surface 94 and a first inclined surface 97 that are inclined in the same direction with respect to the center line CL. For this reason, although the amount of wraps in the circumferential direction between the wrap portions 98 is reduced, it is difficult to collide between the end surfaces of the wrap portions 98 when meshing between the wrap portions 98, so that the helical iron core 1 can be easily bent into an annular shape. .
[0088]
Next, a seventh embodiment of the present invention will be described with reference to FIGS. The same members as those in the first embodiment are denoted by the same reference numerals, and the description thereof is omitted. Hereinafter, only different members will be described. In the helical iron core 1, as shown in FIG. 21C, an arc portion 99 is formed on the inner surface of each connecting bar 2.
[0089]
As shown in FIG. 20A, each arc portion 99 is based on alternately laminating the first steel plate 6 having the arc portion 99 and the second steel plate 7 having the arc portion 99 one by one. As shown in FIG. 21 (c), when the helical iron core 1 is bent into an annular shape around each connecting beam 2, stress acts on the connecting beam 2 so that the connection is made. A crack or the like is prevented from occurring in the crosspiece 2.
[0090]
Each lap portion 14 of the helical iron core 1 is provided with a first protrusion 100 as shown in FIG. Each of these projections 100 is formed on the parallel surface 10 of the first steel plate 6 and the parallel surface 10 of the second steel plate 7 as shown in FIG. As shown in FIG. 20 (a), the end surface has a linear shape parallel to the parallel surface 10, and the protrusion amount (width dimension) of each protrusion 100 with respect to the parallel surface 10 is set to “W / 2”. Has been.
[0091]
Each lap portion 14 of the helical iron core 1 is provided with a second protrusion 101 as shown in FIG. These protrusions 101 are formed on the inclined surface 11 of the first steel plate 6 and the inclined surface 13 of the second steel plate 7 as shown in FIG. As shown in FIG. 20 (a), the end surface has a linear shape parallel to the inclined surface 11 or 13, and the protruding amount of each protrusion 101 with respect to the inclined surface 11 or 13 is set to “W / 2”. Has been.
[0092]
The width dimension “W / 2” of the first protrusion 100 and the width dimension “W / 2” of the second protrusion 101 consider the extension amount “W” of the connecting beam 2 when the helical core 1 is bent. It was decided. When the helical iron core 1 is bent into an annular shape, the plurality of connecting bars 2 extend, but as shown in FIG. 20B, the first protrusion 100 is in surface contact with the second protrusion 101. Based on this, the stator core 15 is formed into a perfect circle as much as possible. For this reason, since the parallel surface 10 reliably contacts the inclined surface 11 or 13 via the first protrusion 100 and the second protrusion 101, the magnetic loss is reduced. In addition, since the amount of overlap in the circumferential direction between the wrap portions 14 is reliably increased, the rotational characteristics and magnetic characteristics of the motor are generally improved.
[0093]
In the seventh embodiment, the first protrusion 100 is formed on the parallel surface 10 of the lap portion 14 and the second protrusion 101 is formed on the inclined surfaces 11 and 13, but this is not limitative. For example, you may comprise as follows. Even in the case of each of these configurations, the helical iron core 1 is bent to a perfect circle as much as possible without being affected by the extension of the crosspiece 2, so that magnetic characteristics are improved.
[0094]
First protrusions having a width dimension “W / 2” are formed on the first inclined surfaces 86 and 90 in FIG. 18. Then, a second protrusion having a width dimension “W / 2” is formed on the second inclined surfaces 87 and 89, and the helical iron core 1 is bent from the plurality of connecting bars 2 into an annular shape. The protrusion is brought into surface contact with the second protrusion adjacent in the circumferential direction.
[0095]
First protrusions having a width dimension “W / 2” are formed on the first inclined surfaces 93 and 97 in FIG. 19. Then, a second protrusion having a width dimension “W / 2” is formed on the second inclined surfaces 94 and 96, and the helical iron core 1 is bent in an annular shape from the plurality of connecting bars 2. The protrusion is brought into surface contact with a second protrusion adjacent in the circumferential direction.
[0096]
Moreover, in the said 1st thru | or 7th Example, although the helical iron core 1 was formed based on laminating | stacking the 1st steel plate 6 and the 7th steel plate 7, it is not limited to this, For example, steel materials The helical iron core 1 may be formed on the basis of cutting or the like.
[0097]
Next, an eighth embodiment of the present invention will be described with reference to FIG. The same members as those in the first embodiment are denoted by the same reference numerals, and the description thereof is omitted. Hereinafter, only different members will be described. A pair of first punching punches 38 is fixed to the punch plate 37 of the press device 30, and the strip steel plate 8 is intermittently conveyed at a set pitch while the punch plate 37 is continuously moved up and down. The first steel plate 6 is punched from the strip-shaped steel plate 8 into a plurality of rows (for example, two rows).
[0098]
When the first steel plate 6 is punched from the strip-shaped steel plate 8, the first steel plate 6 in the upper row is turned over so as to have the same contour shape as the second steel plate 7, as indicated by a two-dot chain line. Then, the first steel plate 6 in the upper row is overlapped with the first steel plate 6 in the lower row to form the helical iron core 1. In this case, it is not necessary to separately use the press machine for forming the first steel plate 6 and the press machine for forming the second steel plate 7, and the apparatus can be downsized.
[0099]
In the eighth embodiment, the first steel plate 6 in the upper row is turned over and stacked on the first steel plate 6 in the lower row, but the present invention is not limited to this. For example, the first steel plate in the lower row 6 may be turned over and overlapped with the first steel plate 6 in the upper row.
[0100]
