阅读说明：本技术 定子的制造方法、定子以及电动机 (Method for manufacturing stator, and motor ) 是由 西川幸男 斋藤光央 野尻尚纪 于 2019-06-20 设计创作，主要内容包括：定子的制造方法包含：调整工序,对包含软磁性合金薄带的层叠组和金属板在内的层叠体的厚度进行调整,其中,该软磁性合金薄带的层叠组在全部或一部分中包含对非晶质合金薄带进行热处理而得到的软磁性合金薄带,该金属板夹持层叠组；绕线工序,将层叠体紧固于基台,在层叠方向上对层叠体的给定部位进行绕线；除去工序,解除层叠体相对于基台的固定,从层叠体的端面除去异物；和紧固工序,再次将层叠体紧固于基台。(The method for manufacturing the stator comprises the following steps: a regulating step of regulating the thickness of a laminate including a stack of soft magnetic alloy ribbons, which includes a soft magnetic alloy ribbon obtained by heat-treating an amorphous alloy ribbon in whole or in part, and a metal plate sandwiching the stack; a winding step of fastening the laminate to the base and winding a predetermined portion of the laminate in the lamination direction; a removing step of removing foreign matter from the end face of the laminate by releasing the fixation of the laminate to the base; and a fastening step of fastening the laminated body to the base again.)

1. A method of manufacturing a stator, comprising:

a regulating step of regulating the thickness of a laminate including a stack of soft magnetic alloy ribbons, which includes a soft magnetic alloy ribbon obtained by heat-treating an amorphous alloy ribbon in whole or in part, and a metal plate sandwiching the stack;

a winding step of fastening the laminate to a base and winding a predetermined portion of the laminate in a lamination direction;

a removing step of removing foreign matter from an end face of the laminate by releasing the fixation of the laminate to the base; and

and a fastening step of fastening the laminated body to the base again.

2. The method of manufacturing a stator according to claim 1,

after the fastening step, foreign matter is removed from the end face of the laminate.

3. The method of manufacturing a stator according to claim 1 or 2,

before the winding process, foreign matter is removed from the end face of the laminate.

4. The method for manufacturing a stator according to any one of claims 1 to 3,

the method for removing foreign matter from the end face of the laminate is a non-contact removal method.

5. The method of manufacturing a stator according to claim 4,

the non-contact removal method is air blowing.

6. The method of manufacturing a stator according to claim 4,

the non-contact removal method is air suction.

7. The method of manufacturing a stator according to claim 4,

the non-contact removal method is adsorption of a magnet.

8. A stator, comprising:

a laminated group of soft magnetic alloy ribbons, which includes, in all or a part thereof, a soft magnetic alloy ribbon obtained by heat-treating an amorphous alloy ribbon;

a metal plate sandwiching the stacked group;

a winding wire that winds a predetermined portion of a laminated body including the laminated group and the metal plate in a laminating direction;

a base that holds the laminate; and

and a fastening mechanism which penetrates the laminated body in the laminating direction and fastens the base and the laminated body.

9. The stator according to claim 8,

the soft magnetic alloy ribbon has a stacking factor of 83 to 99% in the stack.

10. The stator according to claim 8 or 9,

the stack comprises:

a soft magnetic alloy thin strip subjected to heat treatment; and

a thin strip of soft magnetic alloy that has not been heat treated.

11. The jack-up of claim 10, where,

the soft magnetic alloy ribbon that has not been heat-treated is provided in contact with the metal plate.

12. The stator according to any one of claims 8 to 11,

the metal sheet is an electromagnetic steel sheet.

13. The stator according to any one of claims 8 to 12,

the thickness of the laminate is within plus or minus 10% of a predetermined value.

14. An electric motor, comprising:

a stator according to any one of claims 8 to 13; and

and a rotor.

Technical Field

The present disclosure relates to a method of manufacturing a stator in which soft magnetic alloy thin strips are laminated, a stator, and a motor.

Background

In the past, pure iron or electromagnetic steel plates have been generally used for the stator of the motor. In addition, for motors intended to achieve higher efficiency, there is a proposal to form a stator core from a thin ribbon having amorphous and nanocrystalline grains (see, for example, patent document 1).

The stator core of patent document 1 is manufactured by the following steps.

First, an amorphous alloy ribbon produced by a liquid quenching method such as a single roll method or a twin roll method is processed into a predetermined shape by winding, cutting, pressing, etching, and the like.

