JP2009142087A - Electric motor and electric-motor manufacturing method - Google Patents

Electric motor and electric-motor manufacturing method Download PDF

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JP2009142087A
JP2009142087A JP2007316522A JP2007316522A JP2009142087A JP 2009142087 A JP2009142087 A JP 2009142087A JP 2007316522 A JP2007316522 A JP 2007316522A JP 2007316522 A JP2007316522 A JP 2007316522A JP 2009142087 A JP2009142087 A JP 2009142087A
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claw
molded body
electric motor
shaped magnetic
magnetic poles
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Keisuke Abe
恵輔 安部
Kazuo Sato
和雄 佐藤
Susumu Amaike
将 天池
Shuichi Takahashi
秀一 高橋
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Hitachi Industrial Equipment Systems Co Ltd
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Hitachi Industrial Equipment Systems Co Ltd
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a small and thin electric motor while achieving high efficiency and improvement in productivity. <P>SOLUTION: An electric motor is configured as follows: a compact is formed by compressing magnetic powder. The compact has an annular base part 2' and a plurality of claw magnetic poles 2a circumferentially formed while protruding from the base part 2'. The electric motor is provided with a stator core in which the compacts are arranged oppositely to each other. Each claw magnetic pole of the other compact is located between the claw magnetic poles of one compact. The compact has a plurality of recessed parts 2b on the inner peripheral side of the base part 2' and between the claw magnetic poles 2a so as to allow positioning protrusions 5a to be inserted therein. Accordingly, when executing resin-molding in a die 5, it is possible to execute positioning by the protrusions 5a. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

本発明は、電動機及び電動機の製造方法に関するものである。   The present invention relates to an electric motor and a method for manufacturing the electric motor.

電動機は駆動源として種々の用途に用いられており、様々な製品の内部に組み込まれて使用されることが多い。例えば、送風機、冷凍空調用の圧縮機、さらには、自動車のパワーウィンドウやワイパー等のいわゆる補機類等にも用いられている。このように、製品内部に組み込まれる電動機に関しては、高効率化だけではなく、小型化(薄型化)、あるいは組立性の向上が求められている。そして、高効率化、小型化、組立性の向上を図るためのロータあるいはステータの形状が検討されている。   An electric motor is used as a drive source in various applications, and is often used by being incorporated in various products. For example, it is also used for blowers, compressors for refrigeration and air conditioning, and so-called auxiliary machines such as automobile power windows and wipers. As described above, regarding an electric motor incorporated in a product, not only high efficiency but also miniaturization (thinning) or improvement in assemblability is required. And the shape of the rotor or stator for improving efficiency, downsizing, and improving assemblability has been studied.

特許文献1には、小型化や生産性の向上を図るためのステッピングモータの構成が開示され、特許文献2には、コアの回転方向の位置決めを行うために、コア平坦部の外周に位置決め用のV状溝を備えた構成が開示されている。また、特許文献3には、多相クローポール型モータが示され、磁性粉を圧縮成形することで製造の容易化を図りながらも複雑な形状の爪型磁極を得ることで、モータの高効率化を行っている。   Patent Document 1 discloses a configuration of a stepping motor for reducing the size and improving the productivity, and Patent Document 2 discloses positioning for the outer periphery of the core flat portion in order to position the core in the rotational direction. A configuration having a V-shaped groove is disclosed. Further, Patent Document 3 discloses a multiphase claw pole type motor, and it is possible to obtain a claw type magnetic pole having a complicated shape while facilitating manufacture by compressing magnetic powder, thereby achieving high efficiency of the motor. Is going on.

特許文献4〜6には、コアの位置決めに関し、ボビンを用いた構成が開示されている。   Patent Documents 4 to 6 disclose a configuration using a bobbin with respect to positioning of the core.

特開2005-287288号公報JP 2005-287288 A 特開平4-17538号公報Japanese Patent Laid-Open No. 4-17538 特開2006-296188号公報JP 2006-296188 JP 特開平8-116659号公報JP-A-8-116659 特開2005-304164号公報JP 2005-304164 A 特開平10-295070号公報JP-A-10-295070

製造性を向上しつつも電動機の小型化及び高効率化を図るには、コアの位置決めが重要となる。特に、磁極を有するコアを対向して配置する構成においては、両コアの位置ずれが磁界形成に影響を与えるため、位置決めの容易化を図ることが必要となる。   In order to reduce the size and increase the efficiency of the motor while improving the manufacturability, the positioning of the core is important. In particular, in a configuration in which cores having magnetic poles are arranged to face each other, positional deviation between both cores affects magnetic field formation, so that it is necessary to facilitate positioning.

特許文献1は金属板を同一形状に成形したものを一対のステータとして用い、これに位置決め孔及び貫通孔を形成して位置決めを行っている。また、特許文献2ではコア平坦部の外周にV状溝を有し、位置決め用のスライダを用いてコアの回転方向の位置決めを行っている。さらに、特許文献3では、コアに凸部及び凹溝を設けること、あるいは、嵌合突起と嵌合孔を設け(図15〜図18参照)、これによって位置決めを図っている。   In Patent Document 1, a metal plate formed in the same shape is used as a pair of stators, and positioning is performed by forming positioning holes and through holes in the stators. Moreover, in patent document 2, it has a V-shaped groove | channel on the outer periphery of a core flat part, and the positioning of the rotation direction of a core is performed using the slider for positioning. Furthermore, in patent document 3, a convex part and a ditch | groove are provided in a core, or a fitting protrusion and a fitting hole are provided (refer FIGS. 15-18), and positioning is aimed at by this.

