JP2019068593A - Motor, motor unit, and stator - Google Patents

Abstract

To shorten a tact time of a winding process and to improve mass productivity of motors.SOLUTION: A motor comprises: a ring core (12) arranged in a circumferential direction of surrounding a central shaft (J); a wire (13) for winding the ring core (12); and an insulator (14) for insulating between the ring core (12) and the wire (13). The ring core (12) comprises a plurality of core segments (SEG), and a plurality of coupling parts (COM) for coupling the plurality of core segments (SEG) in a circumferential direction. The insulator (14) comprises an insulation part for insulating the ring core (12) and the wire (13), and a terminal part (TER1) coupled to the insulation part. The terminal part (TER1) holds terminals (U, V, and W). One end of the terminals (U, V, and W) extends in a radial direction from the terminal part (TER1). The wire (13) is wound around one end of the terminals (U, V, and W).SELECTED DRAWING: Figure 4

Description

  The present invention relates to a motor, a motor unit, and a stator.

  A motor such as a brushless DC (BLDC) motor achieves, for example, downsizing and cost reduction by narrowing a space between a plurality of slots, that is, a slot groove. Here, the slot groove is a space between two teeth on which a wire is wound.

  However, when the slot groove is narrowed, speeding up and high quality of the winding process of winding the wire around the teeth becomes an issue. This is because, in this case, as the speed of movement of the winding nozzle of the winding machine is increased, the deflection of the operation of the winding nozzle is increased, and the winding nozzle may come into contact with the stator core.

  Straight cores are effective for solving this problem. The straight core has a core back portion and a teeth portion, and the teeth portion extends in the vertical direction with respect to the linearly extending core back portion. The teeth are arranged at equal intervals. The straight core is rounded in a direction toward the central axis of the teeth after the winding process (curling process) to form a ring core. The winding process of the straight core is performed before the curling process. Since the slot grooves in the winding process (before the curling process) are wider than the slot grooves after the curling process, the straight core is suitable for speeding up the winding process.

  Here, as a ring core used for the motor, there are a curling type in which a straight core is curled and a round core type in which electromagnetic steel sheets punched in a circular shape are laminated.

  On the other hand, the problem that the winding nozzle contacts the stator core also occurs when winding the wire around the external terminal of the terminal portion. Here, the terminal portion is a portion where the external terminal of the motor is provided. The external terminal of the motor is an input terminal for inputting a drive signal for driving the motor, for example, an AC signal of U phase, V phase or W phase from the outside (for example, control device) of the motor.

  In the winding process, the wire is wound around the external terminal of the terminal unit before or after being wound around the tooth unit. At this time, if the direction in which the tooth portion protrudes and the direction in which the external terminal of the terminal portion extends are orthogonal, in the winding process, the winding machine must change the direction of the winding nozzle by 90 °. Therefore, as described above, when the speed of movement of the winding nozzle of the winding machine is increased, the deflection of the operation of the winding nozzle becomes large, and the winding nozzle may be in contact with the stator core.

  From such a thing, it is difficult to speed up movement of a winding nozzle conventionally. As a result, the tact time of the winding process becomes long, the mass productivity of the motor can not be improved, and the cost reduction of the motor can not be sufficiently realized.

  Patent Document 1 and Patent Document 2 disclose a technique in which one end of a wire wound around a teeth portion is wound around an internal terminal (winding pin) of a motor.

Patent No. 5622663 gazette JP, 2015-173557, A

  In the technique disclosed in Patent Document 1, the direction in which the tooth portion protrudes is orthogonal to the direction in which the internal terminal of the motor extends. Therefore, in the technique disclosed in Patent Document 1, the winding machine must change the direction of the winding nozzle by 90 ° in the winding process. That is, the winding machine can not speed up the movement of the winding nozzle. As a result, the tact time of the winding process becomes long, the mass productivity of the motor can not be improved, and the cost reduction of the motor can not be sufficiently realized.

  The present invention proposes a technology for shortening the tact time of the winding process and improving the mass productivity of the motor.

  A motor according to an exemplary first invention of the present application comprises a rotor rotatable around a central axis, a circumferentially arranged ring core surrounding the central axis, a wire for winding the ring core, the ring core and the core An insulator for insulating between wires, and the rotor, the ring core, the wire, and a first housing surrounding the insulator. At least one end of the rotor protrudes from the first housing in an axial direction in which a central axis extends. The ring core includes a plurality of core segments and a plurality of connecting portions that connect the plurality of core segments in the circumferential direction. Each of the plurality of core segments includes a core back portion, and a tooth portion which protrudes from the core back portion in a radial direction orthogonal to a central axis and on which the wire is wound. The insulator includes an insulating portion disposed between the tooth portion and the wire, and a terminal portion connected to the insulating portion. The terminal unit holds a terminal. The first end of the terminal extends radially from the terminal portion. The wire is wound around the first end.

  According to the first aspect of the present invention, the tact time of the winding process is shortened, and the mass productivity of the motor is improved.

FIG. 1A is a view showing an example of the outer shape of a motor. FIG. 1B is a cross-sectional view of the motor of FIG. 1A. FIG. 2 is a view showing an example of the outer shape of the first housing. FIG. 3 is a diagram showing an example of the outer shape of the stator and the rotor. FIG. 4 is a diagram showing an example of the stator. FIG. 5 is a diagram showing an example of a ring core. FIG. 6 is a view showing an example of the insulator. FIG. 7 is a view showing the relationship between the insulating portion and the terminal portion. FIG. 8 is a diagram showing an example of the stator. FIG. 9 is a diagram showing an example of a straight core. FIG. 10 is a view showing an example of the insulator. FIG. 11 is a diagram showing an example of a winding machine. FIG. 12 is a view showing an example of a winding process. FIG. 13 is a diagram showing an example of the operation of the winding machine. FIG. 14 is a diagram showing an example of the finishing process. FIG. 15 is a diagram showing an example of a motor assembly process. FIG. 16 is a view showing an example of the outer shape of the motor unit. FIG. 17 is a cross-sectional view taken along line XVII-XVII in FIG. FIG. 18 is a back view of the motor unit of FIG. FIG. 19 shows an example of a control board.