Next, in order to improve the soft magnetic characteristics of the alloy ribbon, the amorphous alloy ribbon is heat-treated to be crystallized. Thus, a soft magnetic alloy ribbon having nano-crystal grains was produced.

Next, a plurality of soft magnetic alloy thin strips are laminated to produce a stator core. At this time, the stator core is bonded with a resin or molded.

The stator core manufactured through the above steps is used in a motor.

Documents of the prior art

Patent document

Patent document 1: JP-A-6-145917

Disclosure of Invention

However, in the motor of patent document 1, since the resin or the adhesive enters between the layers of the alloy ribbon from the side surface, there is a problem that the lamination factor (lamination factor) becomes small and the efficiency becomes poor.

In order to increase the stacking factor, a laminated body of only soft magnetic alloy thin strips is firmly fastened with bolts. However, this has a problem. This problem will be described in detail below with reference to fig. 15A to 15C.

Fig. 15A to 15C show the vicinity of the fastening portion (portion where the bolt 42 is provided) of the laminated body of the soft magnetic alloy ribbon. Fig. 15A is a sectional view near the fastening portion. Fig. 15B is a partially enlarged sectional view of the vicinity of the fastening portion shown in fig. 15A. Fig. 15C is a top view near the fastening portion shown in fig. 15B.

As shown in fig. 15A, the stacked group 41 of soft magnetic alloy thin strips is fixed by bolts 42. The bolt 42 is inserted through the washer 43 and the through hole 45 and fastened to the leg 44 of the base. After the bolts 42 are fastened, as shown in fig. 15B, the soft magnetic alloy ribbon 46 is in close contact with substantially no gap in the stacking direction (the vertical direction in the figure).

However, as shown in fig. 15B, at the portion not restrained by the washer 43, the soft magnetic alloy thin strip 46 has low rigidity, and thus the gap 48 is formed and tends to be enlarged. At this time, the deformed portion 47 is generated in the soft magnetic alloy thin strip 46 around the gasket 43. The bulge generated by the deformation portion 47 increases toward the end of the soft magnetic alloy ribbon in the lamination direction of the lamination group 41.

As shown in fig. 15C, the soft magnetic alloy ribbon 46 is twisted in the direction of the arrow in the figure due to the rotational force of the washer 43 when the bolt 42 is tightened.

If the degree of the bulging or twisting exceeds the limit of the breakage of the soft magnetic alloy ribbon 46, the soft magnetic alloy ribbon 46 is broken or broken. If a breakage occurs, the magnetic circuit at the time of driving becomes discontinuous, unlike the design. As a result, the magnetic properties are degraded. Further, the fragments generated by the breakage enter the rotating portion, and therefore, the driving of the motor is hindered.

An object of one aspect of the present disclosure is to provide a method of manufacturing a stator, and a motor, which can ensure characteristics and reliability of a motor.

A method of manufacturing a stator according to one aspect of the present disclosure includes: a regulating step of regulating the thickness of a laminate including a stack of soft magnetic alloy ribbons, which includes a soft magnetic alloy ribbon obtained by heat-treating an amorphous alloy ribbon in whole or in part, and a metal plate sandwiching the stack; a winding step of fastening the laminate to a base and winding a predetermined portion of the laminate in a lamination direction; a removing step of removing foreign matter from an end face of the laminate by releasing the fixation of the laminate to the base; and a fastening step of fastening the laminated body to the base again.

A stator according to one aspect of the present disclosure includes: a laminated group of soft magnetic alloy ribbons, which includes, in all or a part thereof, a soft magnetic alloy ribbon obtained by heat-treating an amorphous alloy ribbon; a metal plate sandwiching the stacked group; a winding wire that winds a predetermined portion of a laminated body including the laminated group and the metal plate in a laminating direction; a base that holds the laminate; and a fastening mechanism that penetrates the laminated body in the laminating direction and fastens the base and the laminated body.

An electric motor according to one aspect of the present disclosure includes: a stator according to one aspect of the present disclosure; and a rotor.

According to the present disclosure, the characteristics and reliability of the motor can be ensured.

Drawings

Fig. 1A is a side view of a stator of embodiment 1.

Fig. 1B is a top view of fig. 1A.

Fig. 2 is a flowchart showing an overview of a stator manufacturing process according to embodiment 1.

Fig. 3A is a side view of the stator in the adjustment step of embodiment 1.

Fig. 3B is a top view of fig. 3A.

