JP2006014436A - Motor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a motor which lessens iron loss and suppresses the damage of the insulating cover of a lead wire, in a motor using a dust core. <P>SOLUTION: This motor has a stator 1 which has two or more magnetic pole members 10 and a rotor 2 which has magnetic members (magnets 230) and is rotated to the stator 1. Each magnetic pole member 10 has a dust core 110 having a cylindrical surface, and a coil 120 wound on this cylindrical surface. These dust cores 110 are arranged to have mutually independent magnetic circuits. Then, magnetic pole parts 111 made at both ends of this dust core 110 are arranged capably of opposition to the magnets 230 of the rotor. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a motor. In particular, the present invention relates to a motor that can reduce iron loss while using a dust core.

  In recent years, development of electric vehicles and hybrid vehicles using both a battery and an engine has been progressing. Such an automobile uses a motor to drive the vehicle. Usually, the motor is composed of a rotating rotor and a fixed stator. This type of motor is widely used in various technical fields where rotational power is required in addition to motors for driving various electric mechanisms.

  Of these, a typical stator has a structure using a core 400 in which a plurality of T-shaped teeth 420 protrudes inside a cylindrical yoke 410 (for example, Patent Document 1). As shown in FIG. 14, teeth 420 are integrated on the inner peripheral side of the yoke 410, and a coil 450 is formed by winding a conductive wire having an insulation coating on the outside of each tooth 420. A portion of the tooth 420 around which the conductive wire is wound is usually formed in a rectangular cross section.

JP 2004-40871 A (FIG. 2)

However, the above motor has a problem that the core iron loss is large.
There are mainly two reasons why the core loss of the conventional core is large. One is because the magnetic path length becomes long. That is, one end side of each tooth is connected by a yoke, and the magnetic lines of force pass through the yoke portion, so that iron loss is increased by generating iron loss at the passing portion.

  The other is that the connecting portion between the yoke and the tooth is formed at a substantially right angle, so that the magnetic lines of force are sharply bent at this connecting portion and the magnetic lines of force are concentrated, resulting in an increase in iron loss.

  In particular, as in Patent Document 1, a stator core formed with magnetic powder tends to have a larger iron loss than a stator core formed by laminating electromagnetic steel sheets that have been widely used.

  Accordingly, a main object of the present invention is to provide a motor capable of reducing iron loss in a motor using a dust core.

  The present invention achieves the above-mentioned object by using a configuration in which individual teeth are independent, instead of connecting a plurality of teeth with a yoke unlike a conventional stator core.

  The motor of the present invention is a motor having a stator having a plurality of magnetic pole members and a rotor having a magnetic member and rotated with respect to the stator. Each magnetic pole member has a dust core and a coil wound around the dust core. These dust cores are arranged so as to have magnetic circuits independent of each other. And the magnetic pole part formed in the both ends of this powder magnetic core is distribute | arranged so that it can oppose to the magnetic member of a rotor, It is characterized by the above-mentioned.

  By using a dust core for the magnetic pole member of the stator, a magnetic core having a high degree of freedom in shape can be obtained. In particular, a magnetic core having a cylindrical surface can be easily obtained. Since the dust core is obtained by pressing the magnetic powder using a mold, it has a high degree of freedom in shape. For this reason, it is easy to obtain a dust core having a cylindrical surface, and it is possible to avoid damaging the insulating coating of the conductive wire by winding the conductive wire around the cylindrical surface. In that case, the cylindrical surface does not have to be completely circular, and may be an elliptical shape or a polygonal shape with rounded corners.

  Further, by arranging a plurality of magnetic pole members each having a conducting wire wound around a dust core so as to have independent magnetic circuits, the dust cores corresponding to the teeth of a conventional motor are not connected to each other. It is possible to reduce iron loss by shortening the road length.

  Furthermore, the freedom degree of arrangement | positioning of each magnetic pole member can be raised by making each dust core of each magnetic pole member become independent. Therefore, it is not necessary to use a magnetic core having a sharp bent portion, and an increase in iron loss due to concentration of magnetic field lines can be mitigated.

  The following two are mentioned as a more concrete structural example of this invention motor.

(1) Configuration in which dust core is rod-shaped body In this motor, a rotor having a shaft portion and rotating blade portions integrated at both ends of the shaft portion is used. In this rotor, magnetic members are arranged in the circumferential direction on the opposing surfaces of the rotor blades. On the other hand, a linear magnetic core is used for the stator, and a lead wire is wound around the magnetic core to form a magnetic pole member. The plurality of magnetic pole members are arranged at predetermined intervals in the circumferential direction of the rotary blade portion with the axial direction of the powder magnetic core disposed parallel to the shaft portion between the two rotary blade portions. As a result, the magnetic pole portions formed at both ends of the dust core are disposed so as to face the magnetic member of the stator.

