JP3338204B2 - Method of manufacturing slotless stator for electromechanical transducer - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a slotless electrical converter, such as an electric motor, and to a method of manufacturing such a converter so that conductors in a gap are substantially parallel.

[0002]

2. Description of the Related Art Conventionally, most electric motors are manufactured in a slotted structure in which copper conductors of the motor windings are arranged between teeth in slots of a laminated iron rotor or stator structure. I was This slotted structure is
It provides a relatively small air gap for the motor to achieve the desired high permeance. Recently, the emergence of the high energy permanent magnet NdFeB (neodymium iron, boron) has made it possible to realize a slotless structure in any motor, particularly in a high-performance servomotor. See, for example, U.S. Patent No. 4,954,739. In a slotless configuration, the copper winding is located in the air gap, not in the slot.

The structure of a slotless motor can achieve significant advantages over conventional slotted structures. The slotless structure has extremely small eddy current loss, extremely small hysteresis loss, and further has low meshing loss (c
A high level of efficiency is feasible because there is no logging loss and the core is not appreciably lost. High speeds in the range of 40k to 120krpm are easily achievable. In this slotless structure, no teeth mesh with each other, so that a completely smooth operation can be performed over a wide speed range. Furthermore, the absence of magnetostrictive noise due to teeth of normal construction allows extremely quiet operation. Further, since the slotless structure has a low inductance, the response (acceleration / deceleration) of the motor can be further increased.

Various methods have been proposed for manufacturing slotless motors. For example, see the aforementioned U.S. Pat.
No. 54,739, a winding is formed using a cylindrical support having a small diameter at one end. Around the uniform diameter portion, a glass fiber sleeve is placed, followed by a preformed coil in place. When these coils are in place, the turn of the thick end at one end of the winding is expanded inward at the reduced diameter portion of the support, while the other end of the winding is expanded outward. . The winding can then be inserted into the outer shell of the cylindrical backing, with the inwardly extending end of the winding. The support is then withdrawn from the outwardly extending end so that the fiberglass sleeve remains as part of the motor structure. The winding is encapsulated using a suitable resin after inserting the winding into the stator shell.

US Pat. No. 4,130,769 discloses the technique of layered pre-formed windings for producing slotless, brushless DC motors. A holder is used to pre-form a single flat layered coil. The preformed coil is a single (shing)
le) arranged in a cylinder of the back metal in layered form, one of the straight coil portions in the outer layer being in contact with the back metal and the other straight coil portion being in the inner layer.
However, it is believed that this structure can only be applied to windings having a thickness equal to the thickness of the two conductors.

[0006] US Patent No. 4,445,061 discloses a method of making and utilizing a retainer mounted to a cylindrical stator housing having a smooth peripheral wall. Once the stator is positioned in the retainer, the temporary fingers are extended radially inward. The coil is then wrapped around a finger forming a temporary slot similar to that in a slotted motor construction.
The conductor is then pressed outwardly against the inner wall of the backing cylinder by a non-magnetic, expandable, deformable plastic cylinder.

US Pat. No. 4,645,961 discloses the use of long, flexible printed circuit boards insulated on both sides. This printed circuit board has a "jelly roll fascia"
And disposed in a cylindrical body of the back metal of the stator. The windings are connected by soldering the connection wires at appropriate locations.

[0008]

In order to take full advantage of the structural features of the slotless motor, the working conductor portions of the windings in the air gap are linear and relative to each other, preferably the axis of rotation of the motor. Must be parallel with respect to Any deviation of this parallel alignment reduces the rotational torque generated by the current flowing through the conductors, and therefore reduces the efficiency of the motor. Furthermore, if the conductors could not be aligned in parallel, large air gaps would be required, reducing the thermal conductivity when removing heat from the windings. As a result of one or more of these factors, conventional motor structures and methods of making the same have not been able to fully realize the advantages of a slotless structure at a reasonable cost.

One object of the present invention is to provide a slotless structure for a converter, such as an electric motor, and a method of manufacturing the same, wherein the working conductor portions of the windings are straight and mutually separated. Parallel, and in a preferred embodiment, parallel to the axis of rotation over the entire length of the gap.
In the case of a linear motor, the working conductor portions of the windings are preferably parallel to each other and perpendicular to the direction of movement.

