JP7270840B2 - STATOR MANUFACTURING APPARATUS AND STATOR MANUFACTURING METHOD - Google Patents

Description

TECHNICAL FIELD The present disclosure relates to a stator manufacturing apparatus and a stator manufacturing method including a stator core in which a plurality of cores are arranged in an annular shape.

In the manufacture of motor stators, it is required to ensure the roundness of the inner diameter of the annular stator core. Patent Document 1 discloses a technique for ensuring the circularity of the inner diameter of the stator core. In Patent Document 1, a plurality of cores constituting a stator core are arranged on the outer peripheral side of a core metal that can be expanded and contracted in the radial direction, and an annular jig is arranged on the outer peripheral side of the plurality of cores. Then, the diameter of the core metal is expanded to bring the outer peripheral surface of the core metal into contact with the inner peripheral surface of each core, and each core is clamped with the core metal and an annular jig, thereby correcting the posture of each core and forming the stator core. to ensure the roundness of the inner diameter.

JP 2010-098828 A

In Patent Literature 1, the shape of the outer peripheral surface of the metal core that contacts the inner peripheral surface of each core is unknown. Therefore, the core cannot be stably clamped depending on the shape of the outer peripheral surface of the cored bar. If the core cannot be stably clamped, the posture of the core cannot be properly corrected, and there is a problem that it is difficult to ensure the circularity of the stator core.

The present disclosure has been made in view of such points, and an object thereof is to provide a stator manufacturing apparatus and a stator manufacturing method capable of ensuring the roundness of the stator core.

A stator manufacturing apparatus according to the present disclosure is a stator manufacturing apparatus including an annular stator core in which a plurality of cores are arranged in a circumferential shape. and a plurality of pressing pieces arranged on the outer peripheral side of the core at intervals from the core and capable of coming into contact with the outer peripheral surface of the core. and outer shell retainers arranged at intervals in the circumferential direction , and a plurality of cores arranged between the core bar and the outer shell retainer are pressed against the plurality of protrusions of the core bar pieces for each core . It corrects the posture of each core by clamping it with a piece .

A stator manufacturing method according to the present disclosure is a stator manufacturing apparatus including a stator core in which a plurality of cores are arranged in an annular shape, and includes a plurality of protrusions that protrude outward from an outer peripheral surface and have arc-shaped tip surfaces. and a plurality of holding pieces, which are arranged on the outer peripheral side of the core bar and can contact the outer peripheral surface of the core, are arranged at intervals in the circumferential direction. an arranging step of arranging a plurality of cores between the outer shell retainer and moving the core metal and the outer shell retainer in a direction toward each other so that the plurality of cores are formed into a plurality of protrusions of the core bar piece for each core ; and a posture correcting step of correcting the posture of each core by clamping it with a pressing piece .

According to the present disclosure, the outer peripheral surface of the core bar has a plurality of projections for one core, and the core is clamped by the arc-shaped tip surfaces of the plurality of projections and the outer shell retainer, The core can be properly corrected, and as a result, the roundness of the stator core can be ensured.

FIG. 2 is a diagram showing a stator manufactured by the stator manufacturing apparatus according to Embodiment 1; FIG. 2 is a schematic top view showing constituent elements of the stator manufacturing apparatus according to Embodiment 1; FIG. 4 is a flow chart showing a method of manufacturing a stator according to Embodiment 1; FIG. 5 is a diagram showing the connecting core before shape correction in the stator manufacturing method according to the first embodiment; It is a figure which shows the state of step S2 of FIG. It is a figure which shows the state of step S3 of FIG. It is a figure which shows the state of step S4 of FIG. It is a figure which shows the state of step S5 of FIG. It is an explanatory view of step S6 in FIG. 3 and is a side view of the stator core. FIG. 10 is a view showing a clamped state of the core of the comparative example, and is a view when the inner diameter of the stator core is larger than the set diameter. FIG. 4 is a diagram showing a state in which the core is clamped in the stator manufacturing apparatus according to Embodiment 1, and is a diagram when the inner diameter of the stator core is larger than the set diameter. FIG. 10 is a diagram showing a clamped state of the core of the comparative example, and is a diagram when the inner diameter of the stator core is smaller than the set diameter. FIG. 4 is a diagram showing a state in which the core is clamped in the stator manufacturing apparatus according to Embodiment 1, and is a diagram when the inner diameter of the stator core is smaller than the set diameter.