  This configuration is equivalent to a configuration in which a yoke in a conventional stator core does not exist by using powder magnetic cores of linear rod-like bodies and arranging the dust cores independently of each other. Can be reduced. Of course, since the powder magnetic core itself is linear, there is no sharply bent portion, and an increase in iron loss due to concentration of magnetic field lines can be avoided.

(2) Configuration in which the dust core is a C-shaped curved rod-like body This motor uses a disk-shaped rotor having a rotating shaft. Magnetic members are arranged in the circumferential direction of the rotor. On the other hand, a C-shaped curved rod-like body is used for the dust core of the stator, and a lead wire is wound around the magnetic core to form a magnetic pole member. A plurality of magnetic pole members are arranged so that the magnetic member of the rotor is interposed between the magnetic pole portions formed at the end portions of the dust core.

  In this configuration, each dust core is independent, but since the gap between the magnetic pole portions is curved in a C shape, the effect of reducing the iron loss by shortening the magnetic path length cannot be expected as in the above configuration (1). . However, since it has a C-shaped gently curved shape, it is possible to mitigate an increase in iron loss due to concentration of magnetic field lines.

  In the motors of both configurations described above, the configuration of the rotor is such that the magnetic member is arranged at a predetermined interval in the circumferential direction of the rotor blade portion of the configuration (1) or the disk body of the configuration (2), and the portions other than the magnetic member Can be used which is made of non-magnetic material such as resin. Even such a configuration can be rotated as an inductance motor. A magnet or a magnetic material can be used for the magnetic member used in the rotor.

  In any configuration, the dust core is preferably configured by combining a plurality of divided pieces. For example, a rod-shaped body or a C-shaped rod-shaped body can be divided by a longitudinal section of a rod-shaped body or a C-shaped rod-shaped body, and a semi-cylindrical divided piece or a C-shaped segmented section having a semi-cylindrical section can be combined to form a rod-shaped body or a C-shaped curved rod-shaped body Can be mentioned.

  In the case of a dust core that can be divided by this longitudinal section, when a magnetic pole member using this magnetic core is excited, the magnetic lines of force pass along the axial direction or the longitudinal direction of the powder core, so that Never cross. Usually, a nonmagnetic material such as a resin is used for joining the split pieces, and an inevitable gap is generated on the joining surface. Therefore, the magnetic properties of the magnetic core are better when the magnetic field lines do not intersect the joining surface. Such a dust core can be obtained by compressing magnetic powder using a die and a punch. At that time, the magnetic powder is compressed into a flat shape with the axial direction or the longitudinal direction of the dust core as the major axis. That is, since the major axis of the magnetic powder is in the direction along the magnetic field lines, the dust core that can be divided in the longitudinal section also has good magnetic characteristics from this point. Of course, the powder magnetic core may be configured by dividing the powder magnetic core in a cross section and combining short bar-shaped divided pieces.

  Hereinafter, the configuration of each part of the motor of the present invention will be described in more detail.

[Dust core]
<Magnetic pole>
Magnetic pole portions are formed at both ends of the dust core. Usually, it is preferable to form a shape that is slightly larger than the portion other than the magnetic pole portion. When the magnetic pole member is excited, these magnetic pole portions are magnetized to N or S poles.

<Cross sectional shape>
The cross-sectional shape of the dust core may be formed in a circle over substantially the entire length, or may be formed in a circle only at a portion where the conductive wire is wound. In short, it is preferable that at least a portion where the conductive wire is wound is formed of a cylindrical surface. By adopting such a cross-sectional shape, it is possible to suppress the insulation coating of the conducting wire from being damaged due to contact with the dust core. The cylindrical surface does not need to be completely circular, and may be an elliptical shape or a quadrangular shape with rounded corners. In particular, in the case of a circular shape, it is easy to wind the conductor along the dust core shape, and the gap between the wound conductors can be made more compact.

[Molding of dust core]
<Magnetic powder>
The dust core is formed by compressing magnetic powder. Any magnetic powder can be applied to the present invention as long as it is a magnetic powder. Of these, soft magnetic materials are preferred. In general, a soft magnetic material is a ferromagnetic material that is magnetized by an external magnetic field and then returns to its original state when the external magnetic field is removed. Usually, a material having a large magnetic permeability μ, in other words, a material having a small coercive force Hc can be said to be a soft magnetic material. More specifically, pure iron, steel (Fe-N, Fe-C, Fe-P), Fe-Si alloy (silicon iron), Fe-Ni alloy (Permalloy), Fe-Mo- Examples include Ni-based alloys (supermalloy), Fe-Co-based alloys (permendur), Fe-Al-based alloys (Sendust), and MnZn ferrite. In particular, a magnetic powder obtained by coating a soft magnetic powder with an insulating thin film is preferable. By using the powder having such a coating, it is possible to suppress the iron loss in the high frequency region of the obtained dust core and improve the magnetic characteristics such as the magnetic flux density. The insulating thin film is preferably made of an oxide-containing material. More specifically, iron phosphate, manganese phosphate, zinc phosphate, calcium phosphate, aluminum phosphate, silicon oxide, titanium oxide, aluminum oxide, zirconium oxide and the like can be mentioned.