It is another object of the present invention to increase the density of copper wires in order to minimize the air gap required to receive the windings in order to maximize the number of working conductor portions for a given air gap. It is to provide a slotless structure for a transducer such as an electric motor.

It is yet another object of the present invention to provide a slotless structure for a transducer having sufficient thermal conductivity to remove heat from the windings.

Yet another object of the present invention is to provide an efficient method of manufacturing a converter or slotless motor.

[0013]

SUMMARY OF THE INVENTION According to the present invention, there is provided a self-supporting, preformed winding structure that is at least partially rigid and has an active portion and an end turn. A method of manufacturing a slotless stator for an electromechanical transducer includes attaching an insulated wire to a surface of a support, and attaching the insulated wire to the surface of the support or to a wire previously attached. Securing at least the active wire portion with an adhesive such that at least the working conductor portion of the winding structure is in a predetermined substantially constant position with respect to the other working portions of the winding structure;
Encapsulating the winding structure and rigidly attaching the winding structure to a metal structure of a slotless stator; and one or more permanent magnets mounted such that the completed stator is movable with respect to the stator. And combining with.

A preferred method of the present invention is a stator shell including a slotless stator having at least a portion of a rigid winding structure preformed inside a rotor and provided with one or more permanent magnets. A method for manufacturing a rotating electromechanical transducer comprising: (1) depositing an insulated wire on a surface of a cylindrical support, and applying energy to one or both of the wire and / or the surface; In which an adhesive layer which can be activated by applying a coating is provided or provided, wherein (a) a part of the insulated conducting wire faces one end of the surface of the support. (B) distributing in parallel with respect to one end of the surface of the cylindrical support during movement to form a working conductor portion of the winding structure; Loop of the line forming the fold of (C) a portion of the insulated conductor is subsequently distributed while traveling in a reverse direction parallel to the axis to provide another effect of the winding structure. Forming a conductor portion;
(D) a portion of the insulated conductor is then distributed to form a loop of another wire forming an end turn; and (e) all windings of the winding structure. (A) repeating the steps (a) to (d) until the wire coil is completed; and (2) once before forming the next part forming the working part of the winding structure, Attaching at least a portion of each working conductor portion to each other with an adhesive, thereby forming a cylindrical winding structure to which at least the working conductor portions are bonded; and (3) as a material to be encapsulated. Encapsulating the winding structure using a resin composition and simultaneously bonding the winding structure to the outer shell of the stator; and (4) at least one rotating permanent magnet rotor. Complete the assembly of the electromechanical transducer to include the structure And a floor.

[0015] Another preferred method is (1) wire scribing means.
Distributes and adheres the insulated conductor in a state provided on the cylindrical surface, one of the insulated conductor or the cylindrical surface,
Or both of them are provided with an adhesive layer that can be activated by applying energy, and (a) a part of the insulated conductive wire moves toward one end of the surface of the support Meanwhile, being distributed in parallel with respect to one end of the surface of the cylindrical support to form a working conductor portion of the winding structure; and (b) a portion of the insulated conducting wire is (C) a portion of the insulated wire is then distributed while moving in the opposite direction parallel to the axis and the winding is adjusted to form a loop of the wire forming the folded portion; Forming another working conductor portion of the wire structure; and (d) then distributing a portion of the insulated wire to form another wire loop forming an end turn. And (e) all winding coils of the winding structure are And (2) distributing at least a portion of the insulated conductors and simultaneously removing at least a portion of each working portion until the steps (a) to (d) are repeated. (C) bonding the winding structure of the stator outer shell together with the step of forming a cylindrical winding structure to which at least the working conductor portion is bonded by using an adhesive; (4) arranging at least one rotor having a permanent magnetic force in the winding structure to complete the assembly of the electromechanical converter.

In the case of a rotary transducer or motor, an insulated copper wire is attached to the mandrel according to the desired winding configuration.
Preferably, a removable sleeve or film wrap surrounds the mandrel, on which the windings are located. Preferably, the wires are glued at the desired location, ie, at least a portion of the working linear void portion, while they are being glued. The conductor can be adhered continuously or intermittently, or after a portion of the conductor has been deposited, can be adhered as a separate step to the portion where the active winding portion is located. The wires are preferably bonded using a heat sensitive adhesive that is coated on the wires and / or disposed on a cylindrical surface. The adhesive film can be used by disposing the adhesive film on a cylindrical surface or between layers. The thermal activation is preferably performed using ultrasonic energy, but other sources of energy are possible. The windings formed on the mandrel are rigid or substantially rigid structures that can be removed from the mandrel and placed in the cylinder of the motor backing metal.

