JP2006271193A - Motor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a flat motor capable of producing a multipolar motor with various torque characteristics by using core blocks of the same size. <P>SOLUTION: In a stator 7, the body 8a of each of the core blocks 8 formed in a U-shape is wound with a magnetic wire 9. Each of the core blocks 8 in which a magnetic flux action surface is formed on an opposite surface of each of core legs 8b by energizing and an independent magnetic circuit is formed is arranged on a mounting plate 5, around a rotor 1. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a motor such as a DC brushless motor or a stepping motor.

  FIG. 11 shows a DC brushless motor as an example of the inner rotor type motor. The rotor 51 and the stator 56 are provided in a space surrounded by the motor case 53a and the mounting plate 53b. The rotor 51 has an output shaft 52 rotatably supported by bearings (bearings) 54a and 54b provided on the motor case 53a and the mounting plate 53b, respectively. In the rotor 51, an annular magnet 55 is integrally assembled with the output shaft 52. The magnet 55 is magnetized so that the peripheral surface portion is alternately N-pole and S-pole.

In FIG. 12, the stator 56 surrounds the rotor 51 and a stator core 57 is provided on the control board 60. The stator core 57 has a ring-shaped core body 57a and teeth portions 57b projecting radially toward the output shaft 52 (see FIG. 13). A magnet wire 59 is wound around each tooth portion 57b via an insulator 58. The stator core 57 is assembled to the motor case 53b together with the control board 60 provided with a motor drive circuit.
The control unit provided on the control board 60 controls the energization of the magnet wire 59 at a predetermined timing, thereby forming a stator magnetic pole formed on the tip surface of the tooth portion 57b, and a rotor magnetic pole of the magnet 55 facing the tooth portion 57b. The rotor 51 rotates by repeating the repulsive suction.

In FIG. 13, the stator core 57 is a laminated core formed by punching a silicon steel plate and laminating and caulking a plurality of core plates having teeth portions 57 b projecting radially inward from a ring-shaped core body 57 a. It is done.
When such a laminated core is used, material removal of the silicon steel plate as a base material is deteriorated, and material is wasted. Moreover, since it is necessary to leave the space | interval of the teeth part 57b only for the space which the nozzle of a winding machine approachs, there exists a limit in increasing the winding number of the coil wound around each teeth part 57b. Therefore, a motor that requires torque needs to use a stator core 57 with a large diameter or increase the number of stacked stator cores 57. When the size of the stator core 57 is changed, it is necessary to newly raise the stator mold, which increases capital investment.

  The present invention has been made to solve these problems, and an object of the present invention is to provide a flat motor capable of manufacturing multipolar motors having various torque characteristics using core blocks of the same size. It is in.

In order to achieve the above object, the present invention comprises the following arrangement.
In a motor having a rotor and a stator, the stator is provided with a plurality of core blocks each having a magnet wire wound around a body portion of a core block formed in a U-shape in the circumferential direction, and the opposing surfaces of the core legs are energized. A magnetic flux acting surface is formed on each of the core blocks to form an independent magnetic circuit.
Further, the rotor is an inner rotor type motor that supports the rotor integrally with the output shaft and is provided with a stator so as to surround the rotor, and a core block is disposed on the mounting plate so as to surround the rotor.
Each core block is a laminated core in which steel plates punched in a U-shape are laminated, and the laminated end face side is assembled to the mounting plate with the concave portion facing the output shaft.
The core block is characterized in that one piece of L-shaped block pieces is inserted into the through-hole of the core part of the bobbin around which the magnet wire is wound from both sides and assembled to overlap each other.
Alternatively, in the core block, an L-shaped block piece and an I-shaped block piece are connected so as to be deployable via a joint, and the developed I-shaped block piece is wound around a bobbin around which a magnet wire is wound. The bobbin is assembled to the L-shaped block piece through the through-hole of the core portion, and the I-shaped block piece is bent at the joint portion and assembled integrally with the L-shaped block piece.
Further, the mounting plate is a metal plate made of a non-magnetic material.
The rotor is assembled such that the magnetic pole surface of a cylindrical or disk-shaped magnet magnetized in the plate thickness direction and alternately formed with different magnetic poles in the circumferential direction passes through the recess of the core block. To do.
Alternatively, the rotor is a cylindrical or disk-shaped magnet that is magnetized in the plate thickness direction and alternately formed with different magnetic poles in the circumferential direction, and is segmented with nonmagnetic portions interposed between the magnetic poles. It is characterized by being.

  An outer rotor type motor including a rotor provided with a ring-shaped magnet in a rotor housing and rotating around an output shaft; a stator housing that rotatably supports the output shaft; and a stator in which a core block is assembled. Each core block is assembled to the mounting plate with the concave portion facing the magnet.