Moreover, in the said 8th Example, although the 1st steel plate 6 was punched from the strip | belt-shaped steel plate 8, it is not limited to this, For example, you may punch the 2nd steel plate 7. FIG. In this case, the second steel plate 7 in the upper row is turned over to have the same contour shape as the first steel plate 6 and then overlapped with the second steel plate 7 in the lower row, or the second steel plate 7 in the lower row is turned upside down. It is good to overlap with the 2nd steel plate 7 of the upper row, after making it the same outline shape as the steel plate 6. FIG.
[0101]
Next, a ninth embodiment of the present invention will be described with reference to FIG. The same members as those in the first embodiment are denoted by the same reference numerals, and the description thereof is omitted. Hereinafter, only different members will be described. A pair of first punching punches 38 is fixed to the punch plate 37 of the press device 30 and is based on intermittently transporting the strip steel plate 8 at a set pitch while continuously moving the punch plate 37 up and down. The first steel plate 6 is punched from the strip-shaped steel plate 8 into a plurality of rows (for example, two rows) in an opposed state.
[0102]
When the first steel plate 6 is punched from the strip-shaped steel plate 8, the direction of the first steel plate 6 in the lower row is changed by 180 ° to have the same contour shape as that of the second steel plate 7, as shown by a two-dot chain line. And the 1st steel plate 6 of a lower row is piled up on the 1st steel plate 6 of an upper row, and the helical iron core 1 is formed. In this case, it is not necessary to separately use the press machine for forming the first steel plate 6 and the press machine for forming the second steel plate 7, and the apparatus can be downsized.
[0103]
In the ninth embodiment, the orientation of the first steel plates 6 in the lower row is changed by 180 ° and the first steel plates 6 in the upper row are stacked. However, the present invention is not limited to this example. The direction of the first steel plate 6 may be changed by 180 ° and overlapped with the first steel plate 6 in the lower row.
Moreover, in the said 9th Example, although the 1st steel plate 6 was punched from the strip | belt-shaped steel plate 8, it is not limited to this, For example, you may punch the 2nd steel plate 7. FIG. In this case, the orientation of the second steel plate 7 in the upper row is changed by 180 ° and the same contour shape as that of the first steel plate 6 is applied, and then the second steel plate 7 in the lower row is overlapped. After changing the direction by 180 ° to have the same contour shape as that of the first steel plate 6, it is preferable to overlap the second steel plate 7 in the upper row.
[0104]
Moreover, in the said 8th and 9th Example, although the 1st steel plate 6 of 1st Example was stamped out from the strip | belt-shaped steel plate 8, it is not limited to this, For example, 2nd thru | or 7th Example The first steel plate 6 or the second steel plate 7 described in any of the above may be punched and laminated.
[0105]
In the eighth and ninth embodiments, the pair of first steel plates 6 is punched based on intermittently transporting the strip steel plates 8 at a set pitch while moving the pair of punching punches 38 up and down. However, the present invention is not limited to this. For example, N pairs of punching punches 38 are used (where N is a natural number of 2 or more), and the strip steel plates 8 are moved while moving the N punching punches 38 up and down. The pair of first steel plates 6 may be punched based on intermittent conveyance at a set pitch × N ”.
[0106]
In the first to ninth embodiments, the first steel plates 6 and the second steel plates 7 are alternately laminated one by one. However, the present invention is not limited to this. For example, the tenth embodiment of the present invention. As shown in FIG. 24 showing an example, a plurality of (for example, two) sheets may be alternately stacked.
[0107]
Next, an eleventh embodiment of the present invention will be described with reference to FIGS. The same members as those in the first embodiment are denoted by the same reference numerals, and the description thereof is omitted. Hereinafter, only different members will be described. As shown in FIG. 26 (c), the third steel plate 102 has five first punched portions 9, and an inclined surface 13 is formed at the end of the third steel plate 102 in the arrow A direction. And the parallel surface 75 is formed, and the parallel surface 10 is formed in the opposite arrow A direction edge part.
[0108]
As shown in FIG. 26B, the fourth steel plate 103 has five second punched portions 12, and a parallel surface 10 is provided at the end of the fourth steel plate 103 in the arrow A direction. The inclined surface 11 and the parallel surface 75 are formed at the end in the direction opposite to the arrow A. The third steel plate 102 and the fourth steel plate 103 are punched from the strip steel plate 8.
[0109]
As shown in FIG. 25 (b), the helical iron core 1 is formed by repeatedly laminating the first steel plate 6, the third steel plate 102, the fourth steel plate 103, and the second steel plate 7 in this order from the bottom to the top. As shown in FIG. 25A, the helical core 1 is formed with wrap portions 14 positioned at both ends of the unit cores 1A to 1F.
[0110]
The wrap portions 14 at the ends of the unit cores 1B to 1F in the direction of arrow A alternately have two inclined surfaces 13 and two parallel surfaces 10, and the wrap portions 14 at the ends of the unit cores 1A to 1E in the direction of the arrow A are parallel. Two surfaces 10 and two inclined surfaces 11 are alternately provided. Since each lap part 14 is connected to another lap part 14 via the connecting rail 2, it is difficult to move. Moreover, as shown in FIG. 27 (a), since the axial engagement margin 104 (space width dimension) is large, when the helical iron core 1 is formed into an annular shape, the adjacent engagement margin 104 of the wrap portion 14 is inside. Easily meshed.
[0111]
The wrap portion 14 at the end of the unit core 1A in the direction of arrow A, as shown in FIG. 25 (a), has one parallel surface 10 and one inclined surface 13 alternately. The end lap portion 14 has the inclined surfaces 11 and the parallel surfaces 10 alternately one by one. Each of these lap portions 14 is easy to move, and may be caught by the mating lap portion 14 when the helical core 1 is formed into an annular shape. However, since it is elastically deformed and escapes the mating lap portion 14, It is easily engaged in the engagement margin 105 (see b in FIG. 27) of the lap portion 14 on the side.
[0112]
