JP2010166648A - Claw pole type motor and method of manufacturing the claw pole type motor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a highly heat-radiative claw pole type motor and a method of manufacturing the claw pole type motor. <P>SOLUTION: The claw pole type motor 200, which includes the first core 12, the second core 16 opposite to the first core 12, and a ring-shaped coil 14 caught between the first core 12 and the second core 16, includes the first insulator 13 and the second insulator 15. The ring-shaped coil 14 includes the first coil end 14A and the second coil end 14B which are bent edgewise so that they may be larger in diameter than the diameter of the peripheral wall faces 13B and 15B of the first insulator 13 and the second insulator 15, and are created at the winding start and end positions of the ring-shaped coil 14 so as to assembled the ring-shaped coil 14 between the first core 12 and the first insulator 13 and the second core 16 and the second insulator 15 while having narrowed the diameter of the ring-shaped coil 14. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a technique for improving heat dissipation of a stator by devising a coil used for a claw pole type motor.

In recent years, motors for obtaining driving force of vehicles have been actively developed. This is because there is an increasing need to drive a vehicle by the driving force of a motor such as a hybrid vehicle or an electric vehicle.
However, in order to obtain the driving force of the car with a motor, the motor is required to have a high output. And in order to mount in-vehicle, miniaturization of a motor is essential. In particular, a hybrid vehicle is required to be miniaturized because a motor and an engine need to be arranged in an engine room.
Therefore, a small and high-power motor is eagerly desired. However, in order to reduce the size and increase the output of the motor, it is necessary to increase the current flowing through the coil.

However, there is a problem that increasing the amount of current flowing through the motor coil increases the amount of heat generated. The stator can be cooled by increasing the cross-sectional area of the coil to reduce the amount of heat generation or by devising a cooling method for the coil.
Patent Document 1 discloses a technique related to a stator core for a motor.
A wire accommodating groove for accommodating an electric wire is formed in a split stator core, and the bottom surfaces of the winding accommodating grooves facing each other between adjacent teeth are made parallel to each other, so that the dead in the wire accommodating portion between the teeth Space can be reduced as compared with the conventional case. As a result, it is possible to improve the heat dissipation efficiency of the motor while suppressing the heat retaining effect by the air in the dead space.

Further, it is conceivable to increase the cooling efficiency by using a claw pole type stator core as described in Patent Document 2.
Patent Document 2 discloses a technique related to a claw pole type stator.
A stator core is formed by punching a rolled steel plate such as SPCC, and a single phase is formed by sandwiching a coil obtained by edgewise bending a flat wire with the stator core. By superimposing this for three phases, a stator used for a three-phase motor can be obtained.
By using the claw pole type, the space factor of the coil can be improved.
Moreover, iron loss can be reduced by comprising a stator core not with a rolled steel plate but with a dust core.

JP 2005-117844 A JP 2007-181303 A

However, the technique of Patent Document 2 is considered to have the following problems.
In the method of Patent Document 2, the space factor is improved by using a coil in which a flat wire is edgewise bent with respect to a claw pole type stator core, but insulation between the core and the coil is provided around the coil. It depends on the thickness of the enamel formed, and it is necessary to form a thick coating film. As a result, the coating film between the windings also becomes thick, and as a result, the space factor may not be improved.
Moreover, although it is necessary to secure a surface where the coil and the core are in direct contact with respect to heat dissipation, a clearance may be formed because an appropriate clearance is required in consideration of manufacturing accuracy. It is difficult to ensure heat dissipation by being insulated by this gap.

  Accordingly, an object of the present invention is to provide a claw-pole motor with high heat dissipation and a claw-pole motor manufacturing method in order to solve such problems.

In order to achieve the above object, a claw pole type motor according to the present invention has the following characteristics.
(1) A first core having a plurality of claw portions on the circumference, a second core disposed to face the first core, and a ring-shaped coil sandwiched between the first core and the second core In a claw pole type motor having
For the purpose of insulation between the first core and the ring-shaped coil, insulation between the first insulator disposed between the first core and the ring-shaped coil, and the second core and the ring-shaped coil is performed. For the purpose, a second insulator is disposed between the second core and the ring-shaped coil, and the ring-shaped coil is larger than the diameters of the outer peripheral wall surfaces of the first insulator and the second insulator. A rectangular conductor is formed by edgewise bending so as to have a diameter, and the ring coil is wound and squeezed so that the diameter of the ring coil is reduced within the range of elastic deformation. In order to assemble between the insulator, the second core, and the second insulator, there are gripping portions formed at the winding start end and winding end of the ring-shaped coil. It is characterized in.