  A motor having a rotor in which a ring-shaped magnet is provided on a rotor hub and rotates around an output shaft, a stator housing that rotatably supports the output shaft, and a core block that is assembled with the core block on the mounting plate The concave portion is arranged parallel to the axial direction toward the magnet and the body portion is arranged to face the plate surface.

If the above-mentioned various motors are used, a magnet wire is wound around the body of the core block formed in a U-shape, and a magnetic flux acting surface is formed on the opposing surface of the core leg portion by energization, so that an independent magnetic circuit is formed. A plurality of the core blocks to be formed are arranged in the circumferential direction on the mounting plate. Therefore, since a magnetic circuit is independently formed in each core block of the stator by energization, the waste of materials when manufacturing the stator core is reduced, so that the manufacturing cost can be reduced. Further, since the magnet wire is wound around the body portion of the U-shaped core block, the number of turns can be increased, and the torque performance is improved as compared with a motor of the same size.
In addition, the core block is an I-shaped block in which one piece of L-shaped block piece is inserted into the through-hole of the core part of the bobbin around which the magnet wire is wound and overlapped with each other. The piece is passed through the through-hole of the core part of the bobbin around which the magnet wire is wound, and the bobbin is assembled to the L-shaped block piece, and the I-shaped block piece is bent at the joint and integrated with the L-shaped block piece. When assembled, the bobbin and the core can be assembled separately, so that the assembly of the motor is improved.
Further, since the core blocks of the stator core are individually arranged on the mounting plate, the thickness of each core block can be changed or the number of core blocks can be newly increased by changing the radial position. For this reason, flat motors of various sizes can be manufactured without changing the core size in the axial direction, and multipolar motors having different performance can be realized by changing the radial position of the core block of the same size.
The rotor is a cylindrical or disk-shaped magnet that is magnetized in the plate thickness direction and alternately formed with different magnetic poles in the circumferential direction, and is segmented with nonmagnetic portions interposed between the magnetic poles. In this case, the amount of magnetic flux directed from the magnetic pole of the magnet to the magnetic pole of the opposing core can be increased, so an improvement in rotational torque can be expected.

  DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, preferred embodiments of an inner rotor type motor according to the invention will be described with reference to the accompanying drawings. The motor according to the present invention supports the rotor integrally with the output shaft, and the inner rotor type DC motor in which the stator is provided surrounding the rotor, or a ring-shaped magnet is provided in the rotor housing, and the output shaft is the center. The present invention is widely applied to a rotating rotor, a stator housing that rotatably supports an output shaft, and an outer rotor type DC motor including a stator in which a core block is assembled.

A schematic configuration of the inner rotor type motor will be described with reference to FIGS. 1 and 2.
In FIG. 2, the rotor 1 includes a cup-shaped rotating magnetic body 3 having magnets 2 alternately magnetized in the axial direction at the periphery in the axial direction, and an output shaft 4 made of a nonmagnetic material. It comes to rotate. The rotor 1 may be manufactured by integral molding with the magnet 2 and the rotating magnetic body 3 with the output shaft 4 inserted. In FIG. 1, the output shaft 4 is rotatably supported via a bearing 6 supported by a mounting plate 5. The mounting plate 5 is preferably a metal plate made of a non-magnetic material (such as an aluminum plate) in consideration of the influence on the magnetic circuit formed in the core block 8 described later. Alternatively, a magnetic material may be used as long as the influence on the magnetic circuit due to magnetic flux leakage of each core block 8 can be avoided.

  In FIG. 2, the stator 7 is disposed so as to surround the rotor 1. The stator 7 has a U-shaped core block 8 assembled to the mounting plate 5. In FIG. 1, a magnet wire 9 is wound around a body portion 8a of a core block 8, and a magnetic flux acting surface is formed on the opposing surface of the core leg portion 8b by energization to form an independent magnetic circuit ( (See FIG. 3). The magnet wire 9 is wound around the trunk portion 8a via the insulator 10 in a coil shape. Alternatively, the magnet wire 9 may be directly wound around the insulated body portion 8a.

  Thus, since the waste of the material of the lamination | stacking core formed by stamping a steel plate reduces, manufacturing cost can be reduced. Moreover, since the magnet wire 9 is wound around the trunk | drum 8a of the core block 8, since winding space can be ensured widely, a winding number can be earned and torque performance improves compared with the motor of the same size. In addition, since a space for the nozzle of the winding machine to enter can be secured widely, the manufacturing process can be simplified. In addition, since the magnet wire 9 is wound around the body portion 8a of the core block 8, winding using a simple winding machine such as bobbin winding that rotates the core block 8 to wind the magnet wire 9 is also possible.

