JP2014121102A - Coreless electromechanical device, method of manufacturing the same, mobile body, and robot - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve efficiency of a coreless electromechanical device.SOLUTION: A coreless electromechanical device includes: a permanent magnet disposed in a first member; a magnetic coil which is disposed in a second member and has an effective coil part generating a force for moving the first member relatively to the second member, coil end parts, and two connection terminals; and a circuit board which has connection terminals for the magnetic coil to which the connection terminals of the magnetic coil are connected, external connection terminal wiring for connecting the magnetic coil to a driving circuit provided outside, and a wiring pattern for connecting the connection terminals for the magnetic coil and the external connection terminal wiring. The magnetic coil forms an M-phase coil group (M is an integer of 2 or more), and at least one of the two connection terminals is bent inward.

Description

  The present invention relates to a coreless electromechanical device, a manufacturing method of a coreless electromechanical device, a moving body, and a robot.

  An electric motor having an inner coil and an outer coil and bending the coil end portion of the outer coil outward is known (for example, Patent Document 1).

JP 2010-246342 A

  By the way, in a coreless motor, in order to enlarge the magnetic flux which passes a coil, a coil back yoke may be arrange | positioned on the outer side of a coil. In an electric motor in which the coil end portion of the outer coil is bent outward, a coil back yoke and a permanent magnet are inserted so that the coil end portion does not collide with the coil end portion at the time of manufacture, so the distance between the permanent magnet and the coil back yoke is wide. Is formed. If the distance between the permanent magnet and the coil back yoke is wide, the ratio of the mechanical energy output to the input electrical energy (hereinafter referred to as “efficiency”) decreases, so that the coil end portion of the outer coil moves outward. The bent electric motor has a problem that it is difficult to improve efficiency. In order to avoid the problem that the space between the permanent magnet and the coil back yoke is wide, it is possible to divide the coil back yoke and combine the divided coil back yokes, but the manufacturing process becomes complicated or the coil There is a problem that cogging is likely to occur because the magnetic flux becomes discontinuous at the divided portion of the back yoke.

  An object of the present invention is to solve at least a part of the problems described above and to provide a coreless electromechanical device that is easy to manufacture efficiently.

  SUMMARY An advantage of some aspects of the invention is to solve at least a part of the problems described above, and the invention can be implemented as the following forms or application examples.

(1) According to one aspect of the present invention, a coreless electromechanical device is provided. The coreless electromechanical device of this aspect is a coreless electromechanical device having a cylindrical first member and a second member in which the first member and the second member can move relative to each other. A permanent magnet disposed on the first member and an electromagnetic coil disposed on the second member, wherein a force for moving the first member relative to the second member is generated. An electromagnetic coil having an effective coil part, a coil end part, and two connection terminals, an electromagnetic coil connection terminal to which the connection terminal of the electromagnetic coil is connected, and the electromagnetic coil provided outside A circuit board having an external connection terminal wiring connected to the drive circuit and a wiring pattern connecting the electromagnetic coil connection terminal and the electromagnetic coil, and the electromagnetic coil includes an M-phase coil group (M is An integer greater than or equal to 2) , At least one of the two connection terminals is bent inwardly. According to the coreless electromechanical device of this embodiment, when the coreless electromechanical device is assembled, the connection portion of the “connection terminal” between adjacent coils does not interfere with the substrate, and thus the coreless electromechanical device can be easily manufactured. Is possible.

(2) In the coreless electromechanical device of the above aspect, the circuit board may have a wiring pattern for connecting the electromagnetic coil to either a serial connection or a parallel connection for each phase. According to the coreless electromechanical device of this embodiment, it is possible to easily create a coreless electromechanical device in which electromagnetic coils are connected in series and a coreless electromechanical device in which electromagnetic coils are connected in parallel by simply replacing the circuit board. Become.

(3) In the coreless electromechanical device of the above aspect, the circuit board and the connection terminal of the electromagnetic coil may be soldered. According to the coreless electromechanical device of this aspect, the electromagnetic coil and the circuit board can be reliably electrically connected.

(4) The coreless electromechanical device of the above aspect further includes a coil back yoke disposed on the second member, wherein the effective coil portion of the electromagnetic coil is between the permanent magnet and the coil back yoke. The electromagnetic coil has two coil end portions, and the (M-1) phase coil group other than the first phase of the M phase coil group. The coil end portion on the first side of the electromagnetic coil included in the bent portion is bent from the cylindrical surface including the cylindrical region to the permanent magnet side, and has a non-second phase (M−) different from the first phase. 1) Of the two coil end portions of the electromagnetic coil included in the phase coil group, the coil end portion on the second side opposite to the first side is bent from the cylindrical surface to the coil back yoke side. It may be. According to the coreless electromechanical device of this embodiment, since the coil back yoke or the permanent magnet can be inserted from the unbent side of the coil end portion, the permanent magnet and the coil back yoke can be connected without interfering with the coil end portion of the electromagnetic coil. The efficiency of the coreless electromechanical device (“efficiency” refers to “coreless electromechanical device with respect to the electric energy input to the coreless electromechanical device”, and can minimize the distance between the permanent magnet and the coil back yoke. It is possible to improve the ratio of the mechanical energy output from “.”.

(5) In the coreless electric machine of the above aspect, the coil end portion on the first side of the electromagnetic coil of the first phase is disposed on the cylindrical surface or from the cylindrical surface to the permanent magnet The coil end portion on the second side of the electromagnetic coil of the second phase is disposed on the cylindrical surface, or is bent from the cylindrical surface to the coil back yoke side. May be. According to the coreless electromechanical device of this aspect, the coil back yoke can be inserted and arranged from the first side of the electromagnetic coil, and the permanent magnet can be inserted and arranged from the second side. Furthermore, the coil back yoke and the electromagnetic coil It is possible to improve the efficiency of the coreless electromechanical device by narrowing the distance between the permanent magnet and the electromagnetic coil.

(6) In the coreless electromechanical device of the above aspect, when the value of M is 3 or more, the electromagnetic wave included in the (M-2) phase coil group other than the first phase and the second phase. The coil end portion on the first side of the coil has a size smaller than the size of the coil end portion on the first side of the electromagnetic coil of the second phase bent toward the permanent magnet side, and The second coil end portion of the electromagnetic coil included in the (M-2) phase coil group is bent to the permanent magnet side with a different size for each of the first phase electromagnetic coil. The second coil end portion of the electromagnetic coil is smaller in size than the coil back yoke side and the coil end portion of the electromagnetic coil included in the first phase coil group is bent. The smaller the phase, the greater the bending It may be bent in the coil back yoke side in different sizes. According to this form of the coreless electromechanical device, the collision between the electromagnetic coils in the coil end portion can be suppressed, and the M group P electromagnetic coils can be separated into one electromagnetic coil, so that the manufacture is facilitated. .

(7) In the coreless electromechanical device of the above aspect, the electromagnetic coil has two effective coil portions, and the first effective coil portion of the two effective coil portions and the first effective coil portion. The distance between the coil portion and the second effective coil portion may be 2 × (M−1) times as large as the width of the electromagnetic coil in the effective coil portion. According to the coreless electromechanical device of this aspect, the effective coil portion of the electromagnetic coil included in the coil group of the other phase is disposed between the first effective coil portion and the second effective coil portion. Thus, 2 × (M−1) pieces in total can be sandwiched from each other, so that the space factor of the electromagnetic coil can be improved and the efficiency of the coreless electromechanical device can be improved.

(8) In the coreless electromechanical device of the above aspect, the electromagnetic coil has two effective coil portions, and the first effective coil portion of the two effective coil portions and the first effective coil portion. The interval between the coil portion and the second effective coil portion different from the coil portion is (M−1) times the width of the electromagnetic coil in the effective coil portion of the electromagnetic coil, and the M-phase coil group One coil sub-aggregate may be formed by gathering one electromagnetic coil from each of the two. According to the coreless electromechanical device of this aspect, in the coil sub-assembly, the electromagnetic coil included in the first phase coil group of the M phase coil group includes the first effective coil portion and the second effective coil. It is possible to sandwich one effective coil portion of the two effective coil portions of the electromagnetic coil included in the (M-1) phase coil group other than the first phase coil group. Therefore, it is possible to improve the efficiency of the coreless electromechanical device by improving the space factor of the electromagnetic coil.

(9) The coreless electromechanical device according to the above aspect includes a coil back yoke disposed on the second member, wherein the effective coil portion of the electromagnetic coil is a cylinder between the permanent magnet and the coil back yoke. The electromagnetic coil has two coil end portions, and the electromagnetic coil includes a first shape electromagnetic coil and a second shape electromagnetic coil, and the first shape The electromagnetic coil is a cylinder in which a coil end portion on the first side of two coil end portions bends to the permanent magnet side, and a coil end portion on a second side different from the first side includes the cylindrical region. The second shape electromagnetic coil has a coil end portion on the second side bent toward the coil back yoke side, and a coil end portion on the first side has the shape arranged on the surface. On cylindrical surface Each of the two effective coil portions of the two second shape electromagnetic coils between the two effective coil portions of the first shape electromagnetic coil. A total of two effective coil portions are arranged, and a total of two effective coil portions of the two first shape electromagnetic coils is provided between the two effective coil portions of the second shape electromagnetic coil. The electromagnetic coil may be arranged so that two effective coil portions are arranged. According to the coreless electromechanical device of this embodiment, the overlap at the coil end portion of the electromagnetic coil is two layers, so that the coreless motor can be formed small. Further, by changing the wiring between the terminal of the circuit board and the drive circuit, it is possible to cope with various electromagnetic coil connections such as independent connection, star connection, and delta connection.

(10) In the coreless electric machine of the above aspect, M is an odd number, and each phase of the electromagnetic coil may have the same number of the first shape electromagnetic coils and the second shape electromagnetic coils. According to the coreless electromechanical device of this aspect, since the same number of first shape electromagnetic coils and second shape electromagnetic coils are included for each phase, the electrical characteristics of the electromagnetic coils of each phase are the same. Therefore, the electrical characteristics of the electromagnetic coils for each phase are well balanced, and the efficiency of the coreless electromechanical device can be improved.

(11) In the coreless electromechanical device of the above aspect, the M is 3, and the first shape electromagnetic coils of the first phase, the second phase, and the third phase do not cross each other on the cylindrical surface. The two effective coil portions of the second shape electromagnetic coil of the first phase are arranged in an annular shape in order, and the one effective coil portion of the first shape electromagnetic coil of the second phase and the The second shape electromagnetic coil of the first phase is arranged so as to sandwich one effective coil portion of the first shape electromagnetic coil of the third phase, and the second shape electromagnetic of the second phase. The two effective coil portions of the coil sandwich one effective coil portion of the first shape electromagnetic coil of the third phase and one effective coil portion of the first shape electromagnetic coil of the first phase. The second shape electromagnetic core of the second phase And the two effective coil portions of the second shape electromagnetic coil of the third phase are one effective coil portion and the second phase of the first shape electromagnetic coil of the first phase. The second shape electromagnetic coil of the third phase may be arranged so as to sandwich one effective coil portion of the first shape electromagnetic coil.

(12) In the coreless electromechanical device of the above aspect, M is an even number, and the electromagnetic coil has a shape of either the first shape electromagnetic coil or the second shape electromagnetic coil for each phase, The number of the first shape electromagnetic coils and the number of the second shape electromagnetic coils may be the same. According to the coreless electromechanical device of this embodiment, the electromagnetic coil has a shape of either the first shape electromagnetic coil or the second shape electromagnetic coil for each phase, and the first shape electromagnetic coil or the second shape electromagnetic coil. Therefore, the electrical characteristics of the electromagnetic coils for each phase are well balanced, and the efficiency of the coreless electromechanical device can be improved.

(13) In the coreless electromechanical device of the above aspect, the interval between the two effective coil portions of the electromagnetic coil may be twice the width of the electromagnetic coil in the effective coil portion of the electromagnetic coil. . According to this form of the coreless electromechanical device, the space factor of the electromagnetic coil can be increased, and the efficiency of the coreless electromechanical device can be improved.

(14) In the coreless electromechanical device of the above aspect, the M is 3, the two external connection terminals are provided for each phase, and are provided outside the two external connection terminals of each phase. Can be connected to any one of the three-phase independent connection, star connection, and delta connection by connecting to the drive circuit, and the three-phase independent connection means that the two external connection terminals of each phase are independent of each other. The star connection is connected to one external connection terminal of the two external connection terminals of each phase, the other external connection terminal is connected to the drive circuit, and the delta connection is connected to the drive circuit. One of the two external connection terminals of the first phase is connected to one of the two external connection terminals of the second phase, and the two external connections of the first phase The external connection of the other of the connection terminals A terminal is connected to one of the two external connection terminals of the third phase, and the other of the two external connection terminals of the second phase is not connected to the external connection terminal of the first phase And the other external connection terminal that is not connected to the external connection terminal of the first phase among the two external connection terminals of the third phase may be connected.

(15) In the coreless electromechanical device of the above aspect, the electromagnetic coils included in the coil group of each phase may have the same electric resistance value. According to the coreless electromechanical device of this aspect, since the magnitude of the electric resistance value of the electromagnetic coil is the same, it becomes possible to improve the balance of the driving force for each phase of the electromagnetic coil.

(16) In the coreless electromechanical device of the above aspect, a first conductor forming an electromagnetic coil in which the coil end portion is bent and an electromagnetic coil in which the coil end portion is not bent are formed. The two conductors are formed of the same material, the first conductor and the second conductor have the same diameter, and the number of turns of the first conductor of the electromagnetic coil in which the coil end portion is bent. And the number of turns of the second conductor forming the electromagnetic coil in which the coil end portion is not bent is the same, and the electromagnetic coil in which the coil end portion is bent and the electromagnetic in which the coil end portion is not bent The coil may have the same electric resistance value.

(17) According to an aspect of the present invention, a mobile object including the coreless electromechanical device of the above aspect may be used. The coreless electromechanical device of this form can be applied to a moving body.

(18) According to one aspect of the present invention, a robot including the coreless electromechanical device of the above aspect may be used. This form of the coreless electromechanical device can be applied to a robot.