これらの特許文献1〜3に示されるようにコアに位置決め構造を設ける場合には、十分なコア強度が要求される。特許文献1では、金属板を金型で成形したコアを用いているため、位置決め孔を容易に成形できると考えられるが、コア強度が低い場合には貫通孔を設けることでさらに強度が低下し、その後の製造工程における取扱性や信頼性の低下を招くことになる。   As shown in these patent documents 1 to 3, when a positioning structure is provided on the core, sufficient core strength is required. In Patent Document 1, it is considered that a positioning hole can be easily formed because a core obtained by molding a metal plate with a mold is used. However, when the core strength is low, the strength is further reduced by providing a through hole. As a result, the handling and reliability in the subsequent manufacturing process are reduced.

特に、特許文献3は、磁性粉を圧縮成形したコアを用い、磁極の成形をしやすくしているものの、コア自体は磁性粉を圧縮したものに過ぎず、十分な強度を確保することは容易ではない。したがって、貫通孔を設けずに凹凸形状による位置決めを採用しているが、形状の複雑化を招いてしまう。複雑な形状の爪型磁極が得られることが圧縮成形のメリットの一つであるが、位置決め構造は、爪型磁極と異なり、位置決めがなされた後の電動機としては高効率化に寄与しないため、強度の面では単純な形状が望ましい。   In particular, Patent Document 3 uses a core formed by compression molding of magnetic powder to facilitate the formation of magnetic poles, but the core itself is only a compression of magnetic powder and it is easy to ensure sufficient strength. is not. Therefore, although positioning by a concavo-convex shape is employed without providing a through hole, the shape becomes complicated. One of the merits of compression molding is that a claw-shaped magnetic pole with a complicated shape is obtained, but unlike the claw-shaped magnetic pole, the positioning structure does not contribute to high efficiency as an electric motor after positioning is performed. A simple shape is desirable in terms of strength.

特許文献4〜6はボビンを用いて位置決めを行っているが、特許文献4では、ボビンの位置決め用突部とコア外周部に設けた切欠きとの嵌合を用いるものであり(段落0037等参照)、コアに位置決め構造を有する点において特許文献1〜3と同様の課題が生じ得る。   In Patent Documents 4 to 6, positioning is performed using a bobbin. However, in Patent Document 4, a fitting between a bobbin positioning projection and a notch provided in the outer periphery of the core is used (paragraph 0037 and the like). Reference) and the same problem as in Patent Documents 1 to 3 may occur in that the core has a positioning structure.

特許文献5〜6は、ボビンの内周側に突出する位置決め部を備えた例が開示され、これによってコアの位置決めを図っているが、これらはいずれもロータが配置される内周側に突出する構成であるため、位置決め部の存在が磁極の形状や磁極間の距離に影響を与え、高効率化に制約が生じてしまうものであった。   Patent Documents 5 to 6 disclose examples in which a positioning portion that protrudes toward the inner peripheral side of the bobbin is disclosed, and thereby the core is positioned, but these all protrude toward the inner peripheral side where the rotor is disposed. Therefore, the presence of the positioning portion has an influence on the shape of the magnetic pole and the distance between the magnetic poles, and the efficiency is restricted.

上述のように、特に磁性粉を圧縮成形したコアを用いる場合には、強度上、コア形状の単純化が必要となる。1相を形成する2つの対向したコア(以下、両コアを指して「上下コア」という。)の位置決めに際し、単純なコア形状での位置決めを可能とする方法及びそのときに生じ得る課題について一例を示しながら説明する。   As described above, when using a core formed by compression molding of magnetic powder, it is necessary to simplify the core shape in terms of strength. An example of a method that enables positioning in a simple core shape and the problems that may occur at the time of positioning two opposing cores that form one phase (hereinafter referred to as “upper and lower cores” referring to both cores) It demonstrates, showing.

図8は、コアの位置決めのために、コア外周の接合面に凹凸を設け、それを組み合わせることにより爪型磁極の間隔が等しくなるようにした例を示している。この例は、磁性粉を圧縮成形して圧粉磁心を得るにあたって、金型の応力集中による破損防止や、成形体を型から取り出す際に成形体のスプリングバックにより金型と固着し、成形体自身が破損してしまうことを防止するために、この凹凸の形状の側面を傾斜させた場合を示している。   FIG. 8 shows an example in which irregularities are provided on the joint surface on the outer periphery of the core for positioning the core, and by combining them, the distance between the claw-shaped magnetic poles becomes equal. In this example, when magnetic powder is compression molded to obtain a powder magnetic core, damage due to stress concentration of the mold is prevented, and when the molded body is removed from the mold, the molded body is fixed to the mold by the spring back, and the molded body In order to prevent the device itself from being damaged, the case where the side surface of the uneven shape is inclined is shown.

