JP2023168110A - Electric motor and electric motor manufacturing method - Google Patents

Abstract

To provide an electric motor and an electric motor manufacturing method capable of downsizing while maintaining a high space factor.SOLUTION: An electric motor includes a rotor set including a shaft, and a stator set with a plurality of divided core sets, and each of the plurality of divided core sets includes winding, a first end and a second end of the winding extend along the longitudinal direction of the shaft, and from among the plurality of divided core sets, 3×n (n is a natural number) divided core sets are reversed by 180° in the longitudinal direction of the shaft with respect to the remaining divided core sets.SELECTED DRAWING: Figure 1

Description

The present invention relates to an electric motor and a method of manufacturing the electric motor.

In Patent Document 1, one end of two coils is taken out from one end surface of the stator core and connected to the power supply side, and the other end is taken out from the other end surface of the stator core and connected to a neutral point, and the two coils are connected to each other. A stator of a motor is disclosed that is wired so that current flows in parallel.

Patent Document 2 discloses that a crossover wire connecting a first stator coil and a second stator coil includes an end in the axial direction of a coil bobbin, and a rotating electrical machine located closer to the center in the axial direction than the end Disclosed.

Japanese Patent Application Publication No. 2011-055653 Japanese Patent Application Publication No. 2006-333670

However, in the stator of the electric motor disclosed in Patent Document 1, the stator core is integrated and not a divided core, so it is difficult to improve the space factor. Furthermore, in the rotating electrical machine of Patent Document 2, the ends of the windings extend in the same direction, and when all connections are made on the board, the number of lands on the board surface is equal to the number of ends of the windings. This increases the size of the board, which increases the size of the motor.

An object of the present invention is to provide an electric motor that can be downsized while maintaining a high space factor, and a method for manufacturing the electric motor.

An electric motor according to one aspect of the present invention includes a rotor set including a shaft, and a stator set including a plurality of split core sets, each of the plurality of split core sets including a winding, and a first end of the winding. The part and the second end extend along the longitudinal direction of the shaft, and among the plurality of divided core groups, 3×n (n is a natural number) divided core groups are different from the remaining divided core groups in the shaft. It is characterized by being reversed by 180° in the longitudinal direction.

According to the present invention, it is possible to provide an electric motor that can be downsized while maintaining a high space factor, and a method for manufacturing the electric motor.

(a) is an exploded perspective view of the electric motor of Example 1. (b) is a sectional view of the electric motor of Example 1. (a) is a flowchart showing a method for manufacturing the stator assembly of Example 1. (b) is a flowchart showing details of the process in step S202 in (a). (a) is an explanatory diagram of the process of step S202d in FIG. 2(b). (b) is an explanatory diagram of the process of step S204 in FIG. 2(a). FIG. 3 is an explanatory diagram of a method for identifying a first divided core group and a second divided core group. FIG. 3 is a developed diagram of the winding wiring of Example 1. FIG. It is a figure which shows the connection method of an end part. FIG. 7 is a developed view of the wiring of the winding wire in Example 2.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. In each figure, the same reference numerals are given to the same members, and duplicate explanations will be omitted.

FIG. 1(a) is an exploded perspective view of the electric motor 100 of this embodiment. FIG. 1(b) is a cross-sectional view of the electric motor 100. The electric motor 100 includes a rotor set 50 including a shaft 51 and a stator set 10 disposed opposite to the rotor set 50 with a gap therebetween. The stator set 10 includes a plurality of split core sets 20, a case 30, and a substrate 40. The plurality of divided core sets 20, cases 30, and substrates 40 are combined.

The split core set 20 includes a single core 22, an insulator (insulating member) 23 located so as to cover the teeth 22a of the single core 22, and a winding 21 wound around the insulator 23. Note that the teeth portion 22a may be insulated by coating or the like without using the insulator 23.