Before describing the stator manufacturing apparatus and the stator manufacturing method of the present embodiment, the stator of the motor will be described below.

FIG. 1 shows a stator manufactured by a stator manufacturing apparatus according to Embodiment 1. FIG. In the following description, the direction in which the central axis of the stator extends is called the axial direction, the direction perpendicular to the axial direction is called the radial direction, and the direction around the rotation axis is called the circumferential direction.
The stator 1 has an annular stator core 3 in which a plurality of cores 2 are arranged circumferentially. Although an example of 12 cores is shown here, the number of cores is arbitrary. Each core 2 has a back yoke portion 21 having an arc-shaped outer peripheral surface, and tooth portions 22 protruding radially inward from the back yoke portion 21 . A wire (not shown) is wound around the tooth portion 22 of each core 2 via an insulating member (not shown).

A thin connecting portion 23 is provided between the back yoke portions 21 of each core 2 . The stator core 3 is bent at the thin connecting portions 23 to form an annular shape, and is welded at both ends in the circumferential direction. The two cores 2a at both ends in the circumferential direction are formed with stepped portions 24 that are pressed by a pressing mechanism described later. Here, an example of a connected core in which the cores 2 are connected to each other by a thin connecting portion has been described, but the present disclosure is not limited to this, and even if the core 2 is a split core that is completely separated, good. In the following, an example of a concatenated core will be described.

Next, constituent elements of the stator manufacturing apparatus according to Embodiment 1 will be described.

FIG. 2 is a schematic top view showing components of the stator manufacturing apparatus according to Embodiment 1. FIG.
The stator manufacturing apparatus 4 includes an annular outer shell retainer 42 and an annular cored bar 44 . The outer shell presser 42 has a configuration in which a plurality of presser pieces 41 that are expandable and contractible in the radial direction and that can come into contact with the outer peripheral surface of the core 2 are arranged at intervals in the circumferential direction. The outer shell retainer 42 is arranged on the outer peripheral side of the cored bar 44 with a space therebetween. It should be noted that the outer shell retainer 42 is not limited to the structure having a plurality of retainer pieces 41, and may be composed of an annular elastic metal material member or the like that can be expanded and contracted in the radial direction. The cored bar 44 has a configuration in which a plurality of cored bar pieces 43 that can be expanded and contracted in the radial direction and that can come into contact with the inner peripheral surface of the core 2 are arranged in a circumferential shape. The stator manufacturing apparatus 4 further includes a pressure mechanism 45, a welding unit 46, and a pedestal (not shown) on which the multiple cores 2 are placed.

Each cored bar piece 43 of the cored bar 44 has a plurality of protrusions 47 that protrude outward from the outer peripheral surface 43a. A tip surface 47a of the projection 47 is formed in an arc shape. A tip surface 47a of the protruding portion 47 contacts an inner peripheral surface 22a (see FIG. 4 described later) of the core 2 when the diameter of the core bar 44 is expanded. The shape of the tip surface 47a of the protrusion 47 is arcuate in order to suppress variations in the contact of the protrusion 47 due to manufacturing variations in the inner diameter of the core 2 .

Although FIG. 2 shows a configuration in which the number of the cored bar pieces 43 is six and each of the cored bar pieces 43 is provided with four protrusions 47, the configuration is not limited to this. It suffices that the inner peripheral surface 22a of each core 2 is configured such that the plurality of protrusions 47 are in contact with each other. Therefore, for example, the number of core metal pieces 43 may be 12, which is the same as the number of cores 2 , and each core metal piece 43 may be provided with two or more projections 47 . Moreover, the arc-shaped diameter of the tip surface 47a of the protrusion 47 is arbitrary.

The pressurizing mechanism 45 has a pair of pressurizing plates 45a that can move in a direction toward each other. It corrects the positions of both ends. The welding unit 46 is for welding and fixing the welding surfaces of both ends of the stator core 3 .

Next, a stator manufacturing method using the stator manufacturing apparatus according to the first embodiment will be described.

