JP2020078139A - Rotary electric machine and method of manufacturing the same - Google Patents

Abstract

To provide a technique for a rotary electric machine that prevents the generation of winding collapse or the like to improve productivity while securing miniaturization and high efficiency.SOLUTION: A rotary electric machine comprises: teeth; a bobbin having a through hole into which the teeth are inserted; a stator having a plurality of coils wound on the bobbin; and a rotor disposed at a predetermined gap from the teeth. A first coil from the plurality of coils which contacts the bobbin first and a second coil which contacts the bobbin after the first coil are wound so that they are wound with their liner diameters partially overlapped.SELECTED DRAWING: Figure 8

Description

  The present invention relates to a rotary electric machine, and more particularly to a rotary electric machine that forms a stator by winding a coil around a bobbin, and a method for manufacturing the same.

  Generally, there are two methods of manufacturing a rotating electric machine, a method of storing a coil in a status lot and a method of inserting a tooth or a core of a roughly columnar body into a bobbin around which the coil is wound. In the case of manufacturing by winding a coil around a bobbin, when winding the coil around the bobbin, there is known a manufacturing method in which tension is applied to the coil so that winding collapse does not occur.

  Here, in order to reduce the size and increase the efficiency of the rotary electric machine, it is important to arrange the iron core and the coils, which directly contribute to the torque output, in the stator at a high density. The iron core is a skeleton that forms the magnetic path of the rotating electric machine, and by forming it so that the magnetic resistance of the main magnetic flux is small, it becomes possible to effectively utilize the magnetic flux generated by the coil and the permanent magnet. Further, increasing the volume of the coil leads to an increase in wire diameter, assuming the same number of turns. This leads to reduction of Joule loss generated in the coil. On the other hand, if an attempt is made to increase the density of the iron core or the coil, the size of the gap between the parts is reduced, which may lead to deterioration in productivity and increase in cost. Therefore, it is necessary to improve the space factor of the iron core and the coil while maintaining productivity and low cost.

In a structure of a rotary electric machine using such a bobbin, as a means for improving a space factor while ensuring a predetermined performance, for example, as disclosed in Patent Document 1, two coils are wound at the same time. A method of turning is disclosed. Specifically, the nozzle holder that supports the winding nozzle is rotated to arrange a plurality of wire rods 20a and 20b in parallel (in a plane perpendicular to the central axis of the winding core 2) to simultaneously form a multilayer winding. A method of winding and a method of performing bifilar winding by setting the wire rods 20a and 30b to be fed from the nozzle in parallel with the surface of the winding core 2 of the drum core 1 are disclosed.

JP 2004-119922

  However, if the nozzle is inclined at an angle with respect to the center axis of the winding core as in Patent Document 1, when the nozzle is wound around the winding core (or bobbin), the wire material that first comes into contact with the winding core and the next winding wire There is a problem that the direction of the tension applied to the wire material that contacts the core is different, and the winding collapse easily occurs when the wire material is wound in multiple layers.

  If winding collapse occurs in the lower layer (layer closer to the iron core side), the coils wound above the collapsed layer cannot be neatly aligned and wound, creating unnecessary voids between the wires. However, this leads to a decrease in the space factor.

  In addition, when the coil having collapsed is attempted to be wound with a predetermined coil length, the coil becomes thicker by the amount of the voids as compared with the coil which is not collapsed. If the core member is thicker than a predetermined width, the stator may not be formed. In addition, when the stator is fixed with resin, there is a possibility that the gap between the core members, which serves as the resin flow path, may be narrowed and the resin may not sufficiently flow around.

  A technology that improves productivity while ensuring miniaturization and high efficiency is desired.

  In order to solve the problems described above, the invention described in the claims is applied. As an example, in a rotating electric machine, a tooth, a bobbin having a through hole into which the tooth is inserted, a stator having a plurality of coils wound around the bobbin, the tooth, and a predetermined tooth. A rotating electric machine comprising: a rotor arranged via a gap, wherein a first coil of the plurality of coils comes into contact with the bobbin first, and a second coil comes into contact with the bobbin after the first coil. The coil is a coil in which a part of the wire diameter overlaps and is wound.

  Advantageous Effects of Invention According to one aspect of the present invention, it is possible to suppress coil collapse, reduce the size and efficiency of a rotating electric machine, and improve productivity.

  Other problems, configurations and effects of the present invention will be apparent from the following description.

