JP-7855390-B2 - Method for manufacturing the core of a rotating electric machine, apparatus for manufacturing the core, and core

JP7855390B2JP 7855390 B2JP7855390 B2JP 7855390B2JP-7855390-B2

Inventors

牧清久
岩永義斗
服部翔
佐藤毅

Assignees

株式会社三井ハイテック

Dates

Publication Date: 20260508
Application Date: 20220331

Claims (9)

In a method for manufacturing a core, which forms part of the rotor or stator of a rotating electric machine, an insulating portion is provided on at least a portion of an iron core body formed by laminating multiple thin sheets of magnetic metal material, The process includes at least a painting step in which the area where the insulating portion is to be installed in the iron core body is isolated from the area other than the area where the insulating portion is to be installed using a predetermined masking mechanism, and then the area where the insulating portion is to be installed is painted. The iron core body comprises an annular yoke portion and a plurality of teeth portions that protrude from the yoke portion and are arranged radially, and the spaces between the yoke portion and adjacent teeth portions are continuous slots in the direction of thin plate lamination. The surfaces of the yoke portion and the teeth portion facing the slot are designated as the planned locations for the insulating portion. The mask mechanism comprises at least two end face mask portions that contact both end faces of the iron core body in the thin sheet stacking direction and can close the opening of the slot in the thin sheet stacking direction, and a radial mask portion that contacts one end face of the iron core body in the radial direction and can close the opening of the slot in the radial direction. The portion of the end face mask portion that contacts the end face of the core body, and the portion of the radial mask portion that contacts one radial end face of the core body, are made of an elastically deformable elastic body. A core manufacturing method characterized in that, in the painting process, the end face mask portion of the mask mechanism closes the opening of the slot in the thin plate stacking direction, the radial mask portion closes the opening of the slot in the radial direction, and further, the elastic body of the end face mask portion and the elastic body of the radial mask portion come into contact to isolate the slot from the outside, then electrodeposition paint is injected into the slot, electrodeposition painting is performed by energizing through the iron core body, and a coating film that will serve as the insulating portion is formed at the planned placement location.
In the method for manufacturing the core of a rotating electric machine according to claim 1, The iron core body is painted through the painting process while being pressed in the thin plate lamination direction by a predetermined pressure jig, A method for manufacturing the core of a rotating electric machine, characterized in that the pressurizing jig is positioned such that it does not cover the contact points of the elastic body at least in the end face mask portion of the mask mechanism of the iron core body, and does not come into contact with the elastic body in the radial mask portion.
In the method for manufacturing the core of a rotating electric machine according to claim 1 or 2, In the mask mechanism, the elastic body of the end face mask portion and the elastic body of the radial mask portion are made of materials that have different degrees of elastic deformation. A method for manufacturing the core of a rotating electric machine, characterized in that when the elastic body of the end face mask portion and the elastic body of the radial mask portion come into contact during the painting process, each elastic body undergoes elastic deformation such that one bites into the other relative to the other.
In the method for manufacturing the core of a rotating electric machine according to any one of the above claims 1 to 3, The radial mask portion of the mask mechanism is formed to be larger than the dimensions of the iron core body in the thin plate lamination direction, A method for manufacturing the core of a rotating electric machine, characterized in that, in the painting process, when the radial mask portion of the mask mechanism closes the radial opening of the slot, the elastic body of the radial mask portion contacts one radial end face of the iron core body while protruding from the iron core body on both sides in the thin plate lamination direction.
In the method for manufacturing the core of a rotating electric machine according to any one of claims 1 to 4, The radial mask portion of the mask mechanism is A lifting post section having a tapered outer or inner circumferential surface and provided to be vertically movable, A plurality of expanding and contracting moving parts are arranged in a ring shape along the outer or inner circumferential surface of the lifting post section, and each part has an inclined surface that contacts the outer or inner circumferential surface. The mask body, which is an elastic body, is attached to the side of the expanding/contracting moving part opposite to the side with the inclined surface, and is capable of contacting one end face in the radial direction of the iron core body, The system includes a biasing means that biases the expanding/contracting moving part toward the lifting post part, The mask body is arranged so as to protrude by a predetermined amount from the portion of the expanding/contracting movement section that faces one radial end face of the iron core body. A method for manufacturing the core of a rotating electric machine, characterized in that, in the painting step, the radial mask portion is positioned opposite one radial end face of the iron core body, the lifting post portion is moved toward the tapered side of the outer or inner circumferential surface to move the expanding/contracting moving portion in contact with the outer or inner circumferential surface toward one radial end face of the iron core body, and the mask body is brought into contact with one radial end face of the iron core body to close the radial opening of the slot.
