JP2019037132A - Method of manufacturing stator and method of manufacturing brushless motor - Google Patents

Abstract

To realize a small, high torque brushless motor by devising a coil in a stator.SOLUTION: The brushless motor includes: a stator having an annular stator core and first to twelfth teeth sequentially provided in a circumferential direction on an inner peripheral side of the stator core; first to twelfth coils respectively wound around the first to twelfth teeth and delta-connected; and a rotor provided at a central portion of the stator. The first to twelfth coils constitute a W phase in which twelfth, first, sixth and seventh coils are connected in series in order. The eighth, ninth, second and third coils constitute a U phase connected in series in order. The fourth, fifth, tenth and eleventh coils constitute a V phase connected in series in order. In the arrangement in the teeth, coils of different phases adjacent to each other have the same winding direction. Adjacent in-phase coils have mutually opposite winding directions.SELECTED DRAWING: Figure 6

Description

  The present invention relates to a brushless motor.

  Conventionally, motors have been used as drive sources for various devices and products. For example, it is used for power source applications including office equipment such as printers and copiers, various home appliances, and assisting vehicles such as automobiles and electric bicycles. In particular, a brushless motor may be used from the viewpoint of durability and electric noise as a drive source for a movable part with high operation frequency.

  An inner rotor type is known as a kind of brushless motor. A stator is disposed around the rotor, and coils are wound around a plurality of stator teeth provided on the stator. Various methods for winding a coil around each of a plurality of stator teeth have been devised. For example, a synchronous machine in which a coil is connected in a delta connection or a star connection is disclosed (see Patent Document 1).

Special table 2012-517209

  One of the above-mentioned synchronous machines has realized delta connection by continuous connection, but there are a large number of connecting wires that pass coils to stator teeth that are separated from the same phase, and space for arranging connecting wires, bus bars, etc. Alternative parts are required. Moreover, since the connecting wire does not contribute to the generation of the magnetic force of the stator, it is desirable to reduce it as much as possible.

  The present invention has been made in view of such circumstances, and an object of the present invention is to provide a technique for realizing a small and high torque brushless motor by devising a coil in a stator.

  In order to solve the above-described problems, a brushless motor according to an aspect of the present invention includes a stator having an annular stator core and first to twelfth teeth sequentially provided in the circumferential direction on the inner peripheral side of the stator core. And first to twelfth coils wound around the first to twelfth teeth and delta-connected, respectively, and a rotor provided at the center of the stator. The first to twelfth coils constitute a W phase in which the twelfth, first, sixth, and seventh coils are connected in series, and the eighth, ninth, second, and third coils are connected in series. The U-phase, the V-phase in which the fourth, fifth, tenth and eleventh coils are connected in series, and adjacent coils in different phases in the arrangement in the teeth have the same winding direction, Adjacent in-phase coils are wound in opposite directions. The W phase has a first crossover that connects the first coil and the sixth coil. The U phase has a second crossover that connects the ninth coil and the second coil. The V phase has a third crossover that connects the fifth coil and the tenth coil.

  According to this aspect, the connecting wire connecting the separated coils can be shortened. Also, the U-phase end line and the V-phase start line are drawn from adjacent coils, or the V-phase end line and the W-phase start line are drawn from adjacent coils, or the W-phase end line is drawn. Since the wire and the U-phase start line are drawn from adjacent coils, the end line after the coil is wound around each tooth is easy and the connection is shortened. Therefore, the amount of coils that do not contribute to the generation of magnetic force can be reduced, coil resistance can be reduced, and the arrangement space of the coils can also be reduced.

  The 1st-3rd crossover may be arrange | positioned so that it may not mutually cross. As a result, the insulation reliability is improved and the motor is made thinner and smaller.

  The first to third connecting wires may be disposed on the outer edge portion of one end face of both end faces in the axial direction of the stator core. The first crossover line and the third crossover line may be partially overlapped when viewed from the axial direction and may be arranged at different positions in the axial direction. The second crossover line may have a bent portion so as to be positioned above the first crossover line from below the third crossover line as viewed in the axial direction. Thereby, when the stator is viewed from above, the number of crossovers superimposed is two or less, which contributes to the reduction in thickness and size of the motor.

  It should be noted that any combination of the above-described constituent elements and a conversion of the expression of the present invention among components, manufacturing methods, systems, etc. are also effective as an aspect of the present invention.

  According to the present invention, a small and high torque brushless motor can be realized.

