Motor and motor manufacturing apparatus

Abstract

Flat rolled magnetic steel sheets and strip or a die is turned in the press forming process. Rotor cores are stacked with turning through an angle which is an odd number multiple of about (360°/(number of slots in the motor×natural number n×2) and stator cores are stacked with turning through an angle which is an odd number multiple of (360°/(number of poles in the motor×natural number n×2)). Stacking with turning through an angle which is an odd number multiple converts the phases of cogging torques into mutually opposite phases and cancels and reduces the cogging torque caused by magnetic anisotropy.

1 . A motor manufacturing apparatus for manufacturing a motor equipped with a stacked core, comprising: 
 punching means comprising a punching die, wherein    said punching means forms a plurality of cores with different rolling directions by punching out the flat rolled magnetic steel sheets and strip by turning the flat rolled magnetic steel sheets and strip with respect to the punching die or by turning the punching die with respect to the flat rolled magnetic steel sheets and strip through any angle of the below-described clauses (1) through (5) with respect to the rolling direction of the core:    (1) an angle 1 which is an odd number multiple of about (360°/(number of poles in the motor×natural number n×2)), and/or an angle 2 which is an odd number multiple of about (360°/(number of slots in the motor×natural number n×2));    (2) an angle 1 obtained when the value of said natural number n is selected such that the (number of poles in the motor×natural number n) giving the angle 1 in said clause (1) becomes equal to the number of slots in the motor or close thereto, and/or an angle 2 obtained when the value of said natural number n is selected such that the (number of slots in the motor×natural number n) giving the angle 2 in said clause (1) in said clause (1) becomes equal to the number of poles in the motor or close thereto;    (3) an angle 1 such that the difference between angles which are odd number multiples of (360°/(number of poles in the motor×natural number [n1, n2, . . . ]×2)), for no less than two natural numbers (n1, n2, . . . ), is within a prescribed angle range; and/or an angle 2 such that the difference between angles which are odd number multiples of (360°/(number of slots in the motor×natural number [m1, m2, . . . ]×2)), for no less than two natural numbers (m1, m2, . . . ), is within a prescribed angle range.    (4) an angle 1 obtained when the values of said natural numbers n1 and n2 are selected such that the (number of poles in the motor×natural numbers [n1, n2]) giving the angle 1 in said clause (3) becomes equal to the number of slots in the motor or close thereto, and/or an angle 2 obtained when the values of said natural numbers m1 and m2 are selected such that the (number of slots in the motor×natural number [m1, m2]) giving the angle 2 in said clause (3) becomes equal to the number of poles in the motor or close thereto.    (5) an angle 1′ obtained by subtracting the angle 2 and an angle 3 provided by other means from the angle 1, and/or an angle 2′ obtained by subtracting the angle 1 and an angle 3 provided by other means from the angle 2 in each of said clauses (1) through (4).    
   
   
       2 . A motor manufacturing apparatus for manufacturing a motor equipped with a stacked core, comprising: 
 punching means comprising a punching die, wherein    said punching means forms a plurality of cores with different rolling directions by punching out the flat rolled magnetic steel sheets and strip by skewing continuously the flat rolled magnetic steel sheets and strip with respect to the punching die or by skewing continuously the punching die with respect to the flat rolled magnetic steel sheets and strip at angles obtained by proportionally dividing an angle range of one period by the number of stacked pieces, where any angle of the below-described clauses (1) through (5) is the angle range of one period, or at an angle obtained by adding the angle obtained by shifting by an angle which is an integer multiple of said one period angle to those proportionally divided angles, with respect to the core rolling direction:    (1) an angle 1 which is a natural number multiple of about (360°/(number of poles in the motor×natural number n)), and/or an angle 2 which is a natural number multiple of about (360°/(number of slots in the motor×natural number n));    (2) an angle 1 obtained when the value of said natural number n is selected such that the (number of poles in the motor×natural number n) giving the angle 1 in said clause (1) becomes equal to the number of slots in the motor or close thereto, and/or an angle 2 obtained when the value of said natural number n is selected such that the (number of slots in the motor×natural number n) giving the angle 2 in said clause (1) becomes equal to the number of poles in the motor or close thereto;    (3) an angle 1 such that the difference between angles which are natural number multiples of (360°/(number of poles in the motor×natural number [n1, n2, . . . ])), for no less than two natural numbers (n1, n2, . . . ), is within a prescribed angle range; and/or an angle 2 such that the difference between angles which are natural number multiples of (360°/(number of slots in the motor×natural number [m1, m2, . . . ])), for no less than two natural numbers (m1, m2, . . . ), is within a prescribed angle range.    (4) an angle 1 obtained when the values of said natural numbers n1 and n2 are selected such that the (number of poles in the motor×natural numbers [n1, n2]) giving the angle 1 in said clause (3) becomes equal to the number of slots in the motor or close thereto, and/or an angle 2 obtained when the values of said natural numbers m1 and m2 are selected such that the (number of slots in the motor×natural number [m1, m2]) giving the angle 2 in said clause (3) becomes equal to the number of poles in the motor or close thereto.    (5) an angle 1′ obtained by subtracting the angle 2 and an angle 3 provided by other means from the angle 1, and/or an angle 2′ obtained by subtracting the angle 1 and an angle 3 provided by other means from the angle 2 in each of said clauses (1) through (4).    
   