FIG. 1A is a side view and a sectional view showing an overall configuration of an axial gap type rotary electric machine according to a first embodiment to which the present invention is applied. FIG. 1 is a vertical cross-sectional perspective view of an axial gap type rotary electric machine according to a first embodiment of the present invention. FIG. 1 is a vertical cross-sectional perspective view of a stator of an axial gap type rotary electric machine according to a first embodiment of the present invention. FIG. 3 is a perspective view showing a combination of a bobbin and a laminated iron core (core) of the axial gap type rotary electric machine according to the first embodiment of the present invention. [Fig. 4] is a perspective view showing a state in which a coil is wound around the core member shown in (a). FIG. 4 is a plan view showing an annular core member that constitutes a stator of an axial gap type rotary electric machine according to a first embodiment of the present invention. FIG. 4 is a cross-sectional view showing a resin flow path of the axial gap type rotary electric machine according to the first embodiment to which the present invention is applied. FIG. 4 is a schematic diagram showing a winding method in which two coils are simultaneously wound around the same layer in the core member of the axial gap type rotary electric machine according to the first embodiment to which the present invention is applied. FIG. 4 is a schematic diagram showing a winding method in which two coils are further advanced and wound into a second layer in the core member of the axial gap type rotary electric machine according to the first embodiment to which the present invention is applied. FIG. 8 is a schematic diagram showing the characteristics of a winding method for winding adjacent coils in a core member of an axial gap type rotary electric machine according to a second embodiment of the present invention. FIG. 9 is a schematic diagram showing the characteristics of a winding method for winding adjacent coils in a core member of an axial gap type rotary electric machine according to a third embodiment of the present invention.

  Embodiments to which the present invention is applied will be described below with reference to the drawings.

  FIG. 1 shows an overall configuration of an axial gap type rotary electric machine 1 (hereinafter referred to as “rotary electric machine 1”), which is an example to which the present invention is applied, and FIG. 2 is a sectional view. The rotating electric machine 1 includes a stator 2 inside a substantially tubular housing 5, a rotor 3 fixed to an output shaft 4 and co-rotating, an output side end bracket and an output side end bracket connected to the output shaft 4 via a bearing, The cooling fan is connected to the end of the rotating shaft 4 that penetrates the end bracket on the side opposite to the output shaft, and rotates together with the cooling fan. The fan cover guides the cooling air generated by the cooling fan to the outer peripheral side of the housing 5.

  As shown in FIGS. 1 and 2, in an axial air gap type electric motor 1, two annular stators 2 having a magnetic flux in the output shaft direction are provided on the output shaft side and the non-output shaft side and face each other. This is a two-rotor type armature structure that faces the rotor 3 in a plane with a predetermined air gap.

  The present invention is not limited to this, and is applicable to various types of rotary electric machines using a bobbin, such as a single rotor type, a configuration including a plurality of stators and a plurality of rotors, or a radial gap type rotary electric machine. can do.

  FIG. 5 shows the structure of the stator 2 observed from the axial direction. In the stator 2, a plurality of (12 in this example) stator core members 6 are arranged in an annular shape around the output shaft direction. After that, the annular body is molded with a molding material (in this example, resin is used).

  FIG. 3 shows a vertical sectional view after the stator 2 is resin-molded. Each core member 6 is covered with the mold resin except for the core end portion 8a (dotted line portion) of the core 8 and between the core members and between the core member and the housing. The stator 2 is fixed to the inner circumference of the housing 5 by molding. It should be noted that the stator 2 may be individually molded by molding or the like and solidified as a strength member without being directly molded into the housing 5, and may be fixed to the housing 5 with a bolt or the like, or may be resin-molded. Instead, it may be fixed to the housing 5 with a fixing member or the like.

  FIG. 4A and FIG. 4B show the structure of the stator core member 6. The stator core member 6 includes a core 8, a bobbin 7 and a coil 9. The core 8 of this example is a laminated core in which foil metal (tape-shaped) amorphous metal made of a magnetic material is gradually changed in width and laminated in the radial direction from the axis. The core 8 has a substantially columnar shape with a substantially trapezoidal radial cross section, and opposes the rotor surface with the end face in the rotation axis direction as a magnetic flux surface. The core 8 may be formed by stacking foil strips or thin steel plates in the rotating direction, or may be formed of powder.