In the method for manufacturing the core of a rotating electric machine according to any one of claims 1 to 5, The elastic body in at least one of the end face mask portion and the radial mask portion of the mask mechanism has a non-contact portion that is adjacent to the portion that contacts the surface of the iron core body, but does not contact the surface of the iron core body and extends outwards towards the slot side. A method for manufacturing the core of a rotating electric machine, characterized in that, in the painting process, when the elastic body comes into contact with the surface of the iron core body, the non-contact portion of the elastic body, which elastically deforms in response to the pressure on the surface of the iron core body, protrudes into the slot, and the edge of the electrodeposited coating film is substantially chamfered in shape to conform to the shape of the protruding non-contact portion.
In the method for manufacturing the core of a rotating electric machine according to any one of claims 1 to 5, In the end face mask portion of the mask mechanism, the elastic body has a contact portion formed on the part facing the end face in the thin plate lamination direction of the iron core body, located distal to the slot and in contact with the end face, while the proximal side to the slot is a non-contact region that does not contact the end face. A method for manufacturing the core of a rotating electric machine, characterized in that, in the painting process, the contact portion of the elastic body contacts the end face of the iron core body in the direction of thin plate lamination, while in the non-contact region the elastic body is separated from the end face, allowing the electrodeposited paint to come into contact with the end face that overlaps with the non-contact region, and the end of the electrodeposited paint film in the direction of thin plate lamination protrudes by a predetermined amount along the end face that overlaps with the non-contact region.
In a core manufacturing apparatus for producing a core that forms part of the rotor or stator of a rotating electric machine, an insulating portion is provided on at least a portion of an iron core body formed by laminating multiple thin sheets of magnetic metal material, The iron core body is equipped with a masking mechanism that isolates the planned location for the insulating portion from the portion other than the planned location. The iron core body comprises an annular yoke portion and a plurality of teeth portions that protrude from the yoke portion and are arranged radially, and the spaces between the yoke portion and adjacent teeth portions are continuous slots in the direction of thin plate lamination of the iron core body. The surfaces of the yoke portion and the teeth portion facing the slot are designated as the planned locations for the insulating portion. The mask mechanism comprises at least two end face mask portions that contact both end faces of the iron core body in the thin sheet stacking direction and can close the opening of the slot in the thin sheet stacking direction, and a radial mask portion that contacts one end face of the iron core body in the radial direction and can close the opening of the slot in the radial direction. The portion of the end face mask portion that contacts the end face of the core body, and the portion of the radial mask portion that contacts one radial end face of the core body, are made of an elastically deformable elastic body. A core manufacturing apparatus for a rotating electric machine, characterized in that the mask mechanism closes the opening of the slot in the thin plate stacking direction with the end face mask portion, closes the radial opening of the slot with the radial mask portion, and brings the elastic body of the end face mask portion and the elastic body of the radial mask portion into contact to isolate the slot and the planned placement location facing the slot from the outside.
In a core portion that forms part of the rotor or stator of a rotating electric machine, the core body is formed by laminating multiple thin sheets of magnetic metal material, and an insulating portion is provided on at least a part of the core body, The iron core body comprises an annular yoke portion and a plurality of teeth portions that protrude from the yoke portion and are arranged radially, and the spaces between the yoke portion and adjacent teeth portions are continuous slots in the direction of thin plate lamination. The surfaces of the yoke portion and the teeth portion facing the slot are designated as the planned locations for the insulating portion. The insulating portion is formed of a coating film provided by electrodeposition coating, The inner diameter end of the insulating portion is formed in a substantially chamfered shape . The core portion of a rotating electric machine is characterized in that the aforementioned substantially chamfered shape is formed inside the slot .