(19) According to one form of this invention, the manufacturing method of a coreless electromechanical device is provided. The manufacturing method of the coreless electromechanical device of this embodiment is a manufacturing method of a coreless electromechanical device having an electromagnetic coil of M phase (M is an integer of 2 or more), and (a) a step of preparing a plurality of electromagnetic coils; (B) a step of bending the effective coil portion of the electromagnetic coil along the cylindrical region; and (c) two coil ends of the (M-1) phase electromagnetic coil other than the first phase of the M phase. One of the parts is bent to the inner circumference side of the cylindrical region where the effective coil part of the electromagnetic coil is arranged with a different size for each phase, and (M-1) other than the second phase different from the first phase Bending the other coil end portion on the opposite side to the one of the two coil end portions of the electromagnetic coil of the phase to the outer peripheral side of the cylindrical region so as to be larger as the size is smaller, (D) Bending the electromagnetic coil inward for each phase The electromagnetic coil is arranged in the descending order of the size of the electromagnetic coil so that the direction bent inside the electromagnetic coil is the first direction of the two directions along the rotation axis of the coreless electromechanical device. A step of forming an electromagnetic coil in which an effective area of the coil is disposed in a cylindrical region; and (e) a circuit board is disposed in the first direction of the electromagnetic coil, and an end of the wiring of the electromagnetic coil is disposed on the circuit board (F) inserting a coil back yoke or a permanent magnet on the outer peripheral side of the cylindrical surface from the first direction, and connecting the cylindrical surface from the second direction on the opposite side to the first direction. Inserting the coil back yoke or the permanent magnet which is not inserted into the outer peripheral side into the inner peripheral side. According to this method of manufacturing a coreless electromechanical device, it is possible to easily manufacture a coreless electromechanical device in which the distance between the permanent magnet and the coil back yoke is minimized. Further, by changing the wiring between the terminal of the circuit board and the drive circuit, it is possible to cope with various electromagnetic coil connections such as independent connection, star connection, and delta connection.

(20) According to one aspect of the present invention, a method of manufacturing a coreless electromechanical device is provided. The manufacturing method of the coreless electromechanical device of this embodiment is a manufacturing method of a coreless electromechanical device having an electromagnetic coil of M phase (M is an integer of 2 or more), and (a) a step of preparing a plurality of electromagnetic coils; (B) a step of bending the effective coil portion of the electromagnetic coil along the cylindrical region; and (c) two coil ends of the (M-1) phase electromagnetic coil other than the first phase of the M phase. One of the parts is bent to the inner circumference side of the cylindrical region where the effective coil part of the electromagnetic coil is arranged with a different size for each phase, and (M-1) other than the second phase different from the first phase Bending the other coil end portion on the opposite side to the one of the two coil end portions of the electromagnetic coil of the phase to the outer peripheral side of the cylindrical region so as to be larger as the size is smaller, (D) From the M-phase electromagnetic coil, each phase has a total of M Using a magnetic coil to form a coil sub-assembly so that coil end portions bent inside the electromagnetic coil are in the same direction; and (e) the electromagnetic wave included in the coil sub-assembly. The coil sub-assemblies are arranged in the cylindrical shape so that a coil end bent inside the coil is a first direction of two directions along the rotation axis of the coreless electromechanical device, and the electromagnetic coil Forming an electromagnetic coil in which the effective area is arranged in the cylindrical area; and (f) arranging a circuit board in one direction of the electromagnetic coil and connecting an end of the wiring of the electromagnetic coil to the circuit board. And (g) a coil back yoke or a permanent magnet is inserted into the outer peripheral side of the cylindrical surface from the first direction, and the inner periphery of the cylindrical surface from the second direction on the opposite side to the first direction. And a step of inserting a person who has not been inserted into the outer peripheral side of the coil back yoke or the permanent magnet. According to this method of manufacturing a coreless electromechanical device, it is possible to easily manufacture a coreless electromechanical device in which the distance between the permanent magnet and the coil back yoke is minimized. Further, by changing the wiring between the terminal of the circuit board and the drive circuit, it is possible to cope with various electromagnetic coil connections such as independent connection, star connection, and delta connection.

(21) According to one form of this invention, the manufacturing method of a coreless electromechanical device is provided. The manufacturing method of the coreless electromechanical device of this embodiment is a manufacturing method of a coreless electromechanical device having an electromagnetic coil of M phase (M is an integer of 2 or more), and (a) a step of preparing a plurality of electromagnetic coils; (B) the step of bending the effective coil portion of the electromagnetic coil along the cylindrical region, and (c) the first coil end portion of the electromagnetic coil of each phase is bent outside the cylindrical region. A first shape electromagnetic coil having a coil end portion on the second side opposite to the first on the same cylindrical surface as the cylindrical region and not bent outside or inside the cylindrical region; The coil end portion on the second side is bent inward of the cylindrical region, and the coil end portion on the first side is on the same cylindrical surface as the cylindrical region and either on the outer side or the inner side of the cylindrical region. Is not bent A two-shape electromagnetic coil, a forming step, (d) a step of arranging the second shape electromagnetic coils of each phase in the cylindrical region, and (e) a first shape electromagnetic coil of the respective phases arranged in the cylindrical region. And (f) disposing a circuit board in one direction of the electromagnetic coil, and connecting an end of the wiring of the electromagnetic coil to the circuit board, and (g) from the first side of the cylindrical surface Inserting a coil back yoke or permanent magnet on the inner peripheral side, and inserting the one of the coil back yoke or permanent magnet not inserted on the outer peripheral side from the second side to the outer peripheral side of the cylindrical surface And. According to this method of manufacturing a coreless electromechanical device, a small coreless motor having a thin coil end portion can be manufactured. Further, by changing the wiring between the terminal of the circuit board and the drive circuit, it is possible to cope with various electromagnetic coil connections such as independent connection, star connection, and delta connection.

  The present invention can be realized in various forms. For example, in addition to a coreless electromechanical apparatus such as a motor or a power generation apparatus and a manufacturing method thereof, the invention can be realized in the form of a moving body, a robot, or the like using the same. Is possible.

It is explanatory drawing which shows 1st Embodiment. The cross section when the coreless motor of 1st Embodiment is cut | disconnected by the cutting line perpendicular | vertical to a rotating shaft is shown typically. It is explanatory drawing which shows the state which accumulated the electromagnetic coils 100A and 100B. It is explanatory drawing which shows typically the wiring of the electromagnetic coil in 1st Embodiment. It is explanatory drawing which shows the process of winding an electromagnetic coil. It is explanatory drawing which shows the process of bending an electromagnetic coil. It is explanatory drawing which shows the process of forming an insulating film in an electromagnetic coil. It is explanatory drawing which shows the process of forming the integrated module of an electromagnetic coil and a coil back yoke. It is explanatory drawing which shows the molding process by resin. It is explanatory drawing which shows the process of incorporating a rotor. It is explanatory drawing which shows 2nd Embodiment. The cross section when the coreless motor of 2nd Embodiment is cut | disconnected by the cutting line perpendicular | vertical to a rotating shaft is shown typically. It is explanatory drawing which shows the process of winding the electromagnetic coil in 2nd Embodiment. It is explanatory drawing which shows the process of bending the electromagnetic coil in 2nd Embodiment. It is explanatory drawing which shows the process of forming an insulating film in the electromagnetic coil in 2nd Embodiment. It is explanatory drawing which shows the assembly process of the electromagnetic coils 100A and 100B. It is explanatory drawing which shows typically the wiring of the electromagnetic coil in 2nd Embodiment. It is explanatory drawing which shows the process of forming the integrated module of the electromagnetic coil and coil back yoke in 2nd Embodiment. It is explanatory drawing which shows 3rd Embodiment. It is explanatory drawing which shows 4th Embodiment. It is explanatory drawing which shows typically the figure seen from the cross section when the coreless motor of 4th Embodiment is cut by the surface perpendicular | vertical to a rotating shaft. It is explanatory drawing which shows 5th Embodiment. It is explanatory drawing which shows a cross section when 5th Embodiment is cut by the surface parallel to a rotating shaft. It is explanatory drawing which shows 6th Embodiment. It is explanatory drawing which shows the structure of a coreless motor as one Embodiment of an electromechanical device. It is explanatory drawing which shows the structure of a coreless motor as one Embodiment of an electromechanical device. It is explanatory drawing which shows the formation process of an electromagnetic coil. It is explanatory drawing which shows the process of bending the coil end part of an electromagnetic coil. It is explanatory drawing which shows the process of forming an insulating film in an electromagnetic coil. It is a perspective view which shows the fitting state of the electromagnetic coils 100A and 100B. It is explanatory drawing which expands and shows the magnetic sensor side coil end part of FIG. It is explanatory drawing which shows the state which pumped up all the electromagnetic coils to the cylindrical shape. It is explanatory drawing which shows the process of forming the integrated module of the electromagnetic coil and coil back yoke in 7th Embodiment. It is explanatory drawing which shows the molding process by resin. It is a perspective view showing the electromagnetic coil, coil back yoke, and circuit board which were resin-molded. It is explanatory drawing which shows the process of incorporating a rotor. It is explanatory drawing which shows 8th Embodiment. It is explanatory drawing which shows the example of a connection with the electromagnetic coil and circuit board of the coreless motor of 8th Embodiment. It is explanatory drawing which shows the electric bicycle (electric assisted bicycle) as an example of the moving body using the motor / generator by the modification of this invention. It is explanatory drawing which shows an example of the robot using the motor by the modification of this invention. It is explanatory drawing which shows an example of the double-arm 7-axis robot using the motor by the modification of this invention. It is explanatory drawing which shows the vertical articulated robot using the motor by the modification of this invention. It is explanatory drawing which shows the robot with a double arm caster using the motor by the modification of this invention. It is explanatory drawing which shows the rail vehicle using the motor by the modification of this invention.

[First Embodiment]
FIG. 1 is an explanatory diagram showing the first embodiment. FIG. 1 (A) schematically shows a cross section of the coreless motor 10 taken along a plane parallel to the rotation shaft 230 when viewed from a direction perpendicular to the cross section, and FIG. 1 (B) shows the coreless motor. The figure when the cross section when the motor 10 is cut | disconnected by the BB cutting line perpendicular | vertical to the rotating shaft 230 is seen from the direction perpendicular | vertical to a cross section is shown typically. The coreless motor 10 is an inner rotor type motor having a radial gap structure in which a substantially cylindrical stator 15 is disposed outside and a substantially cylindrical rotor 20 is disposed inside. The stator 15 includes a coil back yoke 115 and a plurality of electromagnetic coils 100A and 100B. The coil back yoke 115 is disposed along the inner periphery of the casing 110, and the electromagnetic coils 100 </ b> A and 100 </ b> B are arranged inside the coil back yoke 115. The coil back yoke 115 is made of a magnetic material and has a substantially cylindrical shape. The electromagnetic coils 100 </ b> A and 100 </ b> B are molded with a resin 130. The length of the electromagnetic coils 100A and 100B in the direction along the rotation axis 230 is longer than the length of the coil back yoke 115 in the direction along the rotation axis 230. That is, in FIG. 1A, the left and right ends of the electromagnetic coils 100A and 100B do not overlap the coil back yoke 115. In the present embodiment, a portion of the electromagnetic coil that overlaps with the coil back yoke 115 is referred to as an “effective coil portion”, and a region that does not overlap with the coil back yoke 115 is referred to as a “coil end portion”. In the present embodiment, the effective coil portions of the electromagnetic coils 100A and 100B are arranged in the same cylindrical region. On the other hand, about a coil end part, as demonstrated below, one of two coil end parts is bent from the cylindrical area | region to the outer peripheral side or the inner peripheral side. For example, regarding the electromagnetic coil 100A, as shown in FIG. 1A, the right coil end portion is disposed in the cylindrical region and is not bent, but the left coil end portion is bent from the cylindrical region to the outer peripheral side. Yes. As for the electromagnetic coil 100B, as shown in FIG. 1A, the left coil end portion is disposed in the cylindrical region and is not bent, but the right coil end portion is bent from the cylindrical region to the inner peripheral side. . The electromagnetic coils 100A and 100B are distinguished by their shapes as described above. However, when the electromagnetic coils 100A and 100B are not distinguished, they are simply referred to as the electromagnetic coil 100.

  A magnetic sensor 300 is further arranged on the stator 15. The magnetic sensor 300 functions as a position sensor that detects the phase of the rotor 20. As the magnetic sensor 300, for example, a Hall sensor having a Hall element can be used. The magnetic sensor 300 generates a substantially sinusoidal sensor signal by electric angle drive control. This sensor signal is used to generate a drive signal for driving the electromagnetic coils 100A and 100B. Therefore, two magnetic sensors 300 are provided corresponding to the electromagnetic coils 100A and 100B. However, since the phase of the drive signal for driving the electromagnetic coil 100A and the phase of the drive signal for driving the electromagnetic coil 100B are shifted by π / 2, it is based on the signal from one magnetic sensor 300. Thus, it is possible to adopt a configuration that generates drive signals whose phases are shifted by π / 2. The magnetic sensor 300 is disposed on the circuit board 310, and the circuit board 310 is fixed to the casing 110. In the present embodiment, the magnetic sensor 300 and the circuit board 310 are arranged on the side where the coil end portion of the electromagnetic coil 100A is bent outward. In this embodiment, using the positional relationship between the magnetic sensor 300 and the coil end portion, the coil end portion closer to the magnetic sensor 300 out of the two coil end portions described above is referred to as a “magnetic sensor side coil end portion”. The coil end portion far from the magnetic sensor 300 is referred to as a “non-magnetic sensor side coil end portion”.

  The rotor 20 has a rotating shaft 230 at the center, and has a plurality of permanent magnets 200 on the outer periphery of the rotating shaft 230. Each permanent magnet 200 is magnetized along the radial direction (radial direction) from the center of the rotating shaft 230 toward the outside. In FIG. 1B, the letters N and S attached to the permanent magnet 200 indicate the polarities of the permanent magnet 200 on the electromagnetic coils 100A and 100B side. The permanent magnet 200 and the electromagnetic coil 100 are disposed so as to face the cylindrical surfaces of the rotor 20 and the stator 15 facing each other. Here, the length of the permanent magnet 200 in the direction along the rotation axis 230 is the same as the length of the coil back yoke 115 in the direction along the rotation axis 230. An area on the electromagnetic coil 100A that overlaps the area sandwiched between the permanent magnet 200 and the coil back yoke 115 is an effective coil portion of the electromagnetic coil 100A. Further, the region on the electromagnetic coil 100B that overlaps the region sandwiched between the permanent magnet 200 and the coil back yoke 115 is an effective coil portion of the electromagnetic coil 100B. The rotating shaft 230 is supported by a bearing 240 of the casing 110. A magnet back yoke may be provided between the permanent magnet 200 and the rotating shaft 230, and side yokes may be provided at both ends of the permanent magnet 200 in the direction along the rotating shaft 230. By providing the magnet back yoke and side yoke, leakage of magnetic flux of the permanent magnet 200 can be suppressed. In the present embodiment, a wave spring washer 260 is provided inside the casing 110. The wave spring washer 260 positions the permanent magnet 200. However, the wave spring washer 260 can be replaced with another component.