この圧粉磁心は鉄粉が圧縮成形されて押し固められたものであるため、強度のほか、成形時の加圧方向に対しては寸法精度が得られ難い。したがって、凹凸の高さ方向バラツキが生じ得る。   Since this dust core is made by pressing and compacting iron powder, it is difficult to obtain dimensional accuracy in the pressing direction during molding in addition to strength. Therefore, unevenness in the height direction may occur.

このとき、互いに係合する凹凸のうち、凸部が凹部よりも高くなってしまった場合は上下コア接合面に隙間ができることになる(図8(b)参照)。一方、逆に凸部が凹部深さよりも低くなってしまう場合は、凹凸間の側面に隙間が生じるため(図8(c)参照)、上下コアの位置精度、特に回転方向の精度が悪くなり、位置ずれが生ずる。   At this time, when the convex part becomes higher than the concave part among the concaves and convexes engaged with each other, a gap is formed on the upper and lower core joint surfaces (see FIG. 8B). On the other hand, when the convex portion is lower than the concave portion depth, a gap is formed on the side surface between the concave and convex portions (see FIG. 8C), so that the positional accuracy of the upper and lower cores, particularly the accuracy in the rotation direction is deteriorated. Misalignment occurs.

これらの図8(b)(c)に示される状態は、電動機の特性を悪化させる原因となり、単に電動機の性能低下を招くだけではなく、電動機の性能のばらつき、すなわち、量産される電動機の個体差を生じやすいものとなっていた。   These states shown in FIGS. 8B and 8C cause the deterioration of the characteristics of the motor, and not only cause a decrease in the performance of the motor, but also a variation in the performance of the motor, that is, individual motors to be mass-produced. It was easy to make a difference.

本発明は、上記課題に鑑みてなされたものであり、生産性の向上と高効率化を図りながらも小型、薄型の電動機を提供することを目的としている。   The present invention has been made in view of the above problems, and an object of the present invention is to provide a small and thin electric motor while improving productivity and increasing efficiency.

上記目的を達成するために、円環形状の基部とこの基部から突出して周方向に複数形成される爪型磁極とを有する成形体を、磁性粉を圧縮して成形し、この成形体が対向して配置される固定子コアを備え、一の成形体の爪型磁極の間に他の成形体の爪型磁極が位置するように構成した電動機において、本願の第一の発明は、前記成形体は前記基部の内周側であって前記爪型磁極の間には、位置決め用の突起が挿入される複数の凹状を有することを特徴としている。   In order to achieve the above object, a molded body having an annular base and a plurality of claw-shaped magnetic poles protruding from the base and formed in the circumferential direction is molded by compressing magnetic powder, and the molded body is opposed to the molded body. In the electric motor having a stator core disposed in a manner such that the claw-shaped magnetic pole of another molded body is positioned between the claw-shaped magnetic poles of one molded body, The body is characterized in that it has a plurality of concave shapes into which positioning projections are inserted between the claw-shaped magnetic poles on the inner peripheral side of the base portion.

この第一の発明においては、前記凹状に、モールド金型に設けられた突起が挿入されることをさらなる特徴としている。   This first invention is further characterized in that a protrusion provided on the mold is inserted into the concave shape.

また、電動機の製造方法における発明は、上下金型で前記成形体を保持して樹脂モールドする工程で、前記上下金型に設けられた突起と、前記成形体に設けられる係合部とを係合し、対向配置される成形体の周方向の位置決めを行うことを特徴としている。   Further, the invention in the method of manufacturing an electric motor relates to a protrusion provided on the upper and lower molds and an engagement portion provided on the molded body in the step of resin molding by holding the molded body with the upper and lower molds. In addition, it is characterized in that positioning in the circumferential direction of the molded body that is arranged to face is performed.

さらには、上下金型で前記成形体を保持して樹脂モールドする工程で、前記上下金型に設けられた突起と、前記基部の内周側であって前記爪型磁極の間に設けられる凹状とを係合することを特徴としている。   Further, in the step of holding the molded body with the upper and lower molds and resin molding, a concave shape provided between the protrusion provided on the upper and lower molds and the claw mold magnetic pole on the inner peripheral side of the base portion And is engaged.

本発明によれば、生産性の向上と高効率化を図りながらも小型、薄型の電動機を提供することができる。   According to the present invention, it is possible to provide a small and thin electric motor while improving productivity and increasing efficiency.

以下、図面を用いて本発明の実施の形態を説明する。本欄では、ステータのコアに磁性粉を圧縮した成形体を対向して配置したものを用い、この圧粉磁心からなる成形体に特別な凹凸を付けずに位置決めをする構成を説明する。まず、図1及び図2を用いて本実施形態の電動機の構成を説明する。   Hereinafter, embodiments of the present invention will be described with reference to the drawings. In this section, a configuration will be described in which a molded body formed by compressing magnetic powder is disposed opposite to a stator core, and the molded body formed of the powder magnetic core is positioned without any special unevenness. First, the structure of the electric motor of this embodiment is demonstrated using FIG.1 and FIG.2.

図1は本実施形態の電動機に用いられるステータの1相分(符号3)の分解斜視図である。図1に示すように、上下コアは、磁性粉を圧縮して成形された圧粉コア2を対向したものが用いられ、これによって固定子コアを構成している。すなわち、本実施形態では、同一形状の圧粉コア2を対向配置することで1相分の上下コアを構成している。   FIG. 1 is an exploded perspective view of one phase (reference numeral 3) of a stator used in the electric motor of the present embodiment. As shown in FIG. 1, the upper and lower cores are opposed to a dust core 2 formed by compressing magnetic powder, thereby constituting a stator core. That is, in this embodiment, the upper and lower cores for one phase are constituted by opposingly arranging the dust cores 2 having the same shape.

