JP2013046479A - Brushless motor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a brushless motor capable of simplifying a winding work of a wire when a coil is formed.SOLUTION: Coils 18d are formed on teeth 18b of an annular stator core 18. Winding directions and positions of winding start terminals and winding end terminals of these coils 18d are conformed with each other. As a result, it is not required to change the coil directions of the coils as in the case that a positive phase coil and an anti-phase coil are separately fabricated. Accordingly, a winding work for winding wires around the teeth 18b of the stator core 18 can be simplified.

Description

  The present invention relates to a brushless motor.

  2. Description of the Related Art Conventionally, there has been known a stator in which a conductive winding is wound around a tooth formed along the circumferential direction of an annular yoke (so-called toroidal winding). Further, a three-phase brushless motor configured using this stator is known (for example, see Patent Document 1 below).

JP 2001-37133 A

  However, in the conventional configuration, when the coil is formed by winding the winding around the teeth formed along the circumferential direction of the annular yoke, by changing the winding direction, the phase is opposite to that of the positive phase coil. I made a different coil. In this case, it is conceivable that the winding operation of the winding is complicated, and as a result, the number of manufacturing steps and the manufacturing cost are increased.

  An object of the present invention is to obtain a brushless motor that can simplify the winding work when forming a coil in consideration of the above facts.

  In the brushless motor according to the first aspect of the present invention, a conductive winding is wound along a circumferential direction of a rotor rotating around an output shaft and an annular stator core disposed inside the rotor. A plurality of coils having the same winding direction and winding end and winding end terminals arranged on one side are wound around the stator core in the order of U phase, V phase and W phase. A stator constituted by being arranged along a direction, and a reversing unit arranged adjacent to the stator and connecting the ends of the coil at a predetermined interval and forming a coil having an antiphase And a wire connecting portion provided inside and having an integral structure.

  In the first aspect of the present invention, since the winding direction of the winding is the same, it is necessary to change the winding direction when forming the normal phase coil and the reverse phase coil in the teeth portion of the stator core. There is no. Therefore, the winding work when winding the winding around the teeth portion of the stator core can be simplified.

  A brushless motor according to a second aspect of the present invention is the brushless motor according to the first aspect, wherein the connection portion is configured such that an electric circuit for connecting the coils forms a star connection, and a winding or a terminal is connected. It is characterized in that the number of stacked layers is minimized.

  In the present invention described in claim 2, the electric circuit for connecting the coils is configured to form a star connection, and the number of windings or terminals stacked is minimized. Therefore, it is possible to suppress an increase in the thickness of the connection part itself, and as a result, a compact connection part can be obtained.

  A brushless motor according to a third aspect of the present invention is the brushless motor according to the first aspect, wherein the connection portion is configured such that an electric circuit for connecting the coils forms a delta connection, and a winding or a terminal is connected. It is characterized in that the number of stacked layers is minimized.

  According to the third aspect of the present invention, the electric circuit for connecting the coils is configured to form a delta connection, and the number of windings or terminals stacked is minimized. Therefore, it is possible to suppress an increase in the thickness of the connection part itself, and as a result, a compact connection part can be obtained.

  The brushless motor according to a fourth aspect of the present invention is the brushless motor according to any one of the first to third aspects, wherein the connection portion is an annular shape having an outer diameter smaller than the inner diameter of the stator core or It is an annular shape having an inner diameter that exceeds the outer diameter of the stator core, and is disposed adjacent to a center piece on which the stator core is supported.

  Here, the magnetic flux inside the stator core always changes along the circumferential direction of the stator core. In response to this change in magnetic flux, the current flowing through the connection portion may fluctuate, and the drive of the brushless motor may not be stable. However, in this invention of Claim 4, the connection part is arrange | positioned in said position. In other words, the connection portion is disposed in a portion that is not easily affected by the change in the magnetic flux. Therefore, the drive of the brushless motor can be stabilized.

  A brushless motor according to a fifth aspect of the present invention is the brushless motor according to any one of the first to fourth aspects, wherein the connection portion is formed integrally with a pedestal of the stator core.

