JP2020171134A - Radial gap type rotary electric machine, method for manufacturing radial gap type rotary electric machine, and magnetic type gear - Google Patents

Abstract

To provide a radial gap type rotary electric machine by using an amorphous metal that can achieve high efficiency and is superior in productivity, a method for manufacturing the radial gap type rotary electric machine, and a magnetic type gear.SOLUTION: The radial gap type rotary electric machine is provided with: a rotor which has a rotating shaft and a rotor core which can rotate around the rotating shaft; and a stator including a stator core arranged opposite to the rotor core with a gap. The stator core is provided with: a back yoke 2 which has a circular ring shape and a plurality of concave parts 20 provided along an inner periphery; and teeth 4 fitted into the concave parts of the back yoke. Each of the teeth has a laminate 10 in which an amorphous metal foil band piece having a rectangle in a top surface view is held by mutual friction; and a bobbin 3 which holds the laminate. The bobbin has a structure which has an opening that can attach or detach the laminate in an end on a side of the back yoke, and parts other than the opening with which the laminate is covered.SELECTED DRAWING: Figure 5A

Description

The present invention relates to a radial gap type rotary electric machine, a method for manufacturing a radial gap type rotary electric machine, and a magnetic gear.

High efficiency is required for rotary electric machines (motors) used as power sources for industrial machines and for driving automobiles. To improve the efficiency of the motor, it is common to use a low-loss material for the material used or to use a permanent magnet with a high energy product.

Motor loss mainly consists of copper loss, iron loss, and mechanical loss. When the output characteristics (rotation speed and torque) of the required specifications are determined, the mechanical loss is uniquely determined, so the design reduces copper loss and iron loss. Is important. Copper loss is mainly determined by the relationship between the resistance value of the coil and the current, and the design is such that the reduction of the coil resistance value and the decrease of the residual magnetic flux density of the magnet are suppressed by cooling. Iron loss can be reduced depending on the soft magnetic material used. In a general motor, an electromagnetic steel sheet is used for the iron core portion, and a motor having a different loss level depending on its thickness, Si content, and the like is used.

Soft magnetic materials include high-performance materials such as iron-based amorphous metals and iron-based nanocrystalline alloys, which have higher magnetic permeability and lower iron loss than electrical steel sheets, but these material systems have a higher plate thickness. It is very thin at 0.025 mm, has a Vickers hardness of about 900, and is five times or more harder than an electromagnetic steel sheet, and there are many problems in manufacturing a motor efficiently and inexpensively.

Patent Document 1 is an example of applying an amorphous metal to a radial gap type rotary electric machine. Patent Document 1 discloses a bulk amorphous metal magnetic component for use in a high-efficiency electric motor, which has a polyhedral shape and includes a plurality of amorphous metal strip layers. In Patent Document 1, an amorphous metal strip material is cut into a plurality of strips having a predetermined length, and the bars of the amorphous metal strip material are stacked, and after annealing treatment, the stacked bars are epoxy. A method has been proposed in which bars impregnated with a resin, cured, and stacked bars are cut to a predetermined length to provide a plurality of polyhedral magnetic components having a predetermined three-dimensional shape.

Further, in Patent Document 2, in a method of punching and laminating iron core pieces from an amorphous thin plate material to produce an amorphous laminated iron core, a required portion of the iron core piece is punched and formed from the amorphous thin plate material and a connecting hole is formed to form an iron core piece. Is punched out into the die hole, the die hole is laminated on a pedestal that can be moved forward and backward to a desired thickness, the pedestal is retracted from below the die hole, and the laminated iron core laminated on the pedestal is gripped. A method for producing an amorphous laminated iron core is disclosed, which comprises restraining and injecting and filling an adhesive connecting agent into a connecting hole of the laminated iron core to connect them. Patent Document 2 shows an example of punching a predetermined motor core shape by a progressive remittance mold in the same manner as punching a motor core with an electromagnetic steel plate. In this example, the shape can be processed by punching, but the amorphous foil band is too thin to caulk between the plates, which is realized by the electromagnetic steel plate. Therefore, the adhesive is applied to the core while being laminated on the jig. A method of injecting into a predetermined hole and laminating and fixing has been proposed.

Japanese Unexamined Patent Publication No. 2013-21919 Japanese Unexamined Patent Publication No. 2003-309952

The method of applying an amorphous metal to a radial gap type rotary electric machine described in Patent Documents 1 and 2 described above has problems such as an apparatus for performing special machining for the production thereof and a process that takes too much time.