Fig. 4A is a side view of a stator having a large thickness of the laminate according to embodiment 1.

Fig. 4B is a side view of a stator having a small thickness of the laminate according to embodiment 1.

Fig. 5 is a partial sectional view of a laminated set of soft magnetic alloy thin strips before bolt fastening in embodiment 1.

Fig. 6A is a side view of the stator according to embodiment 1 after releasing the fixation.

Fig. 6B is a top view of fig. 6A.

Fig. 7A is a front view showing an example of a part of an end face of a stacked set of soft magnetic alloy thin strips after the fastening step in embodiment 1.

Fig. 7B is a cross-sectional view of fig. 7A.

Fig. 8 is a cross-sectional view showing an example of a part of an end face of a stacked set of soft magnetic alloy thin strips after the fastening step in embodiment 1.

Fig. 9 is a cross-sectional view showing an example of a part of an end face of a stacked set of soft magnetic alloy thin strips after the fastening step in embodiment 1.

Fig. 10 is a cross-sectional view showing an example of a part of an end face of a stacked set of soft magnetic alloy thin strips after the fastening step of embodiment 1.

Fig. 11A is a front view showing an example of a part of an end face of a stacked set of soft magnetic alloy thin strips after the fastening step in embodiment 1.

Fig. 11B is a cross-sectional view of fig. 11A.

Fig. 12A is a side view of an electric motor using the stator of embodiment 1.

Fig. 12B is a top view of fig. 12A.

Fig. 13A is a side view of an electric motor using the stator of embodiment 2.

Fig. 13B is a top view of fig. 13A.

Fig. 14A is a front view of the stator of embodiment 2 in the vicinity of the fastening portion.

Fig. 14B is a cross-sectional view of fig. 14A.

Fig. 15A is a sectional view of a laminate of conventional soft magnetic alloy ribbons in the vicinity of the fastening portion.

Fig. 15B is a partially enlarged sectional view of fig. 15A.

Fig. 15C is a top view of fig. 15B.

Detailed Description

Hereinafter, embodiments of the present disclosure will be described with reference to the drawings. In addition, the same reference numerals are given to the common components in the drawings, and the description thereof will be omitted as appropriate.

(embodiment mode 1)

Embodiment 1 of the present disclosure will be explained.

< construction of stator >

The structure of the stator 100 of the present embodiment will be described with reference to fig. 1A and 1B. Fig. 1A is a side view of a stator 100 of the present embodiment. Fig. 1B is a top view of fig. 1A.

As shown in fig. 1A, a laminate 1 is formed by a stack 3 of electromagnetic steel sheets 2 (an example of metal sheets) sandwiching a soft magnetic alloy ribbon.

As shown in fig. 1B, the winding 13 is provided to wind an insulated copper wire to a given position of the teeth 14 and to tighten the laminated body 1 in the laminating direction.

As shown in fig. 1A and 1B, the stator 100 fixes the laminated body 1 provided with the winding 13 by the bolts 4. The bolts 4 are inserted through the spring washers 5, the washers 6, and through holes (not shown) of the stacked body 1 and fastened to the legs 7 of the base. In addition, the number of the bolts 4 is, for example, 4. The legs 7 of the base may be simply referred to as a "base".

< Process for producing stator >

The manufacturing process of the stator 100 shown in fig. 1A and 1B will be described with reference to fig. 2. Fig. 2 is a flowchart showing an overview of a manufacturing process of the stator 100.

As shown in fig. 2, the flow includes an adjustment step, a winding step, a removal step, and a fastening step. The outline of each step is described below.

The adjusting step is a step of adjusting the thickness of the laminate 1. In this conditioning step, first, the amorphous alloy ribbon is heat-treated to form a soft magnetic alloy ribbon. Next, a laminated group 3 of a soft magnetic alloy ribbon containing the soft magnetic alloy ribbon entirely or partially is formed. Next, the electromagnetic steel sheets 2 are provided above and below (upper and lower sides in the drawing) the stacked assembly 3 of soft magnetic alloy thin strips to form the stacked body 1. Next, the number of pieces of the soft magnetic alloy ribbon is increased or decreased, and the thickness of the laminated body 1 is adjusted to a desired thickness. The details are described below.