FIG. 3 is a flow chart showing the stator manufacturing method according to the first embodiment. FIG. 4 is a diagram showing the connecting core before shape correction in the stator manufacturing method according to the first embodiment. FIG. 5 is a diagram showing the state of step S2 in FIG. FIG. 6 is a diagram showing the state of step S3 in FIG. FIG. 7 is a diagram showing the state of step S4 in FIG. FIG. 8 is a diagram showing the state of step S5 in FIG. FIG. 9 is an explanatory diagram of step S6 in FIG. 3 and is a side view of the stator core.

In step S1, the diameter of the outer shell retainer 42 is expanded and the diameter of the core metal 44 is decreased to form an arrangement space S (see FIG. 5) between the outer shell retainer 42 and the core metal 44. As shown in FIG. In step S2, as shown in FIG. 5, the connected core 200 before shape correction shown in FIG. 4 is arranged in the arrangement space S formed in step S1. The connecting core 200 is arranged in an open state without being joined at both ends. The above is the arrangement process.

In step S3, as shown in FIG. 6, the core is adjusted so that the diameter of an imaginary circle L connecting the vertices of the protrusions 47 of the core metal 44 is the set diameter preset as the inner diameter of the stator core 3 of the finished product. The gold 44 is expanded. In step S4, as shown in FIG. 7, the diameter of the outer shell retainer 42 is reduced to move the pressing pieces 41 radially inward, and the pressing pieces 41 press the outer peripheral surface of the core 2 radially inward. . Thereby, each core 2 is clamped between each pressing piece 41 and each protrusion 47 of each core metal piece 43 to correct the posture of each core 2 . The action of each protrusion 47 of the cored bar 44 during clamping will be described later.

The number of pressing pieces 41 of the outer shell retainer 42 is 10 while the number of cores 2 is 12, and there are no pressing pieces 41 corresponding to the cores 2a at both ends. Therefore, in step S3, the postures of ten cores 2 excluding the cores 2a at both ends are corrected. By correcting the positions of the ten cores 2 to the proper positions, the bending angle of the thin connecting portion 23, that is, the angle formed by the opposing surfaces of the back yoke portions 21 of the two adjacent cores 2, becomes the proper angle. corrected to Thereby, the connecting core 200 is formed in a generally annular shape. However, since the positions of the cores 2a at both ends are not corrected, a gap 48 is formed between the cores 2a at both ends as shown in FIG.

In step S5, as shown in FIG. 8, a pair of pressure plates 45a of the pressure mechanism 45 presses the stepped portions 24 of the cores 2a at both ends to form the connecting core 200 in an annular shape. As a result, the cores 2a adjacent to each other at both ends are in close contact with each other, so that the entire connecting core 200 is formed in an annular shape, and the roundness is ensured. The above is the posture correcting process.

Then, in the welding process of step S6, the welding surface 51 is welded by the welding unit 46 as shown in FIG. The weld is spot welded as shown at weld point 50 .

If the roundness of the connecting core 200 is not ensured at the stage before welding, in other words, if the bending angle of the thin connecting portion 23 is not appropriate, the connecting core 200 does not become annular, and the connecting core 200 It tends to be a teardrop shape with both ends of .

In order to weld both ends of the connecting core 200 in such a drop-shaped state, it is necessary to correct the shape by the pressure mechanism 45 so that the stator core 3 becomes annular. Since only the thin connecting portion 23 of the portion is bent excessively, the circularity is deteriorated. Further, if the shape of the connecting core 200 is forcibly corrected by the pressing mechanism 45 , the reaction force in the opening direction increases at both ends of the connecting core 200 . In this way, when both ends of the connecting core 200 whose roundness is not ensured are welded before welding, the welding surface 51 is welded from top to bottom to reduce the welding area. It is necessary to increase the size and secure the fixing strength. As a result, the iron loss increases due to an increase in the welding area, resulting in a problem of a decrease in motor efficiency.

On the other hand, in Embodiment 1, the circularity of the connecting core 200 is ensured before welding. Therefore, when fixing both ends of the connecting core 200 to each other, it is possible to reduce the fixing strength, and it is possible to sufficiently fix them by spot welding. Therefore, the welding area can be reduced, and iron loss can be reduced, so that a motor with good efficiency can be provided.

After the above welding process is finished, finally, in step S7, the stator core 3 is taken out from the manufacturing apparatus.