Further, in Patent Document 2, the amorphous metal is pressed and laminated, but since the thickness of the amorphous metal is 1/10 or less of that of the electromagnetic steel sheet, 10 times the number of presses is required. Further, since the amorphous metal is five times as hard as the electromagnetic steel sheet, the influence on the mold is five times as much. Therefore, the effect on the mold is 50 times or more compared to the electromagnetic steel sheet, and the manufacturing is usually performed while re-polishing the mold about every 2 million times, but the number of times until re-polishing is 1/50 or less. Therefore, the manufacturing cost will increase significantly. When pressing at a speed of 180 SPM (shot per minutes) per minute, it reaches 2 million times in about one month, but when pressing at the same speed, the production tact is 10 times due to the number of sheets. Therefore, the re-polishing of the mold must be done in less than a day. In addition, polishing of dies and punches for large dies requires a lot of man-hours including the labor of loading and unloading dies from the press device, so it can be seen that production under these conditions is not realistic.

As described above, regarding the production of a radial gap type motor using an amorphous metal, the actual situation is that a structure, a production apparatus and a production method thereof that can be produced at a practical level have not been found.

In view of the above circumstances, the present invention provides a radial gap type rotary electric machine, a method for manufacturing a radial gap type rotary electric machine, and a magnetic gear using an amorphous metal which can realize high efficiency and is excellent in productivity. The purpose.

One aspect of the radial gap type rotary electric machine of the present invention for solving the above problems is to sandwich a gap between a rotating shaft, a rotor having a rotor core that can rotate around the rotating shaft, and a rotor core. It is provided with a stator including a stator core arranged to face each other, and the stator core has a ring shape and has a back yoke having a plurality of recesses provided along the inner circumference, and a recess of the back yoke. The teeth have a laminate in which amorphous metal foil strips having a rectangular shape in a plan view are held by friction with each other, and a bobbin that holds the laminate. The back yoke side has an opening to which the laminated body can be attached and detached, and a portion other than the opening has a structure for covering the laminated body.

Further, one aspect of the method for manufacturing a radial gap type rotary electric machine of the present invention for solving the above problems is a rotor having a rotating shaft, a rotor core that can rotate around the rotating shaft, and a rotor core. In a method for manufacturing a radial gap type rotary electric machine including a stator including a stator core arranged so as to face each other with a gap in between, the stator core has an annular shape and is provided along the inner circumference. It has a back yoke having a plurality of recesses and a tooth fitted in the recess of the back yoke, and the tooth is a laminated body in which amorphous metal foil strips having a rectangular shape in a plan view are held by friction with each other. , The bobbin has a bobbin that holds the laminate, the bobbin has an opening at the end on the back yoke side to which the laminate can be attached and detached, and the portion other than the opening has a structure that covers the laminate, and is an amorphous metal. The foil strip piece provides a method for manufacturing a radial gap type rotary electric machine, which comprises processing an amorphous metal foil strip having a predetermined width into a rectangular shape by shear cutting.

Further, one aspect of the magnetic gear of the present invention for solving the above problems is to provide a laminate in which amorphous metal foil strips having a rectangle in top view are held by friction with each other, and a bobbin that holds the laminate. It is characterized by having a magnetic pole having.

More specific configurations of the present invention are described in the claims.

According to the present invention, it is possible to provide a radial gap type rotary electric machine, a method for manufacturing a radial gap type rotary electric machine, and a magnetic gear using an amorphous metal which can realize high efficiency and is excellent in productivity.

Issues, configurations and effects other than those described above will be clarified by the description of the following embodiments.

