JP2006050743A - Core member for motor, motor, and manufacturing method for armature - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing technique for the armatures of inner-rotor motors wherein conductors can be easily wound and manufacturing processes are not complicated. <P>SOLUTION: An armature for inner-rotor motors includes: a core member 30 having multiple core elements 31; and multiple coils 35 formed by winding a conductor on each core element 31. The multiple core elements 31 are radially protruded from a virtual circumference established along the outer circumferential surface of a field magnet. The multiple core elements 31 are physically separated on the virtual circumference through a fixing plate 32. They are also magnetically substantially separated and fixed on one another. For this reason, conductors can be easily wound on the core elements 31 from outside as with the armature of an outer-rotor motor without complicating the manufacturing process for the core member 30. As a result, manufacturing processes for inner-rotor motors can be simplified. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to an inner rotor type motor, and more particularly to an armature core member.

  Conventionally, a core member of an inner rotor type motor is provided with a plurality of teeth projecting inwardly on the inner periphery of a cylindrical core back, and a conductive wire is wound around these teeth. The winding is performed manually from an opening on the center side of the core member or by inserting a needle of a winding machine into a narrow groove-like slot between the teeth. Furthermore, there is a case where a technique is employed in which a tooth is inserted into a conducting wire separately wound in advance using a dedicated inserter.

  However, in the inner rotor type motor, since the slot between the teeth opens toward a narrow space along the central axis, skill is required to perform winding manually, and the needle is used even when using a winding machine. The winding amount is limited in order to secure a space for moving the wire. When using an inserter, the teeth are inserted while deforming the shape of the coil, so that the space factor cannot be increased sufficiently, and the end coil part requires some extra portion protruding from the core. End up.

In order to solve the above problems, for example, in Patent Document 1, the separated teeth are temporarily supported from the inside by a ring-shaped support member, and in this state, as in the case of the armature of the outer rotor type motor The armature on the inner rotor side is manufactured by performing winding efficiently, and then, after the core back (yoke part) is fitted and integrated on the outside of the teeth, the inner support member is removed.
Japanese Patent Laid-Open No. 2-7851

  By the way, although the manufacturing method of the armature described in Patent Document 1 is excellent in that the coil can be easily formed, the mounting of the inner supporting member, the mounting of the outer core back, and the supporting member Since the removal work is necessary, the work process becomes complicated. In addition, in the conventional inner rotor type armature, in order to provide a protrusion on the upper surface of the core back to hook the conductive wire wound around one tooth to the adjacent tooth along the core back, It is also necessary to use a large insulator having a portion.

  SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and it is a main object of the present invention to provide an armature manufacturing technique that can easily wind a conducting wire and does not complicate the manufacturing process for an inner rotor type motor. Yes.

  The invention according to claim 1 is a core member for an inner rotor type motor, wherein the plurality of core elements project radially from a predetermined circumference, and the plurality of core elements on the predetermined circumference. And a fixing portion for fixing the plurality of core elements to each other while magnetically separating them.

  Invention of Claim 2 is a core member of Claim 1, Comprising: The said fixing | fixed part is a ring-shaped nonmagnetic body in alignment with the said predetermined periphery.

  Invention of Claim 3 is a core member of Claim 1 or 2, Comprising: The said fixing | fixed part fixes the upper surface of these core elements mutually, and the lower surface of these core elements And a lower plate for fixing the two to each other.

  The invention according to claim 4 is an inner rotor type motor, wherein an armature in which conducting wires are wound around the core elements of the core member according to any one of claims 1 to 3, and the armature A stator member to which the armature is attached, a field magnet inserted in the center of the core member, and the field magnet is attached, and the stator is operated by a magnetic action between the armature and the field magnet. And a rotor member that rotates relative to the member.