  According to the fifth aspect of the present invention, since the connecting portion is formed integrally with the pedestal of the stator core, the wiring work between the coils and the work of fixing the stator to the center piece can be performed substantially simultaneously. That is, the assembly man-hour for the brushless motor can be reduced.

(A) is a top view of the brushless motor of 1st Embodiment, (B) is sectional drawing of the side view of the brushless motor of 1st Embodiment. In addition, in order to make the configuration of the stator and the rotor easier to understand, the configuration of a part of the rotor and the like is not shown in (A). (A) is a perspective view which shows the split core which comprises a stator core, (B) is a perspective view which shows the state by which the coil | winding was wound around the split core and the coil was formed, (C) The split core is It is a perspective view which shows the state arranged. (A) is a perspective view which shows the state by which the wiring between coils was connected using the armature wiring member, (B) is a perspective view which shows the wiring of the terminal in an armature wiring member. It is a specification figure which shows the connection (parallel delta connection) between the coils of the brushless motor of 2nd Embodiment. It is an electric circuit diagram which shows the connection (parallel delta connection) between the coils of the brushless motor of 2nd Embodiment. It is a specification figure which shows the connection (parallel star connection) between coils. It is an electric circuit diagram which shows the connection (parallel star connection) between coils. It is a specification figure which shows the connection (star connection) between coils. It is an electric circuit diagram which shows the connection (star connection) between coils. It is sectional drawing of the side view of the brushless motor of 3rd Embodiment. (A) is a perspective view which shows the state by which the wiring between coils was routed using the wiring cover, (B) is a perspective view which shows the state by which the cover was attached to the wiring cover of (A). It is sectional drawing of the side view of the brushless motor which has arrange | positioned the connection part to the outer side of the stator support part.

<First Embodiment>
The brushless motor according to the first embodiment of the present invention will be described with reference to FIGS.
First, the overall configuration of the brushless motor will be described, and then each element constituting the brushless motor will be described.

(Brushless motor overall configuration)
As shown in FIGS. 1A and 1B, the brushless motor 10 includes a center piece 12 and a stator 18 attached to the center piece 12 and formed in an annular shape. The brushless motor 10 includes a shaft 14 that is pivotally supported by the center piece 12 and a rotor 16 that is press-fitted into the shaft 14. The rotor 16 includes a plurality of magnets, and the rotor 16 is rotated by a magnetic field generated by the stator 18, and the shaft 14 is rotated accordingly. The brushless motor 10 is configured with the above four elements as main components.

(Center piece)
The center piece 12 includes a cylindrical boss portion 12a at the center thereof. A through hole 12b into which a shaft 14 described below is inserted is formed in the boss portion 12a. Steps for holding bearings 21 that rotatably support the shaft 14 are provided at both ends of the through hole 12b. Portions 12c and 12d are formed. The stepped portions 12c and 12d and the bearing 21 have a predetermined tightening allowance, the bearing 21 is press-fitted into the stepped portions 12c and 12d, and the shaft 14 is pivotally supported by the bearing 21.

  Further, the center piece 12 includes a disk portion 12e extending in a disk shape from an end portion on the lower side of the boss portion 12a. Further, the center piece 12 includes a stator support portion 12f that protrudes upward from the upper surface of the disk portion 12e and is formed in an annular shape. 12 g of guide grooves for supporting the stator 18 demonstrated below are formed in the stator support part 12f.

(shaft)
The shaft 14 is formed by quenching a cylindrical steel material and functions as an output shaft of the brushless motor. The shaft 14 is pivotally supported on the boss portion 12 a of the center piece 12 via a bearing 21. A shaft thrust receiver 22 is press-fitted into the shaft 14, and the axial position of the shaft 14 is regulated by the shaft thrust receiver 22. Further, a key groove (not shown) is formed in a portion of the shaft 14 where a rotor 16 described below is press-fitted. By inserting a key (not shown) into this key groove, the displacement of the shaft 14 and the rotor 16 in the rotational direction is restricted.