Top view of amorphous metal foil strips constituting the teeth of the stator core of the radial gap type rotary electric machine of the present invention. Perspective view of a laminate of amorphous metal foil strips constituting the teeth of the stator core of the radial gap type rotary electric machine of the present invention. Top view of a part of the stator core of the radial gap type rotary electric machine of the present invention Schematic diagram of a device for shearing an amorphous metal foil band Schematic diagram of a bobbin holding a laminate of amorphous metal foil strips constituting the stator core of the radial gap type rotary electric machine of the present invention. Schematic diagram of a different angle perspective of a bobbin holding a laminate of amorphous metal foil strips constituting the stator core of the radial gap type rotary electric machine of the present invention. Schematic diagram showing an embodiment of holding a laminated body of amorphous metal foil strips on the bobbins of FIGS. 3A and 3B. Schematic diagram showing a first example of a back yoke constituting a stator core of the radial gap type rotary electric machine of the present invention. Schematic diagram showing a second example of a back yoke constituting a stator core of the radial gap type rotary electric machine of the present invention. Schematic diagram showing a third example of the back yoke constituting the stator core of the radial gap type rotary electric machine of the present invention. Schematic perspective view showing a mode in which the teeth are arranged on the back yoke constituting the stator core of the radial gap type rotary electric machine of the present invention. Top view of the stator core of the radial gap type rotary electric machine of the present invention Schematic perspective view showing a first example of a stator of a radial gap type rotary electric machine of the present invention. Top view of FIG. 6A Schematic perspective view showing a second example of the stator of the radial gap type rotary electric machine of the present invention. Top view of FIG. 7A Schematic diagram showing an example of the configuration of the stator coil Top view of FIG. 8A An exploded perspective view of FIG. 8A Perspective view showing the stator of the radial gap type rotary electric machine of the present invention together with the stator coil. Perspective view showing the positional relationship between the stator and the rotor of the radial gap type rotary electric machine of the present invention. Schematic diagram showing an example of a mode in which the coil tip of the stator of the radial gap type rotary electric machine of the present invention is molded. Schematic diagram showing another example of the embodiment in which the coil tip portion of the stator of the radial gap type rotary electric machine of the present invention is molded. An exploded perspective view showing an example of the radial gap type rotary electric machine of the present invention. Schematic diagram showing a laminate of amorphous metal foil strips and bobbins constituting the magnetic poles of the magnetic gear of the present invention. Schematic diagram showing the magnetic poles of the magnetic gear of the present invention Schematic diagram showing the magnetic gear of the present invention

Hereinafter, embodiments of the radial gap type rotary electric machine and the method for manufacturing the radial gap type rotary electric machine of the present invention will be described with reference to the drawings and the like.

[Teeth]
FIG. 1A is a top view of the amorphous metal foil strips constituting the teeth of the stator core of the radial gap type rotary electric machine of the present invention, and FIG. 1B is a perspective view of the laminate 10 in which the amorphous metal foil strips are laminated. is there. As shown in FIGS. 1A and 1B, the teeth of the present invention have a laminate 10 of amorphous metal foil strips 1 having a rectangular shape when viewed from above.

As shown in FIG. 1A, the amorphous metal foil strip 1 has a rectangular shape, the long sides 1a and 1b and the short sides 1c and 1d are parallel to each other, and the angle between the sides is a right angle. It has become. An example of the size of the amorphous metal foil strip 1 is the length of the long sides 1a and 1b: 30 mm, the length of the short sides 1c and 1d: 6 mm, and the thickness: 0.025 mm. The laminated body 10 shown in FIG. 1B can have a height of about 50 mm by laminating 2000 pieces of the amorphous metal foil strip 1 in the axial direction, for example. In this specification, "rectangle" refers to a rectangle surrounded by four line segments and all corners are right angles (± 1.0 ° in the case of coarse grade of 10 to 50 mm or less), and "square" is used. It shall include.

The material of the amorphous metal is not particularly limited, but for example, Metglass 2605HB1M (composition: Fe-Si-B), Metglass 2605SA1 (composition: Fe-Si-B), Metglass 2605S3A (composition: Fe-Si-B-) made of Metglass. Cr) and Meglas 2705M (composition: Co-Fe-Ni-Si-B-Mo) are preferably used. The above-mentioned "Metglass" is a registered trademark of Metglass Incorporated, a group company of Hitachi Metals, Ltd.

FIG. 1C is a top view of a part of the stator core of the radial gap type rotary electric machine of the present invention. As shown in FIG. 1C, the back yoke 2 constituting the stator core has an annular shape and has a plurality of recesses 20 along the inner circumference. The laminated body 10 is held by the bobbin shown in FIG. 3A, which will be described later, to form the teeth 4, and one end of the laminated body 10 protruding from the bobbin is fitted into the recess 20 (note that the bobbin is shown in FIG. 1C). Absent). FIG. 1C shows an example in which the teeth 4 are evenly arranged at an angle of 7.5 degrees in the circumferential direction of the back yoke 2. In this case, the number of teeth 4 in the circumferential direction is 48.