In the winding step, first, the laminated body 1 whose thickness has been adjusted in the adjusting step is fixed to the legs 7 of the base using a fastening mechanism (for example, bolts 4, spring washers 5, washers 6, and the like). Specifically, as described above, the bolt 4 is inserted through the spring washer 5, the washer 6, and the through hole (not shown) of the stacked body 1, and fastened to the leg 7 of the base. Next, winding is performed in the stacking direction of the fixed stacked body 1. Specifically, as described above, the copper wire is wound around a given position of the teeth 14, and the laminated body 1 is tightened in the laminating direction.

In the removal step, first, the bolts 4 are removed to release the fixation of the stacked body 1. Next, foreign matter (for example, powder, chips, or the like) adhering to the end face of the laminate 1 is removed.

In the fastening step, the laminate 1 from which the foreign matter has been removed is fixed to the legs 7 of the base again using the fastening means (e.g., the bolts 4, the spring washers 5, the washers 6, etc.). Specifically, as in the winding process, the bolt 4 is inserted through the spring washer 5, the washer 6, and a through hole (not shown) of the laminated body 1, and fastened to the leg 7 of the base. Thus, the fastening process may also be referred to as a "refastening process".

The outline of each step is described above. The adjustment step, the removal step, and the fastening step will be described in further detail below.

< adjustment step >

The adjustment process will be described with reference to fig. 3A and 3B. Fig. 3A is a side view of the stator 100 in the adjustment process. Fig. 3B is a top view of fig. 3A. Fig. 3A and 3B are different from fig. 1A and 1B in that the winding wire 13 is not applied.

As described above, in the conditioning step, the soft magnetic amorphous alloy ribbon is laminated after heat treatment, so that the laminated group 3 of soft magnetic alloy ribbons is formed as shown in fig. 3A, for example. Alternatively, the laminated group 3 of soft magnetic alloy thin strips shown in fig. 3A may be formed by laminating soft magnetic amorphous alloy thin strips to form the laminated group 3 of soft magnetic alloy thin strips, and then performing heat treatment on the laminated group 3 of soft magnetic alloy thin strips.

The laminated assembly 3 of soft magnetic alloy thin strips is configured to include the soft magnetic alloy thin strips in all or a part thereof. In the case where the laminated group 3 of soft magnetic alloy thin strips includes a soft magnetic alloy thin strip in a part thereof, the remaining part may include an amorphous thin strip that has not been heat-treated.

As described above, in the conditioning step, the electromagnetic steel sheets 2 are sandwiched between the upper and lower surfaces of the stacked assembly 3 of soft magnetic alloy thin strips to form the stacked body 1. Then, the bolts 4 are inserted through the spring washers 5, the washers 6, and the stacked body 1 in the stacking direction, and are fastened to the legs 7 of the base with a predetermined fastening force.

At this time, the soft magnetic alloy ribbon near the fastening portion (the portion where the bolt 4 is provided) is deformed as described with reference to fig. 15B. As a result, the thickness of the laminated body 1 near the spring washers 5 and 6 (hereinafter referred to as the laminated thickness) is reduced, and the laminated thickness other than near the spring washers 5 and 6 is increased.

In addition, when only a portion where the thickness of the soft magnetic alloy thin strip is small is laminated, the lamination thickness is reduced.

< lamination thickness >

Here, a case where the lamination thickness is increased and a case where the lamination thickness is decreased will be described with reference to fig. 4A and 4B. Fig. 4A is a side view of a stator having a large lamination thickness, and fig. 4B is a side view of a stator having a small lamination thickness.

As shown in fig. 4A, the maximum part 8 of the lamination thickness is generated in the vicinity of the middle of 2 bolts 4.

As shown in fig. 4B, the smallest part 9 of the lamination thickness, which is formed by laminating the parts of the soft magnetic alloy thin strip having a small plate thickness, is also formed in the vicinity of the middle of the 2 bolts 4 in many cases. However, since the distribution of the thickness of the soft magnetic alloy thin strip is also dependent, the location where the smallest portion of the lamination thickness occurs is not necessarily determined.

The amount of increase or decrease in the lamination thickness is not necessarily the same in the upper and lower sides of the laminate 1. If the difference between the upper and lower amounts is large, the accuracy of the outer dimensions of the stator deteriorates, and therefore the assembly accuracy of the motor also deteriorates.

When the thickness of the laminate is increased, if the gap between the thin soft magnetic alloy strips is large, the thin soft magnetic alloy strips that are heat-treated and become brittle will exist as single bodies. Therefore, there is also a problem that the soft magnetic alloy ribbon is easily broken.

Such a change in the lamination thickness can be suppressed by the rigidity of the electromagnetic steel sheets 2 provided above and below the laminated group 3 of soft magnetic alloy thin strips.

