JP4305239B2 - Core manufacturing method - Google Patents

Description

  The present invention relates to a method for manufacturing a core constituting a stator of an axial gap motor.

  For example, as described in Patent Document 1, an iron core that constitutes a stator of an axial gap motor is manufactured by punching a magnetic steel sheet into a predetermined shape to manufacture a unit core, and then laminating the unit cores. Each unit iron core is manufactured by joining by means of adhesive, welding, caulking or the like.

Japanese Patent Laid-Open No. 2004-64041

  However, many axial gap motor cores have a trapezoidal columnar shape as will be described later, and in such a shape core, it is necessary to gradually vary the size of a plurality of unit cores constituting the core in the stacking direction. Therefore, in the production, it is necessary to design and manufacture punching dies used for punching processing according to the size of the different unit cores, which increases the manufacturing cost and the manufacturing efficiency. There was a problem.

  In addition, according to the conventional core manufacturing method, the unit cores are manufactured by punching, so that each unit core has a cut surface that follows the normal direction of each unit core. For this reason, when configuring a core having a surface inclined with respect to the normal direction of the unit core, such as a core having a trapezoidal columnar shape, the leg surface is a combination of the respective cut surfaces and the upper or lower surface of the unit core. When the coil is wound around the core, a gap is generated between the coil and the core, and the magnetic flux density of the portion is lowered, thereby reducing the torque as the electric motor. There was also.

  The present invention has an object to solve the above-described problems, and an object of the present invention is to manufacture a stator core for an axial gap motor by reducing the core manufacturing cost. It is an object of the present invention to provide a method for manufacturing a core that can improve efficiency and eliminate the gap between the coil and the core to improve the torque of the electric motor.

In order to achieve the above object, the invention according to claim 1 is a stator configuration in which a plurality of cores wound around a coil are arranged circumferentially, and the lamination direction of the electromagnetic steel sheets constituting the core is the circumferential shape. When manufacturing a stator core of an axial gap type rotary motor , which is the radial direction of the arrangement circle, after manufacturing a laminated electrical steel sheet by laminating a plurality of strip-shaped electrical steel sheets in advance, the laminated electrical steel sheet is The laminated electromagnetic steel sheet is held in a laminating direction by a plate and a lower surface plate, and the laminated electromagnetic steel sheet is cut into a plurality of cut surfaces in a direction inclined with respect to the normal direction of the electromagnetic steel sheet together with the upper surface plate and the lower surface plate by the cutting means it is characterized in that to produce the core cut Te.

  According to the invention of claim 1, after manufacturing a laminated electromagnetic steel sheet by laminating a plurality of strip-shaped electromagnetic steel sheets, a plurality of the laminated electromagnetic steel sheets are inclined with respect to the normal direction of the electromagnetic steel sheet by a cutting means. Conventionally, a core is manufactured by stacking unit iron cores after manufacturing a core by cutting a magnetic steel sheet into a predetermined shape in advance by punching a magnetic steel sheet into a predetermined shape by cutting the core at a cut surface. As in the manufacturing method of, it is not necessary to design and manufacture punching dies for punching unit cores of different shapes one by one when gradually changing the size of the electrical steel sheets that constitute the core in the stacking direction, thereby reducing the manufacturing cost. While reducing, manufacturing efficiency can be improved.

Here, as the cutting means, a wire-cut electric discharge machine, a water jet device, a laser cutting device, or the like can be used, and any of these cutting means cuts a magnetic steel sheet with a surface inclined in the normal direction. And a mechanism that is movable in a plane parallel to the side surface in the width direction of the laminated electrical steel sheet.
According to this, in manufacturing a core having a cut surface inclined with respect to the normal direction of the electromagnetic steel sheet, the laminated electromagnetic steel sheet can be cut along the cut surface, and the cut surface is not a stepped shape. Therefore, the gap between the coil and the core when the coil is wound around the core can be eliminated, the loss of the magnetic flux density in the coil can be prevented, and the torque of the motor can be increased.

Embodiments of the present invention will be described below in detail with reference to the drawings.
FIG. 1 is a schematic perspective view showing an embodiment of a core manufacturing method of the present invention.
In FIG. 1, 1 is a magnetic steel sheet, 2 is a laminated magnetic steel sheet, 3 is a top plate, 4 is a bottom plate, 5 is a cut surface, and 6 is a core.
Advance after a plurality of strip-shaped electromagnetic steel plate 1 to produce a laminated electromagnetic steel plates 2 are stacked, and holding the laminated electromagnetic steel plates 2 by sandwiching the stacking direction by the upper surface plate 3 and the lower surface plate 4, the multilayer electromagnetic steel plates 2 The core 6 is manufactured by cutting the upper plate 3 and the lower plate 4 together with a plurality of cutting surfaces 5 inclined with respect to the normal direction of the electromagnetic steel sheet 2 by a cutting means (not shown). To do. (Equivalent to claim 1)

  According to this, the shape of the unit core constituting the core, as in the conventional manufacturing method in which the core is manufactured by manufacturing the unit core after punching the electromagnetic steel sheet into a predetermined shape by a punching die in advance. Is changed in the stacking direction, it is not necessary to design and manufacture punching dies for punching unit iron cores having different shapes, thereby reducing the manufacturing cost and increasing the manufacturing efficiency. Further, even a core having a cut surface inclined with respect to the normal line of the electromagnetic steel sheet can have a completely flat cut surface, thereby increasing the magnetic flux density in the coil and increasing the torque of the electric motor. .