In the eleventh embodiment, the unit cores 1A to 1E are formed with the wrap portions 14 having the parallel surfaces 10 and the inclined surfaces 11 alternately in a predetermined unit at the opposite ends in the direction indicated by the arrow A, You may form the lap | wrap part 14 which has the inclined surface 13 and the parallel surface 10 alternately by the predetermined unit of 3 or more sheets in the arrow A direction edge part of 1B-1F.
[0113]
Next, a twelfth embodiment of the present invention will be described with reference to FIG. The same members as those in the fifth embodiment are denoted by the same reference numerals and the description thereof will be omitted. Hereinafter, only different members will be described. As shown in FIG. 28A, the third steel plate 106 has five first punched portions 85, and the second steel plate 106 has a second end at the end in the arrow A direction. An inclined surface 89 is formed, and a first inclined surface 90 is formed at the opposite end of the third steel plate 106 in the direction of the arrow A.
[0114]
As shown in FIG. 28 (d), the fourth steel plate 107 has five second punched portions 88, and the first steel plate 107 has a first punched-out portion at the end in the arrow A direction. An inclined surface 86 is formed, and a second inclined surface 87 is formed at the opposite end of the fourth steel plate 107 in the direction of the arrow A. The third steel plate 106 and the fourth steel plate 107 are punched from the strip steel plate 8.
[0115]
The helical iron core 1 is formed by repeatedly laminating a first steel plate 6, a third steel plate 106, a fourth steel plate 107, and a second steel plate 7 in this order from the bottom to the top. As shown in FIG. 28E, the iron core 1 is formed with wrap portions 91 located at both ends of the unit yokes 1A to 1F.
[0116]
The wrap portions 91 at the ends of the unit cores 1B to 1F in the direction of arrow A alternately have two first inclined surfaces 86 and two second inclined surfaces 89, and the end portions of the unit cores 1A to 1E in the direction of the opposite arrow A The wrap portion 91 has two second inclined surfaces 87 and two first inclined surfaces 90 alternately. Since each of the lap portions 91 has a large engagement margin in the axial direction, the lap portions 91 are easily engaged with the adjacent lap portions 91 when the helical iron core 1 is formed into an annular shape.
[0117]
The wrap portion 91 at the end of the unit core 1A in the direction of arrow A alternately has the first inclined surface 86 and the second inclined surface 89 one by one, and the wrap portion 14 at the end of the unit core 1F in the direction opposite to the arrow A. Has second inclined surfaces 87 and first inclined surfaces 90 alternately one by one. Each of these lap portions 91 is elastically deformed when it is abutted against the counterpart lap portion 91 when the helical iron core 1 is formed into an annular shape, so that it is easily engaged with the counterpart lap portion 91.
[0118]
In the twelfth embodiment, the lap portions 91 having the first inclined surfaces 86 and the second inclined surfaces 89 alternately in predetermined units of three or more at the ends of the unit cores 1B to 1F in the arrow A direction. It is also possible to form the wrap portion 91 having the first inclined surface 90 and the second inclined surface 87 alternately in predetermined units of three or more at the opposite ends of the unit cores 1A to 1E in the direction of the arrow A.
[0119]
Next, a thirteenth embodiment of the present invention will be described with reference to FIG. The same members as those in the sixth embodiment are designated by the same reference numerals and the description thereof is omitted, and only different members will be described below. As shown in FIG. 29A, the third steel plate 108 has five first punched portions 92, and the second steel plate 108 has a second end at the end in the arrow A direction. An inclined surface 96 is formed, and a first inclined surface 97 is formed at the end of the third steel plate 108 in the direction opposite to the arrow A.
[0120]
As shown in FIG. 29 (d), the fourth steel plate 109 has five second punched portions 95, and the first steel plate 109 has a first punched portion at the end in the arrow A direction. An inclined surface 93 is formed, and a second inclined surface 94 is formed at the end of the fourth steel plate 109 in the direction opposite to the arrow A. The third steel plate 108 and the fourth steel plate 109 are punched from the strip steel plate 8.
[0121]
The helical iron core 1 is formed by repeatedly laminating the first steel plate 6, the third steel plate 108, the fourth steel plate 109, and the second steel plate 7 in this order from the bottom to the top. As shown in FIG. 29E, the iron core 1 is formed with wrap portions 98 located at both ends of the unit cores 1A to 1F.
[0122]
The wrap portions 98 at the ends of the unit cores 1B to 1F in the direction of the arrow A alternately have two first inclined surfaces 93 and two second inclined surfaces 96, and the end portions of the unit cores 1A to 1E in the opposite direction of the arrow A The wrap portion 98 has two second inclined surfaces 94 and two first inclined surfaces 97 alternately. Since each of the lap portions 98 has a large meshing amount in the axial direction, the lap portions 98 are easily meshed with the adjacent lap portions 98 when the helical iron core 1 is formed into an annular shape.
[0123]
The wrap portion 98 at the end of the unit core 1A in the arrow A direction has first inclined surfaces 93 and second inclined surfaces 96 one by one, and the wrap portion 98 at the end of the unit core 1F in the opposite direction of the arrow A. Has alternately the second inclined surfaces 94 and the first inclined surfaces 97 one by one. Each lap portion 98 is elastically deformed when it is abutted against the mating lap portion 98 when the helical iron core 1 is formed into an annular shape, and is easily meshed with the mating lap portion 98.
[0124]
In the thirteenth embodiment, the lap portions 98 having the first inclined surface 93 and the second inclined surface 96 alternately in predetermined units of three or more at the ends in the arrow A direction of the unit cores 1B to 1F. You may form the lap | wrap part 98 which has the 1st inclined surface 97 and the 2nd inclined surface 94 alternately by the predetermined unit of 3 or more sheets in the opposite arrow A direction edge part of unit core 1A-1E formed.
[0125]
In the first to thirteenth embodiments, the helical iron core 1 is held in a laminated state based on laser welding on the helical iron core 1, but the present invention is not limited to this. For example, arc welding, beam You may hold | maintain in a lamination | stacking state based on giving high energy processing, such as welding, TIG welding, and YAG welding, and you may hold | maintain in a lamination | stacking state based on crimping and riveting.