Hereinafter, embodiments will be described with reference to the drawings.
In the embodiment, in order to make the description easy to understand, structures or elements other than the main part of the present invention will be simplified or omitted. Further, in the drawings, the dimensions, shapes, numbers, and the like of the respective elements are also an example, and the present invention is not intended to be limited thereto.

  Also, in the following description, the axial direction is defined as the direction in which the rotor (shaft) of the motor extends, that is, the direction in which the central axis of the rotor extends. Further, the radial direction is defined as the direction orthogonal to the central axis of the rotor, and the circumferential direction is defined as the direction surrounding the central axis of the rotor. The circumferential direction is 360 ° around one rotor around the rotor.

  Further, the axial front side is defined as the side from which the rotational output of the motor is taken out, for example, the side from which one end of the rotor protrudes from the first housing. On the other hand, the rear side of the motor is defined as the side opposite to the front side, for example, the side on which a sensor for detecting the rotation of the motor is disposed. In general, the motor is often drawn with the front side up and the rear side down. Therefore, the front side may be referred to as the upper side, and the rear side may be referred to as the lower side. However, in the present specification, the upper side / lower side do not define the upper and lower sides based on something, but simply the upper side means the front side and the lower side means the rear side.

  Also, in the case where the front side is the upper side and the rear side is the lower side, the left and right sides are not determined based on something as well. When the front side is the upper side and the rear side is the lower side in the description, the left side of the central axis of the rotor is simply the left side, and the right side of the central axis of the rotor is the right side. Do.

  Furthermore, the radially inner side means the side toward the central axis of the rotor, and the radially outer side means the side away from the central axis of the rotor.

  Also, as used herein, “xx extends in the direction” means that xx extends parallel to the direction, ie, in the direction of 0 ° with respect to the direction, with respect to the direction , And extends in an oblique direction in a range larger than 0 ° and smaller than 45 °. Also, “xx is orthogonal to the direction” means that xx extends in the direction of 90 ° with respect to the direction, and is larger than 45 ° and more than 135 ° with respect to the direction. It also includes the case of extending in a direction within a small range.

<Motor>
FIG. 1A, FIG. 1B, FIG. 2, FIG. 3, and FIG. 4 show an example of a motor. FIG. 1A shows an example of the outer shape of a motor. FIG. 1B shows a cross section of the motor of FIG. 1A. FIG. 2 shows an example of the outer shape of the first housing. FIG. 3 shows an example of the outer shape of the stator and the rotor. FIG. 4 shows the stator extracted from FIG.

  The motor insulates between the rotor 11 rotatable around the central axis J, the ring core 12 circumferentially arranged around the central axis J, the wire 13 for winding the ring core 12, the ring core 12 and the wire 13 The insulator 14, the rotor 11, the ring core 12, the wire 13, and the first housing 10 surrounding the insulator 14 are provided.

  The type of motor is not particularly limited. The motor can be selected from, for example, a brushless motor, a servomotor, a stepping motor, and a reluctance torque motor. The motor is preferably a three-phase synchronous motor including, for example, three coils of U-phase, V-phase, and W-phase.

  Here, the U-phase coil is a coil driven by a U-phase input signal among a plurality of coils generating a magnetic field for rotating the rotor 11. The V-phase coil is a coil driven by a V-phase input signal among a plurality of coils generating a magnetic field for rotating the rotor 11. Furthermore, the W-phase coil is a coil driven by a W-phase input signal among a plurality of coils that generate a magnetic field for rotating the rotor 11.

  The motor may be an electromechanical integrated motor in which a control device for controlling the rotation of the rotor 11 is disposed in the first housing 10, or a control device for controlling the rotation of the rotor 11 is disposed outside the first housing 10 It may be done. The motor may be of an inner rotor type or an outer rotor type.

  Hereinafter, an inner rotor type brushless motor will be described as an example.

  The first housing 10 comprises, for example, a metal or a metal alloy. However, the first housing 10 is not limited to a conductor, and may be an insulator.

  The rotor 11 extends in the axial direction parallel to the central axis J. The rotor 11 includes a rotor core 111. The rotor core 111 includes a core portion 111A and a magnetic pole portion (rotor magnet) 111B. The rotor 11 is a surface permanent magnet (SPM) in which the magnetic pole portion 111B is disposed on the outer surface in the radial direction of the core portion 111A, but is an interior permanent magnet (IPM) It is also good.

  The magnetic pole portion 111 </ b> B includes a magnet such as a ferrite magnet, an alnico magnet, a samacoba magnet, or a neodymium magnet. The magnetic sensor SEN detects the leakage flux in the axial direction of the magnetic pole portion 111B. The magnetic sensor SEN includes an element capable of detecting this leakage flux, for example, a Hall element, a magnetoresistive element, or the like.

  The rotor 11 is supported by a bearing 112. The type of bearing 112 is not particularly limited. For example, as the bearing 112, a rolling bearing, a sliding bearing or the like can be employed. The thrust washer TW functions as a bearing that receives the force (thrust) acting in the axial direction of the rotor 11.

  One end on the front side of the rotor 11 protrudes from the first housing 10 in the axial direction. The other end on the rear side of the rotor 11 is present in the first housing 10 in the axial direction in which the central axis J extends. However, the other end on the rear side of the rotor 11 may also protrude from the first housing 10.

  The ring core 12 includes a plurality of core segments SEG and a plurality of coupling portions COM circumferentially coupling the plurality of core segments SEG. The ring core 12 has, for example, a structure in which a plurality of electromagnetic steel sheets are axially stacked. The plurality of magnetic steel sheets are connected to one another by caulking or the like.

  In this example, the number of core segments SEG is nine. That is, the motor is a 9-slot type. For example, when the number of magnetic poles of the rotor core 111 integrated with the rotor 11 is eight, the motor is an eight-pole nine-slot type motor. However, the number of magnetic poles and the number of slots of the motor are one example, and the number is not limited to this. In the case of a three-phase synchronous motor, the number of core segments SEG is generally 3 × n (n is a natural number of 1 or more).