  Further, an appropriate amount of lubricant may be added to the magnetic powder. By adding the lubricant, the press body can be more easily extracted from the mold. As the lubricant, for example, fatty acids such as stearic acid and oleic acid can be used. The addition amount of the lubricant is preferably 0.15% by mass or less based on the mixed material with the magnetic powder.

  Further, an appropriate amount of a binder may be added to the magnetic powder. By adding a binder, the strength of the pressed body, particularly the bending strength at high temperatures, can be improved. As this binder, a thermoplastic resin, a thermosetting resin, a non-thermoplastic resin, or the like can be used.

<Molding method>
The dust core is usually formed by placing magnetic powder in a die (die) and applying pressure with an upper punch and a lower punch. For example, in the case of a magnetic core having a circular cross section having magnetic pole portions bulging at both ends, the dust core is preferably formed for each divided piece and then joined to each other rather than being integrally formed. .

  If such a magnetic core having a circular cross section is to be integrally formed with a press, it is necessary to form semi-cylindrical grooves in the upper punch and the lower punch in order to form a cylindrical surface of the magnetic core. For this reason, the opening edges of the grooves of both punches become edges, and when the upper and lower punches are compressed, the edges may be abutted and damaged. On the other hand, if a flat portion is formed instead of the edge portion, a molded product in which the compressed portion between the flat portions protrudes in a burr shape is obtained, and a smooth cylindrical surface can be formed even if divided pieces are combined. I can't.

  Therefore, if it is divided into vertical sections, for example, each divided piece having a semicircular cross section is formed, a desired shape can be produced by using a die die having a semicircular portion, Molding can be performed without causing damage.

  Molding of the powder magnetic core or its divided pieces can be achieved by increasing the density of the molded product and improving the space factor by using the warm molding method and mold lubrication method, which are well-known techniques, to improve the magnetic properties. Connected. The powder temperature during warm forming is preferably 100 to 180 ° C. The pressing conditions depend on the material and particle size of the magnetic powder and the size and shape of the object to be pressed, but a pressing force of about 700 to 1500 MPa is preferable.

<Join of split pieces>
When the dust core is formed by joining divided pieces, it is preferable to use a resin for this joining. Since the green compact is composed of an aggregate of magnetic powders, a resin enters between the fine particles of each magnetic powder particle, and both divided pieces can be strongly bonded to each other by the anchor effect of the inserted resin. However, since the main purpose of this joining is to prevent the split pieces from being scattered when the conducting wire is wound around the dust core, it is only necessary to obtain a joining strength that allows the conducting wire to be wound. As a specific example of this resin, a thermosetting resin such as an epoxy resin is suitable, but a thermoplastic resin, a non-thermoplastic resin, or the like may be used. Needless to say, a split piece having a through hole may be manufactured, and a bolt may be passed through the through hole to connect the split pieces. Alternatively, the split piece may be formed and fitted in advance.

〔coil〕
<Conductor wire>
In the dust core, a conductive wire is wound to form a coil. Various types of conductors such as circular, elliptical, rectangular, and rectangular types can be used as the conducting wire. Usually, the conducting wire has a configuration in which an insulating coating is applied on a metal wire. As a material of the metal wire, copper, aluminum, copper containing silver, nickel-plated copper and the like are preferable. For the insulation coating, polyurethane, polyester, polyamide, ester imide, amide imide, epoxy resin or the like is used. Further, it is preferable that the conducting wire has a fusion layer in addition to the insulating coating. By winding and heating a conducting wire having a fusion layer in a spiral shape, the turns can be integrated, and the shape retention of the coil can be improved. For the material of the fusion layer, polyvinyl butyral, epoxy resin, polyamide resin, and the like are suitable. In addition, in order to prevent the variation between the turns, it is possible to temporarily fix a plurality of turns with a tape that can easily peel the coil.