In order to achieve the above object, a claw pole type motor manufacturing method according to the present invention has the following characteristics.
(2) A first core having a plurality of claw portions on the circumference, a second core disposed opposite to the first core, and a ring-shaped coil sandwiched between the first core and the second core In a claw pole type motor manufacturing method having
The ring-shaped coil has a diameter of an outer peripheral wall surface of a first insulator for the purpose of insulation between the first core and the ring-shaped coil and a second insulator for the purpose of insulation between the second core and the ring-shaped coil. A flat conductor is formed by edgewise bending so as to have a larger diameter, and gripping portions formed at the winding start end and winding end end of the ring coil are formed. The ring-shaped coil is disposed between the first core, the first insulator, the second insulator, and the second core in a state where the ring-shaped coil is held so as to be reduced in size, and by releasing the grip portion. The outer peripheral surface of each of the first and second insulators contacts the outer peripheral surface of the ring-shaped coil.

With the claw pole type motor according to the present invention having such characteristics, the following operations and effects can be obtained.
The invention described in (1) above is sandwiched between a first core having a plurality of claw portions on the circumference, a second core disposed opposite to the first core, and the first core and the second core. In a claw pole type motor having a ring-shaped coil, a first insulator disposed between the first core and the ring-shaped coil for the purpose of insulation between the first core and the ring-shaped coil, and a second core A second insulator disposed between the second core and the ring-shaped coil for the purpose of insulation from the ring-shaped coil, wherein the ring-shaped coil has a diameter greater than that of the outer peripheral wall surfaces of the first insulator and the second insulator. A rectangular conductor is formed by edgewise bending so as to have a large diameter, and the ring coil is wound and squeezed so that the diameter of the ring coil is reduced within the range of elastic deformation. Over data and those having a gripping portion formed on the winding starting end and a winding end of the ring-shaped coil to assemble between the second core and the second insulator.

The ring-shaped coil is formed by being edgewise bent so as to have a diameter larger than the diameter of the outer peripheral wall surface of the first insulator and the second insulator, so that the diameter is reduced and incorporated in the first insulator and the second insulator. When the gripping part is released after being released, the ring-shaped coil expands in diameter and is held in contact with the inner surfaces of the first insulator and the second insulator.
Since the contact state between the ring-shaped coil and the first insulator and the second insulator is maintained by the elastic force of the link-shaped coil, the heat generated in the ring-shaped coil is first through the first insulator and the second insulator. It is transmitted to the core or the second core.
In general, heat transfer is higher in the case of transferring heat in a state where the solids are in contact with each other than in the case of transferring heat from the solid to the gas, and it can be expected that the heat can be cooled. Therefore, when the ring-shaped coil generates heat, it is possible to quickly transmit heat to the first core or the second core disposed on the outside via the first insulator and the second insulator to suppress an increase in heat. Become.
Therefore, the present invention can provide a claw-pole motor with high heat dissipation.

Further, the following operations and effects can be obtained by the claw pole type motor manufacturing method according to the present invention having such characteristics.
The invention described in (2) is sandwiched between a first core having a plurality of claw portions on the circumference, a second core disposed to face the first core, and the first core and the second core. In the claw pole type motor manufacturing method having a ring-shaped coil, the ring-shaped coil is intended to insulate the first insulator from the first core and the ring-shaped coil and the second core from the ring-shaped coil. The rectangular conductor is formed by edgewise bending so that the diameter of the second insulator is larger than the diameter of the outer peripheral wall surface of the second insulator, and the grip portions formed at the winding start end and the winding end end are formed on the ring coil. In a state where the diameter of the core is held so as to be reduced within the range of elastic deformation, it is arranged between the first core, the first insulator, the second insulator, and the second core, and the grip portion is released to form a ring shape. Koi The outer peripheral surface comes into contact with the inner peripheral wall surface of the first insulator and the second insulator which covers the outer surface of the ring-shaped coil.