  Also, for example, in order to smooth the rotation of the motor, it is desirable that the number of magnetic poles and the number of slots of the motor be large. However, in this case, as the miniaturization of the motor progresses, the slot groove narrows, and the winding nozzle may come into contact with the stator core. Therefore, this example is particularly effective for a motor having a relatively large number of slots, for example, a motor having nine or more slots.

  Each of the plurality of core segments SEG projects from the core back portion 15, the core back portion 15 inward in the radial direction orthogonal to the central axis J, and the teeth portion 16 around which the wire 13 is wound; And an umbrella portion UMB that is disposed at the tip and extends in the circumferential direction from the tip of the tooth portion 16. For example, FIG. 5 shows details of the ring core 12 of FIG.

  As apparent from FIG. 5, the core back portion 15 includes a first surface S1 that is a surface facing inward in the radial direction, a second surface S2 that is a surface that faces outward in the radial direction, and a second surface S2. And a first connecting portion F1 disposed. The first connection portion F1 has a concave shape that is recessed radially inward and extends in the axial direction.

  Further, the circumferential width of the umbrella portion UMB is wider than the circumferential width of the teeth portion 16. The umbrella portion UMB has an effect of suppressing magnetic saturation in the teeth portion 16. That is, magnetic saturation in which the magnetic flux density does not increase even if the current supplied to the coil is increased is that the magnetic flux density in the teeth portion 16 is too large. In the umbrella portion UMB, the magnetic saturation at the teeth portion 16 is sufficiently suppressed in order to eliminate the overcrowding of the magnetic flux density.

  The radially inward facing surface of the umbrella portion UMB has, for example, a curved surface centered on the central axis J. In this case, the magnetic flux acting on the rotor 11 from the umbrella portion UMB is substantially uniform. Therefore, this curved surface has the effect of smoothing the rotation of the motor.

  Each of the plurality of connecting portions COM includes an axially extending crevice G and two convexities T along the edge of the crevice G. Each of the two protrusions T has, for example, a tapered shape that gradually tapers inward in the radial direction. Also, the two convex portions T contact each other. The crevice G and the convex T are effective elements when the ring core 12 is a curling type.

  The tearing portion G and the convex portion T have an effect of facilitating the curling process. The configuration in which the split portion G is plastically deformed and the two convex portions T are in contact with each other easily makes the ring core 12 circular, for example, a perfect circle.

  The connection portion COM 'is a portion corresponding to both ends of the straight core. When the straight core is deformed into the ring core 12 by the curling process, the connection portion COM bends, and both ends of the connection portion COM 'are connected to each other. Both ends of the connection portion COM 'are fixed by, for example, a bonding technique such as laser welding or caulking. The shape of the connection part COM 'may be the same as or different from that of the connection part COM.

  The insulator 14 includes an insulating portion ISR disposed between the ring core 12 and the wire 13 and a terminal portion TER1 coupled to the insulating portion ISR. For example, FIGS. 6 and 7 show details of the insulator 14 of FIG.

  As is apparent from FIGS. 6 and 7, the insulating portion ISR includes, for example, a side surface portion E1 covering two surfaces facing the circumferential direction of the teeth portion 16 and an upper and lower sides covering two surfaces facing the axial direction of the teeth portion 16. And a surface portion E2. Further, the insulating portion ISR covers a first surface portion S1 which is a surface facing the inner side in the radial direction of the core back portion 15 and a second surface portion S2 which is a surface which faces the outer side in the radial direction. Thereby, the insulation between the teeth portion 16 and the wire 13 is realized.

  In addition, the insulation part ISR may be comprised from the lower side insulator 17 which covers the lower half of the teeth part 16, and the upper side insulator 18 which covers the upper half of the teeth part 16, for example.

  The insulating portion ISR further includes a second connection portion F2 connected to the first connection portion F1 of the core back portion 15. In this case, the insulator 14 sandwiches the core back portion 15 from both the radially outer surface and the radially inner surface (first and second surface portions S1 and S2), and the second connecting portion F2 It is fixed to the ring core 12 by being connected to the one connection part F1.

  The first connection portion F1 is, for example, concave, and the second connection portion F2 is, for example, convex. In this case, the insulator 14 is easily fixed to the ring core 12 by joining the second connection portion F2 to the first connection portion F1. In addition, if the first coupling portion F1 extends in the axial direction and the second coupling portion F2 can be inserted into the first coupling portion F1 along the axial direction, the insulator 14 is assembled in the motor assembly process, It can be more easily fixed to the ring core 12.

  The terminal portion TER1 is coupled in the axial direction to the insulating portion ISR corresponding to one of the plurality of core segments SEG. The terminal unit TER1 holds a terminal. In this example, the terminals are three external terminals U, V, W. However, the number of external terminals held by the terminal unit TER1 is not limited to this. The number of external terminals held by the terminal TER1 may be one, two, four or more.

  Since this example assumes a three-phase synchronous motor, the plurality of external terminals held by the terminal unit TER1 are an external terminal U for inputting a U-phase input signal, an external terminal V for inputting a V-phase input signal, and W This is an external terminal W for inputting a phase input signal. That is, the rotation of the rotor is controlled by the three-phase input signal, and the terminals are three external terminals to which the three-phase input signal is input. Further, when the U-phase coil, the V-phase coil, and the W-phase coil are so-called star-connected, the terminal portion TER1 is added to the plurality of external terminals U, V, W, or the plurality of external terminals U , V, W may be held to hold the common terminal.

  The terminal portion TER1 has a first end face portion Q1. The first end face portion Q1 is an end face located on the axially upper side of the two end faces of the terminal portion TER1 in the axial direction. The plurality of core segments SEG have a second end face portion Q2. The second end face portion Q2 is an end face located on the lower side in the axial direction among two end faces of the plurality of core segments SEG in the axial direction. Further, in the axial direction, the first end face portion Q1 is located axially lower than the second end face portion Q2. This means that the terminal portion TER1 is disposed axially away from the plurality of core segments SEG.