<Coil type>
A spiral coil is formed using the above-described conductive wire. The winding method of the conducting wire may be either aligned winding or random winding. For example, in the case where a rectangular conductive wire is used, as shown in FIGS. 13 (A) and 13 (B), either an edgewise coil or a flatwise coil can be used. In the case of the edgewise coil, the end of the conducting wire 120A is drawn out to the upper and lower ends of the coil. In the case of a flatwise winding coil, both ends of the conducting wire 120A can be drawn out to the outer periphery of the coil by folding the flat conducting wire into a double and winding the conducting wire with the folded end as the inner peripheral side. Further, as shown in FIG. 13 (C), a random winding coil using a round wire can also be used. The random winding coil can easily wind the conducting wire 120A, and the terminal can be pulled out from any position of the coil.

<Combination of coil and dust core>
For the assembly of the coil and the dust core, different methods can be selected depending on what kind of division is possible. When the dust core can be divided in the longitudinal section, the conductors are wound after joining the divided pieces. When the dust core can be divided in its cross section, a coil is previously formed by spirally winding a conductive wire, each divided piece is inserted from both ends of this coil, and then both divided pieces are joined together Can do. Of course, even in the latter case, it is naturally possible to wind the conducting wire after joining the divided pieces.

  As described above, according to the motor of the present invention, the following effects can be obtained.

  By arranging a plurality of magnetic pole members, each of which has a conductive wire wound around a dust core, to have independent magnetic circuits, the dust cores corresponding to the teeth of a conventional motor are not connected to each other, and the magnetic path length It is possible to reduce iron loss by shortening.

  By making the dust cores of the magnetic pole members independent from each other, the degree of freedom of arrangement of the magnetic pole members can be increased, and there is no need to use a magnetic core having a sharp bend. Therefore, an increase in iron loss due to the concentration of magnetic field lines can be mitigated.

  Embodiments of the present invention will be described below.

(First embodiment)
A motor using a linear powder magnetic core will be described with reference to FIGS.

<Stator and rotor>
FIG. 1 is a schematic diagram of a combination of a stator 1 and a rotor 2 used in the motor of the first embodiment. The motor includes a stator 1 having a plurality of magnetic pole members, and a rotor 2 that can rotate with respect to the stator 1.

  First, as shown in FIG. 2A, the magnetic pole member 10 constituting the stator 1 has a dust core 110 in which both end portions are expanded in a flange shape, and a conductive wire is wound around the outer periphery of the dust core 110. The coil 120 is configured. The dust core 110 has a circular cross section and a cylindrical surface between the magnetic pole portions 111 bulging in a flange shape. Moreover, the metal wire which has insulation coating is used for the conducting wire. A plurality of such magnetic pole members 10 are prepared, arranged on the circumference, and integrated with a nonmagnetic material (see FIG. 1B). Here, the plurality of magnetic pole members 10 are integrally formed by molding the resin 130 in an annular shape. Since each magnetic pole member 10 is integrated with a nonmagnetic material, each powder magnetic core 110 has an independent magnetic circuit when the coil is excited.

  On the other hand, the rotor 2 includes a shaft portion 210 that serves as a rotation shaft, and disk-shaped rotating blade portions 220 that are integrated in a flange shape at both ends of the shaft portion 210. A magnet 230 is fixed as a magnetic member on the opposed surfaces of the pair of rotor blades 220. Here, the plurality of magnets 230 are fixed at substantially equal intervals in the circumferential direction of the rotary blade 220. Further, a portion other than the magnet of the rotor 2 may be a magnetic material or a nonmagnetic material. A resin or the like can be suitably used for the nonmagnetic material. In particular, the portion other than the magnet of the rotor 2 is made of a magnetic material, and the end face of the magnet 230 is not exposed from each of the upper surface of the upper rotor blade 220 and the lower surface of the lower rotor blade 220 in FIG. It is preferable to do. According to this configuration, the magnetic field lines of the magnet 230 do not leak to the outside through the magnetic material other than the magnet, so that a rotor with excellent magnetic characteristics can be configured.

  The stator magnetic pole member 10 is interposed between a pair of rotor blades 220 with the axial direction of the dust core parallel to the shaft portion 210 of the rotor, and the magnetic pole portion 111 of the dust core is the magnet of the rotor. It is arranged to face 230.

  When the coil 120 is excited in the motor having such a configuration, the magnetic pole portion 111 of the dust core is magnetized to the N pole or the S pole, and the rotor 2 rotates with respect to the stator 1 by adsorption and repulsion with the rotor magnet 230. Will be.

  At that time, the dust core 110 of each magnetic pole member is independent as a magnetic circuit, and corresponds to a structure in which a yoke in a conventional stator core does not exist, so that the iron loss can be suppressed by shortening the magnetic path length. . Further, since the dust core 110 is linear and the magnetic lines passing through the magnetic core are not sharply bent, an increase in iron loss due to the concentration of the magnetic lines can be suppressed. Furthermore, since the portion around which the coil 120 of the dust core 110 is wound is formed by a cylindrical surface, even if the conductor is pressed against the dust core 110, the insulation coating is not damaged.