[0126]
Next, a fourteenth embodiment of the present invention will be described with reference to FIG. The same members as those in the first embodiment are denoted by the same reference numerals, and the description thereof is omitted. Hereinafter, only different members will be described. Laser welding 110 is performed on the helical iron core 1 at one side of each connecting bar 2, and laser welding 111 is performed at the end of the unit yoke 1 A. Each of these laser welds 110 and 111 is applied along the laminating direction of the first steel plate 6 and the second steel plate 7 and holds the helical iron core 1 in a laminated state.
[0127]
Stress is concentrated on each connecting beam 2 when the helical iron core 1 is bent, and a swelling force in the stacking direction acts. However, since each connecting beam 2 is reinforced by laser welding 110 and the swelling in the stacking direction is suppressed, the degree of adhesion between the first steel plate 6 and the second steel plate 7 is increased, and vibration and noise are suppressed. . In addition, there is some room left for the first steel plate 6 and the second steel plate 7 to bend in the stacking direction when the helical iron core 1 is bent. It meshes smoothly without any problems.
[0128]
In the fourteenth embodiment, a plurality of laser weldings 110 are performed on the helical core 1 of the first embodiment. However, the present invention is not limited to this, and any one of the second to thirteenth embodiments is described. A plurality of laser weldings 110 may be applied to the helical iron core 1.
[0129]
In the fourteenth embodiment, laser welding 110 is performed along the stacking direction on one side of each connecting beam 2 before the helical iron core 1 is bent. However, the present invention is not limited to this. Laser welding 110 may be performed on both sides of the connecting beam 2 along the stacking direction.
[0130]
Next, a fifteenth embodiment of the present invention will be described with reference to FIG. Note that the same members as those in the fourteenth embodiment are denoted by the same reference numerals and description thereof is omitted, and only different members will be described below. The helical iron core 1 is laser-welded 110 positioned on one side of each connecting beam 2 and is laser-welded 111 positioned on the ends of the unit yokes 1A and 1F. The helical core 1 is laser-welded. After applying 110 and 111, it is bent into an annular shape.
[0131]
Laser welding 112 is applied to the other side of each connecting bar 2 along the stacking direction of the helical iron core 1. Each of these laser weldings 112 is performed after the helical iron core 1 is bent, further increasing the degree of adhesion between the first steel plate 6 and the second steel plate 7, and greatly suppressing vibration and noise.
In the fourteenth and fifteenth embodiments, high energy processing such as arc welding, beam welding, TIG welding, YAG welding or the like may be performed instead of laser welding 110-112.
[0132]
In the first to fifteenth embodiments, the helical iron core 1 is held in an annular shape based on laser welding on the inner surface of the notch 16, but the present invention is not limited to this. For example, the notch The helical iron core 1 may be held in an annular shape by applying high energy processing such as arc welding, beam welding, TIG welding, YAG welding or the like to the inner surface of 16.
[0133]
In the first to fifteenth embodiments, the laser welding notch 16 is formed in the stator core 15. However, the present invention is not limited to this. For example, the notch 16 may be eliminated. In this case, both ends of the helical iron core 1 are preferably held in an annular shape based on caulking or riveting.
[0134]
In the first to fifteenth embodiments, the present invention is applied to the stator of the inner rotor type motor. However, the present invention is not limited to this. For example, the present invention may be applied to the stator of the outer rotor type motor.
[0135]
【The invention's effect】
 As apparent from the above description, the stator of the rotating electrical machine and the method for manufacturing the stator of the present invention have the following effects.
 Claim 1And 4 respectivelyAccording to the means, the comb tooth portion was engaged with the comb tooth portion adjacent in the circumferential direction, and was wrapped in the circumferential direction. For this reason, since the amount of loss of magnetic flux between the unit cores adjacent in the circumferential direction is reduced, the magnetic efficiency is improved. And the end surface of the comb-tooth part was comprised from the 1st inclined surface and 2nd inclined surface which incline in the same direction. For this reason, since it becomes difficult to collide between the end surfaces of a comb-tooth part when meshing between comb-tooth parts, it becomes easy to bend | fold a strip | belt-shaped core annularly.Moreover, a cut-off portion was formed at the tip of the comb tooth portion. For this reason, when the magnet wire is wound around the magnetic pole teeth, the magnet wire is prevented from being caught by the tip of the comb tooth portion and being damaged. In particular, according to the fourth aspect of the invention, the arc portion is provided at the connecting portion between the unit yokes. For this reason, since stress is dispersed and acts on the connecting portion when the belt-shaped core is bent, it is possible to prevent the connecting portion from being cracked.
[0136]
 Claim 2And 5, respectivelyAccording to this means, the comb teeth are meshed with the comb teeth adjacent in the circumferential direction and are wrapped in the circumferential direction, so that the magnetic efficiency is improved. And since the end surface of the comb-tooth part was comprised from the parallel surface and the inclined surface, compared with the means of Claim 1, the amount of lap | wraps of the circumferential direction between comb-tooth parts increases, and magnetic efficiency improves further.Moreover, a cut-off portion was formed at the tip of the comb tooth portion. For this reason, when the magnet wire is wound around the magnetic pole teeth, the magnet wire is prevented from being caught by the tip of the comb tooth portion and being damaged. In particular, according to the means described in claim 5, the arc portion is provided at the connecting portion between the unit yokes. For this reason, since stress is dispersed and acts on the connecting portion when the belt-shaped core is bent, it is possible to prevent the connecting portion from being cracked.