  In this case, the terminal portion TER1 is located on the axially lower side (rear side) of the stator core. When the terminal portion TER1 is located on the lower side in the axial direction, the external terminals U, V, W of the motor are located on the opposite side to the front side of the rotor.

  The terminal portion TER1 includes a first protrusion PJ1 that protrudes from the radial inner side of the first housing 10 toward the radial outer side of the first housing 10. In addition, the first housing 10 includes a first slit SLT1 into which the first protrusion PJ1 is inserted. The first slit SLT1 is a through hole which penetrates the side surface of the first housing 10 in the radial direction. The first protrusion PJ1 protrudes from the radial inner side of the first housing 10 toward the radial outer side of the first housing 10 via the first slit SLT1.

  Therefore, when the insulator 14 is fixed to the ring core 12 and the first projection PJ1 of the terminal portion TER1 contacts the first slit SLT1 of the first housing 10, the ring core 12 and the plurality of core segments SEG are The circumferential alignment can be accurately performed.

  The plurality of external terminals U, V, W are metal bars. The plurality of external terminals U, V, W have a first end EP1 and a second end EP2. The first end portion EP1 is a tip portion extending radially inward from the terminal portion TER1. This means that the direction in which the teeth 16 project is the same as the direction in which the first ends EP1 of the plurality of external terminals U, V, W extend, that is, in the radially inward direction. In addition, the wire 13 is directly wound around the first end EP1 of the plurality of external terminals U, V, W.

In this case, in the winding step, the winding surface of the wire 13 wound around the teeth portion 16 and the winding of the wire 13 wound around the first end EP1 of the plurality of external terminals U, V, W The plane is parallel.
Here, the winding surface of the wire 13 is a plane including the ring-shaped wire 13 for one turn when the wire 13 is wound for one turn around the tooth portion 16 or the first end EP1. It is. In this definition, although there are a plurality of winding surfaces of the wire 13 wound around the teeth portion 16 or the first end portion EP1, any of the plurality of winding surfaces is substantially parallel. It becomes. The winding process is performed, for example, in the state of a straight core shown in FIG. 8 as described later. In FIG. 8, assuming that the first, second, and third directions are the X-axis direction, the Y-axis direction, and the Z-axis direction, respectively, the winding of the wire 13 wound around the teeth portion 16 The surface SF1 and the winding surface SF2 of the wire 13 wound around the first ends EP1 of the plurality of external terminals U, V, W are all parallel to the XZ plane. The first, second, and third directions will be described in detail in the description of the straight core in FIG.

  Thus, in the winding process, for example, the winding machine does not have to change the orientation of the winding nozzle. This means that the manufacturing tact time is shortened by speeding up the movement of the winding nozzle. In addition, the wire 13 is directly wound around the first end EP1 of the plurality of external terminals U, V, W. Therefore, the wiring structure inside the motor is simplified.

  Thus, the fact that the first ends EP1 of the external terminals U, V, W extend radially inward from the terminal portion TER1 means that the miniaturization and cost reduction of the motor are simultaneously realized. .

  The important point is that the winding surface of the wire 13 wound around the teeth portion 16 and the winding surface of the wire 13 wound around the first end EP1 of the plurality of external terminals U, V, W And to be parallel. Therefore, for example, in the case of the outer rotor type in which the teeth portion protrudes radially outward from the core back portion, the first end portions EP1 of the external terminals U, V, W also conform to this, and radially from the terminal portion TER1. It is desirable to extend outward.

  In addition, the winding direction of the wire 13 for winding the teeth portion 16 may be the same as the winding direction of the wire 13 for winding the first end EP1 of the external terminals U, V, W, or , May be different. However, if the winding direction of the wire 13 for winding the teeth portion 16 is the same as the winding direction of the wire 13 for winding the first end EP1 of the external terminals U, V, W, the winding is further performed. The line process can be simplified.

  Here, when the teeth portion 16 is viewed from the tip end side of the teeth portion 16 or when the external terminals U, V, W are viewed from the tip ends of the external terminals U, V, W, the winding direction is The direction in which the wire 13 is wound around the tooth portion 16 or the external terminals U, V, W.

  Further, the tip of the teeth portion 16 is the root of the teeth portion 16, that is, the tip on the opposite side to the portion where the teeth portion 16 is coupled to the core back portion 15. Also, the tips of the external terminals U, V, W are the roots of the external terminals U, V, W, that is, the tips on the opposite side to the portion where the external terminals U, V, W project from the terminal portion TER1. is there. The winding direction is clockwise (CW: clockwise) and left-handed (CCW: counter-clockwise).

  Furthermore, it is desirable that the wire 13 be wound from the radially outer side toward the radially inner side at the first ends EP1 of the external terminals U, V, W. According to this configuration, it is difficult to apply a moment load to the external terminals U, V, W. As a result, when the wire 13 is wound around the external terminals U, V, W, deformation of the external terminals U, V, W can be suppressed.

  The second ends EP2 of the external terminals U, V, W are portions extending in the axial direction from the first projecting portion PJ1 of the terminal portion TER1 in the external terminals U, V, W. When the second end EP2 extends in the axial direction from the first protrusion PJ1, the direction of the first end EP1 of the external terminals U, V, W and the second end of the external terminals U, V, W The direction of the part EP2 is different. That is, the external terminals U, V, W have a bent shape in the terminal portion TER1.

  As a result, the second ends EP2 of the external terminals U, V, W face the core back portion 15 with a gap in the radial direction.

  In this case, the motor of the present example is effective, for example, in a system (motor unit) in which a control board that controls the motor is disposed in a plane orthogonal to the central axis J. This is because such a system facilitates the electrical connection between the motor and the control board. This will be described in detail in the section of motor unit.