   
       3 . The motor manufacturing apparatus according to  claim 1  or  2 , wherein 
 said punching die is a progressive die and comprises    a plurality of stations using dies shifted by said prescribed angle, and/or a common station using dies which do not depend on said prescribed angle.    
   
   
       4 . The motor manufacturing apparatus according to  claim 3 , wherein said progressive die comprises a station for punching out cores of two types with respect to a shape with a comparatively small number of cycles per one turn, and/or comprises a station for punching out cores of one type with respect to a shape with a comparatively large number of cycles per one turn.  
   
   
       5 . The motor manufacturing apparatus according to  claim 3 , wherein when said progressive die comprises stations shifted by said prescribed angle, the die comprises a station for rotating and arranging the cores.  
   
   
       6 . A motor manufacturing apparatus for manufacturing a motor equipped with a stacked core, wherein 
 the core is formed by using dies or progressive dies shifted by half an angle of any of the below-described clauses (1) through (5), and    one core is turned over with respect to the other core and stacked therewith so that the angular difference therebetween becomes equal to said angle:    (1) an angle 1 which is an odd number multiple of about (360°/(number of poles in the motor×natural number n×2)), and/or an angle 2 which is an odd number multiple of about (360°/(number of slots in the motor×natural number n×2));    (2) an angle 1 obtained when the value of said natural number n is selected such that the (number of poles in the motor×natural number n) giving the angle 1 in said clause (1) becomes equal to the number of slots in the motor or close thereto, and/or an angle 2 obtained when the value of said natural number n is selected such that the (number of slots in the motor×natural number n) giving the angle 2 in said clause (1) becomes equal to the number of poles in the motor or close thereto;    (3) an angle 1 such that the difference between angles which are odd number multiples of (360°/(number of poles in the motor×natural number [n1, n2, . . . ]×2)), for no less than two natural numbers (n1, n2, . . . ), is within a prescribed angle range; and/or an angle 2 such that the difference between angles which are odd number multiples of (360°/(number of slots in the motor×natural number [m1, m2, . . . ]×2)), for no less than two natural numbers (m1, m2, . . . ), is within a prescribed angle range.    (4) an angle 1 obtained when the values of said natural numbers n1 and n2 are selected such that the (number of poles in the motor×natural numbers [n1, n2]) giving the angle 1 in said clause (3) becomes equal to the number of slots in the motor or close thereto, and/or an angle 2 obtained when the values of said natural numbers m1 and m2 are selected such that the (number of slots in the motor×natural number [m1, m2]) giving the angle 2 in said clause (3) becomes equal to the number of poles in the motor or close thereto.    (5) an angle 1′ obtained by subtracting the angle 2 and an angle 3 provided by other means from the angle 1, and/or an angle 2′ obtained by subtracting the angle 1 and an angle 3 provided by other means from the angle 2 in each of said clauses (1) through (4).    
   
   
       7 . A motor manufacturing apparatus for manufacturing a motor equipped with a stacked core, wherein 
 the core is formed by using dies or progressive dies at angles obtained by proportionally dividing an angle range of one period by the number of stacked pieces, where half of an angle of any of the below-described clauses (1) through (5) is the angle range of one period, or at angles obtained by adding the angle obtained by shifting by an angle which is an integer multiple of said one period angle to those proportionally divided angles, and    one core is turned over with respect to the other core and stacked therewith so that the angular difference therebetween becomes equal to said angle:    (1) an angle 1 which is a natural number multiple of about (360°/(number of poles in the motor×natural number n)), and/or an angle 2 which is a natural number multiple of about (360°/(number of slots in the motor×natural number n));    (2) an angle 1 obtained when the value of said natural number n is selected such that the (number of poles in the motor×natural number n) giving the angle 1 in said clause (1) becomes equal to the number of slots in the motor or close thereto, and/or an angle 2 obtained when the value of said natural number n is selected such that the (number of slots in the motor×natural number n) giving the angle 2 in said clause (1) becomes equal to the number of poles in the motor or close thereto;    (3) an angle 1 such that the difference between angles which are natural number multiples of (360°/(number of poles in the motor×natural number [n1, n2, . . . ])), for no less than two natural numbers (n1, n2, . . . ), is within a prescribed angle range; and/or an angle 2 such that the difference between angles which are natural number multiples of (360°/(number of slots in the motor×natural number [m1, m2, . . . ])), for no less than two natural numbers (m1, m2, . . . ), is within a prescribed angle range.    (4) an angle 1 obtained when the values of said natural numbers n1 and n2 are selected such that the (number of poles in the motor×natural numbers [n1, n2]) giving the angle 1 in said clause (3) becomes equal to the number of slots in the motor or close thereto, and/or an angle 2 obtained when the values of said natural numbers m1 and m2 are selected such that the (number of slots in the motor×natural number [m1, m2]) giving the angle 2 in said clause (3) becomes equal to the number of poles in the motor or close thereto.    (5) an angle 1′ obtained by subtracting the angle 2 and an angle 3 provided by other means from the angle 1, and/or an angle 2′ obtained by subtracting the angle 1 and an angle 3 provided by other means from the angle 2 in each of said clauses (1) through (4).    
   