  The bobbin 7 is made of an insulating material such as resin, and is made of a tubular body having an inner peripheral shape that substantially matches the outer peripheral shape of the core 8. The bobbin 7 made of a tubular body has a collar portion 7a that extends in a predetermined width in the rotational direction and the radial direction near both ends in the axial direction. When the core members are annularly arranged at the time of resin molding, the protrusions 7b are brought into contact with the protrusions 7b or the flange portions 7a of the adjacent core members 6 in the rotational direction to position the core member 6. Further, the projection 7b is brought into contact with the adjacent bobbin, so that the flow path of the mold resin filling the space 10 between the coils of the adjacent core members 6 is secured. Other means for positioning the core member 6 at a predetermined interval may be used without providing the protrusion 7b. The core 8 is inserted into the bobbin 7 and the coil 9 made of aluminum or copper is wound between the two flange portions 7a in the axial direction, whereby the core member 6 is configured.

  Here, the number of layers of the coil 9 wound around the bobbin 7 is not always the same between the collar portions 7a. This is a requirement that the winding start coil end and the winding end coil end of the other core member 6 should be drawn out on the same side (the output side or the non-output side) in the axial direction. For example, the bobbin size, the coil diameter, and the number of steps are determined in consideration of the length of the coil winding area of the bobbin 7, the wire diameter of the coil 9, the number and number of winding layers, and the withdrawal direction at the winding start and winding end ends. This is because it is difficult to always make the coil diameter, the number of winding stages, and the like uniform from the aspect of output, cost of size variation from manufacturing, and miniaturization of the armature.

  Therefore, in order to prevent the coil 9 from having a coil length scheduled for winding in the middle of the outermost layer or leaving a distance from the winding end coil end to the lead wire opening, the winding end coil end of the outermost layer is It is designed to be folded back and wound so as to match the position of the lead wire opening.

  FIG. 6A schematically shows a vertical cross section when the core members 6 are annularly arranged. As shown in the figure, the two layers on the outer peripheral side of the coil are wound around the one collar portion 7a side by a mold. When the coil is simply wound in the forward direction, the winding start end coil 9s is wound from the output shaft side flange portion 7a, and when the first stage is wound up to the counter output shaft side flange portion 7a, the output shaft side is again wound. It rewinds to the side collar part 7a, and this is repeated until the end of winding and the coil end 9e. At this time, the coil end 9e reaches a predetermined winding amount in the middle of the sixth layer, and does not reach the lead wire opening provided in the flange portion 7a on the output shaft side.

  On the other hand, in the winding method shown in FIG. 6, the coil winding end portion 9e is folded back in the middle of the fifth layer, and the coil winding end terminal 9e is wound around the flange portion 7a on the same side as the winding start coil terminal 9s. That is, a part of the fifth layer is wound as the sixth layer. As a result, the smaller the number of layers, the larger the gap 10 with the adjacent coil 9, and vice versa.

  In the resin molding step, when resin is filled into the void 10 (mainly) from the rotational axis direction (vertical direction in the figure), the resin flow channel width differs between the small portion and the large portion of the void 10. Therefore, it is difficult for the resin to wrap around the portion where the void 10 is small. In order to improve this, as shown in FIG. 6C, the first core member 6a has a large number of winding layers of the coil 9 on the output shaft side, and the second core member 6b has a reverse number of winding layers of the coil 9. Arrange so that there will be more on the side. By arranging the coils having a large number of winding layers and the coils having a small number of winding layers so as to face each other in the adjacent core members in this manner, the width of the gap 10 formed between the adjacent coils can be ensured sufficiently and substantially uniformly. it can.

  FIG. 7 shows a schematic diagram for explaining the winding method of the coil 9 described so far. In the rotary electric machine 1 of the present embodiment, it is assumed that two coils 9 wound around the outer circumference of the cylindrical portion of the bobbin 7 are wound at the same time.

  As shown in FIG. 7 (a), when two coils are wound around the outer circumference of the cylindrical portion of the bobbin 7 simultaneously and continuously, the coil 9a is wound in contact with the outer circumference of the cylindrical portion of the bobbin first. The coil 9b to be wound later is arranged in the same layer. The winding is advanced so that the coils come into close contact with each other in the winding direction, and is wound on the upper layer in the vicinity of the collar portion on the opposite side of the winding start, and similarly, the coils 9a and 9b are arranged in the same layer and wound. Coils the coils close to each other in the moving direction.