Here, as the electromagnetic steel sheet 1, it is preferable to use a thin silicon steel sheet having an inorganic insulating coating on the surface.
Further, by sandwiching the laminated electromagnetic steel sheet 2 between the upper surface plate 3 and the lower surface plate 4 and cutting the whole with a cutting means, it is possible to prevent the laminated electromagnetic steel sheet from being burred by cutting.

Here, preferably, before the laminated electrical steel sheet 2 is cut, the adjacent electrical steel sheets 1 are joined in advance by means such as an adhesive, welding or caulking. (Equivalent to claim 2)
Thereby, after manufacturing the core 6 by cutting the laminated electromagnetic steel sheet 2 with a cutting means, it is possible to prevent the adjacent electromagnetic steel sheets 1 constituting the core from peeling off and the core 6 from being separated. After the manufacture of 6, the coil can be formed by immediately winding a winding around the core.

  Here, the type of resin as the adhesive is not particularly limited. For example, an acrylic resin adhesive, a urethane resin adhesive, an epoxy resin adhesive, a phenol resin adhesive, a nylon resin adhesive, Phenol resin adhesives, synthetic rubber adhesives, vinyl chloride resin adhesives, composite adhesives combining these adhesives, and the like can be used.

Further, as shown in FIG. 1, the core 6 is formed in a trapezoidal columnar shape in which the legs 7 and 8 facing each other are equal, and the upper bottom surface and the lower bottom surface of the adjacent cores 6 in the laminated electromagnetic steel sheet 2 are opposite to each other. (Equivalent to claim 3)
According to this, the trapezoidal columnar core 6 can be continuously cut out from the square columnar laminated electromagnetic steel plate 2 and the cut surface 5 is separated from the cut surface of the core 6 adjacent in the laminated electromagnetic steel plate 2. Therefore, it is possible to reduce the man-hour for cutting the laminated electrical steel sheet by the cutting means, and to shorten the manufacturing time of the core 6.

Here, the trapezoidal leg refers to two sides excluding the parallel upper and lower bases, and the opposite legs are equal means that the lengths of the legs are equal to each other and the trapezoid is line-symmetric. Show. The upper base is shorter than the lower base.
Further, the upper bottom surface of the trapezoidal column includes a surface perpendicular to the trapezoidal end surface including the upper bottom, the lower bottom surface includes a surface perpendicular to the trapezoid including the lower bottom, and the leg surface includes a trapezoidal shape including the legs. A surface perpendicular to the end face is shown.

Here, as shown in FIG. 2, the shape of the cut surface 5 of the core 6 in a plane parallel to the electromagnetic steel plate 1 is point-symmetric about the center in the width direction of the laminated electromagnetic steel plate 2. (Equivalent to claim 4)
According to this, not only the core of the form shown in FIG. 1 but also the core 6 adjacent in the electromagnetic laminated steel sheet 2 when manufacturing a core having a cut surface having a stepped portion as shown in FIG. By alternately reversing the upper bottom surface and the lower bottom surface, the core 6 can be continuously cut out from the quadrangular prism-shaped laminated electrical steel sheet 2.

Furthermore, as shown in FIG. 3, when laminating the electromagnetic steel sheets 1, the angles α and β formed between the plane including the upper end or the lower end of the longitudinal end face of each electromagnetic steel sheet 1 and the electromagnetic steel sheet 1 are set to the trapezoidal columnar shape. The angles γ and δ between the leg surface of the core and the upper or lower bottom surface are the same. (Equivalent to claim 5)
Here, by laminating the electromagnetic steel sheet 1 while inclining in the normal direction, the upper surface plate 3 and the lower surface plate 4 are displaced from each other at both ends in the length direction of the laminated electromagnetic steel sheet 2. In order to hold the laminated electromagnetic steel sheet 2, trapezoidal columnar holding blocks 9 and 10 are provided.

In the manufacturing method as shown in FIG. 1, the laminated electromagnetic steel sheet 2 has a quadrangular prism shape. Therefore, when the trapezoidal columnar core 6 is cut out from the laminated electromagnetic steel sheet 2 and manufactured, both end portions 7 in the longitudinal direction of the laminated electromagnetic steel sheet 2 are inevitably produced. , 8 is a useless part that cannot be used as a core.
However, as shown in FIG. 3, angles α and β (β are defined by the plane between the plane including the upper end or the lower end (here, the lower end) of the longitudinal end face of each electromagnetic steel sheet 1 of the laminated electromagnetic steel sheet 2 and the electromagnetic steel sheet 1. is made to coincide with the angles γ and δ (δ is a complementary angle of γ) formed by the leg surface of the trapezoidal columnar core 6 and the upper and lower bottom surfaces, where δ is the complementary angle of γ. By inclining and laminating with respect to the normal direction, the cores can be obtained simply by cutting out the stepped portions 2A and 2B formed by the lengthwise ends of each electromagnetic steel sheet 1 from both ends of the laminated electromagnetic steel sheet 2. Can be cut out.