  By using such a manufacturing method, when the ring-shaped coil as described in (1) generates heat, the first core or the first core that is quickly disposed outside through the first insulator and the second insulator or It is possible to provide a manufacturing method for manufacturing a claw pole type motor capable of transmitting heat to the second core and suppressing an increase in heat.

It is a disassembled perspective view of the U-phase stack of this embodiment. It is a perspective view of the U phase stack of this embodiment. It is sectional drawing of the U-phase stack of this embodiment, and is AA cross section of FIG. It is a top view of a ring-shaped coil of this embodiment. It is a disassembled perspective view of the claw pole type motor of this embodiment.

First, an embodiment of the present invention will be described.
FIG. 1 shows an exploded perspective view of the U-phase stack. FIG. 2 shows a perspective view of the U-phase stack. FIG. 3 shows a cross-sectional view of the U-phase stack. FIG. 3 is an AA cross section of FIG.
The U-phase stack 10 includes a first core 12, a first insulator 13, a ring coil 14, a second insulator 15, and a second core 16.
The first core 12 is provided with 12 outer circumferential rings 12A and 12 claw portions 12B, which are claw-shaped projections, projecting toward the inner circumferential side of the outer circumferential ring 12A. The claw portion 12B is formed so as to protrude in the axial direction of the outer peripheral ring 12A. Specifically, the inner peripheral wall surface 12Bb provided so as to be orthogonal to the claw portion bottom surface 12Ba and the tapered surface 12Bc intersect with each other to form an intersection on the opposite side of the claw portion bottom surface 12Ba and to be provided on the outer ring 12A. The claw portions 12B are provided on the outer ring 12A alternately with the recesses 12C.
For the first core 12, a powder magnetic core made of a material obtained by finely pulverizing a magnetic material such as iron powder or permalloy and a resin is used. By using such a powder magnetic core, it is possible to reduce iron loss when the U-phase stack 10 is assembled to the stator 100 and used as a motor.

A first cutout portion 12a and a second cutout portion 12b are provided on the surface of the outer peripheral ring 12A on the side where the claw portion 12B protrudes.
The second core 16 has substantially the same shape as the first core 12 and is disposed so as to face the first core 12.
The second core 16 is also provided with a claw portion 16B and a concave portion 16C on the inner peripheral side of the outer peripheral ring 16A, and is provided with a first cutout portion 16a and a second cutout portion 16b. The outer ring 16A corresponds to the outer ring 12A, the claw 16B corresponds to the claw 12B, the recess 16C corresponds to the recess 12C, and the first notch 16a and the second notch 16b correspond to the first notch 12a and the second notch 12b. To do.
The 1st insulator 13 is formed in cyclic | annular form with the resin which has insulation. The cross section is U-shaped, and as shown in FIG. 3, a groove portion 13 </ b> A serving as a groove in which the ring-shaped coil 14 is accommodated is formed.

The second insulator 15 has substantially the same shape as the first insulator 13 and includes a groove portion 15A. In addition, the surface which the 1st insulator 13 and the 2nd insulator 15 oppose and contact is formed in the shape cut diagonally, and the insulation creeping distance of the 1st insulator 13 and the 1st core 12 or the 2nd core 16 is made. Contributes to earning.
The ring-shaped coil 14 is wound in an annular shape by edge-wise bending a rectangular conductor having an insulating coating such as enamel on its surface. The first coil end portion 14 </ b> A and the second coil end portion 14 </ b> B, which are the ends of the flat conductor, have a shape protruding toward the outer peripheral side of the ring-shaped coil 14. The conductor used for the ring coil 14 is preferably a highly conductive material such as copper or aluminum.
The outer diameter of the ring-shaped coil 14 is set to be larger than the diameters of the outer peripheral wall surface 13B and the outer peripheral wall surface 15B of the first insulator 13 and the second insulator 15.
A U-phase stack 10 as shown in FIG. 2 is formed by combining the first core 12, the first insulator 13, the ring coil 14, the second insulator 15, and the second core 16 in the order shown in FIG.