1 is an overall perspective view of a brushless motor according to a first embodiment. It is a side view of the brushless motor concerning a 1st embodiment. It is a disassembled perspective view of the brushless motor which concerns on 1st Embodiment. It is a top view of a stator core. It is a perspective view of a stator. It is the figure which showed typically the delta connection of the stator which concerns on this Embodiment. It is the figure which showed typically the delta connection of the stator which concerns on 2nd Embodiment.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the description of the drawings, the same elements are denoted by the same reference numerals, and repeated descriptions are omitted as appropriate. Moreover, the structure described below is an illustration and does not limit the scope of the present invention at all. Hereinafter, an inner rotor type brushless motor will be described as an example.

[First Embodiment]
(Brushless motor)
FIG. 1 is an overall perspective view of the brushless motor according to the first embodiment. FIG. 2 is a side view of the brushless motor according to the first embodiment. FIG. 3 is an exploded perspective view of the brushless motor according to the first embodiment.

  A brushless motor (hereinafter sometimes referred to as “motor”) 10 according to the first embodiment includes a columnar rotor 12 having a magnet, and a stator 14 having a space in which the rotor 12 is disposed at the center. A front bell 16, a housing body 18, and a power feeding unit 19.

  The front bell 16 is a plate-like member, and a hole 16a is formed at the center so that the rotary shaft 20 can pass therethrough, and a recess 16b that holds the bearing 22 is formed in the vicinity of the hole 16a. The front bell 16 supports a part of the rotating shaft 20 of the rotor 12 via a bearing 22. The housing body 18 is a cylindrical member, and a recess 18b that holds a bearing (not shown) is formed at the center of the base 18a. And the housing main body 18 supports the other part of the rotating shaft 20 of the rotor 12 via a bearing. In the first embodiment, the front bell 16 and the housing main body 18 constitute a housing member that houses the rotor 12 and the stator 14.

(Stator)
Next, the structure of the stator 14 will be described. FIG. 4 is a top view of the stator core. FIG. 5 is a perspective view of the stator 14. The shape of the stator core shown in FIG. 4 is schematic and details are omitted.

  The stator core 36 is a cylindrical (annular) member in which a plurality of plate-shaped stator yokes 38 are stacked. On the inner peripheral side of the stator yoke 38, twelve teeth T1 to T12 provided in order in the circumferential direction are formed toward the center.

  An insulator 40 is attached to each of the teeth T1 to T12. Next, a conductor (copper wire) is wound from above the insulator 40 for each of the teeth T1 to T12 to form the first coil C1 to the twelfth coil C12 (see FIG. 5). And the rotor 12 is arrange | positioned in the center part of the stator 14 completed through such a process.

  FIG. 6 is a diagram schematically showing the delta connection of the stator 14 according to the present embodiment.

  The coil winding state will be described in detail with reference to FIGS. In addition, the connection structure shown in FIG. 6 is the example performed with the nozzle type winding machine. Moreover, even if the U phase, V phase, and W phase are interchanged, they are essentially the same. Below, the case where it forms from the 12th coil C12 is demonstrated.

  As shown in FIG. 6, first, as the W phase, the twelfth coil C12 is formed counterclockwise (CCW), the first coil C1 is formed clockwise (CW), and the first crossover F1 is Then, the sixth coil C6 is formed clockwise, and the seventh coil C7 is formed counterclockwise. Here, the 12th coil C12, the 1st coil C1, the 6th coil C6, and the 7th coil C7 comprise the W phase connected in series in this order.

  After forming the seventh coil C7, the eighth coil C8 is subsequently formed counterclockwise, the ninth coil C9 is formed clockwise, and the second coil C2 is turned clockwise via the second connecting wire F2. The third coil C3 is formed counterclockwise. Here, the eighth coil C8, the ninth coil C9, the second coil C2, and the third coil C3 constitute a U-phase connected in series in this order.

  After forming the third coil C3, the fourth coil C4 is continuously formed counterclockwise, the fifth coil C5 is formed clockwise, and the tenth coil C10 is turned clockwise through the third connecting wire F3. The eleventh coil C11 is formed counterclockwise. Here, the 4th coil C4, the 5th coil C5, the 10th coil C10, and the 11th coil C11 comprise the V phase connected in series in this order. Thereafter, the W-phase start line L1 and the V-phase end line L2 are connected to form a delta connection.

  Moreover, the coils of adjacent different phases (W phase and U phase, U phase and V phase, V phase and W phase) are wound in the same direction, and adjacent coils of the same phase are wound in opposite directions. is there.