The method according to the invention for a linear motor is characterized in that the winding structure is usually formed on a flat surface and the scribing head in two directions on a flat surface.
The same is true except that wires are attached by controlling the movement of ad). In the case of a linear motor, the linear gap where the winding acts is perpendicular to the moving direction.

Once the formed winding structure has been placed with respect to the stator structure, the winding structure must be firmly fixed to the backing metal. This is a two-stage adhesive on the support surface or between the layers of the conductor.
It is desirable to use wire coated with ive) or using a two-stage adhesive film. Under normal conditions at room temperature, the adhesive is in a non-tac state (non-tac) to prevent unwinding and dispensing from the spool.
ky stage). While the wire is being adhered to the mandrel or support surface, the two-step adhesive is heated sufficiently to temporarily secure the wire in place to form a rigid or substantially rigid wound structure. Thereafter, when the pre-formed winding is in place in the stator structure, the assembly is positioned with respect to the furnace and the adhesive resin is cured or thermoset, and the winding is firmly adhered to the backing metal. To do. In some cases, a two-stage adhesive can be used with an encapsulant, both of which can be cured simultaneously. Alternatively, if a two-stage resin is not used when forming the windings, a separate encapsulation resin can be injected and then cured to bond the windings in place. This resin can improve the thermal and magnetic properties of the motor,
It can be a composition filled with fine particles of weak magnetic or other magnetic materials. As an alternative, a wire coated with an adhesive made of a weak magnetic material can be wound around the winding structure to provide a backing. This weak magnetic conductive wire adhesive can be cured simultaneously with the copper wire structure.

The apparatus for manufacturing a winding according to one embodiment preferably comprises a conductor scribing head having a control angle of at least 2 °, preferably 3 °. The rotational position of the mandrel and the longitudinal position of the scribing head are controlled so that the wires can be deposited according to the desired pattern on the cylindrical surface of the mandrel. In the case of multi-layer windings, a control angle of 3 ° is desirable, in which case the height of the scribing head above the mandrel surface must be controlled to accept the previously deposited layer. Often not. The control of the 3 ° angle is desirably realized through a software program of a computer designed to match a desired winding configuration and motor dimensions. A similar device can be used to form the windings of a linear motor, in which case the scribing head is controlled so that the wires can be deposited on a flat surface.

Another optional device for forming the windings is to align the glue-coated insulated wire under tension so that the wire is parallel to the axis of rotation over the length of the gap. . It is desirable to apply energy, preferably ultrasound, to the linear line portion or portions thereof to activate the adhesive. The straight conductor portion is pressed down and adhered to the surface of the mandrel or to the previously attached portion.
When energy is removed, the wire sections form part of the rigid or substantially rigid winding structure that is formed.

[0021]

BRIEF DESCRIPTION OF THE DRAWINGS The above and other objects of the present invention will be apparent from the following detailed description with reference to the accompanying drawings.

The overall structure of the motor formed by the method and apparatus of the present invention is shown in FIGS.

The motor has a cylindrical back metal (back i).
ron) steel shaft 1 surrounded by a sleeve 12
0 is provided. Six permanent magnets 14 to 19 are mounted on the sleeve 12 and extend radially,
Energized to provide alternating north and south poles as shown in FIG. In a preferred embodiment, these magnets
A high-energy generating magnet whose generated energy is 26 MG0 (Mega Gauss Olsted) or more, desirably 30 MG0 or more. Suitable permanent magnets are formed, for example, of neodymium, iron and boron and are available from Neomax (NEOM).
AX) -30H. These magnets are arc-shaped magnets formed by press working, and are mounted on a sleeve 12 surrounding the shaft 10. Alternatively, one or more ring-shaped magnets can be used instead of independent arc-shaped magnets.

A wrap 20 surrounds the rotor structure and holds the magnet in place under high speed centrifugal conditions. The wrap comprises dipping high strength Kevlar filaments into an epoxy, and then includes one or more spiral layers, several hoop layers wrapped around the subsequent rotor, and then Formed by winding several hoop layers.