In the teeth 4, the magnetic flux from the rotor magnet and the magnetic flux generated by the stator coil (hereinafter, may be simply referred to as a coil) flow in the radial direction. Therefore, considering the magnetic flux density, both sides of the teeth 4 There is also an advantage that the magnetic flux density can be made constant when the pieces are parallel in the radial direction. Further, the opening on the rotor side of the stator slot (chamber for arranging the coil (gap groove)) provided in the stator core (the gap on the inside of the slot groove (magnet rotor side)) is a gap. It is necessary to make the teeth 4 smaller in order to reduce the rate of change in magnetic resistance, and one of the advantages is that the opening on the rotor side can be designed to be narrowed by making the teeth 4 rectangular.

[Manufacturing method of laminates constituting teeth]
Here, a method for manufacturing a laminated body in which amorphous metal foil strips are laminated will be described.

FIG. 2 is a schematic view of an apparatus for shearing a foil strip piece from a strip-shaped amorphous metal foil strip. As shown in FIG. 2, the shearing device (mold unit) 100 is composed of a combination of an upper mold and a lower mold. In the lower mold, a mold holder 109 is arranged on a lower base plate 107, and the holder 109 thereof. The lower cutting blade 105 is attached to the. The upper mold has a structure in which a mold holder 108 is attached to the upper base plate 106, and an upper cutting blade 104 is attached to the holder 108. The upper cutting blade 104 is configured to be movable up and down (in the direction of the arrow in FIG. 2) by setting a cutting clearance with respect to the fixed lower cutting blade 105.

The material sheet 101 of the amorphous metal foil band is supplied to the mold holder 109 side at equal pitches by the feed rollers 102 and 103. The material sheet 101 of the amorphous metal foil band sent out to the mold holder 109 is shear-cut by the upper blade 104 and the lower blade 105 to become the amorphous metal foil band piece 1 and is sequentially and continuously laminated on the base plate 107. To manufacture the laminate 10. According to such a method, the cutting mechanism is simplified because only feeding and shearing are repeated. Further, since the cutting blade has a general-purpose shape, it can be easily attached to and detached from the mold, and it is inexpensive and easy to perform maintenance such as re-polishing. Therefore, it is possible to sufficiently suppress the manufacturing cost and efficiently produce the amorphous metal against the disadvantage in manufacturing due to the hardness and thinness of the amorphous metal.

Since the amorphous metal foil band constituting the teeth 4 of the radial gap type rotary electric machine of the present invention is a relatively small part, a press machine that requires a large thrust is not required, and the size is about 30 mm × 6 mm as described above. The cutting speed of parts can be expected to be as high as 500 SPM or more. Further, by supplying a plurality of stacked material sheets 101, the production can be doubled and the production can be performed at a production speed that can be expected to be commercially effective.

As described above, one of the features of the radial gap type rotary electric machine of the present invention is that an amorphous metal foil band can be manufactured by shearing easily and inexpensively. For example, when electric discharge machining is performed, the surface of the work piece may be electrically coupled, which may cause deterioration of the characteristics of the rotary electric machine. If the amorphous metal foil strip and its laminate can be produced only by shearing, the magnetic flux density can be made constant and the gap side opening can be made small as described above, and the characteristics of the rotary electric machine can be prevented from deteriorating. ..

[Bobbin]
3A and 3B are schematic views of a bobbin holding a laminate of amorphous metal foil strips constituting the stator core of the radial gap type rotary electric machine of the present invention. FIG. 3A is a perspective view seen from a surface facing a magnetic gap (hereinafter, simply referred to as a gap), and FIG. 3B is a perspective view seen from the back yoke 2. As shown in FIG. 3B, the bobbin 3 has an opening 32 at the end on the back yoke side to which the laminate 10 of the amorphous teeth metal foil band can be attached and detached, while being installed on the back yoke 2. The portion other than 32 has a structure that covers (wraps) the laminated body 10. The bobbin 3 is preferably made of resin, and a plurality of protrusions (jaws) 30 are provided on both side surfaces of the bobbin. The protrusion 30 serves to guide the position of the coil conductor described later. The protrusion at the end of the bobbin on the opening 32 side is referred to as the flange 31a, and the protrusion at the end of the bobbin on the gap side is referred to as the collar 31c.

As described above, the gap side of the bobbin 3 has a shape closed by the flange portion 31c, and has a structure in which the laminated body 10 cannot move. As a result, the gap interval can be kept constant.