A three-phase drive having a U phase 60, a V phase 61, and a W phase 62 will be described below. When using six split core sets 20 in three phases, the ends 21a of the windings 21 are extended to both ends of the split core sets 20 in the longitudinal direction of the shaft 51, and when coupled to the case 30, the three The divided core sets 20 are reversed by 180° with respect to the longitudinal direction of the shaft 51. When using 12 split core sets 20 in three phases, the ends 21a are extended to both ends of the split core set 20 in the longitudinal direction of the shaft 51, and when coupled to the case 30, 6 split core sets 20 are used. The set 20 is reversed by 180° with respect to the longitudinal direction of the shaft 51. When using 18 split core sets 20 in 3-phase, the end portions 21a are extended to both ends of the split core set 20 in the longitudinal direction of the shaft 51, and when coupled to the case 30, 9 split core sets 20 are used. Set 20 is flipped 180°.

The configurations described above are summarized in Table 1 below.

Therefore, when the number of split core sets 20 is an even number, that is, 3 x 2n (n is a natural number), when connecting to the case 30, 3 x n split core sets 20 are arranged in the longitudinal direction of the shaft 51. Invert it 180 degrees. By extending the end portions 21a to both ends of the split core set 20 in the longitudinal direction of the shaft 51, the number of end portions 21a coming out from one side of the split core set 20 is reduced to 1/2. Therefore, the number of connections for the end portion 21a on one side of the split core set 20 is also halved.

The substrate 40 has on its surface a land 40a that is a circuit pattern for connection processing of the end portion 21a, and is coupled to the plurality of divided core sets 20 in the longitudinal direction of the shaft 51. The board 40 is made of a material commonly used for circuit boards, such as glass epoxy and FPC. The substrate 40 may also function as a lid. In this embodiment, the number of connections to be performed on the end portion 21a on one side of the split core set 20 is halved, so the number of connections to be performed on the board 40 when connecting the end portion 21a to the land 40a is reduced to 1/2. It becomes less. Therefore, since the number of lands 40a can be reduced, the size of the substrate 40 can be reduced.

Hereinafter, a method for manufacturing the electric motor 100 of this embodiment will be explained. First, a method for manufacturing the stator assembly 10 will be described with reference to FIG. 2(a). FIG. 2(a) is a flowchart showing a method for manufacturing the stator assembly 10. As shown in FIG. In the flow of FIG. 2(a), a case will be described in which six divided core sets 20 are manufactured.

In step S<b>201 , the teeth portion 22 a is sandwiched and covered by the insulator 23 in the longitudinal direction of the shaft 51 , and the insulator 23 is coupled to the single core 22 .

In step S202, the winding 21 is wound for each of the plurality of divided core sets 20.

FIG. 2(b) is a flowchart showing details of the process in step S202.

In step S202a, winding of the winding 21 starts. The winding 21 is wound so that the winding direction in all the split core sets 20 is the same. The winding 21 is wound by hand or by a winding machine, for example. Note that when a winding machine is used, the method of winding the nozzle, spindle, etc. is not limited.

In step S202b, the winding 21 is wound around the insulator 23 by a predetermined number of turns in concentrated winding.

In step S202c, winding of the winding 21 is completed.

In step S202d, as shown in FIG. 3(a), in the longitudinal direction of the shaft 51, the winding start 21b1 of the winding 21 is one end of the split core set 20, and the winding end 21b2 of the winding 21 is the end of the split core set 20. pulled out from the other end.

In step S202e, the winding start 21b1 and winding end 21b2 are cut to a predetermined length.

In step S202f, insulation coating treatment is performed on the cut portions of the winding start 21b1 and the winding end 21b2. Note that the insulating coating may be treated by soldering, removing with a file, or the like.

In step S203, the winding 21 is marked in the longitudinal direction of the shaft 51. Note that the process in step S203 is not an essential process.