The rotor can be formed using six magnets, each extending along the entire length of the rotor, or the magnets can be split as shown in FIG. 2A. The advantage of this split magnet is that it is possible to manufacture motors having different horsepower rating values with a single motor structure only by changing the motor length and the number of magnet portions.

The stator structure includes a cylindrical shell 30 of laminated silicon steel that provides an outer backing for the motor. The laminate is assembled and then
It is arranged in an outer housing 32 made of aluminum.
The winding structure 40 is formed to have a linear acting portion parallel to the rotation axis and a folded portion at the end. Once formed, the winding structure 40 is then
Attached inside the arc-shaped back metal shell. The stator structure is slotless, so the windings are located in the motor gap between the permanent magnet of the rotor and the cylindrical inner surface of the stator shell. Since there are no teeth on the stator, the copper of the windings can utilize the entire cylindrical inner surface. If desired, a small notch can be randomly formed in the inner periphery of the laminate to provide better adhesion to the windings to withstand the torque forces created in the motor.

An apparatus for forming a winding on a mandrel for subsequent insertion into a motor is shown in FIG. 4 according to one embodiment. The movement of the conductors relative to the surface of the mandrel 52 of the scribing head 50 is controlled so that the insulated adhesive coated wire is dispensed according to the desired winding pattern 51. The rotational position of the mandrel is controlled by the R driving device 58. The longitudinal position of the scribing head 50 with respect to the mandrel 52 is controlled by an L-drive 56. According to the number of winding layers deposited before it,
Wire scribing head 5 on the surface of the mandrel
The height of 0 is controlled by the Z drive 54. These driving devices 54 and 56 can be of a lead screw type driven by a stepping motor as shown, or can be of a linear positioning type. A head direction control device 60 controls the rotational position of the scribing head about a vertical axis so that the wires are distributed in a direction that follows the direction of movement relative to the plane of the mandrel. These drives 54, 56, 58 are mounted on a frame 62, which is mounted on a large foundation such as a large granite block.

[0028] The mandrel is a Kapton coated on its outer surface with an adhesive similar to that applied to the wire.
n) It is desirable to wrap the film. In order to facilitate the removal of the winding, it is necessary to adopt the wrapping of the Kapton film.

The insulated wires used to form the windings are supplied from a spool 66 mounted above the frame 62. As will be described in more detail below, the insulated wire is coated with an adhesive composition, preferably a two-stage adhesive, which, at normal temperatures, adheres to the wire and thereafter It quickly returns to the non-bonded state and, at high temperatures, cures to its thermoset state, forming a solid winding integrally secured to the stator structure. In a preferred embodiment, the winding structure is inserted into a stator shell that is sheathed with an encapsulant and exposed to a temperature sufficient to cure the encapsulant and adhesive wire coating.

The wire from the spool travels around a drive roller 68, which feeds the wire at the correct speed in response to movement of the scribing head 50 with respect to the mandrel 52. Four idler rollers 70 are pressed against the supply roller to maintain frictional grip on the conductor. An ultrasonic stylus 72 crosses the line where it contacts the surface of the mandrel. The stylus provides sufficient energy to heat the covered portion of the wire to a bond sufficient to bond the wire to the surface of the mandrel. A suitable scribing head structure is disclosed in U.S. Pat.
No. 773 is described in further detail. A suitable insulated wire coated with an adhesive is that sold by Essex Corp under the trade name "Bond M Wire".

The two-stage adhesive suitable for coating wire used in the present invention.
Are described in U.S. Pat. No. 4,642,321. The adhesive composition cures (a) a polymer resin such as a polyester resin, a polyurethane resin, or an epoxy resin, (b) a filler, and (c) a polymer resin, but activates the adhesive composition. It is a curing agent capable of forming cross-links that are hindered and non-reactive under conditions. The adhesive composition is non-adhesive (no
It is important that the coated wire be easily unwound from the spool and pass through the wire scribing head. The adhesive is activated by the ultrasonic energy from the stylus when the conductive wire is deposited, and quickly returns to a cured state when the adhesive cools. The adhesive composition is thermosetting, and therefore can be cured by heating to a temperature sufficiently higher than the temperature at which the adhesive is activated.