Here, the operation of the protrusions 47 provided on the core piece 43 will be described. In Embodiment 1, a plurality of protrusions 27 are provided for each core 2 . In the following, the action of the projecting portion 27 will be described by comparing the structure of the first embodiment with the conventional structure when the diameter of the inner peripheral surface of the stator core 3 is larger and smaller than the set diameter. . The conventional structure is a structure in which a plurality of protrusions are not formed on the core piece, and the outer peripheral surface of the core piece has an arc shape with a set diameter preset as the inner diameter of the stator core 3 .

FIG. 10 is a diagram showing a clamped state of the core of the comparative example, and is a diagram when the inner diameter of the stator core is larger than the set diameter. FIG. 11 is a diagram showing a state in which the core is clamped in the stator manufacturing apparatus according to Embodiment 1, and is a diagram when the inner diameter of the stator core is larger than the set diameter. FIG. 12 is a diagram showing a clamped state of the core of the comparative example, and is a diagram when the inner diameter of the stator core is smaller than the set diameter. FIG. 13 is a diagram showing a state in which the core is clamped in the stator manufacturing apparatus according to Embodiment 1, and is a diagram when the inner diameter of the stator core is smaller than the set diameter.

The inner diameter of the stator core 3 may become larger than the set diameter within the range of manufacturing variation. In this case, in the conventional structure, as shown in FIG. 10, the outer peripheral surface 143a of the core piece 143 contacts the inner peripheral surface 22a of the core 2 at one point. Therefore, since the core 2 is supported at two points in which the radial ends are supported by the outer shell presser 142 and the core piece 143, there is a possibility that the position of the core 2 may be displaced in the circumferential direction. can't

In contrast, in Embodiment 1, a plurality of protrusions 47 are provided for one core 2 . Therefore, during clamping, as shown in FIG. 11, a plurality of projections 47 are in contact with the inner peripheral surface 22a of the core 2. As shown in FIG. Therefore, the core 2 is supported at three or more points by the plurality of projecting portions 47 and the outer shell retainer 42, and can be stably clamped.

Also, the inner diameter of the core 2 may be smaller than the set diameter within the range of manufacturing variation. In this case, in the conventional structure, as shown in FIG. 12, the outer peripheral surface 143a of the core piece 143 contacts the corners 22b of the inner peripheral surface 22a of the core 2 at both ends in the circumferential direction. In this case, since it is supported at three points, although it is effective in preventing positional deviation in the circumferential direction, the core 2 is buckled due to the pressure during clamping, and the posture of the core 2 is not stable.

In contrast, in Embodiment 1, as shown in FIG. 13 , the plurality of projections 47 are arranged on the inner peripheral surface of the core 2 at positions closer to the inner side than both ends of the inner peripheral surface 22a of the core 2 in the circumferential direction. 22a. Therefore, the position of the core 2 can be corrected without causing buckling of the core 2 .

In the above description, the manufacturing method in which the stator core 3 is a connected core has been described, but the stator core 3 may be composed of split cores as described above. In the method of manufacturing the stator core 3 composed of split cores, the number of pressing pieces 41 of the outer shell retainer 42 is 12, which is the same as the number of the cores 2, and the core 2 is held by the pressing pieces 41 and the core metal pieces 43 of the core metal 44. It should be clamped. Further, in the welding process of the method of manufacturing the stator core 3 composed of split cores, the contact surfaces of the split cores may be spot-welded by the welding unit 46 .

In the above description, both the outer shell retainer 42 and the core bar 44 are configured to be expandable and contractible, but only one of them may be configured to be expandable and contractible. In short, it is sufficient that the core 2 is clamped by moving one or both of the outer shell retainer 42 and the core bar 44 toward each other.

Also, in the above example, two protrusions 47 are provided for one core.

The stator manufacturing apparatus according to the first embodiment includes an annular core metal 44 having a plurality of projecting portions 47 projecting outward from an outer peripheral surface 43 a , and an outer peripheral side of the core metal 44 spaced apart from the core metal 44 . An annular outer shell retainer 42 arranged with a space is provided. A plurality of cores 2 arranged between the mandrel 44 and the outer shell retainer 42 are clamped by the plurality of projecting portions 47 of the mandrel 44 and the outer shell retainer 42 for each core 2 to clamp each core 2. It corrects posture.