  The rotor 1 and the stator 7 are accommodated in a space surrounded by the mounting plate 5 and a motor case 11 formed in a cup shape. A control board 12 provided with a motor drive circuit is fixed to the motor case 11. The control unit provided on the control board 12 controls the energization of the magnet wire 9 at a predetermined timing to thereby form a stator magnetic pole formed on the facing surface of the core leg 8b and the rotor of the magnet 2 facing the core leg 8b. The rotor 1 rotates by repeating repulsive suction with the magnetic pole.

  In FIG. 3, each core block 8 is a laminated core obtained by laminating and caulking electromagnetic steel plates (silicon steel plates) punched in a U shape, for example. Or the laminated core which laminated | stacked the electromagnetic steel plate punched out in L shape is combined, and it inserts in the core part of the insulator 10 by which the magnet wire 9 was wound, and the U-shaped core block 8 is formed. In FIG. 2, each core block 8 is radially arranged with the concave portions 8 c directed toward the output shaft 4, and the protruding portions 8 d protruding from the laminated end surface side are fitted into the holes provided in the mounting plate 5 and assembled. .

  FIG. 2 shows an example of stator arrangement for 8 poles and 12 slots. The cup-shaped rotor 1 is assembled so that the magnetic pole surface of the magnet 2 magnetized in the plate thickness direction (axial direction) and alternately formed with different magnetic poles in the circumferential direction passes through the recess 8c of the core block 8 (FIG. 1 and FIG. 3). By arranging the rotor magnetic pole surface so as to pass through the recess 8c of the core block 8, a motor having a large rotor diameter can be manufactured even with a motor of the same size.

  When the motor size is changed, or when it is desired to increase the number of turns of the magnet wire 9 to improve the torque performance, the core block 8 is assembled with the position shifted to the outside in the radial direction of the mounting plate 5 in FIG. As a result, the interval between the core blocks 8 can be widened (or the number of core blocks 8 can be increased), so that flat motors of various sizes can be manufactured without changing the core size in the axial direction. A multi-pole motor with different performance can be realized using the core block 8.

  FIG. 5 shows an example of a 4-pole 6-slot stator arrangement in which the number of core blocks 8 is reduced and each block is shifted radially inward to reduce the size in the radial direction and the height direction. Since the thickness of the core can be increased by an amount corresponding to the interval between the core blocks 8, the flatness with a large torque can be obtained as compared with the motor using the integrated laminated core shown in FIG. A motor can be manufactured.

  Next, an application example to an outer rotor type DC brushless motor will be described with reference to FIG. In FIG. 6, the rotor 13 is provided with a ring-shaped magnet 15 in the rotor housing 14, and rotates around the output shaft 16. A stator housing 18 and a core block 19 are assembled to the stator 17. Specifically, the stator housing 18 supports the output shaft 16 in a rotatable manner. The output shaft 16 is rotatably supported by a bearing 19 provided in a shaft hole of a cylindrical stator housing 18.

  A control board 21 and a mounting plate 22 are integrally assembled with the stator housing 18. The mounting plate 22 may be made of either a nonmagnetic material or a magnetic material as long as there is no influence on the magnetic circuit due to magnetic flux leakage of each core block 19. Core blocks 19 are assembled on the mounting plate 22 at a predetermined interval, and each core block 19 is disposed so as to be surrounded by the rotor 13. A magnet wire 24 is wound around the body portion 19a of each core block 19 via an insulator 23, and independent magnetic circuits in which the opposing surfaces of the core leg portions 19b become magnetic flux acting surfaces are formed by energization. Yes. The core block 19 is a laminated core in which electromagnetic steel plates punched in a U-shape or L-shape are laminated, and a projection 19d that protrudes toward the laminated end face with the recess 19c facing the magnet 15 is attached. The plate 22 is fitted into a hole drilled and assembled.

  The rotor 13 is assembled such that the magnetic pole surface of the ring-shaped magnet 15 magnetized in the plate thickness direction (axial direction) and alternately formed with different magnetic poles in the circumferential direction passes through the recess 19 c of the core block 19. By disposing the magnetic pole surface of the magnet 15 so as to pass through the recess 19c of the core block 19, a motor having the same core size and a small rotor diameter can be manufactured. When the motor size is changed, or when it is desired to increase the number of turns of the magnet wire 24 to improve the torque performance, the core block 19 is assembled with the position shifted to the outside in the radial direction of the mounting plate 22 as in FIG. Thereby, flat motors of various sizes can be manufactured without changing the core size in the axial direction, and multipolar motors having different performances can be realized using the core block 19 of the same size.