  The invention according to claim 5 is a method for manufacturing an armature for an inner rotor type motor, wherein a plurality of core elements project radially from a predetermined circumference, and the plurality of core elements on the predetermined circumference. And a step of preparing a core member including a fixing portion that fixes the plurality of core elements to each other while substantially separating the core elements magnetically, and a step of winding a conductive wire around the plurality of core elements.

  A sixth aspect of the present invention is the armature manufacturing method according to the fifth aspect, wherein the fixing portion is a ring-shaped nonmagnetic material along the predetermined circumference.

  The invention according to claim 7 is the method for manufacturing the armature according to claim 5, wherein the fixing portion is formed of the same material as the plurality of core elements, and the ring extends along the predetermined circumference. A step of preparing the core member includes punching a plate-shaped core material with a mold to form the plurality of core elements on which the magnetic body is laminated; Punching with a mold to form the fixing portion, and fixing the plurality of core elements to the fixing portion.

  In the present invention, the conducting wire can be easily wound around the core element without complicating the manufacturing process of the core member. In the inventions of claims 2 and 6, the magnetic properties of the core member can be improved. In the invention of claim 3, a plurality of core elements can be easily fixed.

  In the invention of claim 4, the manufacturing process of the motor can be simplified. In the invention of claim 7, the core member forming process can be simplified.

  FIG. 1 is a longitudinal sectional view showing an inner rotor type motor 1 according to a first embodiment of the present invention. The motor 1 is covered with a cylindrical housing 11 having a small opening on the upper side and a large opening on the lower side in FIG. 1 and a cover plate 12 that closes other than the central portion of the lower opening. Ball bearings 131 and 132 are attached to the openings of the cover plate 12, and the shaft 21 is rotatably supported by the ball bearings 131 and 132.

  A cylindrical rotor yoke 22 is attached to the shaft 21 in the housing 11, and a field magnet 23 magnetized in multiple poles is fixed to the outer peripheral surface of the rotor yoke 22. On the other hand, the armature 3 is attached to the inner peripheral surface of the housing 11, and the armature 3 has a plurality of core elements (so-called teeth) extending from the inner peripheral surface of the housing 11 toward the shaft 21 (and the field magnet 23). ) 31 and a plurality of coils 35 provided by winding a conducting wire around each of the plurality of core elements 31. The coil 35 is formed by winding a conductive wire in the vertical direction along the outer periphery of the core element 31. The details of the structure of the armature 3 will be described later.

  An insulator 51 is fixed to the inner peripheral surface of the housing 11 on the cover plate 12 side of the armature 3, and the circuit board 52 is positioned between the field magnet 23 and the armature 3 and the cover plate 12. Attached to. The armature 3 and the circuit board 52 are electrically connected through a jumper attached to the insulator 51. The insulator 51 also serves to determine the mounting position of the circuit board 52. A drive circuit for controlling the drive current applied to the armature 3 and a hall sensor 521 are attached immediately below the field magnet 23 on the circuit board 52. The hall sensor 521 rotates the field magnet 23 in the direction of rotation. The rotational position is detected and the drive current to the armature 3 is controlled. That is, the motor 1 is a so-called brushless motor.

  In the motor 1, the drive current supplied to the armature 3 via the circuit board 52 is controlled, and the field magnet 23 inserted together with the rotor yoke 22 in the center of the armature 3 (that is, a core member 30 described later) A rotational force is generated by the magnetic action between the armature 3 and the rotor yoke 22 rotates with respect to the housing 11 together with the shaft 21.

  FIG. 2 is a plan view showing the core member 30 of the armature 3. The core member 30 has a structure in which a plurality of core elements 31 shown in FIG. 3 are fixed by a fixing plate 32 shown in FIG. As shown in FIG. 3, the plurality of core elements 31 are on a virtual circumference (hereinafter referred to as “virtual circle”) 30a set along the outer peripheral surface of the field magnet 23 (see FIG. 1). Projecting radially from. Each core element 31 has a structure in which silicon steel plates, which are magnetic materials, are laminated, and the outer peripheral side protrudes along the circumferential direction, and is substantially T-shaped in a plan view.