  In addition, as a modification of the rotor, a magnetic material 240 may be used instead of the magnet 230, as shown in FIG. In the rotor 2 of this modified example, a plurality of magnetic materials 240 connected from the lower surface of one rotary blade portion 220 to the upper surface of the other rotary blade portion 220 through the outer peripheral surface of the shaft portion 210 are used. Each magnetic material 240 is arranged at a predetermined interval in the circumferential direction of the shaft portion 210 and the rotary blade portion 220, and a nonmagnetic material 250 is used at a place other than the magnetic material 240. For example, resin may be used as the nonmagnetic material 250, and the magnetic material 240 may be molded integrally to form a rotor. In this modification, as the magnetic pole member 10 of the stator is excited, the magnetic material 240 is also magnetized and functions as a magnet, and the rotor is rotated by attraction / repulsion between the magnetic pole member 10 and the magnetic material 240. .

<Manufacture of stator>
The dust core having a circular cross section is configured by combining the divided pieces 110A and 110B shown in FIG. The divided pieces 110A and 110B are of a semi-cylindrical shape obtained when the dust core 110 is divided into two in the longitudinal section. That is, the outer peripheries of the divided pieces 110A and 110B are composed of a semi-cylindrical surface and a plane.

  Such divided pieces 110A and 110B are obtained by compressing the magnetic powder using the die 500 shown in FIG. 4 and the upper punch 600 and the lower punch 700. In the die 500, an opening having a shape corresponding to the shape of the joining surface of the divided pieces 110A and 110B (FIG. 3) is formed, and magnetic powder is filled from the opening during compression. In addition, the lower portion of the die 500 is spaced at both ends, and the lower punch 700 is inserted into the lower portion of the space so as to be movable up and down, and the upper punch 600 is inserted into the upper portion of the die 500 to be moved up and down. (See FIG. 4 (A)). A semi-cylindrical groove 520 is formed in the middle portion of the die 500 to be a portion around which a coil of a dust core is wound (see FIG. 4B). On the other hand, the upper punch 600 has a flat pressing surface and a width that fits into the upper opening of the die 500. Further, the lower punch 700 is a portion where the magnetic pole portion of the dust core is formed, and a semi-cylindrical groove 710 corresponding to the outer diameter of the magnetic pole portion 111 is formed. Therefore, the flat portion 720 is provided. Therefore, in FIG. 3, the magnetic pole portion 111 of the dust core 110 is illustrated as a disk, but the actual magnetic pole portion is not a disk but has a pair of rectangular protrusions at opposing positions on the outer periphery of the disk.

  Using a press machine having such a die 500 and upper and lower punches 600, 700, the die 500 is filled with magnetic powder. As the magnetic powder, for example, Sweden: Hoganas: somaloy500 can be used. The somaloy 500 is a magnetic powder having a soft magnetic powder having a phosphate insulating coating. Subsequently, the magnetic powder is compressed by pressing the upper and lower punches 600 and 700 to form the divided pieces shown in FIG.

  A similar pressing operation is performed to produce a pair of divided pieces 110A and 110B, and the planes of both divided pieces 110A and 110B are joined to each other. For the bonding, for example, a thermosetting resin is used. A thermosetting resin is sandwiched between the planes of the two split pieces 110A and 110B, and the resin is cured by heating in this state. A small circle near the joint surface shown in FIG. 3C exaggerates the magnetic powder particles. Since the thermosetting resin penetrates between the magnetic powder particles, the divided pieces can be effectively joined to each other.

  After the divided pieces 110A and 110B are joined to form the powder magnetic core 110, a conductive wire is wound around the outer periphery to form the coil 120, thereby completing one magnetic pole member 10 (FIG. 1).

  Similarly, a plurality of magnetic pole members 10 are produced, and these magnetic pole members 10 are integrated with a mold resin 130. That is, the plurality of magnetic pole members 10 are arranged at equal intervals on the circumference in the mold. Then, the resin 130 is filled in the mold, and only the both end faces of the powder magnetic core 110 are exposed from the mold resin 130, and the rest are all molded by the mold resin 130. This resin mold body has an annular shape with a central hole formed in the center.

<Combination of stator and rotor>
To configure an actual motor, as shown in FIG. 5, a stator is fixed in the case 3, and the rotor is rotatably supported by the case 3.