 Claim 3And 6, respectivelyAccording to this means, the comb teeth are meshed with the comb teeth adjacent in the circumferential direction and are wrapped in the circumferential direction, so that the magnetic efficiency is improved. In addition, since the end face of the comb tooth portion is composed of the first inclined surface and the second inclined surface that are inclined in different directions, the comb tooth portion is compared with the means according to claim 1 and the means according to claim 2. The amount of wrapping in the circumferential direction is increased, and the magnetic efficiency is further improved.Moreover, a cut-off portion was formed at the tip of the comb tooth portion. For this reason, when the magnet wire is wound around the magnetic pole teeth, the magnet wire is prevented from being caught by the tip of the comb tooth portion and being damaged. In particular, according to the means described in claim 6, the arc portion is provided in the connecting portion between the unit yokes. For this reason, since stress is dispersed and acts on the connecting portion when the belt-shaped core is bent, it is possible to prevent the connecting portion from being cracked.
[0137]
 Claim7According to the described means, the stator core was provided with a notch for high energy processing. For this reason, since the high energy processing range increases, the strength of the stator core increases. In addition, it is possible to prevent the swelled portion subjected to high energy processing from protruding from the surface of the stator core.
[0138]
 Claim8According to the described means, a cutout for high energy processing was formed in the belt-shaped core. For this reason, since the high energy processing range increases, the intensity | strength of a strip | belt-shaped core increases. Moreover, it is possible to prevent the swelled portion subjected to the high energy processing from protruding from the surface of the belt-like core.
 Claim9According to the described means, since the first protrusion is provided on the first inclined surface and the second protrusion is provided on the second inclined surface, the first protrusion is in contact with the second protrusion. The stator core is formed into a perfect circle as much as possible. In addition, since the first inclined surface reliably contacts the second inclined surface via the first protrusion and the second protrusion, the magnetic loss is reduced.
[0139]
 Claim10According to the described means, since the first protrusion is provided on the parallel surface and the second protrusion is provided on the inclined surface, the stator core is based on the contact of the first protrusion with the second protrusion. Is formed into a perfect circle as much as possible. Moreover, since the parallel surface reliably contacts the inclined surface via the first protrusion and the second protrusion, the magnetic loss is reduced.
[0140]
 Claim11According to the described means, the comb-tooth portion having the first inclined surface and the second inclined surface alternately formed on both ends of the belt-like core is formed, and the first inclined surface and the second inclined portion are formed on the remaining portion. Comb teeth having a plurality of inclined surfaces were alternately formed. For this reason, since it becomes easy to mesh a comb-tooth part with the adjacent comb-tooth part in the both ends and the remaining part of a strip-shaped core, the moldability of a strip-shaped core improves.
 Claim12According to the described means, comb teeth having alternately parallel surfaces and inclined surfaces formed on both ends of the belt-shaped core are formed, and a plurality of parallel surfaces and inclined surfaces are alternately formed on the remaining portion. Part was formed. For this reason, since it becomes easy to mesh a comb-tooth part with the adjacent comb-tooth part in the both ends and the remaining part of a strip-shaped core, the moldability of a strip-shaped core improves.
[0141]
 Claim13According to the described means, the first magnetic plate and the second magnetic plate having different contour shapes were sequentially fed and punched. For this reason, it is not necessary to punch out the first magnetic plate and the second magnetic plate by separate press machines, so that the apparatus is miniaturized. In addition, since a punched portion having a shape different from that of both punches is formed based on punching a portion punched by the first punch with the second punch, the number of punches can be reduced.
[0142]
 Claim14According to the described means, the band-shaped core was formed based on reversing the direction of the magnetic plate and overlapping the magnetic plate. For this reason, it is not necessary to punch out a plurality of types of magnetic plates having different contour shapes by separate press machines, so that the apparatus is miniaturized.
 Claim15According to the described means, the belt-like core was formed based on turning the magnetic plate over and superimposing it on the magnetic plate. For this reason, it is not necessary to punch out a plurality of types of magnetic plates having different contour shapes by separate press machines, so that the apparatus is miniaturized.
[0143]
 Claim16According to the described means, at least one side of the connecting portion between the unit yokes was subjected to high energy processing before the belt-shaped core was bent. For this reason, since the adhesion degree between magnetic plates increases, generation | occurrence | production of a vibration and noise is suppressed.
 Claim17According to the described means, high energy processing was performed on one side of the connecting portion between the unit yokes before the band-shaped core was bent. For this reason, the degree of adhesion between the magnetic plates is increased, and the comb teeth are easily meshed with the adjacent comb teeth in the circumferential direction. In addition, since the high energy processing is performed on the other side of the connecting portion between the unit yokes after the belt-shaped core is bent, the degree of adhesion between the magnetic plates is greatly increased, and vibration and noise are greatly suppressed.
[Brief description of the drawings]
FIG. 1 is a diagram showing a first embodiment of the present invention (a is a plan view showing a helical iron core, and b is a cross-sectional view taken along line XX).