  The ring-shaped fixing plate 32 is formed of a silicon steel plate that is the same material as the core element 31, and protrudes radially outward from the ring portion 321 along the virtual circle 30a and the ring portion 321 as shown in FIG. A plurality of protrusions 322 are provided. The plurality of protrusions 322 respectively correspond to the plurality of core elements 31 as shown in FIG.

  FIG. 5 is a perspective view showing one core element 31 and the fixing plate 32 in the vicinity thereof. Fixed plates 32 are attached to the upper surface, the lower surface, and the middle of the core element 31 on which the plate-like magnetic bodies are laminated. The core element 31 and the protrusions 322 of the three fixed plates 32 are formed with holes into which the dowels 33 are inserted, and the dowels 33 and the upper and lower protrusions 322 are fastened by caulking to thereby form a plurality of cores. The elements 31 are physically separated on the virtual circle 30a via the three fixed plates 32, and are fixed to each other while being substantially separated magnetically. Although the fixing plate 32 that fixes the plurality of core elements 31 to each other is a magnetic body, the magnetic characteristics of the core member 30 vary greatly because they are only in contact with each core element 31 at three locations. It can be said that the plurality of core elements 31 are substantially magnetically separated.

  FIG. 6 is a diagram showing the flow of the manufacturing process of the armature 3. When the armature 3 is manufactured, first, a silicon steel plate (as will be described later, the core element 31 is also formed using this material. And the fixed plate 32 is formed and held in a movable laminate portion provided below the mold (step S11). The fixing plate 32 serves as a lower plate that fixes the lower surfaces of the plurality of core elements 31 to each other when the core member 30 is formed.

  FIG. 7 is a plan view showing the fixed plate 32 immediately after being punched from the plate-shaped core material. As shown in FIG. 7, a central portion 323 is provided inside the ring portion 321 of the fixed plate 32, and each protruding portion 322 and the central portion 323 are connected by a thin connection portion 3231. As will be described later, the central portion 323 is removed in the process of forming the core member 30.

  Subsequently, the laminated portion holding the fixing plate 32 moves downward of the mold for the core element 31, and the core material is punched out by the mold for the core element 31, and the members shown in FIG. Element plate ") 310 is formed. The core element plate 310 is a member in the previous stage of the core element 31 shown in FIG. In the stacking unit, a predetermined number of core element plates 310 are positioned and sequentially stacked on the fixed plate 32 (step S12).

  As shown in FIG. 8, the core element plate 310 includes a central portion 323 having the same shape as the central portion of the fixed plate 32 shown in FIG. 7, and a plurality of portions connected to the central portion 323 via the connection portions 3231. A core element piece 311 is provided. The core element pieces 311 project radially from the imaginary circle 30a and are laminated at the laminated portion to form the core elements 31 (see FIG. 2). As shown in FIGS. 7 and 8, each protrusion 322 of the fixing plate 32 and each core element piece 311 of the core element plate 310 are formed by punching the fixing plate 32 and the core element plate 310 out of the core material by a mold. Before the dowels 33 (see FIG. 5) are inserted, holes 330 into which the dowels 33 (see FIG. 5) are inserted are formed in advance, and when the fixing plate 32 and a predetermined number of core element plates 310 are stacked, these holes 330 are formed. Positioning is performed appropriately so that the two overlap.

  When a predetermined number of core element plates 310 are stacked, the stacked portion moves downward of the mold for the fixed plate 32, and the core material is punched by the mold to form the fixed plate 32 (step S13). ). The fixing plate 32 is positioned and held on the core element plate 310 stacked in the stacked portion, and serves as an intermediate plate that fixes the intermediate portions of the plurality of core elements 31 to each other.