  It is desirable that the plurality of external terminals U, V, W be arranged side by side within a predetermined width in the circumferential direction. Assuming that the width of the plurality of external terminals U, V, W in the circumferential direction is a predetermined width H1, and the width from one connecting portion COM in the circumferential direction to the connecting portion COM adjacent thereto is a core back width H2, the predetermined width H1 Is preferably smaller than the core back width H2. This takes account of the ease of connection between the terminal portion TER1 and the insulating portion ISR and the ease of winding of the wire 13 to the first end EP1 of the external terminals U, V, W. It is.

  Although the number of terminal portions TER1 is one in this example, it is not limited to this. The number of terminal units TER1 may be two or more. In this case, each of the plurality of terminal portions is respectively connected to the insulating portion ISR corresponding to one core segment SEG as can be assumed from FIGS. 6 and 7, for example. However, it is desirable that the plurality of terminal portions be respectively connected to the insulating portion ISR corresponding to the core segments SEG separated from each other so that the plurality of terminal portions do not interfere with each other.

  The direction in which the first ends EP1 of the plurality of external terminals U, V, W extend is radial, for example, extending parallel to one another. However, the first ends EP1 of the plurality of external terminals U, V, W may not extend exactly in parallel. For example, one of the plurality of external terminals U, V, W, for example, the central external terminal V extends in the radial direction, and the remaining external terminals U, W are approximately parallel to the external terminal V. It may extend.

  The magnetic sensor SEN is mounted on the circuit board CB. The circuit board CB also has a sensor terminal Tsen. The sensor terminal Tsen outputs a rotation angle detected by the magnetic sensor SEN. The circuit board CB includes a second protrusion PJ2 that protrudes radially inward of the first housing 10 and radially outward of the first housing 10. In addition, the first housing 10 includes a second slit SLT2 into which the second protrusion PJ2 is inserted. The second slit SLT1 is a through hole that penetrates the side surface of the first housing 10 in the radial direction. The second protrusion PJ2 includes a second protrusion PJ2 that protrudes from the radial inner side of the first housing 10 toward the radial outer side of the first housing 10 via the second slit SLT2. .

  The sensor terminal Tsen, like the external terminals U, V, W, is a metal rod. The sensor terminal extends, for example, along the axial direction from the second protrusion PJ2.

  For example, when the rotational angle and rotational speed of the motor are controlled by a controller outside the motor, the motor must output a signal indicating the rotational angle of the rotor 11 to the controller. Therefore, in this case, it is preferable that the motor includes a sensor terminal Tsen that outputs a rotation angle detected by the magnetic sensor SEN such as a Hall element or a magnetoresistive element.

  Similarly to the second end EP2 of the external terminals U, V, W, the sensor terminal Tsen preferably extends in the axial direction.

  As described above, according to the present embodiment, downsizing and cost reduction of the motor can be sufficiently realized.

<Stator (Straight core)>
FIG. 8 shows an example of the stator. FIG. 9 is a diagram showing a straight core extracted from FIG. FIG. 10 is a view extracting and showing an insulator from FIG.

  The stator of this example is used, for example, for the motor shown in FIGS. This stator is a straight core type. This type of stator is used as a motor stator after being transformed into a ring core by the curling process, as described above.

  In the following description, the first direction is the direction in which a plurality of core segments are connected, and corresponds to the circumferential direction of the ring core when the straight core is used as a motor stator. The second direction is the direction in which the teeth extend, and corresponds to the radial direction of the ring core when the straight core is used as a motor stator. The second direction inner side means the tip side of the tooth portion in the second direction, and the second direction outer side means the root side of the tooth portion in the second direction. The root of the tooth portion is a portion where the tooth portion is connected to the core back portion, and the tip of the tooth portion is the tip on the side opposite to the root of the tooth portion. The third direction is a direction orthogonal to the first and second directions, and corresponds to the axial direction of the ring core when the straight core is used as a motor stator. The third direction lower side means the terminal side in the third direction, and the upper side in the third direction means the side opposite to the terminal side in the third direction. However, the inner / outer and lower / upper here are merely to simplify the description, and do not always have to be inner / outer and lower / upper.

  Also, in the following, the characteristic elements of the straight core will be described, and the other elements will be omitted by providing the same reference numerals as the reference numerals of the motor shown in FIGS.

  The straight core 12 ′ includes a plurality of core segments SEG and a plurality of connectors COM that couple the plurality of core segments SEG in a first direction. The straight core 12 ′ has, for example, a structure in which a plurality of electromagnetic steel sheets are axially stacked. The plurality of electromagnetic steel plates are connected to each other by caulking or the like.

  Each of the plurality of core segments SEG protrudes from the core back portion 15, the core back portion 15 in the second direction orthogonal to the first direction, and the teeth portion 16 on which the wire 13 is wound; And Umbrella portion UMB arranged at the tip of the second direction.

  As apparent from FIG. 9, the core back portion 15 includes a first surface portion S1 which is a surface facing inward in the second direction, a second surface portion S2 which is a surface which faces outward in the second direction, and a second surface portion S2. And a first connecting portion F1 disposed in the surface portion S2. The first connecting portion F1 has a concave shape which is recessed inward in the second direction, and extends in the third direction.

  Each of the plurality of connection parts COM includes a groove G ′ extending in the third direction, and two projections T along the edge of the groove G ′. Each of the two protrusions T has, for example, a tapered shape that gradually tapers inward in the second direction. The grooves G ′ and the protrusions T have an effect of facilitating the curling process. The configuration in which the groove portion G ′ is plastically deformed and the two convex portions T are in contact with each other easily makes the ring core 12 circular, for example, a perfect circle.

  The insulator 14 includes an insulating portion ISR disposed between the ring core 12 and the wire 13 and a terminal portion TER1 coupled to the insulating portion ISR.

  As apparent from FIG. 10, the insulating portion ISR is, for example, a side surface portion E1 which is a side surface covering two surfaces facing the first direction of the tooth portion 16 and two surface facing the third direction of the tooth portion 16. And an upper and lower surface portion E2 which is an upper and lower end surface covering the surface. In addition, the insulating portion ISR covers a first surface portion S1 which is a surface facing the inner side in the second direction of the core back portion 15 and a second surface portion S2 which is a surface which faces the outer side in the second direction. Thereby, the insulation between the teeth portion 16 and the wire 13 is realized. That is, the insulator 14 insulates between the ring core and the wire. Alternatively, the insulator 14 insulates between the ring core and the coil.