  At this time, as shown in FIG. 7B, the adjacent coils 9a and 9b are not completely at the same time, but the coil 9a comes into contact with the bobbin first, and then the coil 9b comes into contact with the coil 9a. It is wound around a bobbin. At this time, when the bobbin rotates from the back of the screen to the front of the screen as shown by the arrow in Fig. 7 (a), the nozzle 30 is positioned at the back of the screen with respect to the coil 9a so that the nozzle can be moved at the same timing. The two coils 9a and 9b fed out of the coil create a time difference in contact with the bobbin.

  In this way, by winding the following coil 9b while making contact with the preceding coil 9a, the coil that serves as a guide is always adjacent to the coil to be wound (in the case of the first coil 9a, the guide is the collar portion). Since 7a) is present, it is possible to wind the coils in an aligned manner without generating an unnecessary gap between the coils.

  If the coil 9b comes into contact with the bobbin first and is wound, the coil 9b comes down between the already wound coil and the previously wound 9b. If the gap between the wound coil and 9b is too large or too small as compared with the diameter of 9a, the coil wound on the upper layer will collapse, so that 9b will come to the bobbin after 9a. Contact is desirable.

  FIG. 8A shows a schematic view of a state in which the first layer has been wound and the second layer has been wound. Unlike the first layer (odd layer), the second layer (even layer) comes into contact with the already wound coil first as a guide is the coil 9b opposite to the winding direction. That is, as shown in FIG. 8B, in the second layer, the second layer coil 9b is wound between the first layer coil 9a and the coil 9b. After that, the coil 9a is wound by using the coil 9b as a guide, and the next coil 9b is wound by using the coil 9a as a guide. Although the first coil 9b of the second layer is not in contact with the collar portion 7a, the coil 9a and the coil 9b of the first layer, which are aligned and wound, are wound in contact with each other, so that the lower layer Can be wound in a line by using the coil as a guide. Similarly to the first layer, if the second layer is wound so that the coil 9a first comes into contact with the lower layer, the spacing between the coils 9a may be larger or smaller than the wire diameter of the coil 9b. A collapse will occur. To prevent this, the second layer (even layer) is replaced with the first layer (odd layer) by changing the order of contact with the coil of the lower layer, so that the winding direction is rearward in the same manner as the first layer. Since there is a coil that serves as a guide, winding collapse can be prevented. As for the subsequent layers, the odd layers are wound by the coil 9a contacting the bobbin first as shown in FIG. 7, and the even layers are wound by the coil 9b contacting the lower coil first. It is possible to prevent the winding collapse by replacing the coils that come into contact with the bobbin (or the lower coil) in the odd-numbered layer and the even-numbered layer first. If the winding collapse is eliminated, the gap between the core members can be closed, and it is possible to secure a resin flow path for resin molding.

  As described above, according to the core member 6 of the first embodiment, a coil located at the rear of the winding direction of the coil is brought into contact with the lower layer first to serve as a guide, and a plurality of coils are wound at the same time. Even if it is, roll collapse can be prevented and productivity can be improved.

  Further, according to the core member 6 of the first embodiment, the adjacent core members are arranged such that the coil having a large number of winding layers and the coil having a small number of winding layers face each other, thereby ensuring a flow path for resin molding. It is possible to improve reliability and productivity.

  In the present embodiment, the description has been given by taking the example of winding two round coil wires, but the present invention is also applicable to a winding of a square wire or a plurality of windings of three or more.

  Next, a second embodiment will be described. As shown in FIG. 7B, the coil 9 of the first embodiment is wound so that the coil having the largest wire diameter comes into contact with the adjacent coil.

  On the other hand, the present embodiment is different from the first embodiment in that the coils are contacted and wound so as to overlap with the wire diameters of the adjacent coils.

  FIG. 9A shows a schematic diagram of the winding method in the second embodiment. In the second embodiment, the coils are wound not only in the horizontal direction (rotational axis direction) but also in the vertical direction (stacking direction). That is, when the coil is orthographically projected onto the bobbin, the wire diameters of the coils partially overlap each other. The coil 9a 'at the beginning of winding is in common with the first embodiment in that the coil 9a' is wound in contact with the collar portion 7a, but the next coil 9b 'comes in contact with the coil 9a' in a partially covered form. , Is wound around the bobbin along the outer circumference of the coil 9a '. Similarly, the coil 9a 'which comes into contact with the bobbin at the inner end of the coil to be wound next also comes into contact with the coil 9b' which has already been wound from an oblique direction, and the coil 9b 'while keeping contact with the coil 9b' as it is. It is wound so that it will land on the bobbin along the outer periphery of.