圧粉コア2には爪型磁極2aが複数形成されており、一方の圧粉コア2の爪型磁極2aと他方の圧粉コア2の爪型磁極2aとが互いに干渉しないように、上下コアが組み合わされる。したがって、本実施形態に示す例では、上下コア合わせて24の爪型磁極がステータの内周面に隣り合って配置されることになる。   A plurality of claw-type magnetic poles 2a are formed on the dust core 2, and the claw-type magnetic poles 2a of one dust core 2 and the claw-type magnetic poles 2a of the other dust core 2 do not interfere with each other. Are combined. Therefore, in the example shown in the present embodiment, 24 claw-type magnetic poles including the upper and lower cores are arranged adjacent to the inner peripheral surface of the stator.

これらの対向配置される圧粉コア2に挟まれてボビン1が挟持されている。ボビン1にはコイルが巻き回され、このコイルに電流を流すことによって電動機が回転する。また、ボビン1にはコア位置決め用の突起1aを備えている。突起1aの作用効果については後述する。   The bobbin 1 is sandwiched between the powder cores 2 arranged to face each other. A coil is wound around the bobbin 1, and the electric motor is rotated by passing a current through the coil. The bobbin 1 is provided with a core positioning protrusion 1a. The effect of the protrusion 1a will be described later.

図2は3相クローティース電動機の分解図である。ステータ10は、図1に示す上下コア2、ボビン1及びコイルを3相積層したものであり、このステータ10の中心に、シャフトとロータコアとマグネットを組み合わせて構成したロータ11が挿入される。ステータ10の両側はブラケットが配置され、図2ではステータ10の両端面が、負荷側ブラケット12aと反負荷側ブラケット12bとで挟まれている。ロータ11はベアリング13にて支持され、これらの積層構造を形成するため、貫通ねじ14によって各構成が固定される。   FIG. 2 is an exploded view of the three-phase crotice motor. The stator 10 is obtained by laminating the upper and lower cores 2, the bobbin 1 and the coil shown in FIG. 1 in three phases, and a rotor 11 configured by combining a shaft, a rotor core, and a magnet is inserted into the center of the stator 10. Brackets are arranged on both sides of the stator 10, and in FIG. 2, both end surfaces of the stator 10 are sandwiched between the load side bracket 12a and the anti-load side bracket 12b. The rotor 11 is supported by a bearing 13, and each component is fixed by a through screw 14 in order to form a laminated structure thereof.

図3は図2に示したステータ10の断面を示す図であり、図4はステータ10内部の3相分のステータ形状を示す外観斜視図である。図5は、図4の3相からなるステータ10のうち、1相分3を分解して示した図であり、2つの対向する圧粉コア2の間に、絶縁用ボビン1に銅線を巻き回して製作したコイル4を挟み込んでいることを示している。   3 is a view showing a cross section of the stator 10 shown in FIG. 2, and FIG. 4 is an external perspective view showing a stator shape for three phases inside the stator 10. As shown in FIG. FIG. 5 is an exploded view of one phase 3 of the three-phase stator 10 of FIG. 4, and a copper wire is placed on the insulating bobbin 1 between two opposing dust cores 2. It shows that the coil 4 produced by winding is sandwiched.

また、圧粉コア2の外周側面には凹部が設けられている。上下コアを組み合わせることによって、この凹部が開口部となり、ここから巻き線が引き出される。3相積層の際には、この巻き線引出し部も3箇所になるが、これらを近づけて配置することで、簡易な構成で電動機を構成することができる。   Moreover, the recessed part is provided in the outer peripheral side surface of the powder core 2. As shown in FIG. By combining the upper and lower cores, this recess becomes an opening, from which the winding is drawn. In the case of three-phase lamination, there are also three winding lead portions, but by arranging them close to each other, an electric motor can be configured with a simple configuration.

図1〜5に示すように、圧粉コア2に設けられた爪型磁極2aは、ステータ10の内周面、すなわち、のロータ11と向かい合う部分に、隣り合って配置され、コイル4に電流が流れることによって、互いに隣り合う磁極間に磁束が発生する。これによってロータ11に回転力が生じて電動機として機能することになる。   As shown in FIGS. 1 to 5, the claw-shaped magnetic pole 2 a provided on the dust core 2 is arranged adjacent to the inner peripheral surface of the stator 10, that is, the portion facing the rotor 11, Flows, a magnetic flux is generated between the magnetic poles adjacent to each other. As a result, a rotational force is generated in the rotor 11 to function as an electric motor.

次に、本実施形態における上下コアの位置決めについて、さらに具体的な構成を示しながら説明する。   Next, the positioning of the upper and lower cores in this embodiment will be described while showing a more specific configuration.