  FIG. 2 schematically shows a cross section when the coreless motor 10 of the first embodiment is cut along a cutting line perpendicular to the rotation shaft 230. FIG. 2A shows a cross section when the coreless motor 10 is cut along an AA cutting line perpendicular to the rotation shaft 230 shown in FIG. The AA cutting line cuts the magnetic sensor side coil ends of the electromagnetic coils 100A and 100B. FIG. 2B shows a cross section when the coreless motor 10 is cut along a BB cutting line perpendicular to the rotating shaft 230 shown in FIG. The BB cutting line cuts the effective coil portions of the electromagnetic coils 100A and 100B. FIG. 2C shows a cross section when the coreless motor 10 is cut along a CC cutting line perpendicular to the rotating shaft 230 shown in FIG. The CC cutting line cuts the non-magnetic sensor side coil ends of the electromagnetic coils 100A and 100B. Note that FIG. 2B is the same drawing as FIG.

  As shown in FIG. 2 (B), the effective coil portions of the electromagnetic coils 100A and 100B are all disposed in the same cylindrical region. On the other hand, as shown in FIG. 2A, the coil end portion of the electromagnetic coil 100B is disposed in the same cylindrical region as the cylindrical region in which the effective coil portion of the electromagnetic coil 100B in FIG. 2B is disposed. However, the coil end portion of the electromagnetic coil 100A is disposed on the outer peripheral side (coil back yoke 115 side) with respect to the cylindrical region in which the effective coil portion of the electromagnetic coil 100A is disposed. Further, as shown in FIG. 2C, the coil end portion of the electromagnetic coil 100A is disposed in the same cylindrical region as the cylindrical region in which the effective coil portion of the electromagnetic coil 100A in FIG. 2B is disposed. However, the coil end part of the electromagnetic coil 100B is arranged on the inner peripheral side (permanent magnet 200 side) from the cylindrical region where the effective coil part of the electromagnetic coil 100B is arranged.

  FIG. 3 is an explanatory diagram showing a state in which the electromagnetic coils 100A and 100B are overlapped. FIG. 3A is a plan view seen from the coil back yoke side, and FIG. 3B is a perspective view schematically showing the electromagnetic coils 100A and 100B. 3A shows the coil back yoke 115, FIG. 3B omits the coil back yoke 115 to make the shapes of the electromagnetic coils 100A and 100B easier to see. Only one 100A and two electromagnetic coils 100B are shown. In addition, since the actual electromagnetic coils 100A and 100B are arranged along the side surface of the cylinder, the magnetic sensor side coil end part and the non-magnetic sensor side coil end part have curved surfaces, but FIG. The shapes of the electromagnetic coils 100A and 100B are schematically shown as planes. As shown in FIGS. 3A and 3B, the bundle of conductors of the effective coil portions of the two electromagnetic coils 100B is accommodated between the bundle of two conductors of the effective coil portion of the electromagnetic coil 100A. Here, the electromagnetic coil 100 is formed by winding a conductor a plurality of turns (for example, N turns), and the bundle of conductors means a bundle of N conductors. Also, as shown in FIG. 3A, the bundle of conductors of the effective coil portion of the two electromagnetic coils 100A fits between the bundle of two conductors of the effective coil portion of the electromagnetic coil 100B, and the electromagnetic coils 100A and 100B are , Do not hit each other. FIG. 3B shows only one electromagnetic coil 100A. The magnetic sensor side coil end portion of the electromagnetic coil 100A is bent from the cylindrical region to the coil back yoke 115 side (the outer peripheral side of the cylindrical region), and the magnetic sensor side coil of the electromagnetic coil 100B not bent from the cylindrical region. Does not hit the end. Further, the non-magnetic sensor side coil end portion of the electromagnetic coil 100B is bent from the cylindrical region to the side opposite to the coil back yoke 115 (inner peripheral side of the cylindrical region), and the electromagnetic coil 100A is not bent from the cylindrical region. Does not collide with the non-magnetic sensor side coil end. In this way, the effective coil portion of the electromagnetic coil 100A and the effective coil portion of the electromagnetic coil 100B are arranged on the same cylindrical region, and the conductors of the other two electromagnetic coils are interposed between the two conductor bundles of one electromagnetic coil. The magnetic coils 100A and 100B are arranged by bending the magnetic sensor side coil end portion of the electromagnetic coil 100A to the outer peripheral side and bending the non-magnetic sensor side coil end portion of the electromagnetic coil 100B to the inner peripheral side. , It can be arranged in the cylindrical region so as not to collide with each other. Further, in this embodiment, there is a relationship of L2≈2 × φ1 between the conductor bundle width φ1 of the electromagnetic coils 100A and 100B and the coil bundle interval L2 in the effective coil portion. Here, the width φ1 of the conductor bundle of the electromagnetic coil 100A means the width in the direction along the cylindrical region where the effective coil portion of the electromagnetic coil 100A is arranged, and the interval between the coil bundles means the effective coil of the electromagnetic coil 100A. It means the interval in the direction along the cylindrical region where the part is arranged. The same applies to the electromagnetic coil 100B. That is, since the cylindrical region where the electromagnetic coils 100A and 100B are arranged is almost occupied by the bundle of conductors of the electromagnetic coils 100A and 100B, the space factor of the electromagnetic coil is improved, and the coreless motor 10 (FIG. 1) Efficiency can be improved.

  FIG. 4 is an explanatory view schematically showing the wiring of the electromagnetic coil in the first embodiment. As is apparent from FIG. 4, the winding direction of the electromagnetic coil 100A is alternately clockwise and counterclockwise. The same applies to the electromagnetic coil 100B.

  FIG. 5 is an explanatory diagram showing a process of winding an electromagnetic coil. Until the coil end portion is bent to the outer peripheral side or the inner peripheral side from the cylindrical surface where the effective coil portions of the electromagnetic coils 100A and 100B are arranged, the manufacturing process of the electromagnetic coil 100A and the manufacturing process of the electromagnetic coil 100B are: The same manufacturing process. Therefore, here, the electromagnetic coil 100A will be described as an example. First, in the step shown in FIG. 5A, the electromagnetic coil wiring 105 is prepared, and the both ends of the electromagnetic coil wiring 105 are wound outwardly from the substantially middle so that the electromagnetic coil wiring 105 is α-wound. It will be written. As a result, two coil portions 100 </ b> Aa and 100 </ b> Ab are formed from one electromagnetic coil wiring 105. Here, the arrow in a figure has shown the winding direction. The inner peripheries of the two coil portions 100Aa and 100Ab are connected to each other by the connecting portion 100Ac. Here, when the coil portions 100Aa and 100Ab are overlapped, the two coil portions 100Aa and 100Ab may start to be wound so that the connection portion 100Ac can be wired along the inner periphery of the coil portion 100Aa. preferable. Note that. The specific length of the connection portion 100Ac differs depending on the drawing position of the connection portion 100Ac in the two coil portions 100Aa and 100Ab. For example, in the example shown in FIG. 5A, the length is preferably an integral multiple of the length of the inner periphery of the coil portion 100Aa or the coil portion 100Ab.

  Next, in the step shown in FIG. 5B, the two coil portions 100Aa and 100Ab are overlapped with each other to form the electromagnetic coil 100A. At this time, since the connection portion 100Ac is left, wiring is performed so that the connection portion 100Ac is along the inner periphery of the coil portion 100Aa. As described above, when the length of the connection portion 100Ac is an integral multiple of the length of the inner periphery of the coil portion 100Aa or the coil portion 100Ab, the connection portion 100Ac is connected to the inner periphery of the coil portion 100Aa or the coil portion Ab. It is possible to perform wiring without excess or deficiency.

  FIG. 6 is an explanatory diagram (part 2) illustrating the process of bending the electromagnetic coil. 6A shows the electromagnetic coil 100A, and FIG. 6B shows the electromagnetic coil 100B. The lower left drawing in FIG. 6A is a view showing a cross section taken along the line AA in the upper left drawing, and the right drawing in FIG. 6A is a BB cutting line in the upper left drawing. It is the figure which looked at the cross section cut off by the nonmagnetic sensor side. The lower right drawing of FIG. 6B is a view showing a cross section taken along the line CC of the upper right drawing, and the left drawing of FIG. 6B is a DD cut of the upper right drawing. It is the figure which looked at the cross section cut with the line from the magnetic sensor side. In the process shown here, the electromagnetic coils 100A and 100B are formed as described below. Regarding the electromagnetic coil 100A, as shown in FIG. 6A, the electromagnetic coil 100A is bent along the cylindrical region, and the magnetic sensor side coil end portion 100ACE2 is bent toward the outer peripheral side of the cylindrical region. On the other hand, for the electromagnetic coil 100B, as shown in FIG. 6B, the electromagnetic coil 100B is bent along the cylindrical region, and the non-magnetic sensor side coil end portion 100BCE1 is bent toward the inner peripheral side of the cylindrical region. It is done.

  FIG. 7 is an explanatory diagram showing a process of forming an insulating film on the electromagnetic coil. In the process shown in FIG. 7, the insulating film 101 is formed on the surfaces of the electromagnetic coils 100A and 100B. The electromagnetic coil wiring 105 (see FIG. 5) forming the electromagnetic coils 100A and 100B has an insulating coating (not shown). In the process shown in FIGS. 6A and 6B, the electromagnetic coils 100A and 100B are compressed while being heated, so that the insulation coating of the electromagnetic coils 100A and 100B is thinned, and the withstand voltage of the electromagnetic coil 100A or 100B is reduced. . Therefore, in this step, the insulating film 101 is formed on the surfaces of the electromagnetic coils 100A and 100B, whereby the withstand voltage of the electromagnetic coils 100A and 100B is improved. Since the electric resistance of the conductor (wiring) of the electromagnetic coil 100A or 100B is extremely small, the voltage drop per turn is very small. Therefore, the voltage of the wiring for each turn is substantially the same voltage, and even if the withstand voltage between the wirings forming each turn is low, a problem due to current leakage between the turns hardly occurs. Therefore, it is preferable to improve the space factor even if the coating of the electromagnetic coil wiring 105 is thinned. Further, by providing the insulating film 101 on the surfaces of the electromagnetic coils 100A and 100B, the surface of the electromagnetic coils 100A and 100B can be improved. It is preferable to improve the breakdown voltage.

  FIG. 8 is an explanatory diagram showing a process of forming an integrated module of an electromagnetic coil and a coil back yoke. In the step shown in FIG. 8A, the electromagnetic coil 100 </ b> B is disposed on the outer periphery of the inner mold 401. In FIG. 8, illustration of the insulating film 101 is omitted. The inner die 401 has a shape in which a thick cylinder and a slightly thinner cylinder are concentrically connected, and the thickness of one (right side in FIG. 8) is larger than the thickness of the other (left side in FIG. 8). It is getting thinner. The electromagnetic coil 100B is arranged so that the non-magnetic sensor side coil end portion 100BCE1 bent toward the inner peripheral side of the electromagnetic coil 100B is positioned in the narrowed portion. In addition, it is preferable that the difference of the thickness of this thick cylinder and a thin cylinder is the same thickness as the thickness of an electromagnetic coil. In this way, the magnitude of bending of the non-magnetic sensor side coil end portion 100BCE1 of the electromagnetic coil 100B can be minimized, and the difference in inductance with the electromagnetic coil 100A can be minimized. Moreover, in order to make it easy to remove the inner mold 401, the inner mold 401 having a divided configuration may be adopted.

  In the step shown in FIG. 8B, the electromagnetic coil 100A is arranged. At this time, the effective coil portion of the electromagnetic coil 100A is positioned between the effective coil portions of the electromagnetic coil 100B, and the non-magnetic sensor side coil end of the electromagnetic coil 100A is disposed on the outer peripheral side of the non-magnetic sensor side coil end portion 100BCE1 of the electromagnetic coil 100B. The electromagnetic coil 100A is arranged so that the part 100ACE1 is located.

  In the step shown in FIG. 8C, the coil back yoke 115 is inserted from the non-magnetic sensor side coil end portion 100ACE1 side outside the electromagnetic coil 100A. In the case of the present embodiment, even if the inner diameter of the coil back yoke 115 is reduced to a size slightly larger than the outer diameter of the cylindrical region, the magnetic sensor side coil bent to the outer peripheral side of the electromagnetic coil 100A when the coil back yoke 115 is inserted. End part 100ACE2 does not get in the way. Therefore, the distance between the electromagnetic coils 100A and 100B and the coil back yoke 115 can be narrowed, that is, the distance between the permanent magnet 200 and the coil back yoke 115 can be minimized. As a result, the efficiency of the coreless motor 10 can be improved. In addition, since the coil back yoke 115 is inserted without being divided and remains in a cylindrical shape, the coreless motor 10 can be easily manufactured. In addition, if the coil back yoke 115 is divided, the magnetic flux may be discontinuous at the divided portions and cogging may occur. However, in this embodiment, the coil back yoke 115 is not divided, so There is also an advantage that it hardly occurs. FIG. 8D shows a state where the coil back yoke 115 is inserted.

  FIG. 9 is an explanatory diagram illustrating a molding process using the resin 130. In the step shown in FIG. 9A, the outer molds 402 to 405 are arranged following the step in FIG. The outer molds 402 and 405 have a disk shape and are provided with resin injection ports 402A and 405A, respectively. The outer molds 403 and 404 have a cylindrical shape. First, the outer molds 403 and 404 are arranged on the outer periphery of the coil end portions of the electromagnetic coils 100A and 100B. In this embodiment, in order to expose the coil back yoke 115 to the outside, the outer molds 403 and 404 do not overlap with the coil back yoke 115. The outer molds 403 and 404 may be connected to form an integral outer mold so that the coil back yoke 115 is also covered. In this case, the coil back yoke 115 is not exposed to the outside. After the outer molds 403 and 404 are arranged, the outer molds 402 and 405 are arranged.

  In the step shown in FIG. 9B, the resin 130 is injected from the resin injection ports 402A and 405A, and thermosetting is performed. Although it is difficult to see in FIG. 9B, the resin 130 is also filled between the coil back yoke 115 and the electromagnetic coils 100A and 100B. After the resin 130 is cured, the outer molds 402 to 405 and the inner mold 401 are removed. FIG. 9C shows a state where the inner mold 401 and the outer molds 402 to 405 are removed.