  That is, the rotor shaft portion is configured to be divided into two parts, the upper side and the lower side, between the two rotor blades. The case 3 is also divided into two parts, the lid side 310 and the bottom side 320. A through hole 311 of the shaft portion 210 of the rotor is formed on the upper surface of the case lid portion side 310, and a bearing 312 that rotatably supports the shaft portion 210 is fitted in the through hole 311. On the other hand, a bearing 321 of the rotor shaft 210 is provided at the center of the case bottom 320. Further, a stator fitting recess 330 is formed on the inner surface of the case in the vicinity of the joint between the case lid side 310 and the bottom side 320. The fitting recess 330 supports the outer peripheral portion of the stator 1 which is a resin mold body.

  To combine the stator 1 and the rotor 2, first, a resin mold body in which a plurality of magnetic pole members 10 are integrally formed in an annular shape is sandwiched between the upper and lower sides of the rotor from above and below, and the shaft portion 210 of the rotor is resin-molded. The upper and lower sides of the rotor are joined by passing through the center hole of the body. Next, the shaft portion 210 of the rotor is passed through the through hole 311 on the case lid side, and the shaft portion of the rotor is supported by the bearing 321 on the case bottom side 320. Then, the case lid part 310 and the bottom part 320 are joined to constitute the motor case 3. At that time, the outer periphery of the resin mold body is supported by the fitting recess 330 and the stator is fixed in the case 3.

(Second embodiment)
Next, the motor of the present invention using a dust core having a plane perpendicular to the axial direction of the magnetic core as a split surface will be described.

<Dust core>
In this motor, the configuration of the stator and the rotor is the same as that shown in FIG. 1, and the powder magnetic core used for the stator is formed by joining the divided pieces, but the form of the divided pieces is different.

  That is, in this example, as shown in FIG. 6, the rod-shaped dust core is composed of two divided pieces whose cross section is the joining surface. A concave portion 112 is formed at a joint portion of one divided piece (upper divided piece 110C), and a convex portion 113 fitted into the concave portion 112 is formed at a joint portion of the other divided piece (lower divided piece 110D). Yes.

<Manufacture of dust core>
In order to form such divided pieces, a press shown in FIG. 7 is used. This press machine has a die 500 having a circular opening 510 and upper and lower punches 600 and 700 fitted in the opening 510. The die opening 510 is formed such that the upper portion has a larger opening diameter and the lower portion has a smaller opening diameter. The upper punch 600 has a diameter that matches the upper opening diameter and has a flat pressure contact surface. On the other hand, when forming the lower divided piece 110D, the lower punch 700 has a concave portion 720 that matches the convex portion 113 on the pressure contact surface (see FIGS. 6B and 7A), and the upper divided piece 110C. In the case of molding, a convex portion 730 that fits the concave portion 112 is provided on the pressure contact surface (see FIGS. 6B and 7B). Using such a press machine, if the opening is filled with magnetic powder and pressed by the upper and lower punches 600 and 700, the divided pieces 110C and 110D shown in FIG. 6 can be formed.

  In addition, as shown in FIG. 8, the split pieces 110C and 110D (FIG. 6) of this example may be formed using a CNC press machine or the like. The opening 510 of the die 500 has a constant diameter from the upper part to the lower part, and the lower punch 700 is independently divided into three divided punches, a round bar part 740, a small cylinder part 750, and a large cylinder part 760 arranged concentrically from the center. By controlling the compression amount of the divided punch, the divided pieces 110C and 110D of the present invention can be formed. For example, the lower divided piece 110D can be formed by increasing the pushing height in the order of the round bar portion 740, the small tube portion 750, and the large tube portion 760 (increasing the amount of compression). Further, the upper divided piece 110C can be formed by increasing the pushing height in the order of the large tube portion 760, the round rod portion 740, and the small tube portion 750 (increasing the amount of compression).

  In the case of this example, a coil is formed by winding a conducting wire in advance in a spiral shape, and an upper divided piece 110C and a lower divided piece 110D are inserted from above and below the coil to join both divided pieces to constitute a magnetic pole member. be able to.

  The combined structure of the rotor, stator and case in this example is the same as that shown in FIG.

(Third embodiment)
Next, the motor of the present invention using a C-type dust core will be described.

<Rotor and stator>
FIG. 9 is a schematic diagram of a combination of a stator and a rotor constituting the motor of this example.

  In the above two embodiments, a straight bar-shaped dust core is used, but in this example, a C-shaped curved rod-shaped body is used for the dust core 110. In this example, the rotor 2 has a disk shape.