FIG. 3C is a schematic view showing a mode in which a laminated body of amorphous metal foil strips is held on the bobbins of FIGS. 3A and 3B. As shown in FIG. 3C, the laminated body 10 has a configuration in which it is inserted into the bobbin 3 in a direction parallel to the long side direction. The inserted laminate 10 is held by the frictional force between the surfaces of the amorphous metal foil strips, but is further positioned and fixed by being abutted against the flange 31c of the bobbin 3. On the other hand, on the back yoke side of the bobbin 3, the end portion 10b of the laminate 10 is in a state of protruding from the opening 31 of the bobbin 3, and the end portion of the laminate 10 can be seen as it is. .. The end portion 10b will be fitted and mounted in the recess 20 provided in the back yoke as described later.

[Back yoke]
Next, the back yoke 2 will be described. FIG. 4A is a schematic view of a first example of a back yoke constituting a stator core of the radial gap type rotary electric machine of the present invention. FIG. 4A shows the whole image of the back yoke 2a. In this example, the core back shape in which the ears 40 of the mounting holes are formed at three locations in the circumferential direction of the annular back yoke 2a is shown. The material of the back yoke 2a is not particularly limited, but it is composed of a laminated body obtained by stacking plate materials punched by a press such as an electromagnetic steel plate or a cold rolled steel plate (SPCC). However, the thickness of the back yoke 2a can be selected according to the need, such as 0.2 mm, 0.35 mm, 0.5 mm, and the like. The back yoke 2a can be composed of 100 laminated bodies when the back yoke 2a is designed to be thick with priority given to strength, and when the thickness is 0.5 mm and the laminated thickness is 50 mm, which is the same as that of the teeth 4.

FIG. 4B is a schematic view showing a second example of the back yoke of the present invention. The back yoke 2b shown in FIG. 4B shows an example in which 12 back yoke pieces for 4 slots (units of coil conductors accommodated) are combined on the circumference to form the back yoke 2b. When manufacturing an annular part from a rectangular thin plate such as an electromagnetic steel plate by press working, the material remaining in the peripheral deep part and the four corners must be discarded, so the material utilization rate is extremely poor. Become. For this reason, in order to obtain an annular part, it is preferable to divide the annulus, for example, to hollow out a small block body divided into 12 parts with a press, and use them in combination. By doing so, the utilization efficiency of the material can be improved.

FIG. 4C is a schematic view showing a third example of the back yoke of the present invention. FIG. 4C shows a configuration example in which the back yoke 2c is a wound iron core. Even in this form, the utilization rate of the material can be improved. That is, for example, a mold for hollowing out a square-shaped recess for mounting the end portion 10b of the laminated body of the teeth 4 described above is provided on one side of a constant-width electromagnetic steel plate to form the recess. It is manufactured by a method in which electromagnetic steel sheets are wound in an edgewise shape to fit the recesses and laminated. The feature of this method is that the yield of the material can be higher than that of the above-mentioned split block method.

FIG. 5A is a schematic perspective view showing a mode in which the back yoke 2 and the teeth 4 are assembled, and FIG. 5B is a top view thereof. As shown in FIG. 5A, when the laminated body 10 is inserted into the bobbin 3 as described above, the end portion 10b protrudes. Therefore, the end portion 10b is inserted into the recess 20 of the back yoke 2 and fitted. Assemble. An adhesive may be used for the fitting portion. The positional relationship between the back yoke 2, the bobbin 3 and the teeth 4 is as shown in FIG. 5B, and the laminated body 10 has a configuration in which the bobbin 3 which is an insulator ensures electrical insulation of the slot portion into which the stator coil of the motor is inserted. It becomes.

[stator]
FIG. 6A is a schematic perspective view showing a first example of a stator of the radial gap type rotary electric machine of the present invention, and FIG. 6B is a top view of FIG. 6A. FIG. 6A shows a state in which 48 teeth 4 are assembled in the circumferential direction. As shown in FIG. 6B, in a state where the teeth 4 are assembled in an annular shape, the flanges 31c of the adjacent bobbins 3 are in contact with each other and arranged in an annular shape. As a result, the gap side of the bobbin 3 does not bend or shift in the circumferential direction, and the annular shape can be maintained. On the other hand, the flange portion 31a at the end of the bobbin 3 on the back yoke 2 side is configured to overlap with the flange portion 31b of the adjacent bobbin 3 by shifting its position. By overlapping the flanges 31a and 31b, the surface area of the bobbin is increased and the insulation creepage distance from the coil conductor arrangement portion to the back yoke 2 is increased.