  FIG. 10 is an explanatory diagram showing a process of incorporating the rotor. From the magnetic sensor side coil end side of the resin-molded electromagnetic coils 100A and 100B, the bearing 240, the rotating shaft 230 to which the permanent magnet 200 is attached, the circuit board 310 to which the magnetic sensor 300 is attached, and the bearing 240 are fitted in order. To go. The magnetic sensor side coil end portions of the electromagnetic coils 100A and 100B are not bent toward the inner peripheral side of the cylindrical region. Therefore, even when the permanent magnet 200 whose outer diameter is made slightly larger than the inner diameter of the cylindrical region when the rotating shaft 230 to which the permanent magnet 200 is attached is inserted, the electromagnetic coils 100A and 100B. The coil end portion and the permanent magnet 200 do not interfere with each other. As a result, the interval between the permanent magnet 200 and the electromagnetic coils 100A and 100B is reduced, that is, the interval between the permanent magnet 200 and the coil back yoke 115 can be reduced to the minimum, and the efficiency of the coreless motor 10 is improved. It becomes possible to make it. Thereafter, the casing 110 is fitted, and the coreless motor 10 shown in FIG. 1 is formed.

  As described above, according to the first embodiment, the magnetic sensor side coil end portion 100ACE2 of the electromagnetic coil 100A is bent to the outer peripheral side (coil back yoke 115 side), and the nonmagnetic sensor side coil end portion 100BCE1 of the electromagnetic coil 100B is It is bent to the circumferential side (permanent magnet 200 side). Therefore, when the coreless motor 10 is manufactured, it is easy to insert the coil back yoke 115 from the non-magnetic sensor side and insert the permanent magnet 200 from the magnetic sensor 300 side. And since it becomes possible to narrow the space | interval of the coil back yoke 115 and the effective coil part of electromagnetic coil 100A, 100B and to narrow the space | interval of the permanent magnet 200 and the effective coil part of electromagnetic coil 100A, 100B, a coreless motor The efficiency of 10 can be improved. In addition, since the coil back yoke 115 is not divided in the manufacturing process of the first embodiment, the coreless motor 10 can be easily manufactured and the occurrence of cogging in the coreless motor 10 can be suppressed.

  In this embodiment, since the effective coil portion of the electromagnetic coil 100B can be embedded between the two effective coil portions of the electromagnetic coil 100A without any gap, the space factor of the electromagnetic coil is improved and the efficiency of the coreless motor 10 is improved. It becomes possible.

[Second Embodiment]
FIG. 11 is an explanatory diagram showing the second embodiment. FIG. 11A schematically shows a cross-section when the coreless motor 10 is cut along a cutting line parallel to the rotation shaft 230 when viewed from a direction perpendicular to the cross-section, and FIG. The figure when the cross section when the coreless motor 10 is cut | disconnected by the cutting line perpendicular | vertical to the rotating shaft 230 (BB cutting line of FIG. 11 (A)) is seen from the direction perpendicular | vertical to a cross section is shown typically. . Compared to the first embodiment, in the second embodiment, the number of electromagnetic coils 100A, 100B is halved. On the other hand, the size of one pole of the electromagnetic coils 100A and 100B of the second embodiment is larger than the size of one pole of the electromagnetic coils 100A and 100B of the first embodiment. In the first embodiment, in-phase electromagnetic coils are in contact with each other, but in the second embodiment, in-phase electromagnetic coils are not in contact with each other. That is, the first and second embodiments differ in the size of the electromagnetic coils 100A and 100B and the combination of the electromagnetic coils 100A and 100B.

  FIG. 12 schematically shows a cross section when the coreless motor 10 of the second embodiment is cut along a cutting line perpendicular to the rotation shaft 230. FIG. 12A shows a cross section when the coreless motor 10 is cut along an AA cutting line perpendicular to the rotating shaft 230 shown in FIG. The AA cutting line cuts the magnetic sensor side coil ends of the electromagnetic coils 100A and 100B. FIG. 12B shows a cross section when the coreless motor 10 is cut along a BB cutting line perpendicular to the rotating shaft 230 shown in FIG. The BB cutting line cuts the effective coil portions of the electromagnetic coils 100A and 100B. FIG. 12C shows a cross section when the coreless motor 10 is cut along a CC cutting line perpendicular to the rotating shaft 230 shown in FIG. The CC cutting line cuts the non-magnetic sensor side coil ends of the electromagnetic coils 100A and 100B. Note that FIG. 12B is the same drawing as FIG.

  As shown in FIG. 12B, the effective coil part of the electromagnetic coil 100A and the effective coil part of the electromagnetic coil 100B are arranged in the same cylindrical region. In the first embodiment, as shown in FIG. 2B, adjacent electromagnetic coils 100A or electromagnetic coils 100B are in contact with each other, but in the second embodiment, in-phase 2 The two electromagnetic coils 100A and 100B are not in contact with each other.

  As shown in FIG. 12A, the coil end portion of the electromagnetic coil 100B is disposed in the same cylindrical region as the cylindrical region in which the effective coil portion of the electromagnetic coil 100B in FIG. The coil end portion of the electromagnetic coil 100A is disposed on the outer peripheral side of the cylindrical region where the effective coil portion of the electromagnetic coil 100A is disposed. Further, the electromagnetic coil 100B and the adjacent electromagnetic coil 100B are not in contact with each other and are filled with the resin 130. Similarly, between the electromagnetic coil 100A and the adjacent electromagnetic coil 100A, the electromagnetic coil 100A and the adjacent electromagnetic coil 100A are not in contact with each other and are filled with the resin 130. Since the coil end portion is an area that does not affect the rotational force of the coreless motor 10, even if the resin 130 is filled between the electromagnetic coils of the same phase in the coil end portion, the resin 130 is not filled. However, the electrical characteristics of the coreless motor 10 are hardly changed.

    As shown in FIG. 12C, the coil end portion of the electromagnetic coil 100A is disposed in the same cylindrical region as the cylindrical region in which the effective coil portion of the electromagnetic coil 100A in FIG. The coil end portion of the electromagnetic coil 100B is disposed on the inner peripheral side of the cylindrical region where the effective coil portion of the electromagnetic coil 100B is disposed. Further, as shown in FIG. 12A, the electromagnetic coil 100A and the adjacent electromagnetic coil 100A are not in contact with each other and are filled with the resin 130. The electromagnetic coil 100B and the adjacent electromagnetic coil 100B are not in contact with each other and are filled with the resin 130.

  FIG. 13 is an explanatory diagram illustrating a process of winding an electromagnetic coil according to the second embodiment. FIG. 14 is an explanatory diagram illustrating a process of bending the electromagnetic coil according to the second embodiment. FIG. 15 is an explanatory diagram illustrating a process of forming an insulating film on the electromagnetic coil according to the second embodiment. In the first embodiment, the width of the coil bundle in the effective coil portion of the electromagnetic coil 100A (the width in the direction along the cylindrical region in which the effective coil portion of the electromagnetic coil 100A is disposed) is the interval between the two effective coil portions ( In the second embodiment, the width of the coil bundle in the effective coil portion of the electromagnetic coil 100A is approximately half the size of the effective coil portion of the electromagnetic coil 100A. Is different in that it is approximately the same size as the interval between the two effective coil portions. Except for this point, the formation steps of the electromagnetic coils 100A and 100B are the same as the formation steps (FIGS. 5 to 7) of the electromagnetic coils 100A and 100B in the first embodiment, and thus description thereof is omitted.

  FIG. 16 is an explanatory diagram showing an assembly process of the electromagnetic coils 100A and 100B. In FIG. 16, the description of the insulating film 101 (FIG. 15) is omitted. 16A shows a plan view, AA cross section, BB cross section, CC cross section when viewed from the permanent magnet 200 side when the electromagnetic coils 100A, 100B are incorporated in the coreless motor 10. FIG. Represents. FIG. 16B is a perspective view seen from the coil back yoke 115 side. In the perspective view of FIG. 16B, the interval between the bundles of two wires of the electromagnetic coil 100A (100B) in the effective coil portion and the width of the bundle of wires of the electromagnetic coil 100B (100A) are substantially the same. However, since FIG. 16B becomes difficult to see when the ratio is shown, the interval between the bundles of the two wirings of the electromagnetic coils 100A and 100B is enlarged. Further, FIG. 16B schematically shows the electromagnetic coils 100 </ b> A and 100 </ b> B on a plane as in FIG. 3B. The electromagnetic coil 100A is fitted so that the effective coil portion of the electromagnetic coil 100A is fitted between the two effective coil portions at the central portion of the electromagnetic coil 100B from the radially outer peripheral side of the cylindrical region in which the electromagnetic coil 100B is disposed. Thus, an electromagnetic coil subassembly 150 (coil subassembly) is formed. The electromagnetic coil subassembly 150 forms a part of a cylindrical region formed by the electromagnetic coil 100. The magnetic sensor side coil end portion 100ACE2 of the electromagnetic coil 100A is bent from the cylindrical region in the outer peripheral direction, and the non-magnetic sensor side coil end portion 100BCE1 of the electromagnetic coil 100B is bent from the cylindrical region in the inner peripheral direction.

  FIG. 17 is an explanatory diagram schematically showing wiring of the electromagnetic coil in the second embodiment. Compared with the wiring of the electromagnetic coil of the first embodiment shown in FIG. 4, in the first embodiment, the electromagnetic coils 100A and 100B appear to bite in a complicated manner. On the other hand, in the second embodiment shown in FIG. 17, the electromagnetic coils 100A and 100B each have one pole to form one electromagnetic coil subassembly 150, and the electromagnetic coil subassembly 150 is connected to form an electromagnetic coil. So it looks like a simple configuration. That is, in the second embodiment, the electromagnetic coil subassembly 150 is formed, and the coreless motor 10 is easily formed by combining the electromagnetic coil subassembly 150.

  FIG. 18 is an explanatory diagram illustrating a process of forming an integrated module of an electromagnetic coil and a coil back yoke in the second embodiment. In the step shown in FIG. 18A, the electromagnetic coil subassembly 150 is disposed on the outer periphery of the inner mold 401. The shape of the inner mold 401 is the same as that of the first embodiment. FIG. 18B shows a state where all the electromagnetic coil subassemblies 150 are arranged. The process illustrated in FIG. 18C is similar to the process illustrated in FIG. FIG. 18D shows a state where the coil back yoke 115 is inserted. Subsequent steps are the same as those in the first embodiment shown in FIGS.

[Third Embodiment]
FIG. 19 is an explanatory diagram showing the third embodiment. The first and second embodiments are the inner rotor type coreless motor 10 in which the rotor 20 is disposed inside the stator 15. However, in the third embodiment, the rotor 20 is disposed outside the stator 15. The difference is that it is an outer rotor type electric motor. The electromagnetic coils 100 </ b> A and 100 </ b> B of the third embodiment are connected to the coil arrangement substrate 311 by electromagnetic coil wiring 105. The shape and arrangement of the electromagnetic coils 100A and 100B of the third embodiment are the same as the shape and arrangement of the electromagnetic coils 100A and 100B in the first embodiment, or the shape of the electromagnetic coils 100A and 100B in the second embodiment. The arrangement is the same. However, in 3rd Embodiment, the permanent magnet 200 provided with the magnet back yoke 215 on the back is arrange | positioned at the outer peripheral side of electromagnetic coil 100A, 100B, and the coil back yoke 115 is the inner peripheral side of electromagnetic coil 100A, 100B. Is arranged. In the manufacturing process, the coil back yoke 115 is inserted from the magnetic sensor side. The permanent magnet 200 is inserted from the non-magnetic sensor side as one body with the rotor 20.

[Fourth Embodiment]
In the first to third embodiments, the case where the electromagnetic coil has two phases has been described as an example, but the electromagnetic coil may have three phases or more. FIG. 20 is an explanatory diagram showing the fourth embodiment. FIG. 20 schematically shows a state where the coil back yoke 115 and the rotating shaft 230 to which the permanent magnet 200 is attached are inserted into the three-phase electromagnetic coil. In FIG. 20, the resin 130 is omitted. In this embodiment, the electromagnetic coils 100A to 100C are provided with three-phase electromagnetic coils. In this embodiment, 100A, 100B, and 100C are used as the codes of the electromagnetic coils. However, when the three-phase electromagnetic coils are star-connected or delta-connected, the phases are u phase, v phase, and w phase. The names of 100u, 100v, and 100w can be used as the codes of the electromagnetic coils. The magnetic sensor side coil end portions of the electromagnetic coils 100A and 100B are bent toward the outer peripheral side, and the non-magnetic sensor side coil end portions of the electromagnetic coils 100B and 100C are bent toward the inner peripheral side. Here, the magnitude of the bending of the electromagnetic coil 100B toward the outer peripheral side is smaller than the magnitude of the bending of the electromagnetic coil 100A bent toward the outer peripheral side. Moreover, the magnitude | size of the bending bent to the inner peripheral side of the electromagnetic coil 100B is smaller than the magnitude of the bending bent the electromagnetic coil 100C to the inner peripheral side. The coil back yoke 115 is inserted along the axial direction of the rotating shaft 230 from the non-magnetic sensor side coil end portion side, and the permanent magnet 200 is inserted along the axial direction of the rotating shaft 230 from the magnetic sensor side coil end portion side. Is done.

  FIG. 21 is an explanatory view schematically showing a view seen from a cross section when the coreless motor 10 of the fourth embodiment is cut along a plane perpendicular to the rotation shaft 230. In FIG. 21, the arc schematically shows the coil end portion of the electromagnetic coil, and the larger the arc, the more the coil end portion is bent toward the coil back yoke 215 side. Therefore, the A-phase electromagnetic coil 100A is bent outward (coil back yoke 215 side), and then the B-phase electromagnetic coil 100B is bent outward (coil back yoke 215 side). The C-phase electromagnetic coil 100 </ b> C is not bent by the actual coreless motor 10, and thus it is difficult to see when overlapping with the hatching of the electromagnetic coil when illustrated. In FIG. 21, in order to avoid the difficulty of seeing, an arc indicating the high-interest end region of the C-phase electromagnetic coil 100 </ b> C is illustrated outside the coil back yoke 215.