2A is a plan view showing the punched state of the first steel plate and the second steel plate, FIG. 2B is an enlarged view of the X1 portion, and FIG. 2C is an enlarged view of the X2 portion. , (D) is an enlarged view of the X3 portion, and (e) is an enlarged view of the X4 portion.
FIG. 3 is a plan view showing a stator core.
4A is a plan view showing a stator core in a coiled state, and FIG. 4B is a cross-sectional view taken along line XX.
5A is an enlarged cross-sectional view showing the main part of the press device, and FIG. 5B is a view showing a cam along the line XX.
FIG. 6 is a block diagram schematically showing the configuration of the press apparatus.
7A is a view schematically showing a press apparatus, FIG. 7B is a plan view showing a layout of punches, and FIGS. 7C to 7F are views showing a state in which a strip steel plate is punched.
8A is a diagram schematically showing a press device, FIG. 8B is a plan view showing a layout of punches, and FIG. 8C is a diagram showing a state in which a strip steel plate is cut.
FIGS. 9A and 9B are diagrams schematically showing a pressing device, FIG. 9B is a plan view showing a layout of punches, and FIGS. 9C to 9D are views showing a state in which a strip steel plate is punched.
FIGS. 10A and 10B are diagrams schematically showing a pressing device, FIG. 10B is a plan view showing a layout of punches, and FIGS. 10C to 10E are views showing a state in which a strip steel plate is punched.
FIGS. 11A and 11B are diagrams schematically showing a pressing device, FIG. 11B is a plan view showing a layout of punches, FIG. 11C is a diagram showing a state where a strip steel plate is cut, and FIG. Fig.
FIGS. 12A and 12B are diagrams schematically showing a pressing device, FIG. 12B is a plan view showing a layout of punches, and FIGS. 12C to 12D are views showing a state in which a strip steel plate is punched.
FIGS. 13A and 13B are diagrams schematically showing a pressing device, FIG. 13B is a plan view showing a layout of punches, and FIGS. 13C to 13E are views showing a state in which a strip steel plate is punched.
14A is a view schematically showing a press apparatus, FIG. 14B is a plan view showing a layout of punches, FIG. 14C is a view showing how a strip steel plate is cut, and FIG. 14D is an X part. Fig.
FIG. 15 is a diagram showing a second embodiment of the present invention (a is a plan view showing a helical iron core, b is a plan view showing a part of the first steel plate and the second steel plate in an enlarged manner);
FIG. 16 is a diagram showing a third embodiment of the present invention (plan view showing a helical iron core).
FIG. 17 is a view showing a fourth embodiment of the present invention (a is a plan view showing a cutting punch, and b and c are plan views showing cut end portions of a first steel plate and a second steel plate).
FIG. 18 is a diagram showing a fifth embodiment of the present invention (a is a plan view showing a first steel plate and a second steel plate, b is a plan view showing a helical iron core, and c is a plan view showing a part of a stator core. )
FIG. 19 is a view showing a sixth embodiment of the present invention (a is a plan view showing a first steel plate and a second steel plate, b is a plan view showing a helical iron core, and c is a plan view showing a part of a stator core. )
FIG. 20 is a view showing a seventh embodiment of the present invention (a is a plan view showing a part of the first steel plate in an unfolded state, and b is a plan view showing a part of the first steel plate in a bent state. (Figure)
21A is a plan view showing a first steel plate and a second steel plate, FIG. 21B is a plan view showing a helical iron core, and FIG. 21C is a plan view showing a part of a stator core.
FIG. 22 is a view showing an eighth embodiment of the present invention (plan view showing a punched state of a steel plate).
FIG. 23 is a view showing a ninth embodiment of the present invention (plan view showing a punched state of a steel plate).
FIG. 24 is a view showing a tenth embodiment of the present invention (a cross-sectional view showing a laminated state of steel plates).
FIG. 25 is a view showing an eleventh embodiment of the present invention (a is a plan view showing a helical iron core, and b is a cross-sectional view taken along line XX).
26A is a plan view showing the second steel plate, FIG. 26B is a plan view showing the fourth steel plate, FIG. 26C is a plan view showing the third steel plate, and FIG. Plan view showing steel plate
FIG. 27A is a diagram showing a wrap portion having two inclined surfaces and two parallel surfaces alternately, and FIG. 27B is a diagram showing a wrap portion having one inclined surface and one parallel surface alternately.
FIG. 28 is a view showing a twelfth embodiment of the present invention (a is a plan view showing a third steel plate, b is a plan view showing a first steel plate, c is a plan view showing a second steel plate, and d is a plan view showing the second steel plate. Plan view showing a fourth steel plate, e is a plan view showing a helical iron core)
29 is a view showing a thirteenth embodiment of the present invention (a is a plan view showing a third steel plate, b is a plan view showing the first steel plate, c is a plan view showing the second steel plate, and d is a plan view showing the second steel plate, FIG. Plan view showing a fourth steel plate, e is a plan view showing a helical iron core)
FIG. 30 is a view showing a fourteenth embodiment of the present invention (a perspective view showing an appearance of a helical iron core).
FIG. 31 is a view showing a fifteenth embodiment of the present invention (a perspective view showing the appearance of a helical iron core).
[Explanation of symbols]
1 is a helical iron core (band-shaped core), 1A to 1F are unit cores, 4 is a magnetic tooth, 6 is a first steel plate (magnetic plate, first magnetic plate), and 7 is a second steel plate (magnetic plate, second plate). 9 is a first punched portion, 10 is a parallel surface, 11 is an inclined surface, 12 is a second punched portion, 13 is an inclined surface, 14 is a lap portion (comb tooth portion), and 15 is Stator core, 16 is a notch, 38 is a first punching punch (first punch), 39 is a second punching punch (second punch), and 74 is a third punching part (punching part). , 76 are cut-out portions, 78 and 79 are notched portions, 86 and 90 are first inclined surfaces, 87 and 89 are second inclined surfaces, 91 is a wrap portion (comb tooth portion), and 93 and 97 are first portions. , 94 and 96 are second inclined surfaces, 98 is a lap portion (comb tooth portion), 99 is an arc portion, 100 is a first protrusion, and 101 is a second protrusion. .