  As shown in FIG. 9, this motor also has a plurality of magnetic pole members 10 arranged on the circumference, and each magnetic pole member 10 is composed of a dust core 110 and a coil 120 wound around the outer periphery of the magnetic core 110. . In the dust core 110, a U-shaped portion 110U is integrated with each end of the linear portion 110L, and one end of each U-shaped portion 110U bulges to form a magnetic pole portion 111. Here, the coil 120 is formed by winding a conducting wire around the outer periphery of the straight portion 110L. Therefore, it is preferable that the outer peripheral surface of the straight portion 110L is a cylindrical surface. Even in this case, the outer peripheral surface of the U-shaped portion 110U or the magnetic pole portion 111 other than the straight portion may not be a cylindrical surface. The magnetic pole portions 111 are opposed to each other with a gap, and a rotor 2 described later is interposed in the gap in a non-contact state. The magnetic pole members 10 arranged at regular intervals on the circumference are integrated in a ring shape with a mold resin 130 having a thickness that encompasses the linear portion 110L and the coil 120.

  On the other hand, the rotor 2 has a disk shape, and a plurality of magnets 230 are arranged in the circumferential direction at predetermined intervals. The rotor 2 is interposed between the gaps of the magnetic pole portions 111 so that the magnetic pole portion 111 and the magnet 230 can be opposed to each other.

  Even in the motor having such a configuration, when the coil 120 is excited, the magnetic pole portion 111 of the dust core is magnetized to the N pole or the S pole, and the rotor 2 is fixed to the stator 1 by adsorption and repulsion with the magnet 230 of the rotor magnetic member. Will be rotated.

  In the case of this example, since each dust core 110 is curved in a C shape, the magnetic path length is longer than that of the dust core 110 of the first embodiment, but the curve is abruptly curved so that corners are formed. Therefore, there is no portion where the magnetic lines of force concentrate, and iron loss can be suppressed. Further, the portion around which the coil of the dust core is wound is formed by a cylindrical surface, so that the insulation coating is not damaged even when the conducting wire is pressed against the dust core. The passage of magnetic lines of force in the rotor becomes only the magnetic member, and iron loss in the rotor can be reduced.

<Manufacture of stator>
The powder magnetic core is configured by combining the divided pieces 110E and 110F shown in FIGS. 10 (A) and 10 (B). The divided pieces 110E and 110F are C-shaped and obtained when the powder magnetic core is divided into two in a longitudinal section, and have a semicircular cross section.

  Such divided pieces 110E and 110F are obtained by compressing magnetic powder using the die 500 shown in FIG. 11, the upper punch 600, and the lower punch 700. The configurations of the die opening 510 and the upper and lower punches 600 and 700 are the same as those of the press shown in FIG. 4 except that they are C-shaped. In other words, the divided pieces 110E and 110F are formed by compression of the die 500 and the upper punch 600 as shown in FIG. 11B at the portion corresponding to the straight portion (110L) around which the conducting wire is wound, and the other portions are shown in the figure. As shown in FIG. 11 (C), compression is performed between the upper punch 600 and the lower punch 700 within the opening of the die 500.

  Using a press machine having such a die 500 and upper and lower punches 600, 700, the magnetic powder is filled in the die 500, and the magnetic powder is compressed by pressing the upper and lower punches 600, 700, as shown in FIGS. 10 (A) and 10 (B). Mold the split pieces. The molded body is taken out from the die 500 with the lower punch 700 supporting the molded body.

  A similar pressing operation is performed to produce a pair of divided pieces 110E and 110F, and the planes of both divided pieces 110E and 110F are joined to each other. For the joining, a thermosetting resin, a thermoplastic resin, a non-thermoplastic resin or the like can be used as in the first embodiment.

  After the divided pieces 110E and 110F are joined to form the dust core 110, a conductive wire is wound around the outer periphery of the straight portion to form the coil 120, thereby completing one magnetic pole member 10 (FIG. 9).

  Similarly, a plurality of magnetic pole members 10 are produced, and these magnetic pole members 10 are integrated with a mold resin 130. That is, the plurality of magnetic pole members 10 are arranged at equal intervals on the semicircle in the mold. Then, a resin is filled in the mold, and the U-shaped part 110U and the magnetic pole part 111 of the dust core are exposed from the mold resin 130, and all other parts are integrated with the mold resin 130. This resin mold body is a semi-annular shape in which a semicircular cutout is formed at the center. A pair of the semi-annular bodies are formed and joined to form an annular stator 1.

<Combination of stator and rotor>
To configure an actual motor, as shown in FIG. 12, a stator is fixed in the motor case 3 and the rotor 2 is supported rotatably with respect to the case 3. The combination structure with the case 3 is basically the same as the combination structure of FIG. In the motor of FIG. 12, the disk-shaped rotor 2 is shown with a rotating shaft integrated.

  When combining the rotor 2 and the stator 1, the stator 1 is prepared in a state of being separated into a semi-annular resin molded body. A pair of resin mold bodies are brought close together so as to be sandwiched from the outer peripheral side of the rotor 2, and at that time, the rotor 2 is fitted into the gap of the magnetic pole part 111. Then, a pair of resin mold bodies are joined to form a combined body of the stator 1 and the rotor 2. The method of arranging this combination in the case 3 may be performed according to the first embodiment.