  In general, when an electromagnetic coil of (M + 2) phase (M is a natural number) is included, the magnetic sensor side coil end portion of the first phase electromagnetic coil (the electromagnetic coil 100A in FIG. 20) is the largest on the outer peripheral side (coil back yoke). 115 side), and the non-magnetic sensor side coil end portion of the second phase electromagnetic coil (the electromagnetic coil 100C in FIG. 20) is bent to the largest inner circumference side (permanent magnet 200 side). Yes. The magnetic sensor side coil end portions of the remaining M phase electromagnetic coils (the electromagnetic coils other than the electromagnetic coils 100A and 100C in FIG. 20) are bent to the outer peripheral side with different sizes for each phase. The side coil end portion is bent toward the inner peripheral side with a different size for each phase. At this time, the size of the remaining M-phase magnetic sensor side coil end portion bent toward the outer peripheral side is larger than the size of the magnetic sensor side coil end portion of the first phase electromagnetic coil bent toward the outer peripheral side. small. Further, the size of the non-magnetic sensor side coil end portion bent toward the inner peripheral side is smaller than the size of the second phase electromagnetic coil bent toward the inner peripheral side of the non-magnetic sensor side coil end portion. . Further, the magnitude of bending of the M-phase coil end portion is larger as the magnitude of bending at the magnetic sensor side coil end portion is smaller. . In such a configuration, the collision or interference of the coil end portion is suppressed in the step of arranging the electromagnetic coil in the cylindrical region. In addition, if such electromagnetic coils are formed and arranged, each phase of the electromagnetic coils 100A to 100C can be separated into independent electromagnetic coils 100A to 100C or coreless. Manufacture of the motor 10 becomes easy.

[Fifth Embodiment]
FIG. 22 is an explanatory diagram showing the fifth embodiment. The fifth embodiment includes three-phase electromagnetic coils 100A to 100C as in the fourth embodiment. Also in FIG. 22, as in FIG. 21, the arc indicates the coil end portion. In the fourth embodiment, regarding the coil end portion on the magnetic sensor side, the A-phase electromagnetic coil 100A is bent to the outermost side, and then the B-phase electromagnetic coil 100B is bent to the outer side (coil back yoke 215 side). The C-phase electromagnetic coil 100C is not bent. On the other hand, in the fifth embodiment, there are four A-phase to C-phase electromagnetic coils 100A to 100C, and two in each phase, the magnetic sensor side coil end portion is outside as indicated by the outer arc. In each of the remaining two electromagnetic coils, the coil end portion on the magnetic sensor side is not bent as indicated by the inner arc. In each phase, an electromagnetic coil whose magnetic sensor side coil end is bent outward (hereinafter referred to as “first shape electromagnetic coil”) and an electromagnetic coil whose magnetic sensor side coil end is not bent are: (Hereinafter referred to as “second-shaped electromagnetic coils”), which are the same number and are arranged alternately. In addition, the non-magnetic sensor side coil end portion of the first shape electromagnetic coil is not bent, and the non-magnetic sensor side coil end portion of the second shape electromagnetic coil is bent inward.

  FIG. 23 is an explanatory diagram showing a cross section when the fifth embodiment is cut along a plane parallel to the rotation shaft 230. 23A to 23F show cross sections of the electromagnetic coil when the plane parallel to the rotation shaft 230 is shifted by 30 °. In the electromagnetic coil (first shape electromagnetic coil) in which the left magnetic sensor side coil end portion is bent outward (upper side in the drawing), the right non-magnetic sensor side coil end portion is not bent. On the other hand, in the electromagnetic coil (second shape electromagnetic coil) whose left magnetic sensor side coil end portion is not bent, the right non-magnetic sensor side coil end portion is bent inward (lower side in the drawing). For example, as shown in FIGS. 23F and 23A, the magnetic sensor side coil end portion (left side of the drawing) of the electromagnetic coil 100A is bent outward (upward in the drawing), and the non-magnetic sensor side coil end portion (drawing). The right side is not bent. On the other hand, as shown in FIGS. 23C and 23D, the non-magnetic sensor side coil end portion of the electromagnetic coil 100A is bent inward (downward in the drawing), and the magnetic sensor side coil end portion is bent. Absent. Similarly, as shown in FIGS. 23D and 23E, the magnetic sensor side coil end portion of the electromagnetic coil 100B is bent outward, and the non-magnetic sensor side coil end portion is not bent. On the other hand, as shown in FIGS. 23A and 23B, the non-magnetic sensor side coil end portion of the electromagnetic coil 100B is bent inward, and the magnetic sensor side coil end portion is not bent. As shown in FIGS. 23B and 23C, the magnetic sensor side coil end portion of the electromagnetic coil 100C is bent outward, and the non-magnetic sensor side coil end portion is not bent. On the other hand, as shown in FIGS. 23E and 23F, the non-magnetic sensor side coil end portion of the electromagnetic coil 100C is bent inward, and the magnetic sensor side coil end portion is not bent. Here, each of the electromagnetic coils 100A to 100C includes the same number of first shape electromagnetic coils and first shape electromagnetic coils.

  Comparing the fourth and fifth embodiments with respect to the coil end portion, the fifth embodiment is further characterized in the following points. That is, in the fourth embodiment, there is a portion where the arc is triple. This means that, for example, in the fourth embodiment, as shown in FIG. 20, a portion where the coil end portions overlap in triplicate occurs. On the other hand, in the fifth embodiment, the arc is only double at most. That is, in the fifth embodiment, even if there are three phases, the overlapping of the coil end portions can be double as in the first embodiment shown in FIG. In the fifth embodiment, the size of the coreless motor 10 can be made smaller than that in the fourth embodiment.

  In the fourth embodiment, in the A-phase electromagnetic coil 100A, the magnetic sensor side coil end portion is bent toward the coil back yoke, and the non-magnetic sensor side coil end portion is not bent. In the B-phase electromagnetic coil 100B, the magnetic sensor side coil end is bent toward the coil back yoke, and the non-magnetic sensor side coil end is bent toward the permanent magnet. In the C-phase electromagnetic coil 100C, the magnetic sensor side coil end portion is not bent, and the non-magnetic sensor side coil end portion is bent toward the permanent magnet side. That is, the A-phase to the C-phase have different coil end portions. Accordingly, the electrical characteristics of the electromagnetic coils 100A to 100C are substantially the same because they are mainly determined by the effective coil portion, but strictly speaking, they are slightly different due to the difference in the shape of the coil end portion. On the other hand, in the fifth embodiment, the coreless motor 10 has two first-shaped electromagnetic coils for each of the electromagnetic coils 100A to 100C from the A phase to the C phase. The characteristics are the same. Each of the A-phase to C-phase electromagnetic coils 100 </ b> A to 100 </ b> C has two second-shaped electromagnetic coils, and the electrical characteristics are the same. That is, the electrical characteristics of the A-phase to C-phase electromagnetic coils are the same. Therefore, the coreless motor according to the fifth embodiment is less likely to cause torque fluctuation due to unbalance between phases, and is well balanced. Therefore, the efficiency of the coreless motor can be improved.

  The coreless motor of the fifth embodiment can be manufactured by the same process as that of the first embodiment described with reference to FIG. Similar to the process shown in FIG. 8A, the second shape electromagnetic coil of the two shapes of the electromagnetic coils 100A to 100C on the outer periphery of the inner mold 401 is, for example, A phase, B phase, C Arranged at equal intervals in the order of the phases. Next, as in the step shown in FIG. 8B, the first shape electromagnetic coil is disposed. At this time, two effective coil portions of the first shape electromagnetic coil among the two shapes of electromagnetic coils of the electromagnetic coils 100A to 100C sandwich one effective coil portion of each of the two second shape electromagnetic coils. Be placed. For example, the two effective coil portions of the first shape electromagnetic coil of the electromagnetic coil 100C sandwich one effective coil portion of each of the second shape electromagnetic coil of the electromagnetic coil 100A and the second shape electromagnetic coil of the electromagnetic coil 100B. The two effective coil portions of the first shape electromagnetic coil of 100A sandwich one effective coil portion of each of the second shape electromagnetic coil of the electromagnetic coil 100B and the second shape electromagnetic coil of the electromagnetic coil 100C, and the first effective coil portion of the electromagnetic coil 100B. The two effective coil portions of the shape electromagnetic coil sandwich one effective coil portion of each of the second shape electromagnetic coil of the electromagnetic coil 100C and the second shape electromagnetic coil of the electromagnetic coil 100A. Considering this configuration in the opposite direction, the two effective coil portions of the second shape electromagnetic coil of the electromagnetic coil 100C are one each of the first shape electromagnetic coil of the electromagnetic coil 100A and the first shape electromagnetic coil of the electromagnetic coil 100B. The two effective coil portions of the second shape electromagnetic coil of the electromagnetic coil 100A sandwich the effective coil portion, and each of the effective coil portions of the first shape electromagnetic coil of the electromagnetic coil 100B and the first shape electromagnetic coil of the electromagnetic coil 100C. The two effective coil portions of the second shape electromagnetic coil of the electromagnetic coil 100B sandwich the one effective coil portion of each of the first shape electromagnetic coil of the electromagnetic coil 100C and the first shape electromagnetic coil of the electromagnetic coil 100A. It is. Since the subsequent steps are the same as those in the first embodiment, description thereof will be omitted.

  In the fifth embodiment, the case where the electromagnetic coil has three phases has been described as an example. However, the number of phases is not limited to three, and may be two or more. Here, when the number of phases is an odd number, the electromagnetic coils of each phase have the same number of first shape electromagnetic coils and second shape electromagnetic coils, respectively, as described in the three-phase description above. On the other hand, when the number of phases is two, for example, as shown in the first embodiment, the electromagnetic coil 100A is a first shape electromagnetic coil, and the electromagnetic coil 100B is a second shape electromagnetic coil. In the case of four or more phases, the first and third phase electromagnetic coils are in the first shape electromagnetic coil, and the second and third phase electromagnetic coils are in the second shape electromagnetic coil. Is determined as either the first shape electromagnetic coil or the second shape electromagnetic coil. The number of phases to be the first shape electromagnetic coil and the number of phases to be the second shape electromagnetic coil are the same. Therefore, regardless of the number of phases, the electrical characteristics of the electromagnetic coils of each phase are the same or rotationally symmetric as a whole. Therefore, the coreless motor is less likely to cause torque fluctuation due to imbalance between phases and has a good balance, so that the efficiency of the coreless motor can be improved.

[Sixth Embodiment]
FIG. 24 is an explanatory diagram showing the sixth embodiment. In the sixth embodiment, the electromagnetic coil has three phases, and, similarly to the second embodiment, one electromagnetic coil is gathered from each of the three-phase electromagnetic coils 100A to 100C to perform the electromagnetic coil subassembly. It is the embodiment which forms. In this embodiment, as in the second embodiment, a coreless motor can be easily formed by forming and combining electromagnetic coil subassemblies.

[Seventh Embodiment]
FIG. 25 and FIG. 26 are explanatory views showing the configuration of the coreless motor 10 as the seventh embodiment of the electromechanical device. FIG. 25 schematically shows a cross section of the coreless motor 10 taken along a plane parallel to the rotation axis 230 (25A-25A cut plane in FIG. 26), and FIG. 26 shows a plane perpendicular to the rotation axis 230 of the coreless motor 10. The cross section cut by (26A-26A cut surface of FIG. 25) is shown schematically. In the seventh embodiment, the electromagnetic coil 100A is disposed on the inner side, and the electromagnetic coil 100B is disposed on the outer side. The electromagnetic coil 100A is disposed on the outer side, and the electromagnetic coil 100B is disposed on the inner side. This is different from the embodiment. Another difference is that the wirings 105A and 105B of the electromagnetic coils 100A and 100B are connected to the circuit board 105 disposed on the opposite side of the circuit board 310. Further, in the first embodiment, the rotating shaft 230 is not hollow, but the seventh embodiment is different in that the rotating shaft 230 is hollow. However, whether or not the rotating shaft 230 is hollow does not significantly affect the characteristics of the coreless motor 10.

  The coreless motor 10 is an inner rotor type motor in which a substantially cylindrical stator 15 is disposed on the outer side and a cylindrical rotor 20 is disposed on the inner side. The stator 15 includes electromagnetic coils 100A and 100B, a casing 110, a coil back yoke 115, and a magnetic sensor 300. The rotor 20 includes a rotating shaft 230, a permanent magnet 200, a magnet back yoke 236, magnet side yokes 237 and 238, a bearing portion 240, and a wave spring washer 260.

  The rotor 20 has a rotating shaft 230 at the center, and a cylindrical magnet back yoke 236 is fixedly disposed on the outer periphery of the rotating shaft 230 with an adhesive. In addition, a plurality (six in this example) of permanent magnets 200 are fixedly disposed in a substantially cylindrical shape with an adhesive on the outer periphery of the magnet back yoke 236. The plurality of permanent magnets 200 are permanent magnets magnetized in the direction (radial direction) from the center of the rotating shaft 230 to the outside, and permanent magnetized in the direction (center direction) from the outside toward the center of the rotating shaft 230. And a magnet. The permanent magnets 200 having a radial magnetization direction and the permanent magnets 200 having a central magnetization direction are alternately arranged along the circumferential direction. The symbols “N” and “S” attached to the permanent magnet 200 in FIG. 26 indicate the polarities of the magnetic poles on the outer peripheral side of the permanent magnet 200. In the present embodiment, the magnetization direction of the permanent magnet 200 is described as a radial direction (radial direction or central direction), but may be magnetized in a parallel direction instead of a radial direction.

  Magnet side yokes 237 and 238 are fixedly arranged with an adhesive at both ends (side surfaces) of the permanent magnet 200 in a direction along the rotating shaft 230 (hereinafter, simply referred to as “axial direction”). The magnet side yokes 237 and 238 are substantially disk-shaped members made of a soft magnetic material. Since the magnetic flux passes through the soft magnetic material more easily than in the air, the magnetic side yokes 237 and 238 suppress the magnetic flux leaking in the axial direction of the rotating shaft 230 out of the magnetic flux generated from the permanent magnet 200. . The specific structure of the surface where the magnet side yokes 237 and 238 and the permanent magnet 200 are in contact will be described in detail later.

  The rotating shaft 230 is made of a nonmagnetic material such as carbon fiber reinforced plastic and has a through hole 231. The rotating shaft 230 is supported by the bearing portion 240 and attached to the casing 110. In the present embodiment, a wave spring washer 260 is provided inside the casing 110. The wave spring washer 260 positions the permanent magnet 200. However, the wave spring washer 260 can be omitted.

  The casing 110 is a housing that houses the stator 15 and the rotor 20. The casing 110 includes a first casing portion 110a that is a cylindrical portion at the center in the axial direction, and second and third casing portions 110b and 110c that are lid portions at both ends. The first casing portion 110a is made of a material having good thermal conductivity such as aluminum.