Claims

A stator core formed by annularizing a band-shaped core in a form in which a plurality of unit cores are connected;
A first inclined surface that is provided at both ends in the circumferential direction of each unit core and that is inclined in one direction with respect to the magnetic pole teeth of the stator core and a second inclined surface that is inclined in the same direction as the first inclined surface are alternately arranged. A comb tooth portion
Each comb tooth part meshes with a comb tooth part adjacent in the circumferential direction and wraps in the circumferential direction ,
A stator of a rotating electrical machine, wherein a cut-off portion is formed at a tip portion of each comb tooth portion .

A stator core formed by annularizing a band-shaped core in a form in which a plurality of unit cores are connected;
Comb portions provided at both ends in the circumferential direction of each unit core, and having alternately parallel surfaces substantially parallel to the magnetic teeth of the stator core and inclined surfaces inclined with respect to the magnetic teeth,
Each comb tooth part meshes with a comb tooth part adjacent in the circumferential direction and wraps in the circumferential direction ,
A stator of a rotating electrical machine, wherein a cut-off portion is formed at a tip portion of each comb tooth portion .

A stator core formed by annularizing a band-shaped core in a form in which a plurality of unit cores are connected;
A first inclined surface that is provided at both circumferential ends of each unit core and that is inclined in one direction with respect to the magnetic pole teeth of the stator core and a second inclined surface that is inclined in a direction opposite to the first inclined surface are alternately arranged. A comb tooth portion
Each comb tooth part meshes with a comb tooth part adjacent in the circumferential direction and wraps in the circumferential direction ,
A stator of a rotating electrical machine, wherein a cut-off portion is formed at a tip portion of each comb tooth portion .

A stator core formed by annularizing a band-shaped core in a form in which a plurality of unit cores are connected;
A first inclined surface that is provided at both ends in the circumferential direction of each unit core and is inclined in one direction with respect to the magnetic pole teeth of the stator core and a second inclined surface that is inclined in the same direction as the first inclined surface are alternately arranged. A comb tooth portion
Each comb tooth part meshes with a comb tooth part adjacent in the circumferential direction and wraps in the circumferential direction,
A cut-off portion is formed at the tip of each comb tooth portion,
A stator for a rotating electrical machine, wherein an arc portion is provided at a connecting portion between the unit yokes .