  As described above, the first coil C <b> 1 to the twelfth coil C <b> 12 of the stator 14 according to the first embodiment realizes delta connection by the continuous operation of the winding machine. Moreover, in the stator 14, the connecting wire which connects the distant coils can be shortened. Also, the U-phase end line and the V-phase start line are drawn from between the same teeth of the adjacent coils, or the V-phase end line and the W-phase start line are drawn from between the same teeth of the adjacent coils. Alternatively, since the W-phase end line and the U-phase start line are drawn from between the same teeth of adjacent coils, the end line processing after winding the coil around each tooth is easy and the connection is shortened. . Therefore, the amount of coils that do not contribute to the generation of magnetic force can be reduced, coil resistance can be reduced, and the arrangement space of the coils can also be reduced. That is, a small and high-torque brushless motor can be realized by devising how to wind the coil in the stator.

  Further, the first crossover line F1 to the third crossover line F3 according to the present embodiment are arranged so as not to cross each other. As a result, the connecting wires do not come into contact with each other, the insulation reliability is improved, and the motor is reduced in thickness and size. More specifically, as shown in FIG. 5, the first to third connecting wires F <b> 1 to F <b> 3 are arranged in an arc shape on the outer edge portion 14 a of the insulator on one end surface of both end surfaces in the axial direction Ax of the stator core 36. ing. The first crossover line F1 and the third crossover line F3 are partially overlapped when viewed from the axial direction Ax, and are arranged at different positions in the axial direction. The second crossover line F2 has a bent portion F 'so as to be positioned above the first crossover line F1 from below the third crossover line F3 when viewed from the axial direction. Thereby, when the stator is viewed from above, the number of crossovers superimposed is two or less. Contributes to thinner and smaller motors.

  Note that a locking portion 40 a for controlling the movement of each crossover is formed on the back surface portion (outer peripheral surface) of each insulator 40. Thereby, each crossover can be fixed at a desired position. In particular, the second connecting wire F2 according to the present embodiment can be in a tensioned state by being supported from two different directions by the two locking portions 40a before and after the bent portion F ′. It is firmly fixed to the position.

[Second Embodiment]
FIG. 7 is a diagram schematically showing the delta connection of the stator according to the second embodiment. In addition, the connection structure shown in FIG. 7 is the example performed with the flyer type winding machine. Below, the case where it forms from the 12th coil C12 is demonstrated. Further, description of the same configuration as that of the first embodiment will be omitted as appropriate.

  As shown in FIG. 7, first, as the W phase, the twelfth coil C12 is formed counterclockwise (CCW), the first coil C1 is formed clockwise (CW), and one end face side of the stator ( The sixth coil C6 is formed clockwise and the seventh coil C7 is formed counterclockwise via the first crossover F1 ′ formed on the upper side of FIG. Here, the 12th coil C12, the 1st coil C1, the 6th coil C6, and the 7th coil C7 comprise the W phase connected in series in this order.

  After forming the seventh coil C7, the eighth coil C8 is continuously formed counterclockwise, the ninth coil C9 is formed clockwise, and is formed on the other end face side (lower side in FIG. 7) of the stator. The second coil C2 is formed clockwise through the second connecting wire F2 ′, and the third coil C3 is formed counterclockwise. Here, the eighth coil C8, the ninth coil C9, the second coil C2, and the third coil C3 constitute a U-phase connected in series in this order.

  After forming the third coil C3, the fourth coil C4 is continuously formed counterclockwise, and the fifth coil C5 is formed clockwise, forming from one end surface side of the stator toward the other end surface side. The tenth coil C10 is formed clockwise through the third connecting wire F3 ′, and the eleventh coil C11 is formed counterclockwise. Here, the 4th coil C4, the 5th coil C5, the 10th coil C10, and the 11th coil C11 comprise the V phase connected in series in this order. Thereafter, the W-phase start line L1 and the V-phase end line L2 are connected to form a delta connection.

  Thus, even if a flyer-type winding machine is used, the same effect as the first embodiment can be obtained.

  As described above, the brushless motor according to the embodiment can reduce the number of crossover wires that do not contribute to the motor characteristics and can also shorten the length. Therefore, motor efficiency is improved by reducing the winding (coil) resistance. Further, since the winding procedure for each phase is the same, there is little variation in the winding resistance value of each phase, which leads to stabilization of motor performance. In addition, since the total number of connecting wires can be two or less on both ends of the stator, a space for arranging the connecting wires and connecting wires is reduced, which contributes to a reduction in the thickness of the entire motor. Moreover, all the coils can be formed with continuous electric wires without the need for useless electric wires at the time of opening and closing processing. Moreover, since the start line and the end line are in the same position in any phase, the connection process after winding is facilitated. In addition, by devising the winding structure, the coil wound around each tooth does not loosen, and a high-quality motor without wire loosening can be realized. Further, the brushless motor according to the embodiment can realize a desired connection structure without requiring a bus bar or a complicated connection mechanism.