As described above, the outer peripheral surface 43a of the core bar 44 has a plurality of protrusions 47 for one core, and the core 2 is clamped by the plurality of protrusions 47 and the outer shell retainer 42, so that the core is Correction can be performed appropriately, and as a result, the circularity of the stator core 3 can be ensured. In addition, if the stator core 3 is a connected core, by improving the circularity of the stator core 3, the stress in the opening direction of both ends during manufacturing is reduced, so that the welding area can be reduced. Therefore, it is possible to provide an apparatus capable of reducing iron loss and manufacturing a motor with high efficiency.

The plurality of projecting portions 47 contact the inner peripheral surface 22a of the core 2 at positions closer to the inside than the corners 22b at both ends in the circumferential direction of the inner peripheral surface 22a of the core 2 during clamping. As a result, buckling of the core 2 due to pressure during clamping can be prevented.

The stator 1 of Embodiment 1 described above is installed in, for example, an outdoor unit of an air conditioner, and is used as a stator of a fan motor that rotates a blower that takes in outside air and sends out conditioned air. Alternatively, for example, the stator 1 of the first embodiment is used as a stator of a compressor motor built in a hermetic compressor to drive a compressor mechanism.

Reference Signs List 1 stator 2 core 2a core 3 stator core 4 stator manufacturing apparatus 21 back yoke portion 22 tooth portion 22a inner peripheral surface 22b corner portion 23 thin connecting portion 24 stepped portion 41 pressing piece 42 outside Shell retainer 43 Core metal piece 43a Peripheral surface 44 Core metal 45 Pressure mechanism 45a Pressure plate 46 Welding unit 47 Protrusion 47a Tip surface 48 Gap 50 Welding point 51 Welding surface 142 Outer shell retainer, 143 core bar piece, 143a outer peripheral surface, 200 connecting core, L virtual circle, S arrangement space.

Claims (7)

A stator manufacturing apparatus comprising an annular stator core in which a plurality of cores are arranged in a circumferential shape,
a core metal in which a plurality of core metal pieces protruding outward from an outer peripheral surface and having a plurality of arc-shaped protrusions on the tip surface are arranged in a circumferential shape ;
an outer shell retainer, which is arranged on the outer peripheral side of the core bar at intervals from the core bar and in which a plurality of pressing pieces capable of coming into contact with the outer peripheral surface of the core are arranged at intervals in the circumferential direction;
The plurality of cores arranged between the mandrel and the outer shell retainer are clamped by the plurality of projections of the mandrel piece and the holding piece to adjust the posture of each core . Equipment for manufacturing straightened stators. 2. The manufacturing of the stator according to claim 1, wherein the plurality of protrusions contact the inner peripheral surface of the core at positions closer to the inner side than the corners of both circumferential ends of the inner peripheral surface of the core during the clamping. Device. 3. The stator according to claim 1, further comprising a pressurizing mechanism that presses adjacent two cores of the plurality of cores arranged between the core bar and the outer shell retainer in a direction toward each other. manufacturing equipment. A stator manufacturing apparatus comprising a stator core in which a plurality of cores are arranged in an annular shape,
A core metal in which a plurality of core metal pieces protruding outward from an outer peripheral surface and having a plurality of arc-shaped protrusions on a tip end surface are arranged in a circumferential shape; an arranging step of arranging the plurality of cores between an outer shell holder in which a plurality of holding pieces that can contact the outer peripheral surface of the core are arranged at intervals in the circumferential direction;
The core metal and the outer shell retainer are moved toward each other, and the plurality of cores are clamped by the plurality of projections of the core metal piece and the pressing piece for each core , thereby clamping each core. a posture correction step of correcting the posture of the stator. The plurality of cores are connected cores in which the cores adjacent in the circumferential direction are connected by a connecting portion and bent at the connecting portion,
In the arranging step, the connecting core is arranged in an open state without being joined at both ends,
After the posture correcting step, pressing the both ends of the connecting core in a direction toward each other to close the both ends;
5. The method of manufacturing a stator according to claim 4 , further comprising a welding step of welding the contact surfaces of the both ends of the connecting core whose both ends are closed. the plurality of cores are split cores separated from each other;
5. The method of manufacturing a stator according to claim 4 , further comprising a welding step of welding the contact surfaces of the split cores after the posture correcting step. 7. The method of manufacturing a stator according to claim 5 , wherein spot welding is performed in said welding step.

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