FIG. 7A is a schematic perspective view showing a second example of the stator of the present invention, and FIG. 7B is a top view of FIG. 7A. 7A and 7B show a configuration in which coil conductors are arranged in a space formed by a gap between adjacent bobbins 3 and protrusions 30. Note that FIG. 6B shows a state in which the coil conductor is not arranged, and reference numeral 33 is a space.

[Coil conductor]
The cross section of the space 33 formed by the gap between the adjacent bobbins 3 has a trapezoidal shape because the teeth 4 are rectangular. Therefore, on the inner diameter side (gap side) of the back yoke 2, the width of the space in the circumferential direction is narrow, and the width of the space in the circumferential direction becomes wider toward the outer diameter side (back yoke side). When arranging conductors in such slots, if they are composed of coil conductors having the same cross section, if the coils are arranged in a row, it is necessary to unify the width of the coil conductors on the inner diameter side, and the cross-sectional area of the slots. The ratio of the conductor to the (occupancy ratio) is low. In order to improve this, as shown in FIG. 7B, in the present invention, the cross-sectional area of the coil conductor is increased toward the outer diameter side in pairs (6a, 6b, 6c) of two from the inner diameter side. .. As a result, it is possible to obtain a space factor substantially the same as that of a general segment conductor type radial gap motor having a rectangular cross section.

[Stator coil]
8A is a schematic view showing an example of the configuration of the stator coil, FIG. 8B is a top view of FIG. 8A, and FIG. 8C is an exploded perspective view of FIG. 8A. As shown in FIG. 8A, a drawing is shown in which a hairpin-shaped stator coil 6 having an opening angle of 45 ° is inserted into an insulator 80 attached to a slot portion of the stator core. As shown in FIG. 8C, the stator coil 6 constituting the wave winding has a hairpin-shaped (U-shaped) segment conductor 60 having two legs having a convex tip, which is described below. Attach it to the hole. Further, on the opposite side in the axial direction, 61 and 62 having the same hairpin shape (U-shape) and having a concave tip portion are attached to another hole portion of the stator. The wave winding is formed in this way, and has a structure connected to the conductor coil inside the back yoke 2.

In FIG. 8B, the holes of the stator are numbered. FIG. 8B shows an example in which 48 holes are arranged in the circumferential direction and 6 coils are arranged in the radial direction. FIG. 8B shows the first quadrant. The hole numbers are shown in order from the position at an angle of 0 °, and the numbers from (1) to (12) are shown in order at a 7.5 ° pitch. Further, the coil numbers in the radial direction are shown as the first to sixth layers. The hairpin-shaped stator coil 6d shown here has the right leg inserted in the first layer of the (5) hole and attached, and the left leg is the second layer of the (11) hole. It is a coil that can be inserted and attached. Here, three coils are shown in the radial direction. In the second coil 6e in the radial direction, the right leg is inserted and attached to the third layer of the (5) hole, and the left leg is (11). It is a coil that can be inserted and mounted on the 4th layer of the hole.

Similarly, for the third coil 6f in the radial direction, the right leg is inserted and attached to the 5th layer of the (5) hole, and the left leg is inserted and attached to the 6th layer of the (11) hole. Will be done. The stator coils on the opposite sides in the axial direction are arranged so that the coil connections are wavy as shown in FIG. 8C. As can be seen from this, these stator coils have a configuration in which the first layer and the second layer, the third layer and the fourth layer, and the fifth layer and the sixth layer are connected, respectively. Understandable. Therefore, as shown in FIG. 7B, since the cross section of the coil is trapezoidal in the radial direction, the first and second layers from the narrower side (gap side) have the same cross section, and the third and fourth layers have the same cross section. It is effective that the stitches have the same cross section larger than the 1st layer and the 2nd layer, and the 5th and 6th layers have the same cross section larger than the 3rd layer and the 4th layer. Is.

FIG. 9A is a schematic view of a stator in a state where the stator coil of the radial gap type rotary electric machine of the present invention is attached, and FIG. 9B is an exploded perspective view of the stator and the rotor. As shown in FIGS. 9A and 9B, the rotor 91 in which the permanent magnet 7 is arranged inside the stator 90 is arranged in a state of maintaining a gap. As a result, the tooth 4 which is a magnetic material is attracted by the magnetic force.