(Rotor)
The rotor 16 is formed in a substantially bowl shape having an opening on the lower side in a side view. Specifically, the rotor 16 includes a base portion 16a formed in a disk shape and a cylindrical boss portion 16b protruding upward from the center in a side view. The boss portion 16b is formed with a through hole 16c into which the shaft 14 is inserted. The shaft 14 is inserted into the through hole 16c, and the rotor 16 and the shaft 14 are press-fitted and fixed. In addition, a key groove (not shown) is formed in the through hole 16c, and a key (not shown) is inserted into the key groove, thereby restricting the displacement of the shaft 14 and the rotor 16 in the rotational direction. Is done.

  Further, the rotor 16 has a ring-shaped outer rotor 16d extending downward from the outer peripheral end portion of the base portion 16a and a lower portion in side view from an intermediate portion between the outer peripheral end portion of the base portion 16a and the boss portion 16b. And a ring-shaped inner rotor 16e that extends.

  Permanent magnets 24S and permanent magnets 24N are alternately attached to the inner peripheral surface of the outer rotor 16d in the circumferential direction. A permanent magnet 26S is attached to a position facing the outer peripheral surface of the inner rotor 16e and the permanent magnet 24S attached to the outer rotor 16d. Further, a permanent magnet 26N is attached to a position facing the outer peripheral surface of the inner rotor 16e and the permanent magnet 24N attached to the outer rotor 16d. Further, the permanent magnet 24S is disposed between the permanent magnet 24S attached to the outer rotor 16d and the permanent magnet 26S attached to the inner rotor 16e. A magnet 28S is attached. Further, the permanent magnet 24N is disposed between the permanent magnet 24N attached to the outer rotor 16d and the permanent magnet 26N attached to the inner rotor 16e. A magnet 28N is attached.

(Stator)
Next, a stator that is a main part of the present invention will be described.

  As shown in FIGS. 1 and 2, when the stator 18 is formed as an annular yoke, the stator 18 includes a stator core 18a and a plurality of recesses 18l and 18m formed along the circumferential direction of the stator core 18a. Teeth 18b. In addition, the stator 18 includes a plurality of coils 18d configured by winding conductive windings 18c around the teeth 18b. The stator 18 is configured with the above three elements as main components. Hereinafter, each element constituting the stator 18 will be described in this order.

  The stator core 18a is configured by joining a plurality of divided cores 18e arranged in a ring shape. The split core 18e is formed by laminating thin magnetic steel plates, or has a block shape formed by sintering and forging a magnetic material powder. The split core 18e includes joint surfaces 18f and 18g that are joined to other split cores 18e. Further, the split core 18e is arranged to be opposed to the first gap surface 18h arranged to face the inner circumferential surface of the outer rotor 16d of the rotor 16 and the outer circumferential surface of the inner rotor 16e of the rotor 16. 2 gap surface 18i and 3rd gap surface 18j arrange | positioned facing the lower surface of the base 16a of the rotor 16 are provided. Furthermore, the split core 18e includes a fixed surface 18k that is fixed to the center piece.

  The first gap surface is formed with a recess 181 cut from the third gap surface 18j to the fixed surface 18k. Further, the second gap surface is formed with a recess 18m cut from the third gap surface 18j to the fixed surface 18k. The teeth 18b are formed by forming the recess 18l and the recess 18m in the split core 18e. A coil 18d described below is formed on the tooth 18b. Furthermore, the teeth 18b are provided with an insulator 18n that insulates between the coil 18d and the stator core 18a (divided core 18e).

  As described above, the divided cores 18e are arranged in a ring shape (18 divided cores are used in the present embodiment) and joined to form the stator core 18a. Accordingly, 18 teeth 18b are formed in the stator core 18a along the circumferential direction of the stator core 18a.

  The coil 18d employs a so-called toroidal winding method in which a winding 18c such as a copper wire having good conductivity is wound around the teeth 18b of the annular stator core 18a. One coil 18d is formed by winding a winding around one tooth 18b of the stator core 18a. Thus, 18 coils 18d are formed by winding the winding 18c around all the teeth 18b formed on the stator core 18a.