Since the electrical steel sheets 2 have a limited thickness, when only 1 electrical steel sheet 2 is used and the rigidity and strength are insufficient, a plurality of electrical steel sheets 2 can be stacked.

Instead of the electromagnetic steel sheet 2, another metal sheet may be used. Among them, a soft magnetic metal plate may be used. In the case of using a metal plate other than the soft magnetic metal plate, the copper loss increases and the motor efficiency decreases because the wire becomes long.

Generally, when a stator is manufactured, the lamination thickness is within a plus/minus number%. Further, the gap between the soft magnetic alloy thin strips is set to be several μm or less, thereby preventing the soft magnetic alloy thin strips from being damaged after the heat treatment. Therefore, the variation in the laminate thickness is desirably within plus or minus 10%.

In order to adjust the lamination thickness to within plus or minus 10% of a predetermined specification value, the lamination thickness is adjusted by, for example, repeating selection, combination, and increase and decrease of soft magnetic alloy ribbon having different sheet thickness distributions for the laminate 1 shown in fig. 4A or 4B.

< Stacking factor >

The problem in the adjustment of the laminate thickness described above will be described with reference to fig. 5. Fig. 5 is a partial sectional view of the stack 3 of thin soft magnetic alloy strips before the bolts 4 are tightened during adjustment of the stack thickness.

If the tightening of the bolts 4 is weak, the gaps 12 remain between the layers of the soft magnetic alloy thin strips 22, and the end portions 11 of the soft magnetic alloy thin strips may be deformed and damaged. Therefore, the gap 12 is made as small as possible to prevent the deformation of the end portion 11 due to the vertical movement, displacement, or the like of the soft magnetic alloy thin strip 22.

Although the number of the bolts varies depending on the type of the stator, the fastening force of the bolts 4 needs to be 5N · m or more so as not to cause vertical movement or displacement. In order to improve the motor characteristics, it is necessary to increase the stacking factor, which is the ratio of the soft magnetic alloy ribbon 22 in the soft magnetic alloy ribbon stack 3.

The stacking factor is 77 to 85% in the conventional process, but is increased to 83 to 99% in the removal process and the fastening process of the present embodiment.

The reason why the stacking factor does not reach 100% is considered to be that: the thickness of the soft magnetic alloy thin strips 22 is not constant over the entire surface, and gaps are formed between the soft magnetic alloy thin strips 22, or the soft magnetic alloy thin strips 22 are broken, so that portions where the soft magnetic alloy thin strips 22 are not present are generated within the dimensional specification of the stator 100.

The laminated body 1 whose thickness has been adjusted in the adjusting step as described above is fixed to the legs 7 of the base with a predetermined fastening force by the bolts 4 in the next winding step. Then, as shown in fig. 1A and 1B, the winding wire 13 is wound around a predetermined position of the teeth 14, and the stacked body 1 is tightened in the stacking direction.

< removal step >

The removal step will be described with reference to fig. 6A and 6B. Fig. 6A is a side view of the stator after the winding process. Fig. 6B is a top view of fig. 6A.

In the removal step, as shown in fig. 6A and 6B, all the bolts 4 (see fig. 3A) are removed, and the legs 7 (see fig. 3A) of the base are removed from the stacked body 1. Thereby, the fixation of the laminate 1 is released. Since tightening is performed with the winding 13 even if the fastening by the bolt 4 is released, the laminated body 1 is not disassembled.

Next, as shown in fig. 6A, air 16 is blown from a nozzle 15 at a predetermined pressure onto the end surface (outer circumferential surface) of the stack 3 of soft magnetic alloy thin strips. Air 16 is blown not only to the end face of the stack 3 of soft magnetic alloy thin strips but also to the inner diameter side face and the end face of the tooth 14 to which the winding wire 13 is applied. This enables foreign matter (for example, powder or chips) present on the surface of the stator 100 and between the layers of the soft magnetic alloy thin strip 22 to be removed. The vicinity of the fastening hole 17 shown in fig. 6B is a place where stress generated at the time of fastening is large and foreign matter is particularly likely to be generated.

In the vicinity of the fastening hole 17, the binding force disappears, and therefore the interlayer of the soft magnetic alloy thin strip in the vicinity of the fastening hole 17 is slightly opened. Therefore, even if foreign matter is present between the layers, the foreign matter can be removed more easily than when the bolt 4 is fastened.