[Resin mold]
The resin mold is applied to at least a part of the tip of the coil conductor. Hereinafter, FIG. 10A in which the entire coil 6 conductor is molded and fixed, and FIG. 10B in which a part of the coil 6 is molded and fixed will be described.

FIG. 10A is a schematic view of a stator of the radial gap type rotary electric machine of the present invention. As shown in FIG. 10A, a structure is shown in which the tip portion (end portion of the coil) of the stator coil is molded and fixed by the mold resin 23. The mold covers the stator coil end and the coil end on the opposite side with a mold, injects resin into the mold using a method such as injection molding, and the stator slot (the part where the coil conductor is housed). ) Is formed by injecting resin including the gap between the coil conductor and the bobbin. For resin injection, a method of injecting into a narrow gap by a method such as pressure injection or decompression (evacuation) injection is adopted. By molding in this way, the position can be maintained even if it is attracted by the magnet of the rotor.

FIG. 10B shows a structure in which only a portion of the coil end portion close to the stator end surface is molded. Due to the high current density, some motors used for driving automobiles are cooled by applying oil such as ATF (Automatic transmission fluid) to the coil end portion. Therefore, by covering with a resin having a low thermal conductivity, heat dissipation is deteriorated, so that a part of the coil end can be exposed to enable cooling.

FIG. 11 is a schematic view showing an example of the radial gap type rotary electric machine of the present invention. As shown in FIG. 11, the above-mentioned stator is held in the housing 24, and the rotor is rotatably held via bearings by the front and rear end brackets 25 and 26.

[Magnetic gear]
Next, the magnetic gear of the present invention will be described. FIG. 12A is a schematic view showing bobbins and teeth constituting the magnetic poles of the magnetic gear of the present invention. FIG. 12B is a schematic view showing the magnetic poles of the magnetic gear of the present invention, and FIG. 12C is a schematic view showing the magnetic gear of the present invention. As shown in FIGS. 12A to 12C, the magnetic gear 124 can also be configured by using the laminated body 121 and the bobbin 122 in which the amorphous teeth metal foil strips are laminated. The magnetic gear 124 transmits rotation and torque in a non-contact manner by magnetic force, and has a long life because it does not require lubrication and does not generate dust. In addition, the driving side gear and the driven side gear are provided by a partition wall or the like. Can be isolated.

As shown in FIGS. 12A to 12B, a bobbin 122 on which a laminated body 121 in which rectangular amorphous metal foil strips are laminated is mounted is arranged in a ring shape. As shown in the figure, the left and right side surfaces of the bobbins 122 are alternately formed with steps, and adjacent bobbins are locked by the steps and can be assembled in an annular shape without moving in the radial direction. As shown in FIG. 12C, winding 123 may be provided.

Further, in FIGS. 12A to 12C, although openings for attaching / detaching the amorphous metal foil band laminate are provided at both ends of the bobbin, they may be provided only at one end.

As described above, according to the present invention, a radial gap type rotary electric machine, a method for manufacturing a radial gap type rotary electric machine, and a magnetic gear using an amorphous metal which can realize high efficiency and have excellent productivity can be obtained. It has been proven that it can be provided.

The present invention is not limited to the above-mentioned examples, and includes various modifications. For example, the above-described embodiment has been described in detail in order to explain the present invention in an easy-to-understand manner, and is not necessarily limited to those having all the described configurations. Further, it is possible to replace a part of the configuration of a certain embodiment with the configuration of another embodiment, and it is also possible to add the configuration of another embodiment to the configuration of a certain embodiment. Further, it is possible to add / delete / replace a part of the configuration of each embodiment with another configuration.

The above-mentioned configuration is an example for using a material that is difficult to process, such as amorphous metal, and the iron-based amorphous metal portion is a directional electromagnetic steel strip having a soft-processable glass coating or a nanocrystal alloy. It is also an effective means when using such materials, and it is possible to make various arrangements when using each material.