   
       8 . A motor manufacturing apparatus, wherein flat rolled magnetic steel sheets and strip shifted by an angle of any of the below-described clauses (1) through (5) are inserted in dies or progressive dies, and 
 of the cores formed with said dies or progressive dies, one core is turned over with respect to the other core and stacked therewith so that the angular difference therebetween becomes equal to said angle:    (1) an angle 1 which is an odd number multiple of about (360°/(number of poles in the motor×natural number n×2)), and/or an angle 2 which is an odd number multiple of about (360°/(number of slots in the motor×natural number n×2));    (2) an angle 1 obtained when the value of said natural number n is selected such that the (number of poles in the motor×natural number n) giving the angle 1 in said clause (1) becomes equal to the number of slots in the motor or close thereto, and/or an angle 2 obtained when the value of said natural number n is selected such that the (number of slots in the motor×natural number n) giving the angle 2 in said clause (1) becomes equal to the number of poles in the motor or close thereto;    (3) an angle 1 such that the difference between angles which are odd number multiples of (360°/(number of poles in the motor×natural number [n1, n2, . . . ]×2)), for no less than two natural numbers (n1, n2, . . . ), is within a prescribed angle range; and/or an angle 2 such that the difference between angles which are odd number multiples of (360°/(number of slots in the motor×natural number [m1, m2, . . . ]×2)), for no less than two natural numbers (m1, m2, . . . ), is within a prescribed angle range.    (4) an angle 1 obtained when the values of said natural numbers n1 and n2 are selected such that the (number of poles in the motor×natural numbers [n1, n2]) giving the angle 1 in said clause (3) becomes equal to the number of slots in the motor or close thereto, and/or an angle 2 obtained when the values of said natural numbers m1 and m2 are selected such that the (number of slots in the motor×natural number [m1, m2]) giving the angle 2 in said clause (3) becomes equal to the number of poles in the motor or close thereto.    (5) an angle 1′ obtained by subtracting the angle 2 and an angle 3 provided by other means from the angle 1, and/or an angle 2′ obtained by subtracting the angle 1 and an angle 3 provided by other means from the angle 2 in each of said clauses (1) through (4).    
   
   
       9 . A motor manufacturing apparatus, wherein flat rolled magnetic steel sheets and strip shifted by angles obtained by proportionally dividing an angle range of one period by the number of stacked pieces, where half of an angle of any of the below-described clauses (1) through (5) is the angle range of one period, or by angles obtained by adding the angle obtained by shifting by an angle which is an integer multiple of said one period angle to those proportionally divided angles are inserted in dies or progressive dies, and 
 of the cores formed with said dies or progressive dies, one core is turned over with respect to the other core and stacked therewith so that the angular difference therebetween becomes equal to said angle:    (1) an angle 1 which is a natural number multiple of about (360°/(number of poles in the motor×natural number n)), and/or an angle 2 which is a natural number multiple of about (360°/(number of slots in the motor×natural number n));    (2) an angle 1 obtained when the value of said natural number n is selected such that the (number of poles in the motor×natural number n) giving the angle 1 in said clause (1) becomes equal to the number of slots in the motor or close thereto, and/or an angle 2 obtained when the value of said natural number n is selected such that the (number of slots in the motor×natural number n) giving the angle 2 in said clause (1) becomes equal to the number of poles in the motor or close thereto;    (3) an angle 1 such that the difference between angles which are natural number multiples of (360°/(number of poles in the motor×natural number [n1, n2, . . . ])), for no less than two natural numbers (n1, n2, . . . ), is within a prescribed angle range; and/or an angle 2 such that the difference between angles which are natural number multiples of (360°/(number of slots in the motor×natural number [m1, m2, . . . ])), for no less than two natural numbers (m1, m2, . . . ), is within a prescribed angle range.    (4) an angle 1 obtained when the values of said natural numbers n1 and n2 are selected such that the (number of poles in the motor×natural numbers [n1, n2]) giving the angle 1 in said clause (3) becomes equal to the number of slots in the motor or close thereto, and/or an angle 2 obtained when the values of said natural numbers m1 and m2 are selected such that the (number of slots in the motor×natural number [m1, m2]) giving the angle 2 in said clause (3) becomes equal to the number of poles in the motor or close thereto.    (5) an angle 1′ obtained by subtracting the angle 2 and an angle 3 provided by other means from the angle 1, and/or an angle 2′ obtained by subtracting the angle 1 and an angle 3 provided by other means from the angle 2 in each of said clauses (1) through (4).