In step S204, three split core sets 20 out of the six split core sets 20 produced up to step S203 are reversed by 180 degrees with respect to the longitudinal direction of the shaft 51, as shown in FIG. 3(b). let As a result, the winding start 21b1 and winding end 21b2 are pulled out in opposite directions. That is, in the three inverted split core sets 20, the longitudinal direction of the shaft 51 is reversed by 180 degrees with respect to the remaining three split core sets 20. In the following description, the normal split core set 20 that has not been inverted will be referred to as a first split core set 20a, and the inverted split core set 20 will be referred to as a second split core set 20b.

Here, with reference to FIG. 4, a method for identifying the first divided core group 20a and the second divided core group 20b will be described. FIG. 4A shows a method for identifying the first divided core group 20a and the second divided core group 20b by marking. As shown in FIG. 4(a), after marking the first divided core set 20a, the first divided core set 20a is reversed by 180° with respect to the longitudinal direction of the shaft 51 to form a second divided core set 20b. Thereby, it is possible to identify the first divided core group 20a and the second divided core group 20b. The markings may be placed anywhere as long as the first divided core set 20a and the second divided core set 20b can be distinguished when the divided core set 20 is coupled to the inner periphery of the case 30. FIG. 4B shows a method for identifying the first divided core group 20a and the second divided core group 20b by the colors of the insulators 23. As shown in FIG. 4(b), insulators 23 of different colors are used when covering the single core 22 so as to sandwich it between the insulators 23. Thereby, it is possible to identify the first divided core group 20a and the second divided core group 20b. Note that as long as the first divided core group 20a and the second divided core group 20b can be distinguished, methods other than the above-mentioned method may be used.

In step S205, the first divided core set 20a and the second divided core set 20b are combined in three pieces on the inner periphery of the case 30.

In step S206, the substrate 40 is coupled to the split core set 20 in the longitudinal direction of the shaft 51.

In step S207, one of the two ends 21a (first end) is connected to the land 40a, and the other (second end) is connected to the end 21a of another split core set 20.

Hereinafter, a case where the number of divided core sets 20 is six will be described with reference to a developed view of the wiring of the winding 21 in FIG. Here, the first divided core set 20a in the U phase 60 is designated as U1, and the second divided core set 20b is designated as U2. The end 21a of the winding start 21b1 on the side of the end 20c of U1 is the power source side (power supply side) during driving. For example, as shown in FIG. 6(a), a plurality of ends 21a of the U-phase 60, V-phase 61, and W-phase 62 on the end 20c side are connected with one land 40a on the substrate 40. Good too. The end 21a of the winding end 21b2 on the side of the end 20d of U1 and the end 21a of the winding start 21b1 on the side of the end 20d of U2 are connected in series. The winding end 21b2 on the end 20d side of U1 and the winding start 21b1 on the end 20d side of U2 become the crossover portion 21c. For example, as shown in FIG. 6(b), the ends 21a of the U-phase 60, V-phase 61, and W-phase 62 on the end 20d side are connected so that windings of the same phase are connected in series. It's okay. Alternatively, as shown in FIG. 6(c), the end 21a on the end 20d side may be tied around a pin (protrusion) 45 for connection. The V phase 61 and the W phase 62 are also similar to the U phase 60. The end 21a of the winding end 21b2 on the end 20c side of U2 is set as a common side connected to the end 21a of the winding end 21b2 on the end 20c side of V2 and W2.

Further, as shown in FIG. 6(d), the end 21a on the end 20c side is connected to the land 40a on the first board 40b, and the end 21a on the end 20d side is connected to the second board 40c. The wire may be connected at the upper land 40a. Furthermore, FPC may be used as the material of the substrate 40, and the connection processing of the end portions 21a on the end portion 20c side and the end portion 20d side may be performed using one substrate 40.