  The insulating portion ISR further includes a second connection portion F2 connected to the first connection portion F1 of the core back portion 15. In this case, the insulator 14 sandwiches the core back portion 15 from both the outer surface in the second direction and the inner surface in the second direction (first and second surface portions S1 and S2), and the second connection The portion F2 is fixed to the straight core 12 'by being connected to the first connection portion F1.

  The terminal unit TER1 holds a plurality of external terminals U, V, W. In this example, the terminal unit TER1 holds three external terminals. The terminal portion TER1 has a first end face portion Q1. The first end face portion Q1 is an end face portion located on the upper side in the third direction of the two end face portions of the terminal portion TER1 in the third direction.

  On the other hand, the plurality of core segments SEG have the second end face portion Q2. The second end face portion Q2 is an end face portion located on the lower side in the third direction of the two end face portions of the plurality of core segments SEG in the third direction. Then, in the third direction, the first end face portion Q1 is positioned lower in the third direction than the second end face portion Q2.

  First ends EP1 of the plurality of external terminals U, V, W extend inward in the second direction from the terminal portion TER1. Therefore, the direction in which the teeth 16 project is the same as the direction in which the first ends EP1 of the plurality of external terminals U, V, W extend, that is, the second direction. In addition, the wire 13 is directly wound around the first end EP1 of the plurality of external terminals U, V, W.

  Therefore, in the winding process, the manufacturing tact time can be shortened.

  The winding direction (CW or CCW) of the wire 13 winding the teeth and the winding direction (CW or CCW) of the wire 13 winding the first end EP1 of the external terminals U, V, W And may be the same or different. In addition, the wire 13 is made to approach the tip of the first end EP1 of the external terminal U, V, W gradually, for example, as shown by arrow D in FIG. It is desirable to be wound around the first end EP1 of the external terminals U, V, W towards the inside.

  The second ends EP2 of the external terminals U, V, W extend from the terminal portion TER1 in a third direction. Further, the second ends EP2 of the external terminals U, V, W face the core back portion 15 with a gap in the second direction. Furthermore, when the plurality of external terminals U, V, W are arranged side by side within the predetermined width H1 in the first direction, the predetermined width H1 is larger than the core back width H2 of the core back portion 15 in the first direction. It is desirable to be small.

  As described above, by using the stator (straight core) of the present embodiment, it is possible to sufficiently realize downsizing and cost reduction of the motor.

<Winding process>
FIG. 11 shows an example of a winding machine.
The winding machine 21 includes a control unit 22, a storage unit 23, a drive unit 24, a winding nozzle 25, and a wire supply unit 26.

  The control unit 22 controls a winding process for the stator (straight core) 27. The storage unit 23 stores, for example, a program that executes a winding process. The control unit 22 executes a winding process based on this program. The drive unit 24 actually drives the winding nozzle 25 in response to a control signal from the control unit 22. The wire is supplied from the wire supply unit 26.

FIG. 12 shows an example of a winding process. FIG. 13 shows an example of the operation of the winding machine.
The operation (flow chart) of the winding machine of FIG. 13 corresponds to the winding process of FIG. The stator 27 is the stator (straight core) of FIGS. 8 to 10.
The winding step STw is performed as follows.

  First, the wire 13 is wound around the external terminal W as an input terminal of the W-phase input signal (start of winding START) (step ST01). The winding direction of the wire 13 with respect to the external terminal W is right-handed (CW). When viewed from the third direction, the lead pin P <b> 1 has teeth portions no. It is provided at a position overlapping 3. Thereby, the wire 13 is moved in the third direction along the teeth portion No. Began winding on 3. That is, the wire 13 has teeth portions no. It is wound while extending parallel to the circumferential side surface of 3. As a result, in this example, without wasting the space of the slot groove of the wire 13, the teeth No. 1 and 2 are removed. It can be wound around three. After this, the winding machine forms a first coil having a first phase, for example a W-phase coil. The first coil comprises a plurality of coils. That is, the wire 13 is wound around the third, sixth and ninth tooth portions from the left side shown in FIG. 12 sequentially after passing through the lead pin P1 (step ST02). The winding direction of the wire 13 with respect to the third, sixth, and ninth tooth portions from the left side illustrated in FIG. 12 is also right-handed (CW).

  When the winding of the wire 13 to the ninth tooth portion from the left shown in FIG. 12 is finished, the winding machine then forms a second coil having a second phase, for example, a V-phase coil. The second coil comprises a plurality of coils. That is, after the wire 13 is wound around the lead pin P2 as the intermediate terminal M, the wire 13 is sequentially wound around the eighth, fifth and second teeth portions from the left side shown in FIG. 12 (step ST03 ~ ST04). The winding direction of the wire 13 with respect to the eighth, fifth, and second teeth from the left side shown in FIG. 12 is, for example, left-handed (CCW).

  When the winding of the wire 13 for the second tooth portion from the left shown in FIG. 12 is finished, the wire 13 is then wound around the external terminal V as an input terminal of the V-phase input signal (step ST05). The winding direction of the wire 13 with respect to the external terminal V is, for example, left-handed (CCW). As seen from the third direction, the external terminal V has teeth portions no. It is provided at a position overlapping with 2. Thus, the wire 13 is wound around the external terminal V without applying a tensile load to the external terminal V.

  Thereafter, the wire 13 is wound around the external terminal U as an input terminal of the U-phase input signal after passing through the lead pin P3 (step ST06). The winding direction of the wire 13 with respect to the external terminal U is, for example, right-handed (CW).