  Further, the winding directions of all the coils 18d are the same, and the winding start and winding end terminals are arranged on one side. Further, in the present embodiment, the coil end 18o has an end on the winding start side of the coil 18d bent in a substantially L shape. Further, similarly to the coil terminal 18o, the coil end 18p is formed such that the end portion on the winding end side of the coil 18d is bent in a substantially L shape.

(Connection section)
As shown in FIG. 3, the connection portion 20 includes an armature in which a joint terminal 20 a joined to the coil terminal 18 o and the coil terminal 18 p described above and a terminal 20 b connected between the coils are integrally formed via an insulator. Wiring member. Specifically, as shown in FIG. 3, the joining terminal 20 a whose tip is bent in a U shape is joined to a plurality of terminals formed in a thin plate shape, and the plurality of terminals are made of a resin-based material. The connection part 20 is comprised by being covered. The connection terminal 20a of the connection part 20 is locked to predetermined coil terminals 18o and 18p, whereby the connection between the coils 18d is established. Further, the connecting portion 20 has a substantially annular shape having an outer diameter smaller than the inner diameter of the stator core 18a described above, and is disposed adjacent to the center piece 12 on which the stator core 18a is supported.

  Furthermore, the connection state of the connection part 20 which connects between the some coils 18d is demonstrated using FIG.4 and FIG.5. For ease of explanation, among the 18 coils 18d, the coil 18d constituting the U phase is represented by U1 to U6, the coil 18d constituting the V phase is represented by V1 to V6, and the W phase is configured. The coils 18d to be represented are denoted by W1 to W6.

  As shown in FIG. 4, in the present embodiment, the 18 coils 18d described above are connected by a parallel delta connection. The coils 18d are connected so as to be arranged in the order of the U phase, the V phase, and the W phase along the circumferential direction of the stator core 18a. More specifically, as shown in FIG. 5, in the U phase, the coils U1, U3, U5 connected in series and the coils U4, U2, U6 connected in series are connected in parallel. Moreover, in this embodiment, since the winding direction of the coil 18d is the same, by providing the inversion part T in which the connection of the coils U4, U2, and U6 is reversed, the coil has an opposite phase.

  Further, like the U phase, in the V phase, the coils V1, V3, V5 connected in series and the coils V4, V2, V6 connected in series are connected in parallel. Moreover, it is set as the coil of an antiphase by providing the inversion part T in which the connection of coil V1, V3, V5 is inverted.

  Furthermore, like the U phase and the V phase, in the W phase, the coils W4, W2, and W6 connected in series with the coils W5, W1, and W3 connected in series are connected in parallel. Moreover, it is set as the coil of an antiphase by providing the inversion part T in which the connection of the coils W4, W2, and W6 is inverted.

  The terminal 20b is routed inside the connection portion 20 so as to be connected between the coils 18d described above. In this embodiment, when 18 coils 18d are connected by parallel delta connection, the number of terminals stacked is 6 layers, which is the minimum. Here, the configuration in which the number of laminated terminals is minimized is the configuration of the connection portion when the coils 18d are connected so that the number of terminal layers in the winding specification diagram of FIG. 4 is minimized. Say that.

(Operation and effect of this embodiment)
Next, the operation and effect of this embodiment will be described.

  The process of manufacturing the brushless motor includes a process of forming the coil 18d by winding the winding 18c around the teeth 18b of the stator core 18a. Here, in this embodiment, the coil 18d of the same winding direction is used, without making a normal phase coil and an antiphase coil separately. Therefore, it is not necessary to change the winding direction of the winding as in the case where the positive phase coil and the reverse phase coil are separately formed. Therefore, the winding work when winding the winding around the teeth portion of the stator core can be simplified.

  Further, in the present embodiment, a connection portion (so-called armature wiring member) is used in which a terminal 20b connecting the coils 18d and a joining terminal 20a are integrally configured via an insulator. Therefore, the connection work between the coils 18d can be easily performed. As a result, it is possible to reduce the man-hours for assembling the brushless motor as compared with the case where the wire 18c extending from the coil terminals 18o and 18p of the coil 18d is wired to perform the connection work between the coils 18d.