The case where the number of divided core sets 20 is 12 will be described below. Compared to the case where the number of split core sets 20 is six, it is formed when the end 21a of the winding end 21b2 and the end 21a of the winding start 21b1 are connected in series on the end 20c side. The number of connecting wire portions 21c increases. Further, on the end portion 20d side, the number of crossover wire portions 21c formed when the end portion 21a of the winding end 21b2 and the end portion 21a of the winding start 21b1 are connected in series increases. Every time the number of divided core sets 20 increases by six, each phase increases by one at each of the end portions 20c and 20d.

The basic configuration of the motor of this embodiment is the same as the motor 100 of embodiment 1, except that the number of divided core sets 20 is an odd number. In this embodiment, only the configurations that are different from the first embodiment will be explained, and detailed explanations of the common configurations will be omitted.

When using nine split core sets 20 in three phases, the ends 21a of the windings 21 are extended to both ends of the split core sets 20 in the longitudinal direction of the shaft 51, and when coupled to the case 30, the three The divided core sets 20 are reversed by 180° with respect to the longitudinal direction of the shaft 51. When using 15 split core sets 20 in 3-phase, the end portions 21a are extended to both ends of the split core set 20 in the longitudinal direction of the shaft 51, and when coupled to the case 30, 6 split core sets 20 are used. The set 20 is reversed by 180° with respect to the longitudinal direction of the shaft 51. When using 21 split core sets 20 in 3-phase, the end portions 21a are extended to both ends of the split core set 20 in the longitudinal direction of the shaft 51, and when coupled to the case 30, 9 split core sets 20 are used. The set 20 is reversed by 180° with respect to the longitudinal direction of the shaft 51.

The configurations described above are summarized in Table 2 below.

Therefore, when the number of split core sets 20 is an odd number, that is, 3 x (2n + 1) pieces (n is a natural number), when connecting to the case 30, 3 x n split core sets 20 are attached to the longitudinal axis of the shaft 51. Flip the direction 180°.

Hereinafter, a case where the number of divided core sets 20 is nine will be described with reference to a developed view of the wiring of the winding 21 in FIG. Here, U1 and U3 are the first divided core group 20a, and U2 is the second divided core group 20b. The end 21a of the winding start 21b1 on the side of the end 20c of U1, the end 21a of the winding end 21b2 on the side of the end 20d of U1, and the end 21a of the winding start 21b1 on the side of the end 20d of U2 are even numbers. The same is true for . The end 21a of the winding end 21b2 on the side of the end 20c of U2 and the end 21a of the winding start 21b1 on the side of the end 20c of U3 are connected in series. The winding end 21b2 on the end 20c side of U2 and the winding start 21b1 on the end 20c side of U3 become the crossover portion 21c. The V phase 61 and the W phase 62 are also similar to the U phase 60. The end 21a of the winding end 21b2 on the end 20d side of U3 is the common side connected to the end 21a of the winding start 21b1 on the end 20d side of V3 and W3. Therefore, when the number of split core sets 20 is an odd number, as in the case where it is an even number, each time the number of split core sets 20 increases by 6, the connecting wires are The number of parts that become part 21c increases one by one.