  A coil back yoke 115 is provided on the inner peripheral side of the first casing portion 110a. The axial length of the coil back yoke 115 is substantially the same as the axial length of the permanent magnet 200. The reason why the first casing portion 110a is formed of a material having good thermal conductivity such as aluminum is to easily release the heat generated in the coil back yoke 115 to the outside. The cause of the heat generated in the coil back yoke 115 is a loss due to an eddy current (hereinafter referred to as “eddy current loss”) caused by the rotation of the permanent magnet 200 of the rotor 20. When the radiation is drawn in the radial direction from the rotating shaft 230 toward the coil back yoke 115, the radiation just penetrates the permanent magnet 200. That is, when viewed from the rotating shaft 230, the coil back yoke 115 and the permanent magnet 200 appear to overlap each other.

  Two-phase electromagnetic coils 100 </ b> A and 100 </ b> B are arranged along the inner periphery of the coil back yoke 115 on the inner periphery side of the coil back yoke 115. When the two-phase electromagnetic coils 100A and 100B are not distinguished, the electromagnetic coils 100A and 100B are also collectively referred to as “electromagnetic coil 100”. FIG. 27 is a schematic perspective view showing the electromagnetic coils 100 arranged along the inner periphery of the coil back yoke. There are a plurality of electromagnetic coils 100 </ b> A and 100 </ b> B, respectively, which are connected to the circuit board 305. The electromagnetic coils 100A and 100B have an effective coil portion and a coil end portion. Here, the effective coil portion is a region that applies a Lorentz force in the rotational direction to the rotor 20 when a current flows through the electromagnetic coils 100A and 100B, and the coil end portion has a current applied to the electromagnetic coils 100A and 100B. This is a region where a Lorentz force in a direction different from the rotation direction (mainly a direction perpendicular to the rotation direction) is applied to the rotor 20 when it flows. However, there are two coil end portions across the effective coil portion, and each Lorentz force has the same magnitude and opposite directions, so they cancel each other. In the effective coil portion, the conductor wiring constituting the electromagnetic coils 100A and 100B is in a direction substantially parallel to the rotation shaft 230, and in the coil end portion, the conductor wiring constituting the electromagnetic coils 100A and 100B is parallel to the rotation direction. It is. Further, when radiation is drawn in the radial direction from the rotating shaft 230 toward the coil back yoke 115, the radiation penetrates the effective coil portion but not the coil end portion. That is, when viewed from the rotating shaft 230, the effective coil portion appears to overlap both the permanent magnet 200 and the coil back yoke 115, but the coil end portion does not appear to overlap both the permanent magnet 200 and the coil back yoke 115. . The electromagnetic coils 100A and 100B overlap the permanent magnet 200, but the electromagnetic coils 100A and 100B do not overlap the permanent magnet 200 at the coil end portion.

  Further, the effective coil portions of the electromagnetic coils 100 </ b> A and 100 </ b> B are disposed in a cylindrical region between the permanent magnet 200 and the coil back yoke 115. Of the two coil end portions of the electromagnetic coil 100A, the left coil end portion shown in FIG. 27 is arranged in a cylindrical region between the permanent magnet 200 and the coil back yoke 115, as in the effective coil portion. The right coil end portion is bent inward from the cylindrical region between the permanent magnet 200 and the coil back yoke 115. On the other hand, of the two coil end portions of the electromagnetic coil 100B, the right coil end portion shown in FIG. 27 is arranged in a cylindrical region between the permanent magnet 200 and the coil back yoke 115, like the effective coil portion. However, the left coil end portion is bent outward from the cylindrical region between the permanent magnet 200 and the coil back yoke 115. Thus, by bending one coil end portion of the electromagnetic coil 100A inward and bending one coil end portion of the electromagnetic coil 100B outward, the coil end portion of the electromagnetic coil 100A and the coil end portion of the electromagnetic coil 100B are bent. Interference between the electromagnetic coil 100A and the electromagnetic coil 100B at a portion where the crossing is suppressed. Further, the electromagnetic coils 100A and 100B are only slightly different from each other in the shape of the bent coil end portion, so that the electric resistances of the electromagnetic coil 100A and the electromagnetic coil 100B can be easily set to the same value. Further, the inductance values of the electromagnetic coils 100A and 100B can be set to substantially the same value.

  The stator 15 is further provided with one magnetic sensor 300 as a position sensor for detecting the phase of the rotor 20, corresponding to each phase of the electromagnetic coils 100 </ b> A and 100 </ b> B. In FIG. 25, only one magnetic sensor 300 is displayed. As described above, the number of magnetic sensors 300 may be one. The magnetic sensor 300 is fixed on the circuit board 310, and the circuit board 310 is fixed to the casing 110.

  Here, as described above, the magnet side yokes 237 and 238 are disposed for the purpose of suppressing leakage of magnetic flux from the permanent magnet 200 in the axial direction, but the magnet side yoke on the side where the magnetic sensor 300 is disposed. 238 needs to allow leakage of magnetic flux to such an extent that the magnetic sensor 300 can sense a change in magnetic flux. For this reason, the axial thickness of the magnet side yoke 238 on the side where the magnetic sensor 300 is disposed is set to be thinner than the axial thickness of the magnet side yoke 237 on the side opposite to the side where the magnetic sensor 300 is disposed. ing. When an encoder is provided outside, the magnetic sensor 300 and the circuit board 310 can be omitted.

  FIG. 27 is an explanatory diagram illustrating a process of forming the electromagnetic coils 100A and 100B. This step is the same as the step of forming the electromagnetic coil 100A in the first embodiment shown in FIG. Therefore, the description of FIG. 27 is omitted.

  FIG. 28 is an explanatory diagram illustrating a process of bending the coil end portions of the electromagnetic coils 100A and 100B. FIG. 28A shows the electromagnetic coil 100A, and FIG. 28B shows the electromagnetic coil 100B. In FIG. 6, the AA cut line to the DD cut line are used as the cut lines, but in FIG. 28, the 28A-28A cut line to the 28D-28D cut line are used instead. This change is a change of the sign, and there is no change in content. In the electromagnetic coil 100A according to the first embodiment described with reference to FIG. 6A, the electromagnetic coil 100A is bent along the cylindrical region, and the magnetic sensor side coil end portion 100ACE2 is bent toward the outer peripheral side of the cylindrical region. Yes. On the other hand, in the electromagnetic coil 100A of the seventh embodiment, as shown in FIG. 28A, the electromagnetic coil 100A is bent along the cylindrical region, but the magnetic sensor side coil end portion 100ACE2 is cylindrical. The difference is that the non-magnetic sensor side coil end portion 100ACE1 is bent toward the inner peripheral side of the cylindrical region without being bent toward the outer peripheral side or the inner peripheral side of the region. In the electromagnetic coil 100B of the first embodiment described with reference to FIG. 6B, the electromagnetic coil 100B is bent along the cylindrical region, and the non-magnetic sensor side coil end portion 100BCE1 is bent toward the inner peripheral side of the cylindrical region. It has been. On the other hand, in the electromagnetic coil 100B of the seventh embodiment, as shown in FIG. 28A, the electromagnetic coil 100B is bent along the cylindrical region, but the non-magnetic sensor side coil end portion 100BCE1 is the same. The difference is that the magnetic sensor side coil end portion 100BCE2 is bent toward the outer peripheral side of the cylindrical region without being bent toward the outer peripheral side or the inner peripheral side of the cylindrical region.

  28A and 28B illustrate electromagnetic coil wirings 105A and 105B that form the electromagnetic coils 100A and 100B. In the seventh embodiment, since the electromagnetic coil wirings 105A and 105B are connected to the circuit board 305, they are drawn out of the electromagnetic coils 100A and 100B from the non-magnetic sensor side coil end portion. Further, the electromagnetic coil wirings 105A and 105B are bent inward so as not to interfere with each other in an assembly process described later. Although not shown in the first embodiment shown in FIGS. 6A and 6B, the electromagnetic coil wirings 105A and 105B are connected to the circuit board 310, so that the magnetic sensor side coil end portion It is pulled out to the outside of the electromagnetic coils 100A and 100B. The electromagnetic coils 100A and 100B of the first embodiment and the electromagnetic coils 100A and 100B of the seventh embodiment differ in the drawing positions of the electromagnetic coil wirings 105A and 105B drawn from the electromagnetic coils 100A and 100B. Regarding the other points, the seventh embodiment and the first embodiment are the same, and thus further description is omitted.

  FIG. 29 is an explanatory diagram showing a process of forming the insulating film 101 on the electromagnetic coils 100A and 100B. In FIG. 7, the AA cut line to the DD cut line are used as the cut lines, but in FIG. 29, the 29A-29A cut line to the 29D-29D cut line are used instead. In the step shown in FIG. 29, the insulating film 101 is formed on the surfaces of the electromagnetic coils 100A and 100B, as in the step shown in FIG. 7 of the first embodiment. Since it is the same process as the process of 1st Embodiment, the description beyond this is abbreviate | omitted.

  FIG. 30 is a perspective view showing a fitting state of the electromagnetic coils 100A and 100B. The non-magnetic sensor side coil end portion of the electromagnetic coil 100A is bent to the back side (inner peripheral side of the cylindrical region) of the figure, and the magnetic sensor side coil end portion of the electromagnetic coil 100B is front side (outer peripheral side of the cylindrical region) of the figure. ) Turns out to be bent. Let L be the total length from the outer edge of the non-magnetic sensor side coil end portion of the electromagnetic coils 100A, 100B to the outer edge of the magnetic sensor side coil end portion.

  FIG. 31 is an explanatory view showing, on an enlarged scale, the magnetic sensor side coil end portion of FIG. 30. In the present embodiment, the thickness of the electromagnetic coils 100A and 100B is D. The bending loss of the electromagnetic coils 100A and 100B has a correlation with the thickness D of the electromagnetic coils 100A and 100B. By reducing the thickness D, the total length L can be shortened and bending loss can be reduced. And it becomes possible to make the external dimension of the coreless motor 10 small. In addition, it is possible to reduce the copper loss, which can reduce the electric resistance of the electromagnetic coils 100A and 100B that affect the motor characteristics.

  FIG. 32 is an explanatory diagram showing a state in which all the electromagnetic coils 100A and 100B are drawn up in a cylindrical shape. It can be seen that the electromagnetic coils 100 </ b> A and 100 </ b> B alternately form effective coil portions to form a substantially cylindrical cylindrical region. The non-magnetic sensor side coil end portion of the electromagnetic coil 100A is bent toward the inner peripheral side from the cylindrical region, and the magnetic sensor side coil end portion of the electromagnetic coil 100B is bent toward the outer peripheral side from the cylindrical region. I understand.

  FIG. 33 is an explanatory diagram showing a process of forming an integrated module of an electromagnetic coil and a coil back yoke in the seventh embodiment. In the step shown in FIG. 33A, the electromagnetic coil 100A is disposed on the outer periphery of the inner mold 401. 33, illustration of the insulating film 101 is omitted as in FIG. The inner die 401 has a shape in which a thick cylinder and a slightly thinner cylinder are concentrically connected, and the thickness of one (right side in FIG. 33) is larger than the thickness of the other (left side in FIG. 33). It is getting thinner. Since the circuit board 305 is disposed in a later process, the length of the thin cylinder of the inner mold 401 is longer by the thickness of the circuit board 305 than the length of the thin cylinder of the mold 401 used in FIG. It has become. A non-magnetic sensor side coil end portion 100ACE1 bent toward the inner circumference side of the electromagnetic coil 100A is disposed in the narrowed portion. The electromagnetic coil wiring 105A of the electromagnetic coil 100A is on the right side in FIG. The difference in thickness between the thick cylinder and the thin cylinder of the mold 401 is preferably the same thickness D as the thickness of the electromagnetic coil. In this way, the magnitude of the bending of the non-magnetic sensor side coil end portion 100ACE1 of the electromagnetic coil 100A can be minimized, and the difference in inductance with the electromagnetic coil 100B can be minimized. In order to facilitate the removal of the inner mold 401, the inner mold 401 having a divided configuration may be employed.

  In the process shown in FIG. 33B, the electromagnetic coil 100B is disposed. At this time, the effective coil portion of the electromagnetic coil 100B is positioned between the effective coil portions of the electromagnetic coil 100A, and the non-magnetic sensor side coil end of the electromagnetic coil 100B is disposed on the outer peripheral side of the non-magnetic sensor side coil end portion 100ACE1 of the electromagnetic coil 100A. The electromagnetic coil 100A is arranged so that the portion 100BCE1 is located. The electromagnetic coil wiring 105B of the electromagnetic coil 100B is on the right side in FIG.

  In the step shown in FIG. 33 (C), the electromagnetic coils 100A and 100B are disposed on the non-magnetic sensor side ends on the circuit board 305, and on the outside of the electromagnetic coil 100A, the non-magnetic sensor side coil end portion 100ACE1 side is coil back yoke. 115 is inserted. A through hole (not shown) is formed in the circuit board 305, and the electromagnetic coil wirings 105A and 105B are fixed to the circuit board 305 by, for example, soldering after passing through the through hole. FIG. 33D shows a state where the coil back yoke 115 is inserted. The electromagnetic coil wirings 105A and 105B protruding from the circuit board 305 may be cut off.

  FIG. 34 is an explanatory view showing a molding process using the resin 130. In the step shown in FIG. 34A, outer molds 402 to 405 are arranged following the step in FIG. The shapes of the outer molds 402 to 405 are substantially the same as the outer molds 402 to 405 used in the first embodiment. However, because the circuit board 305 is disposed, the length of the outer mold 404 of the seventh embodiment is longer than the length of the outer mold 404 of the first embodiment by the thickness of the circuit board 305. . Since other steps are the same as those in the first embodiment, the description thereof is omitted. Also, the process in FIG. 34B is the same as the process shown in FIG. The soldering process described above may be performed after the molding process using the resin 130. By injecting the resin 130, the electromagnetic coil wirings 105 </ b> A and 105 </ b> B are washed away, and the electromagnetic coil wirings 105 </ b> A and 105 </ b> B can be prevented from being cut. Further, the cutting of the electromagnetic coil wires 105A and 105B protruding from the circuit board 305 may be performed after the soldering process. FIG. 34C shows a state where the inner mold 401 and the outer molds 402 to 405 are removed. It can be seen that the circuit board 305 is connected to the end of the non-magnetic sensor side coil end of the electromagnetic coils 100A and 100B.

  33 to 35, each of the electromagnetic coils 100A and 100B is arranged on the outer periphery of the inner mold 401. However, as described in FIG. 18, the electromagnetic coil subassembly 150 is created, The electromagnetic coil subassembly 150 may be disposed on the outer periphery of the inner mold 401.