  Furthermore, in this embodiment, when 18 coils 18d are connected by parallel delta connection, the number of stacked terminals 20b in the connection part 20 is six layers, which is the minimum. Therefore, it is possible to suppress an increase in the thickness of the connection part itself, and as a result, a compact connection part can be obtained. Moreover, in this embodiment, since the terminal is comprised by the thin plate shape, it is suppressed more that the thickness of connection part itself increases.

  Furthermore, in this embodiment, the connection part 20 is made into the substantially cyclic | annular form made into the outer diameter smaller than the internal diameter of the stator core 18a, and is arrange | positioned adjacent to the center piece 12 with which the stator core 18a is supported. In other words, the connection part 20 is arrange | positioned in the part which is hard to receive the influence by the change of the magnetic flux of the stator core 18a. Therefore, the drive of the brushless motor 10 can be stabilized.

Second Embodiment
Next, a brushless motor according to a second embodiment of the present invention will be described with reference to FIGS. In addition, the same code | symbol is attached | subjected about the member same as 1st Embodiment, and the description is abbreviate | omitted.

  As shown in FIGS. 4 and 5, the brushless motor of this embodiment is characterized in that 18 coils 18d are connected by parallel star connection in the brushless motor 10 of the first embodiment.

  The configuration of the connection of these 18 coils 18d will be described. As shown in FIG. 5, in the U phase, the coils U4, U5, U6 connected in series with the coils U1, U2, U3 connected in series, Are connected in parallel. Moreover, in this embodiment, since the winding direction of the coil 18d is the same, by providing the inversion part T in which the connection of the coils U2, U4, and U6 is reversed, the coil has an opposite phase.

  Further, like the U phase, in the V phase, the coils V1, V2, V3 connected in series and the coils V4, V5, V6 connected in series are connected in parallel. Moreover, it is set as the coil of an antiphase by providing the inversion part T in which the connection of coil V1, V3, V5 is inverted.

  Further, like the U phase and the V phase, in the W phase, the coils W4, W5, W6 connected in series with the coils W1, W2, W3 connected in series are connected in parallel. Moreover, it is set as the coil of an antiphase by providing the inversion part T in which the connection of the coils W2, W4, and W6 is inverted.

  The terminal 20b is routed inside the connection portion 20 so as to be connected between the coils 18d described above. In the present embodiment, when 18 coils 18d are connected by parallel star connection, the number of terminals stacked is 4 layers, which is the minimum.

(Operation and effect of this embodiment)
Next, the operation and effect of this embodiment will be described.

  In the present embodiment, since 18 coils 18d are connected by parallel star connection, the following effects can be obtained in addition to the effects of the brushless motor of the first embodiment.

  In this embodiment, when 18 coils 18d are connected by parallel star connection, the number of layers of terminals 20b in the connection portion 20 is four layers, which is the minimum. Therefore, the number of stacked terminals can be further reduced as compared with the case where the electrical circuit connecting the coils 18d is a delta connection (in this embodiment, compared with the case of a parallel delta connection, It was possible to reduce the number of layers by two). Therefore, it becomes possible to suppress further that the thickness of the connection part 20 itself increases, and as a result, the more compact connection part 20 can be obtained.

  In the present embodiment, an example in which the connection between the coils 18d is a parallel delta connection has been described. However, as shown in FIGS. 8 and 9, a star connection in which the coils 18d of each phase are connected in series may be used. . Even in this case, the number of stacked terminals 20b can be four as in the present embodiment. As a result, it is possible to further suppress an increase in the thickness of the connection part 20 itself, and a more compact connection part 20 can be obtained.

<Third Embodiment>
Next, a brushless motor according to a third embodiment of the present invention will be described with reference to FIG. In addition, the same code | symbol is attached | subjected about the member same as 1st Embodiment, and the description is abbreviate | omitted.