The method for removing the foreign matter is not particularly limited. Among them, in the contact-type removing method using a brush, bristles, or the like, the brush, bristles, or the like may peel off and remain as foreign matter on the stator side. Therefore, the above-mentioned non-contact removal method such as blowing of the air 16 is preferable.

As a non-contact removal method other than the blowing of the air 16, for example, a removal method by air suction, a removal method by adsorption of a magnet, or the like is used. Since the powder and the chips are small and the amount thereof is small, the reduction rate of the lamination factor of the stator after the removal step is 1% or less, and the number of the lamination factor hardly changes greatly.

< fastening Process >

The fastening step is the same as the fastening step of the bolt 4 in the adjustment step described above. That is, the bolts 4 are inserted through the spring washers 5, the washers 6, and the stacked body 1 in the stacking direction, and are fastened to the legs 7 of the base with a predetermined fastening force. This completes the production of the stator 100 shown in fig. 1A and 1B.

Since the tightening is performed with a predetermined tightening force in the adjustment step and the foreign matter is removed in the removal step, there is a low possibility that new foreign matter exists in the stator 100 after the tightening step.

After the fastening step, the step of removing foreign matter from the end face of the laminate 1 may be performed again. In this case, the fixation of the laminate 1 is not released.

Further, a step of removing foreign matter from the end face of the laminate 1 may be performed before the winding step. In this case, foreign matter present in the vicinity of the winding 13 can be removed more reliably.

< State of end faces of laminated group >

The state of the end face of the soft magnetic alloy ribbon stack 3 after the fastening step will be described in detail. Fig. 7A is a front view showing an example of a part of an end face of the soft magnetic alloy ribbon stack 3 after the fastening step. Fig. 7B is a cross-sectional view of fig. 7A.

As shown in fig. 7A and 7B, when a thin soft magnetic alloy strip 22a having a substantially uniform thickness and a thin soft magnetic alloy strip 22B having a thin plate thickness are laminated, a gap 23 is formed between these layers. Although not shown, a gap is similarly generated when the soft magnetic alloy thin strip 22a having a substantially uniform thickness and the soft magnetic alloy thin strip having a thick portion are laminated. Generally, the thickness of the soft magnetic alloy thin strip 22 is often 0.02mm to 0.06 mm.

The deviation of the sheet thickness is often set to within plus/minus% of the sheet thickness. In addition, fine irregularities of 1 μm or less are present on the surface of the soft magnetic alloy ribbon 22. In addition, the minute holes may penetrate in the plate thickness direction. In this case, a gap of 0.0001mm to 0.06mm exists in at least a part of the layers of the soft magnetic alloy ribbon 22 on the end face of the soft magnetic alloy ribbon stack 3.

An example of an end face different from the end faces shown in fig. 7A and 7B will be described with reference to fig. 8. Fig. 8 is a cross-sectional view showing an example of a part of an end face of the soft magnetic alloy ribbon stack 3 after the fastening step.

As shown in fig. 8, when the soft magnetic alloy ribbon 24 having a defective end portion exists among the plurality of soft magnetic alloy ribbons 22, a gap 25 is generated at the end face. The maximum gap appearing at the end face corresponds to the plate thickness. However, as shown in fig. 8, when the end portions of the soft magnetic alloy thin strips above and below the gap 25 are inclined toward the gap 25, the gap 25 appearing on the end face becomes narrower than the thickness of the soft magnetic alloy thin strip 22.

In addition, an example of the other end surface will be described with reference to fig. 9. Fig. 9 is a cross-sectional view showing an example of a part of an end face of the soft magnetic alloy ribbon stack 3 after the fastening step.

In the example of fig. 9, a chip 26 is present in a gap 27 between the soft magnetic alloy thin strip 24 with a defective end and the laminated end face (the rightmost end face in the drawing). The chips 26 are not removed by, for example, a removal process.

Even if there are fragments 26 that have not been removed in the removal process, the fragments 26 are less likely to fall off the laminated end face because a compressive force acts in the lamination direction in the subsequent fastening process.

Further, when the removal step is performed after the fastening step as described above, the possibility that the chips 26 will fall off from the laminated end face is further reduced.

In addition, an example of the other end surface will be described with reference to fig. 10. Fig. 10 is a cross-sectional view showing an example of a part of an end face of the soft magnetic alloy ribbon stack 3 after the fastening step.

In the example of fig. 10, there are cracks 28 in 1 of the plurality of thin strips 22 of soft magnetic alloy.