図1に示すように、上下コアに磁性粉の成形体からなる圧粉コア2を対向したものが用いられ、圧粉コア2に設けられた爪型磁極2aが隣り合って配置される。また、ボビン1はコア位置決め用の突起1aを複数備えている。突起1aは、ボビン1を挟む圧粉コア2に向かって上下両側に突出しており、この突起1aが圧粉コア2の爪型磁極2aの間に挿入される。なお、図1に示すように、上下両側に突出する突起1aは、上下で互い違いに突出しており、後述する凹状2b内への挿入が行いやすくなっている。   As shown in FIG. 1, the upper and lower cores are opposed to a dust core 2 made of a magnetic powder compact, and claw-shaped magnetic poles 2a provided on the dust core 2 are arranged adjacent to each other. The bobbin 1 includes a plurality of core positioning protrusions 1a. The protrusion 1a protrudes on both the upper and lower sides toward the dust core 2 that sandwiches the bobbin 1, and the protrusion 1a is inserted between the claw-type magnetic poles 2a of the dust core 2. In addition, as shown in FIG. 1, the protrusions 1a protruding on both the upper and lower sides protrude alternately in the upper and lower directions, and can be easily inserted into a concave shape 2b described later.

圧粉コア2及びボビン1には円環形状のものを用い、図1に示すように、一方の圧粉コア2の爪型磁極2aと他方の圧粉コア2の爪型磁極2aとが互い違いに並ぶように、両コアが組み合わされる。このとき、上下コアが組み合わされた状態で互いに隣り合う爪型磁極2a間の距離をL4とする。   The dust core 2 and the bobbin 1 are of an annular shape, and the claw-shaped magnetic pole 2a of one dust core 2 and the claw-shaped magnetic pole 2a of the other dust core 2 are alternately arranged as shown in FIG. Both cores are combined so that they line up. At this time, the distance between the claw-shaped magnetic poles 2a adjacent to each other in a state where the upper and lower cores are combined is defined as L4.

このように上下コアが組み合わされるため、ステータ10の内周面を構成する爪型磁極2aは、円周方向の幅L2が、爪型磁極2a間の距離L1よりも小さくなっている。   Since the upper and lower cores are combined in this way, the claw-type magnetic pole 2a constituting the inner peripheral surface of the stator 10 has a circumferential width L2 smaller than the distance L1 between the claw-type magnetic poles 2a.

また、円環状の圧粉コア2は平面形状の基部2’において、爪型磁極2a間に凹状2bを備えている。この凹状2bは、図に示すとおり、爪型磁極2aの間において、基部2’の円環面において凹み形状となっているものであり、基部2’の円環面に切り欠き等のような特別の凹凸形状を設けることなく形成される。   Further, the annular dust core 2 is provided with a recess 2b between the claw-shaped magnetic poles 2a in the planar base 2 '. As shown in the figure, the concave shape 2b has a concave shape in the annular surface of the base portion 2 ′ between the claw-shaped magnetic poles 2a, and is notched in the annular surface of the base portion 2 ′. It is formed without providing a special uneven shape.

上下コアが組み合わされた状態では、他方の圧粉コア2の爪型磁極2aの先端部が、凹状2b内に位置するため、圧粉コア2の内周部における凹状2bの幅はL2よりも大となっている。また、この凹状2bの根元部には、ボビン1の突起1aが挿入される。したがって、凹状2bの円周方向の幅L3は、圧粉コア2とボビン1とが組み合わされた状態でボビン1に設けられた突起1aの幅L3と同じ幅となっている。   In the state where the upper and lower cores are combined, the tip of the claw-shaped magnetic pole 2a of the other dust core 2 is located in the recess 2b, so the width of the recess 2b in the inner peripheral portion of the dust core 2 is larger than L2. It has become big. Further, the protrusion 1a of the bobbin 1 is inserted into the root portion of the concave shape 2b. Therefore, the circumferential width L3 of the concave shape 2b is the same as the width L3 of the protrusion 1a provided on the bobbin 1 in a state where the dust core 2 and the bobbin 1 are combined.

上記の構成を備えたことによって、ボビン1の突起1aが圧粉コア2の凹状2bに挿入されて上下コアの位置決めがなされ、圧粉コア2が回転方向にずれることはない。また、突起1aは内周側ではなく、各圧粉コア2側に突出しているため、ロータ11側で隣り合う爪型磁極2aの配置に影響を与えることはなく、隣り合う爪型磁極2a間の距離L4を所望の値に収めることができる。   By providing the above configuration, the protrusion 1a of the bobbin 1 is inserted into the concave shape 2b of the dust core 2 so that the upper and lower cores are positioned, and the dust core 2 is not displaced in the rotational direction. Moreover, since the protrusion 1a protrudes not on the inner peripheral side but on each dust core 2 side, it does not affect the arrangement of the adjacent claw-type magnetic poles 2a on the rotor 11 side, and between adjacent claw-type magnetic poles 2a. The distance L4 can be set to a desired value.

また、爪型磁極2aの先端部を、凹状2b内に収めることによって、対向する圧粉コアの基部2’と干渉することなく、ロータ11と向かい合う内周部に爪型磁極2aを並べることができる。すなわち、爪型磁極2aの先端部を、対向する圧粉コア2の基部2’の円環面まで延伸可能な構成となり、効果的な磁路形成が可能となる。   Further, by placing the tip of the claw-shaped magnetic pole 2a in the concave shape 2b, the claw-shaped magnetic pole 2a can be arranged on the inner peripheral portion facing the rotor 11 without interfering with the base 2 ′ of the opposing dust core. it can. That is, it becomes a structure which can extend | stretch the front-end | tip part of the nail | claw-shaped magnetic pole 2a to the annular | circular surface of the base 2 'of the dust core 2 which opposes, and an effective magnetic path formation is attained.