  The winding machine then forms a third coil having a third phase, for example a U-phase coil. The third coil comprises a plurality of coils. That is, after passing through the lead pin P4, the wire 13 is wound around the first, fourth and seventh tooth portions from the left side shown in FIG. 12 (step ST07). The winding direction of the wire 13 with respect to the first, fourth and seventh teeth from the left side shown in FIG. 12 is, for example, right-handed (CW). When viewed from the third direction, the lead pin P4 has teeth portions No. 1 and No. It is provided at a position overlapping with 1. That is, the wire 13 has teeth portions no. It is wound while extending in parallel with the circumferential side surface of 1. As a result, in this example, without wasting the space at the coil end of the wire 13, the teeth portion No. 3 is not used. It can be wound around three.

  When the winding of the wire 13 to the seventh tooth portion from the left shown in FIG. 12 is finished, the winding machine finally ties the tip of the wire 13 to the lead pin P2 (step ST08).

  Thereafter, the wire 13 is cut, and the winding process is completed (step ST09).

  Of the wire 13 wound around the straight core, the portion from the coil wound around one tooth portion to the coil wound around the other one tooth portion is called crossover wire Pcw. The winding machine controls the movement of the winding nozzle such that the crossover Pcw passes through the radially inner side of the wire guide GD of the insulator 14.

  Incidentally, in FIG. 12, the crossovers indicate only the portions connecting the third teeth portion, the sixth teeth portion, and the ninth teeth portion. Other parts are omitted in order to make the drawing intelligible.

  The lead pins P1 to P4 are provided independently of the stator 27. The lead pins P1 to P4 may be a jig or the like provided in the winding machine.

  Furthermore, as is clear from FIG. 10, the wire guide GD is a part of the insulator 14 and has a plate shape extending from the insulating portion ISR of the insulator 14 to the upper side in the third direction or the lower side in the third direction. That is, the insulator 14 has the wire guide GD located at the lower end of the plurality of core segments SEG in the third direction. The plurality of coils are connected in series with one another via the inside of the wire guide GD in the second direction. Insulation between the crossover Pcw and the housing 10 is performed by the wire guide GD.

FIG. 14 shows an example of the finishing process.
After the winding process STw for the stator (straight core) is completed, the finishing process STf is performed.

  The common terminal C indicates a common terminal (common node) when the U-phase coil, the V-phase coil, and the W-phase coil are so-called star-connected. The common terminal C in FIG. 14 corresponds to the common terminal C in FIG.

  Further, when the winding process STw is completed, the wire 13 is only wound around the external terminals U, V, W, and is not fixed to the external terminals U, V, W with certainty. In addition, the wire 13 has a structure in which a conductor such as an enameled wire, a polyurethane wire, or a polyester wire is covered with an insulating film.

  Therefore, the wire 13 wound around the external terminals U, V, W is fixed to the external terminals U, V, W by an operation such as soldering in the finishing process STf, for example. Further, since the insulating film covering the surface of the wire 13 is peeled off by the heat at the time of soldering, the electrical connection between the wire 13 and the external terminals U, V, W is secured. Similarly, with regard to the common terminal C, the insulating film covering the wire 13 is peeled off by an operation such as soldering.

<Assembly process of motor>
FIG. 15 shows an example of a motor assembly process.

First, the straight core and the insulator are assembled. The straight core is, for example, the straight core 12 'of FIG. Moreover, an insulator is the insulator 14 of FIG. 10, for example. After the straight core 12 'and the insulator 14 are assembled, a winding process STw and a finishing process STf are performed.
When the winding process STw and the finishing process STf end, for example, the stator (straight core) of FIG. 8 is completed.

  Next, the curling step STc is performed. The curling process STc is performed by the curling device. The stator finished the curling step STc is, for example, the same as the stator shown in FIG. Finally, the motor is completed by combining the rotor, the stator subjected to the curling process, the first housing, and the like in the assembly process STa.

  <Example of application>

  Hereinafter, an example of a system (motor unit) in which the output of the motor according to the embodiment is output from the shaft (output shaft) via a gear such as a reduction gear will be described.

  FIG. 16 shows an example of the outer shape of the motor unit. FIG. 17 is a cross-sectional view taken along line XVII-XVII in FIG. FIG. 18 is a view of the motor unit of FIG. FIG. 19 shows an example of a control board.

  The motor 30 is, for example, the motor shown in FIGS. The control substrate 31 is disposed in a plane orthogonal to the central axis J. The control substrate 31 has a hole portion H which is a through hole penetrating in the axial direction. External terminals U, V. The second end EP 2 of W penetrates the control circuit 31.

  The controller 32 and the driver 33 are mounted on the control board 31. The control device 32 outputs, for example, a control signal that controls the rotation of the motor 30. The control signal is, for example, a pulse width modulation (PWM) signal. The driver 33 receives the control signal and outputs a drive signal for driving the motor 30. The drive signal is, for example, a drive current generated by turning on / off a plurality of field effect transistors.

  When the motor 30 is a three-phase synchronous motor, the drive signal is a three-phase (U-phase, V-phase, and W-phase) AC signal.

  The shaft 34 functions as an output shaft AX of the motor unit. The shaft 34 is rotatable about the output axis AX. The gear 35 mechanically connects the rotor 11 and the shaft 34 of the motor 30. The gear 35 is, for example, a reduction gear.

  The second housing 36 encloses the motor 30, the control board 31, the shaft 34 and the gear 35. The second housing 36 comprises, for example, a metal or a metal alloy. However, the second housing 36 is not limited to a conductor, and may be an insulator. The second housing 36 can be selected from, for example, aluminum, aluminum alloy, carbon fiber reinforced plastic (CFRP), and the like. The second housing 36 may include magnesium.

  At least one end of the shaft 34 projects from the second housing 36.

  In addition, external terminals U, V. The second end EP 2 of W extends in the axial direction, and the control board 31 is disposed in a plane perpendicular to the central axis J of the motor 30. In this case, external terminals U, V. The second end portion EP2 of W is easily inserted into the hole portion H of the control substrate 31. Therefore, the connection between the motor 30 and the control board 31 is facilitated.

(End)
As described above, according to the embodiment of the present invention, the tact time of the winding process is shortened, and the mass productivity of the motor is improved.

