Method of manufacturing cores for rotary electric machines

• US 20010005933A1
• Filed: 02/14/2001
• Published: 07/05/2001
• Est. Priority Date: 09/30/1996
• Status: Active Grant

• Current Assignee: Matsushita Electric Industrial Company Limited (Panasonic Holdings Corporation)
• Original Assignee: Matsushita Electric Industrial Company Limited (Panasonic Holdings Corporation)
• Inventors: Kato, Hisataka, Kazama, Katsutoshi, Takinami, Kadai, Okamoto, Manabu
• Granted Patent: US 6,658,721 B2
• Time in Patent Office: Days
• US Class Current: 29/596
• CPC Class Codes: H02K 1/12 Stationary parts of the magnetic circuit
• CPC Class Codes: H02K 1/148 Sectional cores H02K1/141 takes precedence
• CPC Class Codes: H02K 15/02 of stator or rotor bodies
• CPC Class Codes: H02K 15/022 with salient poles or claw-shaped poles
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine
• CPC Class Codes: Y10T 29/49078 Laminated

Abstract

A stator core which assures a favorable workability for coupling core segments and has favorable magnetic characteristics even when made by coupling core segments that are formed by laminating core division sheets. A method of manufacturing a core for rotary electric machines includes forming a coupling convexity having an arc-like planar shape and a coupling concavity engageable with the coupling convexity on core segments, forming a serial core segment assembly by engaging the coupling convexity on one of the core segments with the coupling concavity formed on an adjacent core segment so as to be rotatable by more than 180 degrees, and forming a magnetic circuit by bending the serial core segment assembly into an annular form.

Claims

1. A manufacturing method of a core for rotary electric machines comprising:

a step to compose a plurality of core segments by laminating core division sheets on which tees are formed; and

a step to form a magnetic circuit by composing a serial core segment assembly by coupling adjacent core segments with one another, bending the serial core segment assembly into an annular form so that yokes of all the adjacent core segments are brought into contact with one another and bringing yokes of core segments located at both ends of the serial core segment assembly into contact with each other.

2. A manufacturing method of a core for rotary electric machines according to

claim 1

wherein the adjacent core segments are coupled with each other, at the stage to compose the serial core segment assembly by coupling the adjacent core segments with one another, at a location which is to constitute an outer circumference when a magnetic circuit is formed by bending the serial core segment assembly into the annular form.

3. A manufacturing method of a core for rotary electric machines according to

claim 1

wherein both the ends of the serial core segment assembly are fixed to each other by welding or cementing after the magnetic circuit is formed by bending the serial core segment assembly into the annular form and bringing yokes of core segments located at both the ends of the serial core segment assembly into contact with each other.

4. A manufacturing method of a core for rotary electric machines according to

claim 1

wherein both the ends of the serial core segment assembly are coupled with each other with a coupling device after the magnetic circuit is formed by bending the serial core segment assembly into the annular form and bringing yokes of core segments located at both the ends of the serial core segment assembly into contact with each other.

8. A manufacturing method of a core for rotary electric machines according to

claim 1

wherein both the ends of the serial core segment assembly are coupled with each other by engaging a first engaging portion formed at one end of the serial core segment assembly with a second engaging portion formed at the other end of the serial core segment assembly after the magnetic circuit is formed by bending the serial core segment assembly into the annular form and bringing both the ends of the serial core segment assembly into contact with each other.

9. A manufacturing method of a core for rotary electric machines according to

claim 8

wherein the first and second engaging portions are engaged by overlapping them in a radial direction of the serial core segment assembly bent in the annular form.

10. A manufacturing method of a core for rotary electric machines according to

claim 8

wherein the first and second engaging portions are engaged by overlapping the serial core segment assembly in a laminated direction of the core division sheets.

14. A manufacturing method of a core for rotary electric machines according to

claim 1

or

2

configured to engage a coupling convexity which is formed on one of adjacent core segments and has an arc-like tip in a planar shape thereof with the other core segment rotatably over 180 degrees so that an arm connecting a root to a tip of a convexity for coupling core segments is not plastically deformed at the stages to compose a serial core segment assembly by engaging the coupling convexity formed on one of the adjacent core segment with the other core segment, and to form the magnetic circuit by bending the serial core segment assembly into the annular form and bringing the yokes of the core segments located at both the ends of the serial core segment assembly into contact with each other.

15. A manufacturing method of a core for rotary electric machines according to

claim 1

or

2

configured to engage a coupling convexity which is formed on one of adjacent core segments and has an arc-like tip in a planar shape thereof with the other core segment rotatably within a defined range over 180 degrees and allow an arm connecting a root to a tip of the coupling convexity on the core segment to be plastically deformed in the course to bend the serial core segment assembly into the annular form at the stages to compose the serial core segment assembly by engaging the coupling convexity formed on one of the adjacent core segments with the other core segment, and to form the magnetic circuit by bending the serial core segment assembly into the annular form and bringing the yokes of the core segments located at both the ends of the serial core segment assembly into close contact with each other.

16. A manufacturing method of a core for rotary electric machines according to

claim 1

or

2

configured to fit a coupling convexity formed on one of adjacent core segments into the other core segment and allow an arm connecting a root to a tip of the coupling convexity on the core segment to be plastically deformed in the course to bend the serial core segment assembly into the annular form at the stages to compose the serial core segment assembly by engaging the coupling convexity formed on one of the adjacent core segment with the other core segment, and to form the magnetic circuit by bending the serial core segment assembly into the annular form and bringing the yokes of the core segments located at both the ends of the serial core segment assembly into contact with each other.