  Next, FIG. 7 shows still another embodiment of a motor. The same members as those in FIG.

  The rotor 25 is provided with a ring-shaped magnet 27 on the outer periphery of the rotor hub 26. One end of the output shaft 16 is integrally assembled with the rotor hub 26, and the rotor 25 rotates about the output shaft 16. A stator housing 29 and a core block 19 are assembled to the stator 28. Specifically, the stator housing 29 supports the output shaft 16 so as to be rotatable. The output shaft 16 is rotatably supported by a bearing 19 provided in a shaft hole of a cylindrical stator housing 29.

  A mounting plate 22 is integrally assembled with the stator housing 29. The mounting plate 22 may be made of either a nonmagnetic material or a magnetic material as long as there is no influence on the magnetic circuit due to magnetic flux leakage of each core block 19. The core block 19 is assembled on the mounting plate 22 at a predetermined interval. A magnet wire 24 is wound around the body portion 19a of each core block 19 via an insulator 23, and independent magnetic circuits in which the opposing surfaces of the core leg portions 19b become magnetic flux acting surfaces are formed by energization. Yes. The core block 19 is a laminated core in which electromagnetic steel plates punched in a U shape or an L shape are laminated.

  Each core block 19 is arranged with the recess 19c parallel to the axial direction and facing the magnet 15, with the body portion 19a facing the plate surface, and on both sides of the core leg portion 19b on the holding portion 22a protruding from the mounting plate 22. It is sandwiched and assembled to the mounting plate 22. The mounting plate 22 is formed with an escape recess 22b between the holding portions 22a for avoiding interference with the insulator 23 and the magnet wire 24. A motor case 30 is assembled to the mounting plate 22 so as to cover the rotor 25 and the stator 28. A control board 31 is fixed in the motor case 30.

  The rotor 25 is assembled so that the magnetic pole surface of the ring-shaped magnet 27 magnetized in the radial direction passes through the recess 19 c of the core block 19. As described above, when the rotor 25 is arranged in the middle with respect to the stator 28 and the rotor magnetic pole surface passes through the recess 19c of the core block 19, the core block 19 of the same size is used to make any rotor diameter (the length of the rotor hub 26). Can be manufactured. When changing the motor size or increasing the number of turns of the magnet wire 24 to improve the torque performance, the mounting plate 22 is replaced and the radial position of the core block 19 is changed and assembled. Thereby, flat motors of various sizes can be manufactured without changing the core size in the axial direction, and multipolar motors having different performances can be realized using the core block 19 of the same size.

Here, other examples of the rotor and the stator will be described with reference to FIGS.
In FIG. 8 (a), the rotor is a disc shape in which N poles (S poles) and S poles (N poles) are magnetized in the plate thickness direction (axial direction) and different magnetic poles are alternately formed in the circumferential direction. The magnet 32 is used. In this case, in FIG. 8B, it is preferable that the magnetic poles are segmented with nonmagnetic portions 33 interposed between the magnetic poles of the magnet 32. As a result, in FIG. 8C, the amount of magnetic flux acting on the opposing core block 34 is increased by reducing the magnetic flux from the magnetic pole of the magnet 32 to the adjacent different magnetic pole, so that improvement in rotational torque can be expected.

  Next, in FIG. 9A, the core block 35 may be formed by combining L-shaped block pieces 35a and 35b. In this case, in FIG. 9B, one piece 35c, 35d of the block pieces 35a, 35b is inserted from both sides into the through hole 37a of the core part of the bobbin 37 around which the magnet wire 36 is wound, and overlapped with each other. Block 35 is assembled. For example, in FIG. 9B, by passing the through hole 37a of the bobbin 37 through one piece 35d of the block piece 35b and inserting the one piece 35c of the block piece 35a into the through hole 37a, the one piece 35c and the one piece 35d overlap each other. Can be assembled together.

  10 (a) and 10 (b), the core block 38 may be formed such that an L-shaped block piece 38a and an I-shaped block piece 38b are connected in a deployable manner via a joint portion 38c. Concave portions 38d and convex portions 38e are provided on end surfaces of the L-shaped block piece 38a and the I-shaped block piece 38b. When the I-shaped block piece 38b is rotated so as to stand up around the joint portion 38c, the convex portion 38e is fitted into the concave portion 38d and assembled into a U-shape.