  Subsequently, the stacking portion moves again below the mold for the core element 31 and, like step S12, a predetermined number of core element plates 310 are formed by punching from the core material, and are fixed as intermediate plates. Positioned on the plate 32 and sequentially stacked (step S14). When a predetermined number of core element plates 310 are stacked, the stacked portion moves again below the mold for the fixed plate 32, and the core material is punched by the mold to form the fixed plate 32 (step). S15). The formed fixing plate 32 is positioned and stacked on the core element plates 310 stacked in step S14, and serves as an upper plate that fixes the upper surfaces of the plurality of core elements 31 to each other.

  When the fixed plate 32 serving as the upper plate is stacked on the stacked portion, the holes 330 (FIGS. 7 and 8) formed in the protrusions 322 of the fixed plate 32 and the core element pieces 311 of the core element plate 310 are formed. The dowels 33 (see FIG. 5) are inserted into the dowels 33, and the dowels 33 and the protrusions 322 of the upper and lower fixing plates 32 are fastened by caulking, whereby a plurality of core element plates are interposed via the three fixing plates 32 310 is fixed (step S16). A plurality of core elements in which core element pieces 311 that are magnetic bodies are stacked are obtained by punching and removing the central portion 323 and the connecting portion 3231 from the fixed plate 32 and the core element plate 310 that are integrally fixed. 31 is formed, and the plurality of core elements 31 are physically separated, and the core member 30 fixed to the three fixing plates 32 while being substantially magnetically separated is prepared (step S17).

  Then, after the core element 31 and the fixing plate 32 of the core member 30 shown in FIG. 2 are coated with an insulating material such as a resin, each of the core elements 31 is cored by a winding machine (or by another method). When the conducting wire is wound from the outside of the member 30, a plurality of coils 35 are formed, and the manufacture of the armature 3 is completed (step S18).

  In the motor 1, the plurality of core elements 31 projecting radially from the ring portion 321 are fixed to each other while being substantially magnetically separated by the fixing plate 32, so that the manufacturing process of the core member 30 is not complicated and the outer rotor is not complicated. As in the case of the armature of the type motor, the lead wire can be easily wound around the core element 31. As a result, the manufacturing process of the inner rotor type motor 1 can be simplified. Further, the plurality of core elements 31 are easily fixed by being sandwiched by the fixing plate 32 from the upper surface side and the lower surface side.

  In the motor 1, since the fixed plate 32 and the core element 31 are formed of the same material (that is, a silicon steel plate), the fixed plate 32 and the core element plate 310 can be formed in the same process and sequentially stacked. . As a result, the process of forming the core member 30 can be simplified, and the manufacturing cost of the motor 1 can be reduced. Further, the fixing plate 32 and the core element plate 310 can be easily aligned and stacked. Further, in the motor 1, a plurality of core element pieces 311 are stacked in a state where they are connected by the central portion 323 (that is, as the core element plate 310), and after being fixed by the fixing plate 32, the central portion 323 is removed and the plurality of core element pieces 311 are removed. Therefore, the plurality of core elements 31 can be aligned and fixed to the fixing plate 32 more easily and accurately.

  In the core member 30, when a conducting wire wound around one core element 31 is led to the adjacent core element 31, the conducting wire can be led along the ring portion 321 of the fixing plate 32. In the motor of the mold, the protrusion for hooking the conductive wire required on the upper surface of the core back which is a ring outside the teeth can be omitted.

  FIG. 9 is a diagram showing the flow of the manufacturing process of the armature of the inner rotor type motor according to the second embodiment of the present invention. In the motor according to the second embodiment, the three fixing plates 32 are formed of a nonmagnetic material such as stainless steel (for example, SUS303), which is a different material from the core element 31. Other configurations are the same as those of the motor 1 according to the first embodiment shown in FIG. 1, and the same reference numerals are given in the following description.

  When the motor armature 3 according to the second embodiment is manufactured, first, as shown in FIG. 10, a large number of core element pieces 311 are punched from the silicon steel plate 91 by a mold for the core element 31. A predetermined number of core element pieces 311 are laminated to form a block shape. Hereinafter, the plurality of core element pieces 311 stacked in a block shape are referred to as “core element blocks”. In the present embodiment, 18 core element blocks are formed (step S21).