FIG. 4 shows a plan view of the ring coil.
When the ring-shaped coil 14 is assembled, the ring-shaped coil 14 is housed between the first insulator 13 and the second insulator 15 in the state shown in FIG.
At this time, as shown in FIG. 4, the gripping means 70 squeezes the first coil end portion 14 </ b> A and the second coil end portion 14 </ b> B by applying a force in the arrow direction so that the ring-shaped coil 14 is reduced in diameter.
In this state, the outer diameter of the ring-shaped coil 14 is sized to fit in the groove 13A of the first insulator 13 and the groove 15A of the second insulator 15, so the first core 12, the first insulator 13, the ring-shaped coil 14, The second insulator 15 and the second core 16 are sequentially assembled.
Thereafter, the first coil end portion 14A and the second coil end portion 14B are released by moving the gripping means 70 away from each other.
In this way, the U-phase stack 10 is formed.

Since the V-phase stack 20 and the W-phase stack 30 have the same configuration as that of the U-phase stack 10, the description thereof is omitted here.
FIG. 5 shows an exploded perspective view of the claw pole type motor.
In this way, the U-phase stack 10, the V-phase stack 20, and the W-phase stack 30 are stacked as shown in FIG. 5 and sandwiched between the first bracket 61 and the second bracket 62, and the first fixing bolt 63A to the third fixing bolt 63C are used. The stator 100 is formed by fixing.
The 1st bracket 61 and the 2nd bracket 62 are annular plates, and are provided with the hole which penetrates the 1st fixing bolt 63A, the 2nd fixing bolt 63B, and the 3rd fixing bolt 63C in the outer peripheral part, and the hole to fasten. The first fixing bolt 63A is fastened to the first fastening hole 62A formed in the second bracket 62, the second fixing bolt 63B is fastened to the second fastening hole 62B, and the third fixing bolt 63C is fastened to the third fastening hole 62C. . Thus, the stator 100 is configured.
A rotor 50 and an output shaft 40 connected thereto are provided on the inner peripheral side of the stator 100 and function as a claw pole type motor 200.

Since the claw pole type motor 200 of the present embodiment is configured as described above, the following operations and effects are achieved.
The claw pole type motor 200 of the present embodiment includes a first core 12 having a plurality of claw portions on the circumference, a second core 16 disposed to face the first core 12, the first core 12, and the first core 12. In the claw pole type motor 200 having the ring-shaped coil 14 sandwiched between the two cores 16, it is arranged between the first core 12 and the ring-shaped coil 14 for the purpose of insulation between the first core 12 and the ring-shaped coil 14. A first insulator 13 and a second insulator 15 disposed between the second core 16 and the ring-shaped coil 14 for the purpose of insulation between the second core 16 and the ring-shaped coil 14. The coil 14 is formed by edgewise bending so as to have a diameter larger than the diameters of the outer peripheral wall surface 13B and the outer peripheral wall surface 15B of the first insulator 13 and the second insulator 15. The ring-shaped coil 14 is placed between the first core 12 and the first insulator 13 and the second core 16 and the second insulator 15 in a state where the diameter of the ring-shaped coil 14 is reduced so as to be reduced within the range of elastic deformation. In order to assemble, it has the 1st coil end part 14A and the 2nd coil end part 14B which were formed in the winding start end and the winding end end of the ring-shaped coil 14.

The ring-shaped coil 14 is formed by being edgewise bent so as to have a diameter larger than the diameters of the outer peripheral wall surface 13B of the first insulator 13 and the outer peripheral wall surface 15B of the second insulator 15, so that the first insulator is reduced in diameter. When the first coil end portion 14A and the second coil end portion 14B are released after being incorporated into the inside of the first insulator 13 and the second insulator 15, the ring-shaped coil 14 is expanded in diameter, and the inner surfaces of the first insulator 13 and the second insulator 15 are expanded. And held in contact with the
Since the material of the ring coil 14 is copper or aluminum, a large elastic force cannot be expected. For this reason, when applying pressure with the gripping means 70, it is necessary to apply pressure within the range of elastic deformation. However, the force which presses the ring-shaped coil 14 to the 1st insulator 13 and the 2nd insulator 15 does not necessarily require so much force. If a relatively soft material is selected for the first insulator 13 and the second insulator 15, it is possible to ensure adhesion between the first insulator 13 and the second insulator 15 and the ring coil 14.