Even if there are cracks 28 or breaks in the soft magnetic alloy ribbon 22, deterioration of the cracks 28 or breaks can be suppressed because a compressive force acts in the lamination direction in the fastening step. Therefore, the possibility that the fragments generated by the crack 28 or the break fall off from the laminated end face is low.

Fig. 11A and 11B are used to describe an example of the other end surface. Fig. 11A is a front view showing an example of a part of an end face of the soft magnetic alloy ribbon stack 3 after the fastening step. Fig. 11B is a cross-sectional view of fig. 11A.

The soft magnetic alloy ribbon 22 becomes hard by heat treatment, but becomes brittle. Therefore, in the manufacturing process of the stator 100, when an object harder than the soft magnetic alloy ribbon 22 hits the end face of the stack 3 of soft magnetic alloy ribbons, for example, as shown in fig. 11A and 11B, a plurality of missing portions 29 may be formed across the soft magnetic alloy ribbon 22.

Powder or chips may remain in the missing portion 29. Among these foreign substances, foreign substances that are likely to fall off from the end faces of the laminate are removed by the above-described removal step. In addition, the breakage in the surface of the deletion portion 29 hardly progresses.

In fig. 11A and 11B, the boundary between the layers of the soft magnetic alloy ribbon 22 is clear at the missing portion 29, but the boundary may not be clear.

< Motor >

A motor 200 using the stator 100 described above will be described with reference to fig. 12A and 12B. Fig. 12A is a side view of the motor 200 using the stator 100. Fig. 12B is a top view of fig. 12A.

As shown in fig. 12A and 12B, the rotor 18 is provided inside the teeth 14 with respect to the stator 100 manufactured through the above-described series of manufacturing steps, thereby completing the motor 200. In the motor 200, when the coil 13 is energized, the rotor 18 is rotationally driven.

In the present embodiment, the description has been given taking the case where the rotor 18 is provided on the inner diameter side of the stator 100 as an example, but the rotor 18 may be provided on the outer circumferential side of the stator 100.

As described above, in the method of manufacturing the stator 100 according to the present embodiment, first, the adjustment step of adjusting the thickness of the laminated body 1 is performed, in which the laminated body 1 includes the laminated group 3 of soft magnetic alloy ribbon and the metal plate (for example, the electromagnetic steel plate 2), the whole or a part of the laminated group 3 of soft magnetic alloy ribbon includes the soft magnetic alloy ribbon 22 obtained by heat-treating the amorphous alloy ribbon, and the metal plate sandwiches the laminated group 3 of soft magnetic alloy ribbon.

Next, a winding step is performed in which the laminate 1 is fastened to a base (for example, the legs 7 of the base), and a predetermined portion of the laminate 1 is wound in the lamination direction.

Next, a removal step of removing foreign matter from the end face of the laminate 1 by releasing the fixation of the laminate 1 to the base is performed.

Next, the fastening step of fastening the laminate 1 to the base is performed again. The stator is manufactured by these steps. The stator is used to manufacture an electric motor.

Therefore, fragments of the soft magnetic alloy ribbon and the like can be prevented from falling off from the end faces of the laminated body. Therefore, the characteristics and reliability of the motor can be ensured.

(embodiment mode 2)

Embodiment 2 of the present disclosure will be explained.

< construction of stator >

The structure of the stator 110 according to the present embodiment will be described with reference to fig. 13A and 13B. Fig. 13A is a side view of the motor 210 of the present embodiment. Fig. 13B is a top view of fig. 13A.

The motor 210 shown in fig. 13A and 13B is the same as the motor 200 according to embodiment 1 shown in fig. 12A and 12B, except that the structure of the laminated body 31 is different.

As shown in fig. 13A and 13B, the laminated body 31 of the present embodiment includes a laminated group 34 of soft magnetic alloy ribbon that has not been heat-treated between the laminated group 33 of soft magnetic alloy ribbon that has been heat-treated and the electromagnetic steel sheet 2.

The soft magnetic amorphous alloy ribbon not subjected to heat treatment had a clear metallic luster. On the other hand, the soft magnetic alloy ribbon subjected to the heat treatment is colored, and the metallic luster is weakened. Therefore, the stack 33 of the soft magnetic alloy thin strips and the stack 34 of the soft magnetic alloy thin strips subjected to the heat treatment can be easily distinguished.