さらに、互いに対向する上下コアにおいては、隣り合う爪型磁極2a間で磁路が形成されるが、爪型磁極2aの先端部と基部2’との間の距離L5を隣り合う爪型磁極2a間の距離L4よりも大きくするとともに、爪型磁極2aの先端部と基部2’との間に絶縁材料からなるボビン1の突起1aを位置させるため、磁束の漏れを抑制し、高効率な構成とすることができる。すなわち、互いに隣り合う爪型磁極間の距離L4が、爪型磁極2aの先端部と凹状2bの底部(基部2’)との距離L5よりも小さいため、通電時に形成される磁束に及ぼす影響を低減できる。併せて、突起1aの径方向の幅L6もL5とほぼ同一としているため、磁束漏れ低減に寄与している。   Further, in the upper and lower cores facing each other, a magnetic path is formed between the adjacent claw-shaped magnetic poles 2a, but the distance L5 between the tip portion of the claw-shaped magnetic pole 2a and the base 2 'is set to the adjacent claw-shaped magnetic pole 2a. Since the protrusion 1a of the bobbin 1 made of an insulating material is positioned between the distal end portion of the claw-type magnetic pole 2a and the base portion 2 ', the magnetic flux leakage is suppressed and the configuration is highly efficient. It can be. That is, since the distance L4 between the claw-type magnetic poles adjacent to each other is smaller than the distance L5 between the tip portion of the claw-type magnetic pole 2a and the bottom portion (base portion 2 ′) of the concave shape 2b, the influence on the magnetic flux formed during energization is affected. Can be reduced. In addition, since the radial width L6 of the protrusion 1a is substantially the same as L5, it contributes to magnetic flux leakage reduction.

上記のように、ボビンを用いる場合には、ボビン1の両面にコア2と勘合するような突起1aを設け、ボビン1とコア2を組み合わせることで、コア2を組み合わせて固定子コアを形成する際に、両者を必要な角度に位置決めすることができる。また、凹状2b、突起1a、爪型磁極2aの位置関係から、磁束の漏れの抑制が図られ、高効率化を図ることができる。   As described above, when a bobbin is used, the bobbin 1 is provided with protrusions 1a to be fitted with the core 2 on both sides, and the bobbin 1 and the core 2 are combined to combine the cores 2 to form a stator core. In doing so, they can be positioned at the required angle. Further, the leakage of magnetic flux can be suppressed from the positional relationship of the concave shape 2b, the protrusion 1a, and the claw-shaped magnetic pole 2a, and high efficiency can be achieved.

図6は、実施例1とは異なる上下コアの位置決めを行う例を示す図である。上述したように、本実施形態の圧粉コア2は、磁性粉を圧縮した成形体からなっており、この点は実施例2においても同様である。以下では、特に示した構成を除いて実施例1と共通するため、詳細な説明は省略する。   FIG. 6 is a diagram illustrating an example of positioning the upper and lower cores different from the first embodiment. As described above, the dust core 2 of the present embodiment is made of a molded body obtained by compressing magnetic powder, and this point is the same as in Example 2. In the following, since the configuration is the same as that of the first embodiment except for the configuration specifically shown, the detailed description is omitted.

実施例2の特徴は、上下コアの位置決めに金型を用いることにある。具体的には、次の通りである。本実施形態では、磁性粉を圧縮した成形体が対向して配置されたコア2を用いることとしているが、この圧粉コア2は樹脂でモールドして使用される。成形体をモールドする際、成形体を保持するために金型を用いる。   The feature of the second embodiment is that a mold is used for positioning the upper and lower cores. Specifically, it is as follows. In the present embodiment, the core 2 is used in which the molded body obtained by compressing the magnetic powder is opposed to the core. The powder core 2 is used after being molded with a resin. When the molded body is molded, a mold is used to hold the molded body.

図6は、実施例2において用いられる金型の例を示す図である。このモールド金型5は成形体の保持部を備え、この保持部にモールドされる成形体が設置される。本実施形態では、圧粉コア2を対向配置することによって固定子コアを構成しているため、金型も上金型と下金型をセットにして用いられる。なお、以下の説明では、図6は下金型を示すものとする。すなわち、図6の左図は下金型の上面図であり、右図は中心線の断面図である。   FIG. 6 is a diagram illustrating an example of a mold used in the second embodiment. The mold 5 includes a molded body holding portion, and a molded body molded in the holding portion is installed. In the present embodiment, since the stator core is configured by arranging the dust cores 2 so as to face each other, the upper die and the lower die are also used as a set. In the following description, FIG. 6 shows a lower mold. That is, the left figure of FIG. 6 is a top view of the lower mold, and the right figure is a sectional view of the center line.

このような金型を用いると、圧粉コア2を対向配置して樹脂でモールドする際に、上下の金型において、それぞれ周方向の位置決めがなされれば、モールド後の上下コアを位置決めして固定することができることになる。したがって、圧粉コア2の周方向の位置決めを、ボビンを用いることなく行うことができる。   When such a mold is used, when the powder core 2 is placed oppositely and molded with resin, if the upper and lower molds are positioned in the circumferential direction, the upper and lower cores after molding are positioned. It can be fixed. Therefore, the circumferential positioning of the dust core 2 can be performed without using a bobbin.