Description

This invention relates to a method for manufacturing the core portion of a stator or rotor of a rotating electric machine, and more particularly to a manufacturing method for arranging an insulating portion on a portion of the surface of an iron core. In the stators or rotors of rotating electric machines such as electric motors and generators, laminated iron cores are generally used as the cores on which the coils are arranged. These laminated iron cores typically have an annular yoke section and a plurality of teeth sections that protrude from the yoke section and are arranged radially, and the coils are arranged in a wound state on each of the teeth sections of the laminated iron core. In laminated iron cores, it was common practice to apply an insulating film to the surface of the laminated iron core for purposes such as rust prevention and ensuring proper insulation between the laminated iron core and the coil. One specific method for providing an insulating film to the laminated iron core of such conventional designs is electrodeposition coating. Examples of methods for providing an insulating film by electrodeposition coating are disclosed in Japanese Patent Publication No. 5-268738 and Japanese Patent Publication No. 6-327199. Japanese Patent Application Publication No. 5-268738Japanese Patent Application Publication No. 6-327199 This is a schematic diagram of a core manufacturing apparatus according to the first embodiment of the present invention.This is a schematic cross-sectional diagram illustrating a core manufacturing apparatus according to the first embodiment of the present invention.This is a schematic plan view of the upper end face mask portion and the pressure jig removed from the core manufacturing apparatus according to the first embodiment of the present invention.This is an explanatory diagram illustrating the slot closing state by the radial mask portion in a core manufacturing apparatus according to the first embodiment of the present invention.This is a cross-sectional view of the main part of the upper and lower end face mask portion in the core manufacturing apparatus according to the first embodiment of the present invention.This is an enlarged explanatory diagram illustrating the pressing state of the upper end surface of the iron core body by the mask body of the upper end surface mask portion in the core manufacturing apparatus according to the first embodiment of the present invention.This is an enlarged explanatory diagram illustrating the pressing state of the inner circumferential surface of the iron core body by the mask body of the radial mask portion in the core manufacturing apparatus according to the first embodiment of the present invention.Figure 8(a) is a plan view of the core obtained by the core manufacturing method according to the first embodiment of the present invention, and Figure 8(b) is an enlarged view of part A in Figure 8(a).This is an enlarged explanatory diagram illustrating the pressing state of the upper end surface of the iron core body by the mask body of the upper end surface mask portion in a core manufacturing apparatus according to a second embodiment of the present invention.This is a schematic cross-sectional diagram illustrating a core manufacturing apparatus according to a third embodiment of the present invention.This is an explanatory diagram illustrating the slot closing state by the radial mask portion in a core manufacturing apparatus according to a third embodiment of the present invention. (First embodiment of the present invention) The following describes a method for manufacturing the core portion of a rotating electric machine according to the first embodiment of the present invention, based on Figures 1 to 8. In this embodiment, an example of a method for manufacturing the core portion, which forms part of the stator of an electric motor as a rotating electric machine, will be described. In each figure, the core manufacturing method according to this embodiment includes at least a painting step in which the planned location for the insulating portion 15 in the iron core body 11 is isolated from other parts using a predetermined masking mechanism 30, and then painted on the planned location. In this painting step, the slot 13 of the iron core body 11 is isolated from the outside by the masking mechanism 30, electrodeposition paint is injected into the slot 13, and electrodeposition painting is performed by applying current through the iron core body 11, thereby forming a coating 81 that will become the insulating portion 15 on the planned location facing the slot 13. The core manufacturing apparatus 1 to which the core manufacturing method according to this embodiment is applied performs a painting process in which electrodeposition coating is applied to the surface of the iron core body 11 facing each slot 13 of the iron core body 11, which is in a pressurized state by a pressurizing jig 20, where the insulating portion 15 is