  FIG. 35 is a perspective view showing the resin-molded electromagnetic coils 100A and 100B, the coil back yoke 115, and the circuit board 305. The circuit board 305 has terminals 306A1, 306A2, 306B1, and 306B2. The terminals 306A1 and 306A2 are connected to both ends of the series connection when the plurality of electromagnetic coils A are connected in series in the circuit board 305, respectively. The terminals 306B1 and 306B2 are also connected to both ends of the series connection of the electromagnetic coils 100B connected in series. Note that the electromagnetic coils 100A and 100B may be connected in parallel instead of in series. Terminals 306A1, 306A2, 306B1, and 306B2 are connected to drive circuits (not shown) of electromagnetic coils 100A and 100B.

  FIG. 36 is an explanatory diagram showing a process of incorporating the rotor. From the magnetic sensor side coil end side of the resin-molded electromagnetic coils 100A and 100B, the bearing 240, the rotating shaft 230 to which the permanent magnet 200 is attached, the circuit board 310 to which the magnetic sensor 300 is attached, and the bearing 240 are fitted in order. To go. The magnetic sensor side coil end portions of the electromagnetic coils 100A and 100B are not bent toward the inner peripheral side of the cylindrical region. Therefore, even when the permanent magnet 200 whose outer diameter is made slightly larger than the inner diameter of the cylindrical region when the rotating shaft 230 to which the permanent magnet 200 is attached is inserted, the electromagnetic coil 100A, The coil end portion of 100B and the permanent magnet 200 do not interfere with each other. As a result, the interval between the permanent magnet 200 and the electromagnetic coils 100A and 100B can be narrowed, that is, the interval between the permanent magnet 200 and the coil back yoke 115 can be minimized, and the efficiency of the coreless motor 10 can be improved. Is possible. Thereafter, the casing 110 is fitted, and the coreless motor 10 shown in FIG. 21 is formed. If the outer diameter of the bearing 240 is larger than the inner diameter of the circuit board 305, the bearing 240 may be disposed between the casing 110 and the resin-molded electromagnetic coils 100A and 100B.

  As described above, according to the seventh embodiment, the magnetic sensor side coil end portion 100BCE2 of the electromagnetic coil 100B is bent to the outer peripheral side (coil back yoke 115 side), and the nonmagnetic sensor side coil end portion 100ACE1 of the electromagnetic coil 100A is Since it is bent to the circumferential side (permanent magnet 200 side), it is possible to easily insert the coil back yoke 115 from the non-magnetic sensor side and insert the permanent magnet 200 from the magnetic sensor side. And since it becomes possible to narrow the space | interval of the coil back yoke 115 and the effective coil part of electromagnetic coil 100A, 100B and to narrow the space | interval of the permanent magnet 200 and the effective coil part of electromagnetic coil 100A, 100B, a coreless motor The efficiency of 10 can be improved. Further, since the coil back yoke 115 is not divided, the manufacture is facilitated and the occurrence of cogging can be suppressed.

  Further, according to the seventh embodiment, the electromagnetic coil 100A is connected to the circuit board 305 and connected in series. And both ends of the serial connection of the electromagnetic coil 100A are connected to the terminals 306A1 and 306A2. The same applies to the electromagnetic coil 100B. By adopting such a configuration, it is possible to facilitate connection between the electromagnetic coils 100A and 100B and a drive circuit (not shown) of the electromagnetic coil.

[Eighth Embodiment]
FIG. 37 is an explanatory diagram showing the eighth embodiment. FIG. 37 (A) is an explanatory diagram showing a surface perpendicular to the rotation shaft 230 of the coreless motor. The coreless motor 10 according to the eighth embodiment is a three-phase motor including three-phase electromagnetic coils of electromagnetic coils 100A, 100B, and 100C and six permanent magnets 200. The electromagnetic coils 100A, 100B, and 100C can be easily changed in wiring to any one of independent connection, star connection, and delta connection, as will be described later. A coil back yoke 115 is disposed on the outer peripheral side of the electromagnetic coils 100A to 100C.

  FIG. 37B is an explanatory diagram illustrating an induced voltage waveform of the coreless motor 10 according to the eighth embodiment. The induced voltage waveform generated in each of the electromagnetic coils 100A to 100C has a sine wave shape, and the phase is shifted by 2 / 3π.

  FIG. 38 is an explanatory diagram illustrating a connection example between the electromagnetic coils 100 </ b> A to 100 </ b> C of the coreless motor of the eighth embodiment and the circuit board 305. FIG. 38A shows an independent connection, FIG. 38B shows a star connection, and FIG. 38C shows a delta connection. The circuit board 305 includes six terminals 306A1, 306A2, 306B1, 306B2, 306C1, and 306C2. As shown in FIG. 38A, none of the six terminals are connected to each other, and the six terminals 306A1, 306A2, 306B1, 306B2, 306C1, and 306C2 are independently connected to the drive circuit 600. When connected to, it becomes a three-phase independent connection. Further, as shown in FIG. 38 (B), terminals 306A2, 306B2, and 306C2 are connected to one, and terminals 306A1, 306B1, and 306C1 are connected to a drive circuit 601 of an electromagnetic coil, so that a three-phase star connection is achieved. It becomes. As shown in FIG. 38C, the terminals 306A1 and 306B2 are connected, the terminals 306B1 and 306C2 are connected, the terminals 306C1 and 306A2 are connected, and the terminals 306A1, 306B1, and 306C1 are connected to the driver circuit 602. By connecting to, it becomes a three-phase delta connection.

  As described above, according to the eighth embodiment, by changing the connection between the terminals 306A1, 306A2, 306B1, 306B2, 306C1, 306C2 and the drive circuit 600 (601, 602), the three-phase independent connection, the three-phase It is possible to easily change the wiring to either the star connection or the three-phase delta connection.

  The seventh and eighth embodiments are different from the first to sixth embodiments in that the electromagnetic coil wires 105A and 105B are drawn from the nonmagnetic sensor side and connected to the circuit board 305. Is different. Therefore, other components in the seventh and eighth embodiments may have the same configuration as that described in the first to sixth embodiments.

  FIG. 39 is an explanatory diagram showing an electric bicycle (electric assist bicycle) as an example of a moving body using a motor / generator according to a modification of the present invention. In this bicycle 3300, a motor 3310 is provided on the front wheel, and a control circuit 3320 and a rechargeable battery 3330 are provided on a frame below the saddle. The motor 3310 assists traveling by driving the front wheels using the electric power from the rechargeable battery 3330. Further, the electric power regenerated by the motor 3310 is charged in the rechargeable battery 3330 during braking. The control circuit 3320 is a circuit that controls driving and regeneration of the motor. As the motor 3310, the above-described various coreless motors 10 can be used.

  FIG. 40 is an explanatory diagram showing an example of a robot using a motor according to a modification of the present invention. The robot 3400 includes first and second arms 3410 and 3420 and a motor 3430. This motor 3430 is used when horizontally rotating the second arm 3420 as a driven member. As the motor 3430, the various coreless motors 10 described above can be used.

  FIG. 41 is an explanatory diagram showing an example of a double-armed seven-axis robot using a motor according to a modification of the present invention. The double-arm 7-axis robot 3450 includes a joint motor 3460, a gripper motor 3470, an arm 3480, and a gripper 3490. The joint motor 3460 is disposed at a position corresponding to a shoulder joint, an elbow joint, and a wrist joint. The joint motor 3460 includes two motors for each joint in order to move the arm 3480 and the grip portion 3490 in a three-dimensional manner. In addition, the gripper motor 3470 opens and closes the gripper 3490 and causes the gripper 3490 to grip an object. In the double-arm 7-axis robot 3450, the above-described various coreless motors can be used as the joint motor 3460 or the gripping motor 3470.

  FIG. 42 is an explanatory view showing a vertical articulated robot using a motor according to a modification of the present invention. As shown in FIG. 42, the vertical articulated robot 3640 includes a main body portion 3641, an arm portion 3642, a robot hand 3645, and the like. The main body 3641 is fixed on, for example, a floor, a wall, a ceiling, or a movable carriage. The arm portion 3642 is provided movably with respect to the main body portion 3641. The main body portion 3641 has a drive unit (not shown) that generates power for rotating the arm unit 3642, and a control unit that controls the drive unit. Etc. are built-in. As the drive unit, the above-described coreless motor 10 can be used.

  The arm portion 3642 includes a first frame 3642a, a second frame 3642b, a third frame 3642c, a fourth frame 3642d, and a fifth frame 3642e. The first frame 3642a is connected to the main body 3641 so as to be rotatable or refractable via a rotational refraction axis. The second frame 3642b is connected to the first frame 3642a and the third frame 3642c via a rotational refraction axis. The third frame 3642c is connected to the second frame 3642b and the fourth frame 3642d via a rotational refraction axis. The fourth frame 3642d is connected to the third frame 3642c and the fifth frame 3642e via the rotational refraction axis. The fifth frame 3642e is connected to the fourth frame 3642d via the rotational refraction axis. The arm portion 3642 is configured such that each frame 3642a to 3642e moves by being rotated or refracted around each rotational refraction axis under the control of a control portion (not shown).

  A hand connection portion 3634 is connected to the side of the arm portion 3642 opposite to the side on which the fourth frame 3642d is provided in the fifth frame 3642e, and a robot hand 3645 is attached to the hand connection portion 3634.

  The robot hand 3645 includes a base 3645a and a finger 3645b connected to the base 3645a. A coreless motor 10 for moving the finger 3645b is incorporated in the base 3645a. Note that the finger portion 3645b may have a joint portion. In this case, the coreless motor 10 may be incorporated in the joint portion of the finger portion 3645b. When the coreless motor 10 is driven, the finger portion 3645b is bent and the object can be gripped. The coreless motor 10 is an ultra-small motor, and can realize a robot hand 3645 that reliably holds an object while being small. As a result, it is possible to provide a highly versatile vertical articulated robot 3640 that can perform complex operations using a small and lightweight robot hand 3645.

  FIG. 43 is an explanatory view showing a robot with a double arm caster using a motor according to a modification of the present invention. As shown in FIG. 43, a robot 3762 with a double-arm caster includes a vehicle body portion 3763. The vehicle body portion 3763 includes a vehicle body main body 3763a, and four wheels 3763b are installed on the ground side of the vehicle body main body 3763a. The vehicle body 3763a has a built-in rotation mechanism that drives the wheels 3763b. Further, a control unit 3764 for controlling the posture and operation of the robot 3762 is built in the vehicle body 3766a.

  A main body rotation portion 3765 and a main body portion 3766 are stacked in this order on the vehicle body main body 3763a. The main body rotation unit 3765 is provided with a rotation mechanism that rotates the main body unit 3766. The main body 3766 rotates about the vertical direction as the center of rotation. A pair of imaging devices 3767 is installed on the main body 3766, and the imaging device 3767 images the periphery of the robot 3762 with a double-arm caster. Then, the distance between the photographed object and the imaging device 3767 can be detected.

  A left arm portion 3768 and a right arm portion 3769 are installed on two opposing surfaces of the side surface of the main body portion 3766. Each of the left arm portion 3768 and the right arm portion 3769 includes an upper arm portion 3770, a lower arm portion 3771, and a hand portion 3772 as movable portions. The upper arm portion 3770, the lower arm portion 3771, and the hand portion 3772 are connected so as to be rotatable or bendable. The main body 3766 includes a rotation mechanism 3773 that rotates the upper arm 3770 with respect to the main body 3766. The upper arm portion 3770 includes a rotation mechanism 3773 that rotates the lower arm portion 3771 with respect to the upper arm portion 3770. The lower arm portion 3771 includes a rotation mechanism 3773 that rotates the hand portion 3772 with respect to the lower arm portion 3771. Further, the lower arm portion 3771 incorporates a rotation mechanism 3773 that twists with the longitudinal direction of the lower arm portion 3771 as the rotation axis.

  The hand portion 3772 includes a hand main body 3772a and a gripping portion 3772b as a pair of plate-like movable portions located at the tip of the hand main body 3772a. The hand main body 3772a incorporates a linear motion mechanism 3774 that moves the gripping portion 3772b to change the interval between the gripping portions 3772b. The hand portion 3772 can grip the object to be gripped by opening and closing the grip portion 3772b.

  The rotation mechanism 3773 and the linear motion mechanism 3774 are provided with the coreless motor 10 and the speed reducer. The coreless motor 10 is the electromechanical device described in the above embodiment. Therefore, the rotation mechanism 3773 can smoothly change the rotation direction without rattling even when the rotation direction is reversed. The linear motion mechanism 3774 can smoothly change the moving direction without rattling even when the moving direction is reversed. Accordingly, the robot 3762 with a two-arm caster can move the left arm portion 3768 and the right arm portion 3769 with high positional accuracy.

  FIG. 44 is an explanatory view showing a railway vehicle using a motor according to a modification of the present invention. The railway vehicle 3500 has an electric motor 3510 and wheels 3520. The electric motor 3510 drives the wheel 3520. Furthermore, the electric motor 3510 is used as a generator when the railway vehicle 3500 is braked, and electric power is regenerated. As the electric motor 3510, the various coreless motors 10 described above can be used.

  The embodiments of the present invention have been described above based on some embodiments. However, the embodiments of the present invention described above are for facilitating the understanding of the present invention and limit the present invention. It is not a thing. The present invention can be changed and improved without departing from the spirit and scope of the claims, and it is needless to say that the present invention includes equivalents thereof.