  As shown in FIG. 10, the brushless motor 30 of the present embodiment is characterized in that the connection part 32 is configured integrally with the center piece 12. Specifically, an annular connection portion 32 is formed integrally with the boss portion 12a and the disk portion 12e so as to surround the outer periphery of the boss portion 12a of the center piece 12. More specifically, the center piece 12 and the connection part 32 are molded of a resin material, and the terminal 20b is cast in the connection part 32, and the connection part 32 is engaged with the coil terminals 18o and 18p. This is a configuration in which the tip of the connecting terminal 20a protrudes.

(Operation and effect of this embodiment)
Next, the operation and effect of this embodiment will be described.

  In this embodiment, since the connection part 32 is comprised integrally with the center piece 12, in addition to the effect of the brushless motor 10 of the said 1st Embodiment, the following effects can be acquired.

  In the process of assembling the brushless motor, a process of connecting between the coils 18d (for example, attaching the connection part 20 to the stator 18 in the first embodiment) and a process of fixing the stator 18 and the connection part 20 to the center piece 12 are involved. It is possible.

  However, in this embodiment, since the connection part 32 is integrally molded with the center piece 12, the wiring work between the coils 18c and the work for fixing the stator 18 to the center piece 12 can be performed substantially simultaneously. That is, the assembly man-hour for the brushless motor can be reduced.

  As described above, in the first to third embodiments, the connection between the coils 18d is made using the armature wiring member in which the joint terminal 20a and the terminal 20b that connects the coil 18d are integrally formed via the insulator. Although the example which performed was demonstrated, this invention is not limited to this, You may use another connection method. For example, as shown in FIG. 11, by winding or welding the winding 18c extending from the end of the coil 18d and routing the winding 18c using the groove 36 provided in the wiring cover 34. The connection between the coils may be performed. As described above, the connection method may be appropriately set in consideration of the assembly of the brushless motor, the material yield, and the like.

  In the first embodiment to the third embodiment, the connection portion 20 is set to be equal to or smaller than the inner diameter of the stator core 18a, and the example in which the connection portion 20 is disposed adjacent to the center piece 12 is described. However, as illustrated in FIG. The inner diameter of the stator core 18 a may be larger than the outer diameter of the stator core 18 a, and may be disposed on the outer periphery of the stator support portion 12 f in the center piece 12.

  Furthermore, in the first to third embodiments, a 6-pole 18-slot three-phase brushless motor has been described. However, for example, a 4-pole 12-slot or a 3-pole 9-slot may be used. As described above, the number of poles and the number of slots may be appropriately set in consideration of the output and physique of the motor.

  Although one embodiment of the present invention has been described above, the present invention is not limited to the above, and various modifications other than the above can be implemented without departing from the spirit of the present invention. Of course.

10 Brushless motor
12 Centerpiece
14 Shaft (Output shaft)
16 Rotor
18 Stator
18a Stator core
18c winding
18d coil
20 Connection part
30 Brushless motor
32 Connection section
40 brushless motor
44 Connection
T reversing part

Claims (5)

A rotor that rotates around the output shaft,
Winding in a toroidal winding system in which a conductive winding is wound along the circumferential direction of an annular stator core disposed inside the rotor, and the winding direction is the same, and the winding start and winding end terminals A plurality of coils arranged on one side are arranged along the circumferential direction of the stator core in the order of U phase, V phase, and W phase;
A wiring portion that is arranged adjacent to the stator, has a reversing portion for forming a coil having an opposite phase and is connected to the terminal of the coil at a predetermined interval, and is formed as an integral structure;
Brushless motor with   2. The brushless motor according to claim 1, wherein the connection portion is configured such that an electric circuit for connecting the coils forms a star connection, and the number of windings or terminals stacked is minimized.   2. The brushless motor according to claim 1, wherein the connection portion is configured such that an electric circuit connecting the coils forms a delta connection, and the number of windings or terminals stacked is minimized.   The connection portion is an annular shape having an outer diameter less than an inner diameter of the stator core or an annular shape having an inner diameter exceeding the outer diameter of the stator core, and is disposed adjacent to a center piece on which the stator core is supported. The brushless motor according to any one of claims 1 to 3.   The brushless motor according to any one of claims 1 to 4, wherein the connection portion is molded integrally with a center piece.