  While certain embodiments of the present invention have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the present invention. These embodiments can be implemented in various forms other than those described above, and various omissions, substitutions, changes, and the like can be made without departing from the scope of the present invention. These embodiments and modifications thereof are included in the scope and spirit of the present invention, and the invention described in the claims and equivalents thereof are also included in the scope and spirit of the present invention.

10: first housing, 11: rotor, 12: ring core, 12 ': straight core, 13: wire, 14: insulator, 15: core back portion, 16: teeth portion, 17: lower insulator, 18: upper insulator , J: central axis, TER1: terminal, PJ1: first protrusion, PJ2: second protrusion, U, V, W: external terminal, TW: thrust washer, SEN: magnetic sensor, Tsen: sensor terminal , SLT1: first slit, SLT2: second slit, SEG: core segment, COM: joint, F1: first joint, F2: second joint, G: crevice, G ': groove , T: Convex part, ISR: Insulated part, CB: Circuit board.

Claims (20)

A rotor rotatable around a central axis,
A circumferentially disposed ring core surrounding the central axis;
A wire for winding the ring core;
An insulator that insulates between the ring core and the wire;
A first housing surrounding the rotor, the ring core, the wire, and the insulator;
Equipped with
At least one end of the rotor protrudes from the first housing in an axial direction in which a central axis extends,
The ring core includes a plurality of core segments, and a plurality of coupling portions that circumferentially connect the plurality of core segments,
Each of the plurality of core segments includes a core back portion, and a tooth portion that protrudes from the core back portion in a radial direction orthogonal to a central axis and on which the wire is wound;
The insulator includes an insulating portion disposed between the tooth portion and the wire, and a terminal portion coupled to the insulating portion.
The terminal unit holds a terminal,
The first end of the terminal extends radially from the terminal portion,
The wire is wound around the first end,
motor. The insulator is fixed to the ring core,
The first housing has a first slit and
The terminal portion includes a first protrusion projecting from a radial inner side of the first housing toward a radial outer side of the first housing via the first slit.
The first protrusion contacts the first slit,
The motor according to claim 1. The second end of the terminal extends axially from the first projection,
The motor according to claim 2. A sensor that detects a rotation angle of the rotor;
And a circuit board on which the sensor is mounted.
The circuit board has a sensor terminal for outputting the rotation angle detected by the sensor,
The first housing has a second slit,
The circuit board includes a second protrusion projecting from the radial inner side of the first housing toward the radial outer side of the first housing via the second slit.
The sensor terminal extends axially from the second projection,
The motor according to claim 3. The rotation of the rotor is controlled by a three phase input signal,
The terminals are three external terminals to which the three-phase input signal is input,
The motor according to any one of claims 1 to 4. The terminal portion is coupled to the insulating portion corresponding to one of the plurality of core segments,
The three external terminals are arranged side by side within a predetermined width in the circumferential direction,
The predetermined width is smaller than the circumferential width of the core back portion,
The motor according to claim 5. The wire is wound around the terminal from radially outward to radially inward.
The motor according to claim 1. The winding direction of the wire wound around the terminal is the same as the winding direction of the wire wound around the tooth portion.
The motor according to claim 1. Each of the plurality of connection portions includes an axially extending tear-off portion and a protrusion along the tear-off portion.
A motor according to any one of the preceding claims. A motor according to claim 1;
A controller for controlling the motor;
A control board on which the control device is mounted;
A rotatable shaft about the output shaft,
A gear connecting the rotor and the shaft;
The motor, the control board, the shaft, and a second housing surrounding the gear;
Equipped with
At least one end of the shaft protrudes from the second housing,
The control substrate is disposed in a plane orthogonal to the central axis, and has a hole penetrating in the axial direction,
The second end of the terminal penetrates the control board,
Motor unit. The stator of the motor,
A circumferentially disposed ring core surrounding the central axis;
A wire for winding the ring core;
An insulator that insulates between the ring core and the wire;
Equipped with
The ring core includes a plurality of core segments, and a plurality of coupling portions that circumferentially connect the plurality of core segments,
Each of the plurality of core segments includes a core back portion, and a tooth portion that protrudes from the core back portion in a radial direction orthogonal to a central axis and on which the wire is wound;
The insulator includes an insulating portion disposed between the tooth portion and the wire, and a terminal portion coupled to the insulating portion.
The terminal unit holds a terminal,
The first end of the terminal extends radially from the terminal portion,
The wire is wound around the first end,
Stator. An axially upper first end surface portion in which the central axis of the terminal portion extends is located axially lower than an axially lower second end surface portion of one of the plurality of core segments.
The stator according to claim 11. A second end of the terminal is radially opposed to the core back portion with a gap.
The stator according to claim 11 or 12. The terminals are three external terminals to which a three-phase input signal is input,
The stator according to any one of claims 11 to 13. Each of the plurality of connection portions includes an axially extending tear-off portion and a protrusion along the tear-off portion.
The stator according to claim 12. The stator of the motor,
A straight core extending in a first direction,
A wire for winding the straight core;
An insulator that insulates between the straight core and the wire;
Equipped with
The straight core includes: a plurality of core segments; and a plurality of connecting portions connecting the plurality of core segments in a first direction in a straight line,
Each of the plurality of core segments includes a core back portion, and a tooth portion which protrudes from the core back portion in a second direction orthogonal to the first direction and on which the wire is wound;
The insulator includes an insulating portion disposed between the tooth portion and the wire, and a terminal portion coupled to the insulating portion.
The terminal unit holds a terminal,
A first end of the terminal extends in a second direction from the terminal portion;
The wire is wound around the first end,
Stator. The first end face portion of the third direction upper side orthogonal to the first and second directions of the terminal portion is closer to the second end face portion of the third direction lower than one of the plurality of core segments. Also located below the third direction,
The stator according to claim 16. A second end of the terminal faces the core back portion with a gap in a second direction,
The stator according to claim 16 or 17. The terminals are three external terminals to which a three-phase input signal is input,
The stator according to any one of claims 16 to 18. Each of the plurality of connection parts includes a groove extending in a third direction, and a protrusion along the edge of the groove.
The stator according to claim 17.

Images