DESCRIPTION OF SYMBOLS 10 ... Coreless motor 15 ... Stator 20 ... Rotor 100ACE1, 100ACE2 ... Coil end part of electromagnetic coil 100A 100BCE1, 100BCE2 ... Coil end part of electromagnetic coil 100B 100, 100A, 100B, 100C ... Electromagnetic coil 100Aa ... Coil part 100Ab ... Coil part DESCRIPTION OF SYMBOLS 100Ac ... Connection part 101 ... Insulating film 105, 105A, 105B ... Wiring for electromagnetic coils 110 ... Casing 110a ... 1st casing part 110b ... 2nd casing part 110c ... 3rd casing part 115 ... Coil back yoke 130 ... Resin DESCRIPTION OF SYMBOLS 150 ... Electromagnetic coil subassembly 200 ... Permanent magnet 215 ... Magnet back yoke 230 ... Rotating shaft 240 ... Bearing 260 ... Wave spring washer 300 ... Magnetic sensor 305 ... Time Substrate 306A1, 306A2, 306B1, 306B2, 306C1, 306C2 ... Terminal 310 ... Circuit board 401 ... Inner die 402, 403, 404, 405 ... Outer die 402A, 405A ... Resin injection port 600 ... Drive circuit φ1 ... Electromagnetic coil Conductor bundle width (thickness)
L2 ... Coil bundle spacing in the effective coil portion of the electromagnetic coil 3300 ... Bicycle 3310 ... Motor 3320 ... Control circuit 3330 ... Rechargeable battery 3400 ... Robot 3410 ... Second arm 3420 ... Second arm 3430 ... Motor 3450 ... Dual arm 7 axis Robot 3460 ... Joint motor 3470 ... Gripping part motor 3480 ... Arm 3490 ... Gripping part 3500 ... Railway vehicle 3510 ... Electric motor 3520 ... Wheel 3640 ... Vertical articulated robot 3641 ... Main body part 3642 ... Arm part 3642a ... First frame 3642b ... First 2 frames 3642c ... 3rd frame 3642d ... 4th frame 3642e ... 5th frame 3643 ... Hand connection part 3645 ... Robot hand 3645a ... Base 3645b ... Finger part 3762 ... B with double-arm caster 3763 ... Car body part 3763a ... Car body 3763b ... Wheel 3764 ... Control part 3765 ... Main body rotating part 3766 ... Main body part 3767 ... Imaging device 3768 ... Left arm part 3769 ... Right arm part 3770 ... Upper arm part 3771 ... Lower arm part 3772 ... Hand Part 3772a ... hand body 3772b ... grip part 3773 ... rotation mechanism 3774 ... linear motion mechanism

Claims (21)

A coreless electromechanical device having a cylindrical first member and a second member, wherein the first member and the second member are movable relative to each other,
A permanent magnet disposed on the first member;
An electromagnetic coil disposed on the second member, an effective coil portion for generating a force for moving the first member relative to the second member; a coil end portion; An electromagnetic coil having a connection terminal;
An electromagnetic coil connection terminal to which the connection terminal of the electromagnetic coil is connected, an external connection terminal wiring for connecting the electromagnetic coil to a drive circuit provided outside, and a wiring for connecting the electromagnetic coil connection terminal and the above A circuit board having a pattern;
With
The electromagnetic coil forms an M-phase coil group (M is an integer of 2 or more),
A coreless electromechanical device, wherein at least one of the two connection terminals is bent inward. The coreless electromechanical device according to claim 1,
The said circuit board is a coreless electromechanical apparatus which has a wiring pattern which connects the said electromagnetic coil to either a serial connection or a parallel connection for every phase. The coreless electromechanical device according to claim 1 or 2,
The coreless electromechanical device, wherein the circuit board and the connection terminal of the electromagnetic coil are soldered. The coreless electromechanical device according to any one of claims 1 to 3, further comprising:
A coil back yoke disposed on the second member;
The effective coil portion of the electromagnetic coil is disposed in a cylindrical region between the permanent magnet and the coil back yoke,
The electromagnetic coil has two coil end portions,
The coil end portion on the first side of the electromagnetic coil included in the (M-1) phase coil group other than the first phase in the M phase coil group is formed from the cylindrical surface including the cylindrical region to the permanent surface. Bent to the magnet side,
Of the two coil end portions of the electromagnetic coil included in the (M-1) phase coil group other than the second phase different from the first phase, the second side opposite to the first side The coil end portion is bent from the cylindrical surface to the coil back yoke side,
Coreless electromechanical device. The coreless electric machine according to claim 4,
The coil end portion on the first side of the electromagnetic coil of the first phase is disposed on the cylindrical surface, or is bent from the cylindrical surface to the permanent magnet side,
The coreless electromechanical device, wherein the second-side coil end portion of the second-phase electromagnetic coil is disposed on the cylindrical surface or is bent from the cylindrical surface toward the coil back yoke. . The coreless electromechanical device according to claim 4 or 5,
When the value of M is 3 or more,
The coil end portion on the first side of the electromagnetic coil included in the (M-2) phase coil group other than the first phase and the second phase is a first end of the second phase electromagnetic coil. The coil end portion on the side is bent to the permanent magnet side in a size smaller than the size bent to the permanent magnet side and different in each phase,
The coil end portion on the second side of the electromagnetic coil included in the (M-2) phase coil group is configured such that the second coil end portion on the second side of the first phase electromagnetic coil is the coil back yoke. A size that is smaller than the size that is bent to the side and that is different for each phase so that the phase that the coil end portion of the electromagnetic coil included in the coil group of the first phase is bent is larger as the phase is smaller. Now bent to the coil back yoke side,
Coreless electromechanical device. The coreless electromechanical device according to any one of claims 1 to 6,
The electromagnetic coil has two effective coil portions,
The distance between the first effective coil portion of the two effective coil portions and the second effective coil portion different from the first effective coil portion is the width of the electromagnetic coil in the effective coil portion. Coreless electromechanical device that is 2 × (M−1) times larger. The coreless electromechanical device according to any one of claims 1 to 6,
The electromagnetic coil has two effective coil portions,
The interval between the first effective coil portion of the two effective coil portions and the second effective coil portion that is different from the first effective coil portion is the electromagnetic wave in the effective coil portion of the electromagnetic coil. The coil is (M-1) times as large as the width of the coil,
A coreless electromechanical device, wherein one coil sub-aggregate is formed by collecting one electromagnetic coil from each of the M-phase coil groups. In the coreless electromechanical device according to any one of claims 1 to 3,
A coil back yoke disposed on the second member;
The effective coil portion of the electromagnetic coil is disposed in a cylindrical region between the permanent magnet and the coil back yoke,
The electromagnetic coil has two coil end portions,
The electromagnetic coil includes a first shape electromagnetic coil and a second shape electromagnetic coil,
In the first shape electromagnetic coil, a coil end portion on the first side of two coil end portions is bent toward the permanent magnet side, and a coil end portion on a second side different from the first side is the cylinder. It has a shape that is placed on a cylindrical surface that includes the area,
The second shape electromagnetic coil has a shape in which the coil end portion on the second side is bent toward the coil back yoke, and the coil end portion on the first side is disposed on the cylindrical surface. And
A total of two effective coil portions, each one of the two effective coil portions of the two second shape electromagnetic coils, are disposed between the two effective coil portions of the one first shape electromagnetic coil,
A total of two effective coil portions of each of the two effective coil portions of the two first shape electromagnetic coils are arranged between the two effective coil portions of the one second shape electromagnetic coil. A coreless electromechanical device in which the electromagnetic coils are arranged. The coreless electric machine according to claim 9,
M is an odd number;
The coreless electromechanical device, wherein each phase electromagnetic coil has the same number of the first shape electromagnetic coils and the second shape electromagnetic coils. The coreless electromechanical device according to claim 9 or 10,
M is 3;
The first shape electromagnetic coils of the first phase, the second phase, and the third phase are arranged in an annular shape in order without intersecting each other on the cylindrical surface,
The two effective coil portions of the second shape electromagnetic coil of the first phase are one effective coil portion of the first shape electromagnetic coil of the second phase and the first shape of the third phase. The second shape electromagnetic coil of the first phase is arranged so as to sandwich one effective coil part of the electromagnetic coil,
The two effective coil portions of the second shape electromagnetic coil of the second phase are one effective coil portion of the first shape electromagnetic coil of the third phase and the first shape of the first phase. The second shape electromagnetic coil of the second phase is arranged so as to sandwich one effective coil part of the electromagnetic coil,
The two effective coil portions of the second shape electromagnetic coil of the third phase are one effective coil portion of the first shape electromagnetic coil of the first phase and the first shape of the second phase. The second shape electromagnetic coil of the third phase is arranged so as to sandwich one effective coil portion of the electromagnetic coil.
Coreless electromechanical device. The coreless electromechanical device according to claim 9,
M is an even number;
The electromagnetic coil has a shape of either the first shape electromagnetic coil or the second shape electromagnetic coil for each phase,
The coreless electromechanical device, wherein the number of the first shape electromagnetic coils and the number of the second shape electromagnetic coils are the same. The coreless electromechanical device according to any one of claims 9 to 12,
The coreless electromechanical device, wherein an interval between two effective coil portions of the electromagnetic coil is twice as large as a width of the electromagnetic coil in the effective coil portion of the electromagnetic coil. In the coreless electromechanical device according to any one of claims 1 to 13,
M is 3;
Two external connection terminals are provided for each phase,
By connecting the two external connection terminals of each phase and the drive circuit provided outside, it is possible to connect to any of three-phase independent connection, star connection, and delta connection,
In the three-phase independent connection, the two external connection terminals of each phase are independently connected to the drive circuit,
In the star connection, one external connection terminal of the two external connection terminals of each phase is coupled to one, and the other external connection terminal is connected to a drive circuit,
The delta connection is
One of the two external connection terminals of the first phase is connected to one of the two external connection terminals of the second phase;
The other external connection terminal of the two external connection terminals of the first phase is connected to one of the two external connection terminals of the third phase,
Of the two external connection terminals of the second phase, the external connection terminal of the first phase, the other external connection terminal not connected, and the two external connection terminals of the third phase The other external connection terminal not connected to the external connection terminal of the first phase is connected,
Coreless electromechanical device. The coreless electromechanical device according to any one of claims 1 to 14,
The coreless electromechanical device, wherein the electromagnetic coils included in the coil group of each phase have the same electric resistance value. The coreless electromechanical device according to any one of claims 1 to 15,
The first conductor forming the electromagnetic coil whose coil end portion is bent and the second conductor forming the electromagnetic coil whose coil end portion is not bent are formed of the same material,
The first conductor and the second conductor have the same diameter.
The number of turns of the first conductor of the electromagnetic coil with the coil end portion bent is the same as the number of turns of the second conductor forming the electromagnetic coil with the coil end portion not bent,
The coreless electromechanical device, wherein the electromagnetic coil in which the coil end portion is bent and the electromagnetic coil in which the coil end portion is not bent have the same electric resistance value.   A moving body comprising the coreless electromechanical device according to claim 1.   A robot comprising the coreless electromechanical device according to any one of claims 1 to 16. A method of manufacturing a coreless electromechanical device having an electromagnetic coil of M phase (M is an integer of 2 or more),
(A) preparing a plurality of electromagnetic coils;
(B) bending the effective coil portion of the electromagnetic coil along the cylindrical region;
(C) One of the two coil end portions of the (M-1) phase electromagnetic coil other than the first phase of the M phase is placed on the inner peripheral side of the cylindrical region in which the effective coil portion of the electromagnetic coil is disposed. The other coil end portion on the opposite side to the one of the two coil end portions of the electromagnetic coil of the (M-1) phase other than the second phase, which is bent with a different magnitude for each phase. Bending to the outer peripheral side of the cylindrical region so that the smaller the size bent to the inner peripheral side is,
(D) The direction in which the electromagnetic coil is bent inward in each phase in descending order, and the direction in which the electromagnetic coil is bent inward is in two directions along the rotation axis of the coreless electromechanical device. A step of forming an electromagnetic coil in which the effective region of the electromagnetic coil is disposed in a cylindrical region, the electromagnetic coil being disposed so as to be in a first direction.
(E) arranging a circuit board in the first direction of the electromagnetic coil, and connecting an end portion of the wiring of the electromagnetic coil to the circuit board;
(F) A coil back yoke or a permanent magnet is inserted on the outer peripheral side of the cylindrical surface from the first direction, and the coil is inserted on the inner peripheral side of the cylindrical surface from the second direction on the opposite side to the first direction. Inserting a back yoke or one of the permanent magnets that is not inserted into the outer peripheral side;
A method for manufacturing a coreless electromechanical device. A method of manufacturing a coreless electromechanical device having an electromagnetic coil of M phase (M is an integer of 2 or more),
(A) preparing a plurality of electromagnetic coils;
(B) bending the effective coil portion of the electromagnetic coil along the cylindrical region;
(C) One of the two coil end portions of the (M-1) phase electromagnetic coil other than the first phase of the M phase is placed on the inner peripheral side of the cylindrical region in which the effective coil portion of the electromagnetic coil is disposed. The other coil end portion on the opposite side to the one of the two coil end portions of the electromagnetic coil of the (M-1) phase other than the second phase, which is bent with a different magnitude for each phase. Bending to the outer peripheral side of the cylindrical region so that the smaller the size bent to the inner peripheral side is,
(D) Using a total of M electromagnetic coils for each phase from the M phase electromagnetic coils, the coil sub-assemblies are arranged side by side so that the coil end portions bent inside the electromagnetic coils are in the same direction. Forming a step;
(E) The coil sub so that a coil end portion bent inside the electromagnetic coil included in the coil sub aggregate is a first direction out of two directions along the rotation axis of the coreless electromechanical device. Arranging the assemblies in the cylindrical shape to form an electromagnetic coil in which an effective area of the electromagnetic coil is disposed in the cylindrical area;
(F) arranging a circuit board in one direction of the electromagnetic coil, and connecting an end of the wiring of the electromagnetic coil to the circuit board;
(G) A coil back yoke or a permanent magnet is inserted on the outer peripheral side of the cylindrical surface from the first direction, and the coil is inserted on the inner peripheral side of the cylindrical surface from the second direction on the opposite side to the first direction. Inserting a back yoke or one of the permanent magnets that is not inserted into the outer peripheral side;
A method for manufacturing a coreless electromechanical device. A method of manufacturing a coreless electromechanical device having an electromagnetic coil of M phase (M is an integer of 2 or more),
(A) preparing a plurality of electromagnetic coils;
(B) bending the effective coil portion of the electromagnetic coil along the cylindrical region;
(C) For each phase of the electromagnetic coil, the coil end portion on the first side is bent outside the cylindrical region, and the coil end portion on the second side opposite to the first is the same as the cylindrical region. A first shape electromagnetic coil that is not bent outside or inside the cylindrical region and a coil end portion on the second side is bent inside the cylindrical region, and A second shape electromagnetic coil having a coil end portion on the same side as the cylindrical region and the same cylindrical surface as that of the cylindrical region and not bent either outside or inside the cylindrical region; and
(D) arranging the second shape electromagnetic coils of each phase in the cylindrical region;
(E) arranging the first shape electromagnetic coils of each phase in the cylindrical region;
(F) arranging a circuit board in one direction of the electromagnetic coil, and connecting an end of the wiring of the electromagnetic coil to the circuit board;
(G) A coil back yoke or a permanent magnet is inserted from the first side to the inner peripheral side of the cylindrical surface, and the coil back yoke or the permanent magnet is inserted from the second side to the outer peripheral side of the cylindrical surface. Inserting the one not inserted on the outer peripheral side, and
A method for manufacturing a coreless electromechanical device.

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