  FIG. 9 (b) shows a schematic view of the winding method of the second layer. It is common to the first embodiment that the order of the coils contacting the lower layer is changed from that of the first layer. Similarly to the first layer, the second layer and subsequent layers are wound so that a part of the wire diameter of the coil that is wound next overlaps the coil that is wound first.

  As described above, according to the core member 6 of the second embodiment, a part of the wire diameter of the coil is overlapped and wound as compared with the first embodiment, so that the gap between the coils is further reduced as compared with the first embodiment. Can be aligned and wound. Therefore, it is possible to provide a rotating electric machine that can be miniaturized and highly efficient by improving productivity and increasing the space factor.

  In a third embodiment, a method will be described in which, in addition to the winding method of the second embodiment, a force is further applied to adjacent coils so that the coils are in contact with each other and aligned.

  FIG. 10 shows a schematic diagram of the winding method in the third embodiment. In the third embodiment, when the coil wound around the bobbin is wound, the already wound coils 9b ′ and 9a ′ are pressed in the lateral direction (rotational axis direction) and then wound. The nozzle 30 presses the coil 9b 'against the coil 9b' as shown in FIG. 10 (a) every time the coil makes a round around the bobbin cylinder, and thus, in addition to the effect of the second embodiment, the coil 9b 'already wound. Is pressed to the side of the coil 9a ', and a pressure for aligning the wound coil can be applied. Therefore, it becomes possible to prevent the coil from collapsing because the coils contact each other and are wound tightly.

  Although the embodiments to which the present invention is applied have been described above, the present invention is not limited to the above-described various embodiments, and it goes without saying that various modifications can be made without departing from the spirit of the present invention. Yes. For example, when two coils having different wire diameters are wound at the same time, or three coils are wound at the same time, adjacent coils are formed by winding the coils with different conductor diameters or a combination of a plurality of coils. The difference in wire diameter of the wound coils and the number of coils wound at the same time are not limited as long as a void shape that is effective as a resin flow path during resin molding can be formed between the coils.

DESCRIPTION OF SYMBOLS 1 ... Rotating electric machine, 2 ... Stator, 3 ... Rotor, 4 ... Output shaft, 5 ... Housing, 6 ... Core member, 7 ... Bobbin, 8 ... Laminated core (core), 9, 9a, 9b ... Coil, 10 ... Resin Channels, 20 ... Mold resin, 30, 30a, 30b ... Nozzles.

Claims (8)

A stator having a tooth, a bobbin having a through hole into which the tooth is inserted, a plurality of coils wound around the bobbin, and a rotor arranged via the tooth and a predetermined gap. A rotating electric machine,
A first coil of the plurality of coils that comes into contact with the bobbin first and a second coil that comes into contact with the bobbin after the first coil are wound such that a part of the wire diameters overlap each other. A rotating electric machine. The rotating electric machine according to claim 1,
A rotary electric machine in which the positional relationship between the first coil and the second coil in the first layer of the coil is opposite to that in the second layer. The rotating electric machine according to claim 1,
A rotating electric machine, wherein the rotating electric machine is a radial gap type or an axial gap type. The rotating electric machine according to claim 3,
A rotating electric machine in which a resin molds the stator. A method of manufacturing a rotating electric machine, comprising a bobbin around which a plurality of coils are wound,
Of at least two coils wound at the same timing, a first step of winding the first coil in contact with an end portion in the rotation axis direction of the outer peripheral surface of the inner cylindrical portion of the bobbin,
A second step of winding a second coil in contact with the first coil,
A method of manufacturing a rotating electric machine, wherein the first coil comes into contact with the bobbin earlier than the second coil. The manufacturing method according to claim 5, wherein
In the second step, the method of manufacturing a rotating electric machine, wherein the wire diameter of the first coil partially overlaps with the wire diameter of the second coil. The manufacturing method according to claim 5, wherein
In the odd layer of the coil,
A fourth step of pressing the first coil from the rotation axis direction with respect to the second coil already wound around the bobbin,
A method of manufacturing a rotary electric machine, comprising: a fifth step of winding the first coil along the second coil pressed in the fourth step. The manufacturing method according to claim 5, wherein
A sixth step of reversing the positional relationship between the first coil and the second coil when winding the first layer and advancing the first coil in the winding direction of the coil; Production method.

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