Method of manufacturing cores for rotary electric machines

Details Method of manufacturing cores for rotary electric machines Method of manufacturing cores for rotary electric machines

2001-02-14

2003-12-09

Vidovich, Gregory (Department: 3726)

Metal working

Method of mechanical manufacture

Electrical device making

C310S216006

Reexamination Certificate

active

06658721

ABSTRACT:

FIELD OF THE INVENTION
The present invention relates to a manufacturing method of a core for rotary electric machines which is composed of laminated magnetic steel sheets.
BACKGROUND OF THE INVENTION
Among the conventional methods for manufacturing stator cores for rotary electric machines, there is a first method by which a cylindrical core is manufactured by punching out annular sheet cores by press work and laminating these sheet cores.
This first manufacturing method by which the annular sheet cores are punched out by the press work produces waste portions inside and outside of the sheet cores, thereby lowering yield.
A second manufacturing method, which improves the yield, is illustrated in FIGS.
20
(
a
) through
20
(
d
).
According to the second method, a core division sheet
1
which has an engaging concavity
1
a
and an engaging convexity
1
b
as shown in FIG.
20
(
a
) is first punched out by press work. A core segment
2
is composed by laminating such core division sheets
1
as shown in FIG.
20
(
b
), the engaging convexity
1
b
of the core segment
2
is positioned against one end of the engaging concavity
1
a
of an adjacent core segment
2
as shown in FIG.
20
(
c
) and the convexity
1
b
is slid or inserted into the concavity
1
a
for coupling the core segments
2
, thereby forming a cylindrical stator core
3
, as shown in FIG.
20
(
d
).
DISCLOSURE OF THE INVENTION
The second manufacturing method by which the divided core sheets
1
are punced out by the press work does not produce waste portions unlike the first manufacturing method and provides a favorable yield, but poses a problem that workability is low at the coupling stage shown in FIG.
20
(
c
). Speaking of a measure to obtain a favorable stator core
3
by lowering magnetic reluctance, it is necessary to reduce clearance between the coupled core segments, including the concavity
1
a
and the engaging convexity
1
b
, so as to eliminate a play among the coupled core segments
2
, but a smaller play will require higher dimensional precision for coupling the core segments
2
.
Further, a stronger inserting force is required at a stage to engage a starting end of the engaging concavity with one end of the engaging convexity and slide the core segment
2
since the engaging convexity is inserted while causing friction not only between the engaging concavity
1
a
and the engaging convexity
1
b
but also over the entire joined surfaces including those of the engaging concavity and the engaging convexity.
A primary object of the present invention is to provide a stator core which allows core segments to be coupled with high workability and has favorable magnetic characteristics even when the stator core is manufactured by punching out core division sheets by press working and coupling core segments formed by laminating the divided core sheets so as to obtain a favorable blanking yield.
A method of manufacturing a core for rotary electric machines according to the present invention is configured to compose serial core segment assembly by coupling a plurality of core segments which are composed of laminated core division sheets, and then form a cylindrical core by bringing both ends of the serial core segment assembly into contact with each other so as to bend it into an annular form.
According to the present invention, it is possible to obtain a stator core which assures a high blanking yield, high workability for core segment coupling and favorable magnetic characteristics.
A method of manufacturing a core for rotary electric machines, according to a first aspect of the present invention, includes forming a plurality of core segments by laminating core division sheets on which tees are formed, forming a serial core segment assembly by coupling adjacent core segments with one another, bend 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, thereby forming a magnetic circuit.
A method of manufacturing a core for rotary electric machines, according to a second aspect of the present invention, includes coupling adjacent core segments with each other at a location which will form an outer circumference when the magnetic circuit is formed by bending the serial core segment assembly into the annular form at the stage to compose the serial core segment assembly by coupling the adjacent core segments with one another.
A method of manufacturing a core for rotary electric machine, according to a third aspect of the present invention, includes fixing both the ends of the serial core segment assembly by welding or cementing them to each other after the magnetic circuit is formed by bending the serial core segment assembly into the annular form and bringing the yokes at both the ends of the serial core segment assembly into contact with each other.
A method of manufacturing a core for rotary electric machine, in accordance with a fourth aspect of the present invention, includes coupling both the ends of the serial core segment assembly with each other using a coupling device 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 located at both the ends of the serial core segment assembly into contact with each other.
A method of manufacturing a core for rotary electric machines, according to a fifth aspect of the present invention, includes laminating core division sheets on which tees are formed, molding resin on surfaces of the core segments except end surfaces of yokes thereof, forming a serial core segment assembly by coupling adjacent core segments with one another, bend the serial core segment assembly into an annular form so that yokes of all adjacent core segments are brought into contact with one another, bring yokes of core segments located at both the ends of the serial core segment assembly into contact with each other for forming a magnetic circuit and coupling both the ends of the serial core segment assembly by welding the molded material at both the ends of the serial core segment assembly.
A method of manufacturing a core for rotary electric machine, according to a sixth aspect of the present invention, includes forming a plurality of core segments by laminating core division sheets on which tees are formed, forming a serial core segment assembly by coupling adjacent core segments with one another, molding resin on the surfaces of the serial core segment assembly except end surfaces of yokes of the core segments, 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, forming a magnetic circuit by bringing yokes of core segments located at both the ends of the serial core segment assembly into contact with each other and 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.
A method of manufacturing a core for rotary electric machines, according to a seventh aspect of the present invention, includes forming a plurality of core segments by laminating core division sheets on which tees are formed, forming 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 adjacent core segments are brought into contact with one another, forming a magnetic circuit by bringing yokes of the core segments disposed at both ends of the serial core segment assembly into contact with each other and couple both the ends of the serial core segment assembly with each other by molding resin on the serial core segment assembly bent in the annular form.
A method of manufacturing a core for rotary electric machines, according to an eighth aspect of the present invention, includes coupling both the ends of the

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