Method of manufacturing cores for rotary electric machines

• US 6,658,721 B2
• Filed: 02/14/2001
• Issued: 12/09/2003
• Est. Priority Date: 09/30/1996
• Status: Expired due to Fees

• Current Assignee: Matsushita Electric Industrial Company Limited (Panasonic Holdings Corporation)
• Original Assignee: Matsushita Electric Industrial Company Limited (Panasonic Holdings Corporation)
• Inventors: Okamoto, Manabu, Kato, Hisataka, Kazama, Katsutoshi, Takinami, Kadai
• Primary Examiner(s): Vidovich, Gregory
• Assistant Examiner(s): Kenny, Stephen
• Application Number:
  US09/782,252
• Publication Number:
  US 20010005933A1
• Time in Patent Office: 1,028 Days
• Field of Search: 295/96, 295/98, 296/06, 296/07, 296/09, 310/154, 310/156, 310/254, 310/216
• 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 method for manufacturing a core for rotary electric machines comprising:

assembling a plurality of core segments by laminating core division sheets each comprising a tee-shaped portion having yokes;

assembling a serial core segment assembly having two ends by coupling adjacent core segments with one another;

molding resin on a circumferential surface of each core segment of the serial core segment assembly, said circumferential surface extending along a circumference of each core segment to an end of each yoke, said end not having resin molded on a surface portion extending between said circumferential surfaces;

forming 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 yokes of core segments located at both ends of the serial core segment assembly are brought into contact with one another to form abutting ends; and

coupling the abutting ends of the serial core segment assembly with each other by welding the molded resin located on the circumferential surfaces of the abutting ends of the serial core segment assembly.

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

assembling a plurality of core segments by laminating core division sheets each comprising a tee-shaped portion having yokes;

molding resin on a circumferential surface of each core segment, said circumferential surface extending along a circumference of each core segment to an end of each yoke, said end not having resin molded on a surface portion extending between said circumferential surfaces;

assembling a serial core segment assembly having two ends by coupling adjacent said core segments having resin molded thereon with one another;

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

coupling the abutting ends of the serial core segment assembly with each other by welding the molded resin located on the circumferential surfaces of the abutting ends of the serial core segment assembly.

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

assembling a plurality of core segments by laminating core division sheets each comprising a tee-shaped portion; and

forming a magnetic circuit by assembling a serial core segment assembly having two ends 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, wherein;

the ends of the serial core segment assembly are coupled with each other by engaging a first coupling portion formed at one end of the serial core segment assembly with a second coupling 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 ends of the serial core segment assembly into overlapping engagement with each other by simultaneously moving the ends in both radial and circumferential directions of the serial core segment assembly while in the annular form.

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

assembling a plurality of core segments by laminating core division sheets each comprising a tee-shaped portion; and

forming a magnetic circuit by assembling a serial core segment assembly having two ends 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, wherein;

the ends of the serial core segment assembly are coupled with each other by engaging a first coupling portion formed at one end of the serial core segment assembly with a second coupling 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 ends of the serial core segment assembly into contact with each other by locating in alternating sequence core division sheets of respective ends of the first and second coupling portions.

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; 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,

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 coupling 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.

6. A method for manufacturing a core for rotary electric machines according to claim 5, wherein the serial core segment assembly, which is bent into an annular form to form a magnetic circuit, comprises coupling locations located along an outer circumference of the serial core segment assembly.

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

assembling a plurality of core segments by laminating core division sheets each comprising a tee-shaped portion;

coupling adjacent core segments with each other using a coupling pin to form a serial core segment assembly and bending the serial core segment assembly into an annular form by deforming the coupling pin and bringing the yokes of the core segments located at both the ends of the serial core segment assembly into contact with each other to form a magnetic circuit.

8. A method for manufacturing a core for rotary electric machines according to claim 7 wherein the serial core segment assembly, which is bent into an annular form to form a magnetic circuit, comprises coupling locations located along an outer circumference of the serial core segment assembly.

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

assembling a plurality of core segments by laminating core division sheets each comprising a tee-shaped portion; and

forming a magnetic circuit by assembling a serial core segment assembly having two ends 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, wherein;

the ends of the serial core segment assembly are coupled with each other with a coupler located between both ends 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 yokes of core segments located at both ends of the serial core segment assembly into contact with each other, and

the coupling device comprises a coupling pin.

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

assembling a plurality of core segments by laminating core division sheets each comprising a tee-shaped portion;

assembling a serial core segment assembly having two ends by coupling adjacent core segment with one another;

mounting an insulator made of resin on each of the core segments of the serial core segment assembly;

forming 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 yokes of core segments located at both ends of the serial core segment assembly are brought into contact with each other; and

coupling both the ends of the serial core segment assembly with each other by welding the insulators located at both ends of the serial core segment assembly.

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

assembling a plurality of core segments by laminating core division sheets each comprising a tee-shaped portion;

forming a magnetic circuit by assembling a serial core segment assembly having two ends 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, wherein

the ends of the serial core segment assembly are coupled with each other by engaging a first coupling portion formed at one end of the serial core segment assembly with a second coupling 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 ends of the serial core segment assembly into contact with each other; and

coupling both 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 an outside surface of said forcibly expanded concavity.