  Below, the specification of the brushless motor which can use this invention suitably is demonstrated. The brushless motor according to the present embodiment has an outer diameter of about 30 to 140 mm, preferably about 35 to 85 mm. The number of stator grooves (teeth) is twelve. The number of magnets is preferably 10 or 14. Further, the magnetic force of the main surface of the magnet is 8 MGOe or more, preferably 10 MGOe or more, more preferably 30 MGOe or more. Further, the diameter of the rotor is preferably about 20 to 70 mm.

  As described above, the present invention has been described with reference to the above-described embodiments. However, the present invention is not limited to the above-described embodiments, and the configurations of the embodiments are appropriately combined or replaced. Those are also included in the present invention. Further, it is possible to appropriately change the combination and processing order in each embodiment based on the knowledge of those skilled in the art and to add various modifications such as various design changes to each embodiment. Embodiments to which is added can also be included in the scope of the present invention.

  C1 first coil, F1 first connecting wire, T1 teeth, C2 second coil, F2 second connecting wire, C3 third coil, F3 third connecting wire, C4 fourth coil, C5 first coil 5 coil, C6 6th coil, C7 7th coil, C8 8th coil, C9 9th coil, C10 10th coil, C11 11th coil, 12 rotor, C12 12th coil, 14 Stator, 14a outer edge, 36 stator core.

Claims (5)

A cylindrical stator core that is integrally connected, and first to twelfth teeth that are sequentially provided in the circumferential direction on the inner peripheral side of the stator core, and the first to twelfth teeth, respectively. In the manufacturing method of the stator having the first to twelfth coils,
Of the U-phase, V-phase, and W-phase, the starting line of the first phase is drawn from between the eleventh tooth and the twelfth tooth,
Winding the twelfth coil in one direction clockwise or counterclockwise;
Winding the first coil in the other direction clockwise or counterclockwise;
Winding the sixth coil in the other direction through a first crossover,
Winding the seventh coil in the one direction;
Drawing a terminal line from between the seventh tooth and the eighth tooth to form the first phase;
Of the U-phase, V-phase, and W-phase, draw the start line of the second phase from between the seventh tooth and the eighth tooth,
Winding the eighth coil in the one direction;
Winding the ninth coil in the other direction;
Winding the second coil in the other direction through a second crossover,
Winding the third coil in the one direction;
Drawing an end line from between the third teeth and the fourth teeth to form the second phase;
The start line of the third phase out of the U phase, V phase, and W phase is drawn from between the third tooth and the fourth tooth,
Winding the fourth coil in the one direction;
Winding the fifth coil in the other direction;
Winding the tenth coil in the other direction through a third crossover,
Winding the eleventh coil in the one direction;
Drawing a terminal line from between the eleventh tooth and the twelfth tooth to form the third phase,
The end line drawn in the step of forming the first phase is used as the start line drawn in the step of forming the second phase as it is, and the end line drawn in the step of forming the second phase is used as it is. A stator manufacturing method characterized by being used as it is as a starting line drawn in the step of forming the third phase. In the step of forming the second phase, a bent portion is formed that bends the second connecting line between the twelfth tooth and the first tooth in the axial direction of the first connecting line. , Arranged in the axial direction above the first connecting line,
In the step of forming the third phase, the third connecting line is arranged in the axial direction above the first connecting line and the second connecting line.
The method of manufacturing a stator according to claim 1. The first to third connecting wires are arranged along the same first circumference,
The start line of the W phase and the end line of the V phase, the start line of the V phase and the end line of the U phase, and the start line of the U phase and the end line of the W phase are the first circle The stator manufacturing method according to claim 1, wherein the stator is disposed along a second circumference having a different diameter from the circumference. The stator core is a cylindrical core (except for a split core) in which annular portions are integrally connected,
The said 1st-12th coil and the said 1st-3rd crossover wire (however, except the crossover wire provided with the contact) are continuous electric wires, The Claims 1 thru | or 3 characterized by the above-mentioned. A method for manufacturing a stator according to any one of the preceding claims. A step of manufacturing a stator by the method of manufacturing a stator according to any one of claims 1 to 4,
Disposing a rotor in the center of the stator;
Of manufacturing a brushless motor.

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