  As another example of the division of the dust core 110, as shown in FIG. 10 (C), it is conceivable to divide and join the linear portion 110L, the U-shaped portion 110U, and the magnetic pole portion 111.

  The motor of the present invention can be widely used in various technical fields where rotational power is required, such as motors for driving electric vehicles and hybrid cars, as well as motors for driving various electric mechanisms.

FIG. 2 is an assembly schematic diagram of a stator and a rotor constituting the motor of the first embodiment, where (A) shows a longitudinal section and (B) shows a transverse section. FIG. 6 is a schematic diagram of a modification of the rotor constituting the motor of the first embodiment, where (A) shows a longitudinal section and (B) shows an AA section of FIG. (A). FIG. 1 shows a dust core used in the first embodiment, (A) is a perspective view, (B) is a sectional view taken along the line AA, and (C) is a longitudinal sectional view showing the dust core before split piece joining. (A) is a schematic view of a press machine for pressing a dust core, (B) is a BB cross-sectional view thereof, and (C) is a CC cross-sectional view thereof. It is a schematic diagram of the motor of the state which accommodated the stator and rotor of FIG. 1 in the case. The dust core in the second embodiment is shown, (A) is a front view, and (B) is an exploded perspective view. (A) is a schematic view of a press machine for forming a lower divided piece in the second embodiment, and (B) is a schematic view of a press machine for forming an upper divided piece. It is a schematic diagram of a CNC press. FIG. 4 is an assembly schematic diagram of a stator and a rotor constituting a motor of a third embodiment, where (A) shows a longitudinal section and (B) shows a transverse section. The dust core used in the third embodiment is shown, (A) is a front view, (B) is a right side view, (C) is a plan view of a dust core that is different from the magnetic core shown in (B). It is. (A) is a schematic view of a press machine for pressing a powder magnetic core used in the third embodiment, (B) is an AA sectional view, and (C) is a BB sectional view. FIG. 9 is a schematic diagram of a motor in a state where the stator and rotor of FIG. 8 are housed in a case. (A) is a perspective view of an edgewise winding coil, (B) is a perspective view of a flatwise winding coil, and (C) is a perspective view of a random winding coil. It is a schematic block diagram which shows the conventional stator.

Explanation of symbols

1 Stator 2 Rotor 3 Case 10 Magnetic pole member
110A, 110B, 110E, 110F Split piece 110C Upper split piece 110D Lower split piece
110 Powder magnetic core 110U U-shaped part 110L Straight part 110 Magnetic core 111 Magnetic pole part
112 Concave 113 Convex 120 Coil 120A Conductor 130 (Mold) Resin
210 Shaft 220 Rotor 230 Magnet 240 Magnetic material 250 Non-magnetic material
310 Lid side 311 Through hole 312 Bearing 320 Bottom side 330 Mating recess
400 core 410 yoke 420 teeth 450 coils
500 die 510 opening 520 groove 600 top punch
700 Lower punch 710 Groove 720 Concave part 730 Convex part 740 Round bar part 750 Small tube part
760 Large tube

Claims (7)

A motor having a stator having a plurality of magnetic pole members and a rotor having a magnetic member and rotated with respect to the stator;
Each of the magnetic pole members has a dust core and a coil wound around the dust core,
These dust cores are arranged to have independent magnetic circuits,
The motor is characterized in that the magnetic pole portions formed at both ends of the dust core are disposed so as to be opposed to the magnetic member of the rotor.   The motor according to claim 1, wherein the magnetic member of the rotor is a magnet. The dust core is a rod-shaped body,
The rotor includes a shaft portion and rotary blade portions integrated at both ends of the shaft portion, and magnetic members are arranged in a circumferential direction on opposing surfaces of the rotary blade portions,
The magnetic pole member is disposed at a predetermined interval in a circumferential direction of the rotary blade portion with the axial direction of the dust core disposed between the rotary blade portions in parallel with the shaft portion. The motor according to 1 or 2.   The motor according to claim 3, wherein the dust core is configured by combining divided pieces. The dust core is a C-shaped curved rod,
The rotor is a disc body having a rotation axis,
3. The motor according to claim 1, wherein a plurality of magnetic pole members are arranged such that a magnetic member of a rotor is interposed between both magnetic pole portions formed at an end portion of the dust core.   The rotor disk includes a plurality of magnetic pole members such that magnetic members are arranged in a circumferential direction of the disk body, and the magnetic member of the rotor is interposed between both magnetic pole portions formed at the end of the dust core. The motor according to claim 5, wherein the motor is arranged.   The motor according to claim 5 or 6, wherein the dust core is configured by combining divided pieces.

Images