  When the plurality of core element blocks are formed, as shown in FIG. 11, the stainless steel plate 92 is punched out by a mold for the fixed plate 32, and the fixed plate 32 is formed (step S22). The fixing plate 32 serves as a lower plate that fixes the lower surfaces of the plurality of core elements 31 to each other when the core member 30 (see FIG. 2) is formed. The core element block is placed while being positioned on each protrusion 322 of the fixed plate 32 (step S23). As shown in FIGS. 10 and 11, each core element piece 311 and each protrusion 322 of the fixing plate 32 are formed with holes 330 into which dowels 33 (see FIG. 5) are inserted in advance. When the element block is formed and when the core element block is placed on the fixed plate 32, positioning is appropriately performed so that these holes 330 overlap.

  When nine core element blocks are placed on the fixing plate 32, the stainless steel plate 92 is punched out by a mold for the fixing plate 32 to form the fixing plate 32 serving as an intermediate plate, and the fixing serving as the lower plate. It is placed while being positioned on the core element block placed on the plate 32 (step S24). Subsequently, the core element block is placed while being positioned on each protrusion 322 of the fixed plate 32 serving as an intermediate plate (step S25). Next, the stainless steel plate 92 is punched out by a mold for the fixed plate 32 to form the fixed plate 32 serving as the upper plate, and is positioned on the core element block placed on the fixed plate 32 serving as the intermediate plate. It is mounted (step S26).

  Thereafter, the dowels 33 are inserted into the respective protrusions 322 of the fixing plate 32 and the holes 330 (see FIGS. 10 and 11) formed in the core element pieces 311 constituting the core element block. The plurality of core element blocks are fixed through the three fixing plates 32 by being fastened to the respective protrusions 322 of the fixing plate 32 by caulking. The core member 30 having the core element 31 is prepared (step S27).

  Then, after the core element 31 and the fixing plate 32 of the core member 30 are covered with an insulating material such as a resin, each of the plurality of core elements 31 is outside the core member 30 by a winding machine (or by another method). As a result, the plurality of coils 35 are formed and the armature 3 is manufactured (step S28). The core element piece 311 and the fixing plate 32 may be formed in parallel by separate press machines. Further, after all the core element pieces 311 and the fixing plate 32 necessary for forming the core member 30 are formed, the core element block may be formed and placed on the fixing plate 32.

  Alternatively, the core member 30 may be formed by placing the core element block on the non-magnetic fixing plate 32 and fixing it after covering with an insulating material. In this case, it is not necessary to uniformly coat the core member 30 having a complicated shape including the core element 31 and the fixing plate 32 with the insulating material, and the coating process of the core element 31 with the insulating material can be simplified. By winding a conducting wire around the core member 30 formed in this manner, the armature 3 of the motor can be efficiently manufactured.

  In the armature 3 of the motor according to the second embodiment, since the fixing plate 32 that fixes the plurality of core elements 31 to each other is formed of a nonmagnetic material, the plurality of core elements 31 are further magnetically separated. Can do. As a result, the magnetic characteristics of the core member 30 can be improved, and the driving efficiency of the motor can be further improved.

  Moreover, as shown in FIG. 10, the silicon steel plate 91 can be efficiently used by efficiently laying out and punching a large number of core element pieces 311 on the silicon steel plate 91. Note that the multiple core element pieces 311 laid out on the silicon steel plate 91 do not necessarily have to face the same direction as shown in FIG. 10. For example, some of the multiple core element pieces 311 shown in FIG. The core element pieces 311 arranged in the opposite direction and adjacent in the vertical direction may be arranged so as to face each other.