本実施例の金型5は、図6に示すように、上下のモールド金型に成形体の保持部を有し、この保持部に圧粉コア2の爪型磁極2aあるいは凹状2bと精密に係合する突起5aを備えている。この突起5aが圧粉コア2に設けられる係合部と係合することによって、圧粉コア2が金型5上において周方向の移動が規制されて位置決めされる。他方、この圧粉コア2と対向配置される圧粉コアも、図示しない上金型によって同様に位置決めがなされる。   As shown in FIG. 6, the mold 5 of this embodiment has holding parts for the molded bodies in the upper and lower mold dies, and the claw-shaped magnetic poles 2a or the recessed parts 2b of the dust core 2 are precisely placed in the holding parts. The projection 5a to be engaged is provided. By engaging the protrusion 5 a with an engaging portion provided on the dust core 2, the dust core 2 is positioned on the mold 5 while being restricted from moving in the circumferential direction. On the other hand, the dust core disposed opposite to the dust core 2 is similarly positioned by an upper mold (not shown).

したがって、上下金型を組み合わせ、この状態を保持しながらモールド樹脂成型を行うことにより、位置決めされた状態で固定子コアを得ることができる。したがって、爪型磁極2aを等ピッチに配置できる。また、その後の製造工程においてステータ3の取扱性の向上が図られる。   Therefore, a stator core can be obtained in a positioned state by combining upper and lower molds and performing molding resin molding while maintaining this state. Therefore, the claw-shaped magnetic poles 2a can be arranged at an equal pitch. In addition, the handleability of the stator 3 can be improved in the subsequent manufacturing process.

図7は、上述の実施例1や実施例2で示した電動機を用いた一例を示す図であり、この例ではFFUを示している。電動機20の回転軸にはファン21が取り付けられており、フィルタ23と共に筐体22に収められて、ファンフィルタユニット(FFU)を構成している。筐体22は上方に開口部を有しており、ファン21が回転することによって開口部から空気が取り込まれる。すなわち、ファン21の回転によって図中の上部から空気が吸い込まれ、ファン21の下方に取り付けられたフィルタ23を通過する。   FIG. 7 is a diagram showing an example using the electric motor shown in the first and second embodiments. In this example, an FFU is shown. A fan 21 is attached to a rotating shaft of the electric motor 20 and is housed in a housing 22 together with a filter 23 to constitute a fan filter unit (FFU). The housing 22 has an opening on the upper side, and air is taken in from the opening as the fan 21 rotates. That is, air is sucked from the upper part in the drawing by the rotation of the fan 21 and passes through the filter 23 attached below the fan 21.

したがって、フィルタ23を通過する際に空気がろ過され、フィルタ23の下流側(図中の下部)へは清浄な空気として排出される。FFUの運転中はクリーンルーム内に塵埃等が除去された空気を供給し続け、クリーンルーム内を清浄に保つことができる。   Therefore, when passing through the filter 23, the air is filtered and discharged to the downstream side (lower part in the figure) of the filter 23 as clean air. During operation of the FFU, it is possible to keep supplying clean air in the clean room by continuously supplying air from which dust or the like has been removed.

本実施形態のFFUは、クリーンルームの天井部に取り付けられるため、薄型化の要求が強い。FFUは、筐体22にフィルタ23、電動機20、ファン21が取り付けられるため、電動機20の小型化を図ることにより、FFUとしても薄型化が可能となる。   Since the FFU of this embodiment is attached to the ceiling of a clean room, there is a strong demand for thinning. Since the filter 23, the electric motor 20, and the fan 21 are attached to the housing 22, the FFU can be reduced in thickness as the FFU by reducing the size of the electric motor 20.

ステータの1相分(符号3)の分解斜視図。The disassembled perspective view of 1 phase (code | symbol 3) of a stator. 3相クローティース電動機の分解図。The exploded view of a three-phase Crotice motor. ステータの断面を示す図。The figure which shows the cross section of a stator. ステータ内部の3相分のステータ形状を示す外観斜視図。The external appearance perspective view which shows the stator shape for three phases inside a stator. 3相からなるステータのうち、1相分を分解して示した図。The figure which decomposed | disassembled and showed one phase part among the stators which consist of three phases. 上下コアの位置決めを行う他の例を示す図。The figure which shows the other example which positions the up-and-down core. 本実施形態のFFUの構造を示す図。The figure which shows the structure of FFU of this embodiment. コアの位置決め例と課題を示す図。The figure which shows the example of positioning of a core, and a subject.

符号の説明Explanation of symbols

1…ボビン、1a…突起、2…圧粉コア、2’…基部、2a…爪型磁極、2b…凹状、3…1相分、4…コイル、5…金型、5a…突起、10…ステータ、11…ロータ、12…ブラケット、13…ベアリング、14…貫通ねじ、20…電動機、21…ファン、22…FFU筐体、23…フィルタ。   DESCRIPTION OF SYMBOLS 1 ... Bobbin, 1a ... Protrusion, 2 ... Powder core, 2 '... Base, 2a ... Claw-shaped magnetic pole, 2b ... Concave shape, 3 ... One phase, 4 ... Coil, 5 ... Mold, 5a ... Protrusion, 10 ... Stator, 11 ... rotor, 12 ... bracket, 13 ... bearing, 14 ... through screw, 20 ... electric motor, 21 ... fan, 22 ... FFU housing, 23 ... filter.