The disclosure of this embodiment includes the following configuration and method.
(Configuration 1)
a rotor set including a shaft;
and a stator set including a plurality of split core sets,
Each of the plurality of divided core sets includes a winding,
The first end and the second end of the winding extend along the longitudinal direction of the shaft,
An electric motor characterized in that 3×n (n is a natural number) divided core sets among the plurality of divided core sets are reversed by 180° in the longitudinal direction of the shaft with respect to the remaining divided core sets. .
(Configuration 2)
The electric motor according to configuration 1, wherein the number of the plurality of divided core sets is 3×2n.
(Configuration 3)
The electric motor according to configuration 1, wherein the number of the plurality of divided core groups is 3×(2n+1).
(Configuration 4)
The first end is connected in series to connect windings on the power supply side, the common side, or the same phase,
3. The electric motor according to configuration 1 or 2, wherein the second end portion is connected so that windings of the same phase are connected in series.
(Configuration 5)
The first end is connected to connect windings on the power supply side or in the same phase in series,
4. The electric motor according to configuration 1 or 3, wherein the second end is connected to connect windings on a common side or in the same phase in series.
(Configuration 6)
Structures 1 to 5, characterized in that the 3×n divided core sets are configured to be able to identify that the longitudinal direction of the shaft is reversed by 180 degrees with respect to the remaining divided core sets. An electric motor according to any one of the following configurations.
(Configuration 7)
The stator set includes a substrate;
7. The electric motor according to any one of configurations 1 to 6, wherein the plurality of first ends are connected at one land of the substrate.
(Configuration 8)
The stator set includes a substrate;
the first end is wired at the substrate;
8. The electric motor according to any one of configurations 1 to 7, wherein the second end is connected to another winding.
(Configuration 9)
The stator set includes a substrate;
the first end is wired at the substrate;
8. The electric motor according to any one of configurations 1 to 7, wherein the second end portion is connected to the convex portion by being tied to the convex portion.
(Configuration 10)
The stator set includes a first substrate and a second substrate,
the first end is wired at the first substrate,
8. The electric motor according to any one of configurations 1 to 7, wherein the second end portion is wired at the second board.
(Method 1)
A method for manufacturing an electric motor having a rotor set including a shaft and a stator set including a plurality of split core sets each including a winding, the method comprising:
winding the winding;
A method for manufacturing an electric motor, comprising the step of inverting 3×n divided core sets among the plurality of divided core sets with respect to the remaining divided core sets by 180° in the longitudinal direction of the shaft. .

Although preferred embodiments of the present invention have been described above, the present invention is not limited to these embodiments, and various modifications and changes can be made within the scope of the invention.

100 Electric motor 10 Stator set 20 Split core set 21 Winding 50 Rotor set 51 Shaft

Claims (11)

a rotor set including a shaft;
and a stator set including a plurality of split core sets,
Each of the plurality of divided core sets includes a winding,
The first end and the second end of the winding extend along the longitudinal direction of the shaft,
An electric motor characterized in that 3×n (n is a natural number) divided core sets among the plurality of divided core sets are reversed by 180° in the longitudinal direction of the shaft with respect to the remaining divided core sets. . The electric motor according to claim 1, wherein the number of the plurality of divided core sets is 3×2n. The electric motor according to claim 1, wherein the number of the plurality of divided core sets is 3×(2n+1). The first end is connected in series to connect windings on the power supply side, the common side, or the same phase,
The electric motor according to claim 1 or 2, wherein the second end is connected to connect in-phase windings in series. The first end is connected to connect windings on the power supply side or in the same phase in series,
4. The electric motor according to claim 1, wherein the second end is connected to connect common side or in-phase windings in series. 2. The 3×n divided core sets are configured to be able to identify that the longitudinal direction of the shaft is reversed by 180 degrees with respect to the remaining divided core sets. The electric motor mentioned. The stator set includes a substrate;
The electric motor according to claim 1, wherein the plurality of first ends are connected at one land of the substrate. The stator set includes a substrate;
the first end is wired at the substrate;
The electric motor according to claim 1, wherein the second end is connected to another winding. The stator set includes a substrate;
the first end is wired at the substrate;
The electric motor according to claim 1, wherein the second end is connected to a convex portion by being wrapped around the convex portion. The stator set includes a first substrate and a second substrate,
the first end is wired at the first substrate,
The electric motor according to claim 1, wherein the second end is wired at the second board. A method for manufacturing an electric motor having a rotor set including a shaft and a stator set including a plurality of split core sets each including a winding, the method comprising:
winding the winding;
A method for manufacturing an electric motor, comprising the step of inverting 3×n divided core sets among the plurality of divided core sets with respect to the remaining divided core sets by 180° in the longitudinal direction of the shaft. .