When the first insulator 13 and the second insulator 15 and the ring-shaped coil 14 are in close contact with each other, the first insulator 13 is pressed against the first core 12 and the second insulator 15 is pressed against the second core 16.
When the claw pole motor 200 is energized to drive the output shaft 40, the ring-shaped coil 14 generates heat by resistance, and thus requires heat dissipation.
At this time, the ring-shaped coil 14 is transferred to the first core 12 and the second core 16 via the first insulator 13 and the second insulator 15. The heat transfer through the solid is more efficient than the case where there is a gap between the ring-shaped coil 14 and the first insulator 13 or the second insulator 15 and there is an air layer, and to improve heat dissipation. It is advantageous.

Since the 1st insulator 13 and the 2nd insulator 15 are resin products, it is difficult to ensure manufacture accuracy. Moreover, since the dust cores are used for the first core 12 and the second core 16, the manufacturing accuracy depends on the mold. Since the ring-shaped coil 14 is also formed by edgewise bending a rectangular conductor, it is difficult to increase the manufacturing accuracy.
For this reason, the product tolerance must be increased, and the assembly accuracy of the first core 12, the first insulator 13, the ring-shaped coil 14, the second insulator 15, and the second core 16 is limited to that of the ring-shaped coil 14. There is a situation where it is difficult to secure a contact area.
For this reason, it is possible to maintain a state in which the outer peripheral surface of the ring-shaped coil 14 is in contact with the inner wall surfaces of the first insulator 13 and the second insulator 15 by winding and assembling the ring-shaped coil 14 without improving manufacturing accuracy. Is an advantage in improving heat dissipation.

Although the invention has been described according to the present embodiment, the invention is not limited to the embodiment, and by appropriately changing a part of the configuration without departing from the spirit of the invention. It can also be implemented.
For example, change of the material of the exemplified parts is not hindered.

10 U-phase stack 12 1st core 12A Outer peripheral ring 12B Claw part 12C Recess 13 First insulator 13A Groove part 13B Outer wall surface 14 Ring-shaped coil 14A First coil end part 14B Second coil end part 15 Insulator 15A Groove part 15B Outer wall surface 16 Second core 16A Outer ring 16B Claw portion 16C Recess 20 V-phase stack 30 W-phase stack 40 Output shaft 50 Rotor 61 First bracket 62 Second bracket 70 Grasping means 100 Stator 200 Claw pole type motor

Claims (2)

A claw having a first core having a plurality of claw portions on the circumference, a second core disposed opposite to the first core, and a ring coil sandwiched between the first core and the second core In the pole type motor,
A first insulator disposed between the first core and the ring-shaped coil for the purpose of insulating the first core and the ring-shaped coil;
A second insulator disposed between the second core and the ring coil for the purpose of insulating the second core and the ring coil;
The ring coil is
A rectangular conductor is formed by edgewise bending so as to have a diameter larger than the diameter of the outer peripheral wall surface of the first insulator and the second insulator,
The ring coil is assembled between the first core, the first insulator, the second core, and the second insulator in a state in which the diameter of the ring coil is reduced so as to be reduced within the range of elastic deformation. Therefore, a claw pole type motor having grip portions formed at the winding start end and the winding end end of the ring coil. A claw having a first core having a plurality of claw portions on the circumference, a second core disposed opposite to the first core, and a ring coil sandwiched between the first core and the second core In the pole type motor manufacturing method,
The ring-shaped coil has a diameter of an outer peripheral wall surface of a first insulator for the purpose of insulation between the first core and the ring-shaped coil and a second insulator for the purpose of insulation between the second core and the ring-shaped coil. A flat conductor is formed by edgewise bending to have a larger diameter,
The first core and the first core are held in such a manner that grip portions formed at the winding start end and the winding end end are held on the ring coil so that the diameter of the ring coil is reduced within a range of elastic deformation. Arranged between the insulator and the second insulator and the second core,
A claw pole type motor in which the outer peripheral surface of the ring-shaped coil abuts on the inner peripheral wall surfaces of the first insulator and the second insulator covering the outer surface of the ring-shaped coil by releasing the grip portion. Production method.

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