Claims (4)

円環形状の基部とこの基部から突出して周方向に複数形成される爪型磁極とを有する成形体を、磁性粉を圧縮して成形し、この成形体が対向して配置される固定子コアを備え、一の成形体の爪型磁極の間に他の成形体の爪型磁極が位置するように構成した電動機において、
前記成形体は前記基部の内周側であって前記爪型磁極の間には、位置決め用の突起が挿入される複数の凹状を有する電動機。
A stator core having an annular base and a plurality of claw-shaped magnetic poles protruding from the base and formed in the circumferential direction is formed by compressing magnetic powder, and the stator is disposed so as to face the molded body. An electric motor configured such that the claw-shaped magnetic pole of another molded body is positioned between the claw-shaped magnetic poles of one molded body,
The molded body is an electric motor having a plurality of concave shapes into which positioning protrusions are inserted between the claw-shaped magnetic poles on the inner peripheral side of the base portion.
前記凹状には、モールド金型に設けられた突起が挿入されることを特徴とする請求項1記載の電動機。   The electric motor according to claim 1, wherein a protrusion provided on the mold is inserted into the concave shape. 磁性粉を圧縮した円環形状の成形体が対向して配置される固定子コアを備え、前記成形体は周方向に複数の爪型磁極を有し、一の成形体の爪型磁極の間に他の成形体の爪型磁極が位置するように構成した電動機の製造方法において、
上下金型で前記成形体を保持して樹脂モールドする工程で、前記上下金型に設けられた突起と、前記成形体に設けられる係合部とを係合し、対向配置される成形体の周方向の位置決めを行うことを特徴とする電動機の製造方法。
An annular molded body in which magnetic powder is compressed is provided to face each other, the molded body has a plurality of claw-shaped magnetic poles in the circumferential direction, and between the claw-shaped magnetic poles of one molded body. In the manufacturing method of the electric motor configured so that the claw-shaped magnetic pole of the other molded body is located in the
In the step of holding and molding the molded body with the upper and lower molds and engaging the protrusions provided on the upper and lower molds with the engaging portions provided on the molded body, A method for manufacturing an electric motor, comprising positioning in a circumferential direction.
円環形状の基部とこの基部から突出して周方向に複数形成される爪型磁極とを有する成形体を、磁性粉を圧縮して成形し、この成形体が対向して配置される固定子コアを備え、一の成形体の爪型磁極の間に他の成形体の爪型磁極が位置するように構成した電動機の製造方法において、
上下金型で前記成形体を保持して樹脂モールドする工程で、前記上下金型に設けられた突起と、前記基部の内周側であって前記爪型磁極の間に設けられる凹状とを係合することを特徴とする電動機の製造方法。
A stator core having an annular base and a plurality of claw-shaped magnetic poles protruding from the base and formed in the circumferential direction is formed by compressing magnetic powder, and the stator is disposed so as to face the molded body. A method of manufacturing an electric motor configured such that a claw-shaped magnetic pole of another molded body is positioned between the claw-shaped magnetic poles of one molded body,
In the step of resin molding by holding the molded body with the upper and lower molds, the protrusion provided on the upper and lower molds and the concave shape provided on the inner peripheral side of the base and between the claw-shaped magnetic poles are engaged. A manufacturing method of an electric motor characterized by combining.
JP2007316522A 2007-12-07 2007-12-07 Electric motor and electric-motor manufacturing method Pending JP2009142087A (en)

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Publication number Priority date Publication date Assignee Title
JP2014093825A (en) * 2012-11-01 2014-05-19 Asmo Co Ltd Rotor and motor
US9887608B2 (en) 2013-01-24 2018-02-06 Asmo Co., Ltd. Rotor, stator and motor

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Publication number Priority date Publication date Assignee Title
JPS614459A (en) * 1984-06-18 1986-01-10 Matsushita Electric Ind Co Ltd Step motor
JPH0898498A (en) * 1994-09-21 1996-04-12 Minebea Co Ltd Method and structure for assembling stator of electric rotating machine
JP2006296188A (en) * 2005-03-18 2006-10-26 Hitachi Industrial Equipment Systems Co Ltd Multiple phase claw-pole type motor

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS614459A (en) * 1984-06-18 1986-01-10 Matsushita Electric Ind Co Ltd Step motor
JPH0898498A (en) * 1994-09-21 1996-04-12 Minebea Co Ltd Method and structure for assembling stator of electric rotating machine
JP2006296188A (en) * 2005-03-18 2006-10-26 Hitachi Industrial Equipment Systems Co Ltd Multiple phase claw-pole type motor

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2014093825A (en) * 2012-11-01 2014-05-19 Asmo Co Ltd Rotor and motor
US9887608B2 (en) 2013-01-24 2018-02-06 Asmo Co., Ltd. Rotor, stator and motor
US10862380B2 (en) 2013-01-24 2020-12-08 Denso Corporation Rotor, stator and motor

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