Next, the structure in the vicinity of the fastening portion (the portion where the bolt 4 is provided) of the stator 110 described above will be described with reference to fig. 14A and 14B. Fig. 14A is a front view of the stator 110 near the fastening portion. Fig. 14B is a cross-sectional view of fig. 14A.

The laminated group 34 of soft magnetic alloy thin strips that have not been heat-treated shown in fig. 13A includes 2 pieces of soft magnetic amorphous alloy thin strips 36 that have not been heat-treated shown in fig. 14A and 14B.

The laminated set 33 of soft magnetic alloy thin strips subjected to heat treatment shown in fig. 13A includes a plurality of soft magnetic alloy thin strips 35 shown in fig. 14A and 14B. The soft magnetic alloy ribbon 35 is a soft magnetic alloy ribbon subjected to heat treatment.

As shown in fig. 14A and 14B, the bolt 4 is inserted through the spring washer 5, the washer 6, and the through hole 40. The stacked body 31 shown in fig. 13A is tightened in the stacking direction by the fastening of the bolts 4.

In this case, the tightening force acting on the stacked assembly 34 of the soft magnetic alloy ribbon that has not been heat-treated is strongest directly below the magnetic steel sheet 2. Here, the soft magnetic amorphous alloy ribbon 36 is not easily broken because of its high ductility. Therefore, as shown in fig. 14A and 14B, a soft magnetic amorphous alloy ribbon 36 is preferably disposed directly below the magnetic steel sheet 2. In other words, the soft magnetic amorphous alloy ribbon 36 is preferentially provided in contact with the electromagnetic steel sheet 2.

In the example of fig. 14A and 14B, a case is shown in which a gap 37 exists in the stack 33 of the soft magnetic alloy thin strips subjected to the heat treatment including the soft magnetic alloy thin strip 35, and fragments 38 of the soft magnetic alloy thin strip remain in the gap 37. In this case, as shown in fig. 14A and 14B, the soft magnetic amorphous alloy ribbon 36 is deformed in accordance with the deformation of the end portion of the electromagnetic steel sheet 2. Thereby, the fragments 38 are pressed from the upper side in the drawing and restrained.

When the chips 38 remain after the removal process (removal work by air or magnets), the chips 38 are subjected to a compressive force in the stacking direction in the fastening process, and therefore are less likely to be detached by driving of the motor.

Further, although depending on the size of the gap 37, a gap 39 may remain between the electromagnetic steel sheet 2 and the soft magnetic amorphous alloy ribbon 36 as shown in fig. 14A and 14B.

The number of the soft magnetic amorphous alloy thin strips 36 constituting the soft magnetic alloy thin strip stacked layer 34 that has not been subjected to heat treatment may be 1. The soft magnetic amorphous alloy ribbon 36 can also function as a buffer against breakage even at a position other than a position directly below or directly above the magnetic steel sheet 2 (for example, a position within the stack 33 of soft magnetic alloy ribbons subjected to heat treatment).

The present disclosure is not limited to the description of the embodiments, and various modifications can be made without departing from the scope of the present disclosure.

Industrial applicability

According to the manufacturing method of the stator, the stator and the motor, the characteristics and the reliability of the motor can be ensured. Further, the stator of the present disclosure can be applied to an electronic component for magnetic application such as a transformer, in addition to a motor.

Description of the reference numerals

1 laminated body

2 electromagnetic steel sheet

3 lamination of thin soft magnetic alloy strips

4 bolt

5 spring washer

6 gasket

7 legs of base station

8 maximum part of the lamination thickness

9 minimum part of the stack thickness

10 plus or minus

11 end of the tube

12 gap

13 winding wire

14 teeth

15 spray nozzle

16 air

17 fastening hole

18 rotor

22 soft magnetic alloy thin strip

22a soft magnetic alloy ribbon

22b soft magnetic alloy thin strip

23 gap

24 soft magnetic alloy thin strip

25 gap

26 pieces

27 gap

28 cracks

29 missing part

31 laminated body

33 laminated set of soft magnetic alloy thin strips subjected to heat treatment

34 soft magnetic alloy thin strip not heat treated

35 soft magnetic alloy thin strip

36 soft magnetic amorphous alloy ribbon

37 gap

38 pieces

39 gap

40 through hole

41 stack of thin soft magnetic alloy strips

42 bolt

43 washer

44 legs of base station

45 through hole

46 soft magnetic alloy thin strip

47 deformation part

48 gaps

100 stator

110 stator

200 motor

210 motor.