A stator core formed by annularizing a band-shaped core in a form in which a plurality of unit cores are connected;
Comb portions provided at both ends in the circumferential direction of each unit core, and having alternately parallel surfaces substantially parallel to the magnetic teeth of the stator core and inclined surfaces inclined with respect to the magnetic teeth,
Each comb tooth part meshes with a comb tooth part adjacent in the circumferential direction and wraps in the circumferential direction,
A cut-off portion is formed at the tip of each comb tooth portion ,
A stator for a rotating electrical machine, wherein an arc portion is provided at a connecting portion between the unit yokes .

A stator core formed by annularizing a band-shaped core in a form in which a plurality of unit cores are connected;
A first inclined surface that is provided at both circumferential ends of each unit core and that is inclined in one direction with respect to the magnetic pole teeth of the stator core and a second inclined surface that is inclined in a direction opposite to the first inclined surface are alternately arranged. A comb tooth portion
Each comb tooth part meshes with a comb tooth part adjacent in the circumferential direction and wraps in the circumferential direction,
A cut-off portion is formed at the tip of each comb tooth portion,
A stator for a rotating electrical machine, wherein an arc portion is provided at a connecting portion between the unit yokes .

The stator core is formed with notches extending in the axial direction located at both ends of the strip-shaped core,
The stator for a rotating electrical machine according to any one of claims 1 to 3, wherein the stator core is held in an annular shape based on performing high energy processing along an inner surface of the notch .

A belt-shaped core formed on the basis of laminating a plurality of magnetic plates,
The strip-shaped core is formed with a notch extending in the axial direction,
The stator for a rotating electrical machine according to any one of claims 1 to 3, wherein the belt-like core is held in a laminated state based on performing high energy processing along an inner surface of the notch .

The first inclined surface is provided with a first protrusion,
The stator of the rotating electrical machine according to claim 1 or 3, wherein the second inclined surface is provided with a second protrusion that contacts the first protrusion adjacent in the circumferential direction .

The parallel surface is provided with a first protrusion,
The stator of the rotating electrical machine according to claim 2, wherein the inclined surface is provided with a second protrusion that contacts the first protrusion adjacent in the circumferential direction .

A belt-shaped core formed on the basis of laminating a plurality of magnetic plates,
Comb portions having the first inclined surface and the second inclined surface alternately formed one by one are formed at both ends of the belt-shaped core,
The comb-tooth part which alternately has a plurality of said 1st inclined surfaces and said 2nd inclined surfaces is formed in the remaining part of the said strip | belt-shaped core, The Claim 1 or 3 characterized by the above-mentioned. Stator for rotating electrical machines.

A belt-like core formed on the basis of laminating a plurality of magnetic plates,
At both ends of the belt-like core, comb teeth having alternately the parallel surface and the inclined surface are formed,
The stator of the rotating electrical machine according to claim 2, wherein a comb tooth portion having a plurality of the parallel surfaces and a plurality of inclined surfaces alternately is formed in the remaining portion of the belt-like core.

In the method of manufacturing the stator of the rotating electrical machine according to any one of claims 1 to 3,
A step of sequentially feeding and punching the first magnetic plate and the second magnetic plate having different contour shapes;
Forming a strip-shaped core having a plurality of comb-tooth portions based on overlapping the first magnetic plate and the second magnetic plate;
Engaging the comb-tooth portion with a comb-tooth portion adjacent in the circumferential direction based on annularizing the belt-shaped core,
In punching the first magnetic plate and the second magnetic plate, a punched portion having a shape different from both punches is formed based on punching a portion punched by the first punch with the second punch. A method of manufacturing a stator for a rotating electrical machine, characterized by comprising:

In the method of manufacturing the stator of the rotating electrical machine according to any one of claims 1 to 3,
Forming a strip-shaped core having a plurality of comb teeth based on reversing the direction of the magnetic plate and overlapping the magnetic plate;
Method of manufacturing a rotary electric machine stator, characterized in that the strip-shaped core and a step of meshing in a tooth portion adjacent the comb teeth in the circumferential direction based on the circularization.

In the method of manufacturing the stator of the rotating electrical machine according to any one of claims 1 to 3,
Forming a strip-shaped core having a plurality of comb teeth based on turning the magnetic plate over and superimposing on the magnetic plate;
Method of manufacturing a rotary electric machine stator, characterized in that the strip-shaped core and a step of meshing in a tooth portion adjacent the comb teeth in the circumferential direction based on the circularization.

Comprising a higher facilities to engineering high energy machining along the stacking direction of at least one said the side magnetic plates of the connecting portion between the unit yokes of the strip core,
The method of manufacturing a stator for a rotating electrical machine according to any one of claims 13 to 15 , wherein the step is performed before the belt-shaped core is bent .

A first step of applying high energy processing along the laminating direction of the magnetic plate on one side of the connecting portion between the unit yokes in the strip-shaped core;
A second step of performing high energy processing along the stacking direction on the other side of the connecting portion of the strip-shaped core,
The first step is performed before the band-shaped core is bent,
16. The method of manufacturing a stator for a rotating electrical machine according to claim 13, wherein the second step is performed after the band-shaped core is bent.