17. A manufacturing method of a core for rotary electric machines according to

claim 1

or

2

configured to engage an arc-shaped tip of a coupling convexity formed on one of adjacent core segments with an arc-shaped coupling concavity formed in the other core segment and press or insert the coupling convexity toward depth of the coupling concavity at the stages to compose the serial core segment assembly by engaging the coupling convexity formed on one of the adjacent core segments with the other core segment, and to form the magnetic circuit by bending the serial core segment assembly into the annular form and bringing the yokes of the core segments located at both the ends of the serial core segment assembly into contact each other.

18. A manufacturing method of a core for rotary electric machines according to

claim 1

or

2

configured to couple adjacent core segments with each other using a coupling pin and bend the serial core segment assembly into the annular form by deforming the coupling pin at the stages to compose the serial core segment assembly by engaging the coupling convexity formed on one of the adjacent core segments with the other core segment, and to form the magnetic circuit by bending the serial core segment assembly into the annular form and bringing the yokes of the core segments located at both the ends of the serial core segment assembly into contact with each other.

19. A manufacturing method of a core for rotary electric machines according to

claim 4

wherein the coupling device is a coupling pin.

20. A manufacturing method of a core for rotary electric machines according to

claim 1

configured to form a magnetic circuit by continuously winding a wire in series over a plurality of tees of a serial core segment assembly and bending the serial core segment assembly having the continuous windings into an annular form.

21. A manufacturing method of a core for rotary electric machines according to

claim 1

configured to fix by welding a portion which is to constitute an outer circumference of a coupled portion between both ends of a serial core segment assembly after the magnetic circuit is formed by bending the serial core segment assembly into the annular form and bringing the yokes of the core segments of the serial core segment assembly into contact with each other.

23. A manufacturing method of a core for rotary electric machines according to

claim 8

configured to couple both the ends of the serial core segment assembly by forcibly expanding a concavity formed at one end of the serial core segment assembly, inserting a convexity formed at the other end of the serial core segment assembly into said forcibly expanded concavity in a radial direction of the serial core segment assembly bent in the annular form and then applying a pressure to outside said forcibly expanded concavity.

5. A manufacturing method of a core for rotary electric machines comprising:

a step to compose a plurality of core segments by laminating core division sheets on which tees are formed;

a step to mold resin on surfaces of the core segments except end surfaces of yokes;

a step to compose a serial core segment assembly by coupling adjacent core segments with one another;

a step to form a magnetic circuit by bending the serial core segment assembly into an annular form so that yokes of all the adjacent core segments are brought into contact with one another and bringing yokes of core segments located at both ends of the serial core segment assembly into contact with one another; and

a step to couple both the ends of the serial core segment assembly by welding the molded material at both the ends of the serial core segment assembly.

6. A manufacturing method of a core for rotary electric machines comprising:

a step to compose a plurality of core segments by laminating core division sheets on which tees are formed;

a step to compose a serial core segment assembly by coupling adjacent core segments with one another;

a step to mold resin on surfaces except end surfaces of yokes of the core segments of the serial core segment assembly;

a step to form a magnetic circuit by bending the serial core segment assembly into an annular form so that yokes of all the adjacent core segments are brought into contact with one another and bringing yokes of core segments located at both ends of the serial core segment assembly into contact with each other; and

a step to couple both the ends of the serial core segment assembly with each other by welding the molded material at both the ends of the serial core segment assembly.

7. A manufacturing method of a core for rotary electric machines comprising:

a step to compose a plurality of core segments by laminating core division sheets on which tees are formed;

a step to compose a serial core segment assembly by coupling adjacent core segments with one another;

a step to form a magnetic circuit by bending the serial core segment assembly into an annular form so that yokes of all the adjacent core segments are brought into contact with one another and bringing yokes of core segments located at both ends of the serial core segment assembly into contact with each other; and

a step to couple both the ends of the serial core segment assembly by molding resin on the serial core segment assembly bent in the annular form.

11. A core for rotary electric machines having a magnetic circuit which is formed by composing a plurality of core segments by laminating core division sheets on which tees are formed, composing a serial core segment assembly by coupling adjacent core segments with one another, bending the serial core segment assembly into an annular form so that yokes of all the adjacent core segments are brought into contact with one another and bringing yokes of core segments located at both ends of the serial core segment into contact with each other,

wherein coupling portions for coupling the adjacent core segments with one another are formed on end surfaces of the yokes of the core segments over an entire region in a laminated direction of the core segments.

12. A core for rotary electric machines having a magnetic circuit which is formed by composing a plurality of core segments by laminating core division sheets on which tees are formed, composing a serial core segment assembly by coupling adjacent core segment with one another, bending the serial core segment assembly so that yokes of all the adjacent core segments are brought into contact with one another and bringing yokes of core segments located at both ends of the serial core segment assembly into contact with each other,

wherein coupling portions for coupling the adjacent core segments are formed on end surfaces of the yokes within a partial region in a laminated direction of the core segments.

13. A core for rotary electric machines according to

claim 12

wherein as coupling portions for coupling adjacent core segments with one another concavities are formed on end surfaces of the yokes of the core segments over an entire region in the laminated direction of the core division sheets and convexities are formed on the other end surfaces in the laminated direction of the core division sheets at locations corresponding to said concavities.

22. A manufacturing method of a core for rotary electric machines comprising:

a step to compose a plurality of core segments by laminating core division sheets on which tees are formed;

a step to compose a serial core segment assembly by coupling adjacent core segment with one another;

a step to mount an insulator made of resin on each of the core segments of the serial core segment assembly;

a step to form a magnetic circuit by bending the serial core segment assembly into an annular form so that yokes of all the adjacent core segment are brought into contact with one another and bringing yokes of core segments located at both ends of the serial core segment assembly into contact with each other; and

a step to couple both the ends of the serial core segment assembly with each other by welding the insulators located at both the ends of the serial core segment assembly