1 ... Amorphous metal foil strip, 2,2a, 2b, 2c ... Back yoke, 20 ... Recessed, 3 ... Bobbin, 30 ... Protrusion (jaw), 31,31a, 31b, 31c ... Flange, 32 ... Opening Part, 33 ... Space, 4 ... Teeth, 6,6a, 6b, 6c, 6d, 6e, 6f, 60, 61, 62 ... Coil, 7 ... Permanent magnet, 8 ... Rotor core, 9 ... Rotating shaft (shaft) 10, 10 ... Laminated body, 10b ... End of the laminated body, 23 ... Mold resin, Laminated body of amorphous metal foil strip, 40 ... Mounting hole ear, 90A ... Stator core, 90, 901, 902 ... Stator, 91 ... Rotor,
100 ... Shearing device (mold unit), 101 ... Amorphous metal foil band material sheet, 102, 103 ... Feed roller, 104 ... Upper blade, 105 ... Lower blade, 106 ... Upper base plate, 107 ... Lower base plate, 108, 109 ... Mold holder,
200 ... Radial gap type rotary electric machine, 24 ... Housing, 25 ... Front end bracket, 26 ... Rear end bracket, 120 ... Magnetic pole, 121 ... Amorphous tooth metal foil strip laminate, 122 ... Bobbin, 123 ... Winding, 124 ... Magnetic gear

Claims (12)

A rotor having a rotating shaft and a rotor core that can rotate around the rotating shaft, and
A stator including a stator core, which is arranged so as to face the rotor core with a gap in between, is provided.
The stator core has a ring shape, a back yoke having a plurality of recesses provided along the inner circumference, and a tooth fitted in the recesses of the back yoke.
The teeth have a laminate in which amorphous metal foil strips having a rectangular shape when viewed from above are held by friction with each other, and a bobbin that holds the laminate.
The bobbin has an opening to which the laminated body can be attached and detached at an end on the back yoke side, and a portion other than the opening has a structure for covering the laminated body. .. A plurality of protrusions are provided on the side surface of the bobbin.
The radial gap type rotary electric machine according to claim 1, wherein the protrusions provided at the tip of the adjacent bobbins on the side facing the gap are in close contact with each other. A plurality of protrusions are provided on the side surface of the bobbin.
The radial gap type rotary electric machine according to claim 1 or 2, wherein the protrusions provided at the tip of the adjacent bobbins on the back yoke side are configured to overlap each other. The radial gap type rotary electric machine according to any one of claims 1 to 3, wherein the back yoke is a laminated body in which annular thin plate pieces made of a soft magnetic material are laminated. The radial gap type rotary electric machine according to any one of claims 1 to 3, wherein the back yoke is made of a soft magnetic material divided into a plurality of parts in the circumferential direction. The radial gap type according to any one of claims 1 to 3, wherein the back yoke is a laminated body formed by winding a soft magnetic material piece in an edgewise shape in the circumferential direction. Rotating electric machine. The stator has a slot arranged between the bobbins and a coil conductor arranged inside the slot, and the coil conductors are characterized by having two different cross-sectional areas from the gap side. The radial gap type rotary electric machine according to any one of claims 1 to 3. The radial gap type rotary electric machine according to claim 7, wherein at least a part of the tip portion of the coil conductor is molded with a resin. A rotor having a rotating shaft and a rotor core that can rotate around the rotating shaft, and
In a method for manufacturing a radial gap type rotary electric machine, which comprises a stator including a stator core arranged so as to face each other with a gap between the rotor cores.
The stator core has a ring shape, a back yoke having a plurality of recesses provided along the inner circumference, and a tooth fitted in the recesses of the back yoke.
The teeth have a laminate in which amorphous metal foil strips having a rectangular shape in a plan view are held by friction with each other, and a bobbin that holds the laminate.
The bobbin has an opening at the end on the back yoke side to which the laminated body can be attached and detached, and a portion other than the opening has a structure that covers the laminated body.
The amorphous metal foil strip is a method for manufacturing a radial gap type rotary electric machine, characterized in that an amorphous metal foil strip having a predetermined width is processed into a rectangular shape by shear cutting. A magnetic gear comprising a laminated body in which amorphous metal foil strips having a rectangular shape in a top view are held by friction with each other, and a magnetic pole having a bobbin holding the laminated body. It has a laminate in which amorphous metal foil strips having a rectangular shape when viewed from above are held by friction with each other, and a bobbin that holds the laminate.
The bobbin is a magnetic gear having an opening at least one end to which the laminated body can be attached and detached, and a portion other than the opening has a magnetic pole having a structure for covering the laminated body. The magnetic gear according to claim 10 or 11, wherein the magnetic pole has a winding.

Images