In order to assemble the bobbin 37 to the core block 38, in FIG. 10A, the developed I-shaped block piece 38b is passed through the through hole 37a of the core part of the bobbin 37 around which the magnet wire 36 is wound. 37 is assembled to the L-shaped block piece 38a.
Next, in FIG. 10B, the I-shaped block piece 38b is bent around the joint portion 38c, and the L-shaped block piece 38a and the end surfaces are brought into contact with each other to be assembled together.
Thus, the assembly of the motor is improved because the bobbin 37 and the core block 38 can be assembled separately.

  In the present embodiment, the DC brushless motor is exemplified, but the present invention is not limited to this, and can be applied to other motors such as a stepping motor.

It is a half-section explanatory drawing of an inner rotor type DC brushless motor. It is a top view which shows the example of a layout of a rotor and a stator. It is a perspective explanatory view of a core block. It is a top view which shows the example of a layout of a rotor and a stator. It is a top view of the rotor and stator which concern on another example. It is a half-section explanatory drawing of an outer rotor type DC brushless motor. It is a half-section explanatory drawing of the brushless motor which concerns on another example. It is the perspective view of the rotor which concerns on another example, and arrangement | positioning block diagram of a rotor and a stator. It is the exploded view and assembly explanatory drawing of the stator core which concern on another example. It is assembly explanatory drawing of the stator core which concerns on another example. It is half-sectional explanatory drawing of the conventional DC brushless motor. It is a top view which shows the example of a layout of the conventional rotor and a stator. It is a top view of the conventional stator core.

Explanation of symbols

1, 13, 25, rotor 2, 15, 27, 32 magnet 3 rotating magnetic body 4, 16 output shaft 5, 22 mounting plate 6, 20 bearing 7, 17, 28 stator 8, 19, 34, 35, 38 core block 8a, 19a Body portion 8b, 19b Core leg portion 8c, 19c Recessed portion 8d, 19d Protrusion portion 9, 24, 36 Magnet wire 10, 23 Insulator 11, 30 Motor case 12, 21, 31 Control board 14 Rotor housing 18, 29 Stator Housing 22a Holding portion 22b Escape recess 26 Rotor hub 33 Non-magnetic portion 35a, 35b, 38a, 38b Block piece 37 Bobbin 37a Through hole

Claims (10)

In a motor with a rotor and a stator,
The stator is provided with a plurality of core blocks each having a magnet wire wound around the core portion of the core block formed in a U-shape in the circumferential direction, and a magnetic flux acting surface is formed on the opposing surface of the core leg portion by energization. An independent magnetic circuit is formed by a core block.   2. An inner rotor type motor in which a rotor is integrally supported with an output shaft and a stator is provided so as to surround the rotor, and a core block is disposed on the mounting plate so as to surround the rotor. The motor described.   2. The motor according to claim 1, wherein each core block is a laminated core in which steel plates punched in a U-shape are laminated, and the laminated end face side is assembled to the mounting plate with the concave portion facing the output shaft.   2. The core block is constructed by inserting one piece of L-shaped block pieces into a through-hole of a core part of a bobbin around which a magnet wire is wound from both sides and overlapping each other. Motor.   In the core block, an L-shaped block piece and an I-shaped block piece are connected in series so as to be expandable via a joint portion, and the core portion of the bobbin around which the magnet wire is wound around the developed I-shaped block piece 2. The motor according to claim 1, wherein the bobbin is assembled to the L-shaped block piece by passing through the through-hole, and the I-shaped block piece is bent at the joint portion and assembled integrally with the L-shaped block piece. .   2. The motor according to claim 1, wherein a metal plate made of a non-magnetic material is used as the mounting plate for assembling the core block.   The rotor is assembled such that a magnetic pole surface of a cylindrical or disk-shaped magnet magnetized in the plate thickness direction and alternately formed with different magnetic poles in the circumferential direction passes through the recess of the core block. Item 1. The motor according to Item 1.   The rotor is a cylindrical or disk-shaped magnet that is magnetized in the plate thickness direction and alternately formed with different magnetic poles in the circumferential direction, and is segmented with nonmagnetic portions interposed between the magnetic poles. The motor according to claim 1.   An outer rotor type motor including a rotor provided with a ring-shaped magnet in a rotor housing and rotating around an output shaft, a stator housing that rotatably supports the output shaft, and a stator in which a core block is assembled. The motor according to claim 1, wherein each core block is assembled to the mounting plate with the concave portion facing the magnet.   A motor having a rotor in which a ring-shaped magnet is provided on a rotor hub and rotates around an output shaft, a stator housing that rotatably supports the output shaft, and a core block that is assembled with the core block on the mounting plate 2. The motor according to claim 1, wherein the concave portion is disposed parallel to the axial direction toward the magnet and the body portion is opposed to the plate surface.

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