  In the armature 3 of the motor according to the second embodiment, as in the motor 1 according to the first embodiment, a plurality of core elements 31 protruding radially from the ring portion 321 (see FIG. 2) are fixed plates. By fixing them to each other while being substantially magnetically separated by 32, it is possible to easily connect the conductors to the core element 31 as in the case of the armature of the outer rotor type motor without complicating the manufacturing process of the core member 30. Can be wound. As a result, the manufacturing process of the inner rotor type motor can be simplified. The plurality of core elements 31 are easily fixed by being sandwiched by the fixing plate 32 from the upper surface side and the lower surface side.

  The armature manufacturing method shown in FIG. 9 can also be applied when the fixing plate 32 is formed of the same material as the core element piece 311 (that is, a silicon steel plate).

  As mentioned above, although embodiment of this invention has been described, this invention is not limited to the said embodiment, A various change is possible.

  For example, each protrusion 322 of the fixing plate 32 and the core element 31 may be fixed by caulking with a plurality of dowels 33. As still another method, when the fixing plate 32 and the core element piece 311 are laminated, they may be sequentially bonded with an adhesive or the like.

  The plurality of core elements 31 may be fixed from the upper and lower surfaces of the core element 31 by only two fixing plates 32, and a plurality of fixing plates 32 are provided between them to be stronger than the case shown in FIG. It may be fixed.

1 is a longitudinal sectional view showing an inner rotor type motor according to a first embodiment. It is a top view which shows a core member. It is a top view which shows a some core element. It is a top view which shows a fixed plate. It is a perspective view which shows the fixing plate in one core element and its vicinity. It is a figure which shows the flow of the manufacturing process of an armature. It is a top view which shows a fixed plate. It is a top view which shows a core element plate. It is a figure which shows the flow of the manufacturing process of the armature of the motor which concerns on 2nd Embodiment. It is a top view which shows a some core element piece. It is a top view which shows a fixed plate.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Motor 3 Armature 11 Housing 22 Rotor yoke 23 Field magnet 30 Core member 30a Virtual circle 31 Core element 32 Fixed plate S11-S18, S21-S28 Step

Claims (7)

A core member for an inner rotor type motor,
A plurality of core elements projecting radially from a predetermined circumference;
A fixing portion that fixes the plurality of core elements to each other while substantially magnetically separating the plurality of core elements on the predetermined circumference;
A core member comprising: The core member according to claim 1,
The core member, wherein the fixing portion is a ring-shaped nonmagnetic material along the predetermined circumference. The core member according to claim 1 or 2,
The fixing part is
An upper plate for fixing upper surfaces of the plurality of core elements to each other;
A lower plate for fixing the lower surfaces of the plurality of core elements to each other;
A core member comprising: An inner rotor type motor,
An armature in which a plurality of core elements of the core member according to any one of claims 1 to 3 are wound with conductive wires,
A stator member to which the armature is attached;
A field magnet inserted in the center of the core member;
A rotor member attached to the field magnet, and rotated with respect to the stator member by a magnetic action between the armature and the field magnet;
A motor comprising: A method of manufacturing an armature for an inner rotor type motor,
A plurality of core elements projecting radially from a predetermined circumference; and a fixing portion for fixing the plurality of core elements to each other while substantially magnetically separating the plurality of core elements on the predetermined circumference. Preparing a core member;
Winding a conducting wire around the plurality of core elements;
A method of manufacturing an armature, comprising: It is a manufacturing method of the armature according to claim 5,
The armature manufacturing method, wherein the fixing portion is a ring-shaped non-magnetic body along the predetermined circumference. It is a manufacturing method of the armature according to claim 5,
The fixed portion is formed of the same material as the plurality of core elements, and is a ring-shaped magnetic body along the predetermined circumference,
Preparing the core member comprises:
A step of punching a plate-like core material with a mold to form the plurality of core elements laminated with magnetic bodies;
Punching the core material with another mold to form the fixing portion, and fixing the plurality of core elements to the fixing portion;
A method of manufacturing an armature, comprising:

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