  Thereby, the whole laminated electromagnetic steel sheet 2 can be used as a core almost without waste, and the material yield can be improved. Of course, it is preferable that the length of the laminated electrical steel sheet 2 is approximately equal to the integral multiple of the upper base of the trapezoidal columnar core 6 and the integral multiple of the lower base.

FIG. 4 is a schematic cross-sectional view showing an axial gap motor to which the core manufactured by the core manufacturing method of the present invention is applied.
As shown in FIG. 4, the axial gap motor includes a rotating shaft 11, the rotating shaft 11 is rotatably supported by a case 14 via a radial bearing 12 and a thrust bearing 13, and a disk rotor 15 is connected to the rotating shaft 11. A pair of stators 16 are provided on the outer peripheral side of the disk rotor 15 and opposed to both side surfaces of the disk rotor 15. The stator 16 includes a plurality of cores 17 wound with coils 19 via insulators 18, and a gap formed by a plurality of radially arranged guides 21 by bolt fastening to a back yoke 20 fastened to the case 14. It is inserted from the outer peripheral side and fixed to the case 14.

5 is a schematic diagram showing a stator of an axial gap motor to which the core manufactured by the core manufacturing method of the present invention is applied.
Here, twelve stators 16 in which coils 19 are wound around cores 17 via insulators 18 are arranged on the stator 16, and twelve guides 21 are arranged radially on the back yoke 20 fastened to the case 14 by bolt fastening. It is inserted into twelve gaps formed between the outer peripheral sides and fixed to the case 14.
Here, the core 17 is provided at twelve locations on the circumference. When a rotating magnetic field is formed in the circumferential direction by the coil 19 excited by an inverter (not shown), a plurality of permanent magnets having different polarities alternately in the circumferential direction are formed. The embedded disk rotor 15 is attracted and repelled by the rotating magnetic field and rotates at a synchronous speed.

  In addition, this invention is not limited only to the said embodiment, Many deformation | transformation or a change is possible.

  The core manufacturing method of the present invention is particularly suitable for application to the manufacture of the stator core of an axial gap motor.

It is a model perspective view which shows one Embodiment of the manufacturing method of the core which concerns on this invention. It is a model perspective view which shows other embodiment of the manufacturing method of the core which concerns on this invention. It is a model perspective view which shows other embodiment of the manufacturing method of the core which concerns on this invention. It is a schematic cross section which shows the axial gap electric motor using the core manufactured by the manufacturing method of the core which concerns on this invention. It is a schematic diagram which shows the stator of the axial gap electric motor using the core manufactured by the manufacturing method of the core which concerns on this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Magnetic steel plate 2 Laminated electromagnetic steel plate 3 Upper surface plate 4 Lower surface plate 5 Cutting surface 6 Core 7 Both end portions 8 Both end portions 9 Holding block 10 Holding block 11 Rotating shaft 12 Radial bearing 13 Thrust bearing 14 Case 15 Disc rotor 16 Stator 17 Core 18 Insulator 19 Coil 20 Back yoke 21 Guide

Claims (5)

An axial gap type rotary electric motor having a stator configuration in which a plurality of cores wound around a coil are circumferentially arranged, and the laminating direction of the electromagnetic steel plates constituting the core is the radial direction of the circle in the circumferential arrangement. In manufacturing the stator core of the above, after laminating a plurality of strip-shaped electrical steel sheets to produce a laminated electrical steel sheet, the laminated electrical steel sheet is sandwiched and held in the laminating direction by the upper surface plate and the lower surface plate, core manufacturing method, characterized by laminating electromagnetic steel plates was cut in a direction inclined with respect to the normal direction of the electromagnetic steel plates with the top plate and the lower surface plate by the cutting means to produce the core. Advance before cutting the laminated magnetic steel sheets, the manufacturing method of a core according to claim 1 formed by joining the magnetic steel sheets adjacent. The core, the facing legs are equal trapezoidal columnar, the in interlaminar electrical steel sheet, a manufacturing method of a core according to claim 1 or 2 comprising a bottom surface and a bottom surface on said core adjacent the opposite to each other. The core manufacturing method according to claim 1 or 2, wherein a shape of the cut surface of the core in a plane parallel to the electromagnetic steel sheet is point-symmetric about a width direction center of the electromagnetic steel sheet. Upon laminating the electromagnetic steel plates, the angle between the plane containing the upper or lower end of the longitudinal end surfaces of the respective magnetic steel sheets with an angle between the electromagnetic steel plates, the leg surface and the upper bottom or the lower bottom of the trapezoid pillar-shaped core The method for manufacturing a core according to claim 3, wherein the core is the same.

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