[0032] The windings can follow virtually any desired pattern. FIG. 4 shows a first coil 51 of a winding suitable for a six-pole motor. The coil is in the form of a longitudinal spiral, starting at its center and extending until it covers about one third of the surface of the mandrel. Two similar additional coils can be formed such that a single layer of winding covers the surface of the mandrel. Next, a further winding layer can be formed on the previous layer. Of particular importance is that the working conductor portion located in the air gap of the completed motor between the end turns is formed in a straight line and parallel to the axis of rotation. Such parallel conductors make the most efficient torque conversion of energy,
Increased copper packing density improves heat dissipation by minimizing the molding compound required to secure the windings. Using the method and apparatus of the present invention, it is possible to form windings with straight and parallel conductors in a substantially rigid self-supporting form before insertion into the stator structure and before curing of the resin. Becomes

The winding apparatus shown in FIG. 4 is preferably controlled by software through a suitable computer. The computer controls the rotational position of the mandrel through the R drive 58 while controlling the longitudinal position of the scribing head with respect to the mandrel through the L drive 56 and further deposits it in front of it via the Z drive 54. The height of the scribing head above the plane of the mandrel can be controlled according to the layer of wires, the direction of the head can be controlled through a controller 60, and the drive roller 68 can be controlled to distribute the wires at the appropriate speed. Interconnected as if they were. By simply changing the software through software control and changing the size of the mandrel, windings of different types or sizes can be easily formed, resulting in a completely flexible system.

FIGS. 5A and 5B are cross-sectional views showing alternative embodiments of the ultrasonic stylus of the scribing head. FIG. 5A shows the tip of a stylus for a single conductor 81. The tip of the stylus surrounds a portion of the conductor and activates the adhesive surrounding the conductor to provide ultrasonic energy to adhere to the conductor. In the alternative embodiment shown in FIG.
4 is configured to surround a portion of the three conductors 85 to 87 that are simultaneously attached.

FIG. 6 shows another alternative embodiment in which three scribing heads are used simultaneously to form a three-phase winding. Scribing heads 91, 92, 9
3 are displaced from each other by 120 ° about the mandrel 90. The scribing heads 91-93 receive lines from separate spools 94, 95, 96, respectively. In the case of this structure, three coils of a three-phase winding are formed simultaneously.

FIG. 7 shows a winding device having a tapered mandrel. As shown, a mandrel sized for a particular motor has a diameter at one end of 3 mm.
7.85mm (1.49 inches), other end diameter 3
6.78 mm (1.448 inches). By tapering the mandrel, it becomes easy to remove the winding structure after formation.

FIG. 8 shows a tapered mandrel that forms a "drag-up" winding structure. The mandrel is tapered, as in the case of the mandrel of FIG. 7, to facilitate removal of the winding structure. The reduced end of the mandrel has a reduced diameter portion that can receive a turn at the end forming the bottom of the "cup".

Another optional device for forming a self-supporting winding structure according to the present invention is shown in FIGS.
In this embodiment, the adhesive-coated insulated conductor is not continuous, but is partially adhered at some point. This line is aligned parallel to the axis of rotation, placed in tension, and then pushed into the plane below it while applying energy to activate the adhesive. In this way, the entire working part, or a part thereof, is adhered simultaneously.

The mandrel 100 (FIG. 9) has an enlarged diameter portion 1 having a diameter corresponding to the diameter of the rotor in the motor being manufactured.
01 is provided. The length of this enlarged diameter portion corresponds to the working winding portion in the air gap of the motor. The ends 102, 103 of the mandrel are reduced in diameter to accommodate the turn at the end of the winding. The mandrel is positioned with accuracy within the angular range of the arc using the rotary position drive 105.

The enlarged diameter portion of the mandrel is a mylar (M
ylar) film is wound so that the wound structure can be easily removed after formation. The film is coated with a suitable thermoplastic such as Kapton.

The pair of guide pins 107 and 108 are used to position the insulated conductor 110 distributed from the appropriate conductor distribution bobbin 112. As shown in FIG. 9, one end of the conductor is secured and the other end of the bobbin 112 can place the linear line portion 110 in tension parallel to the axis of rotation.

Ultrasonic energy is applied to activate the adhesive on the surface of the mandrel or on the coated conductor. As shown in FIG. 10, the amplifier 114 is connected to a drive coil 116 surrounding the ultrasonic transducer 117. A microphone 120 picks up the transducer's vibration frequency, and the microphone 120 is used to provide a feedback signal that keeps the transducer's resonant frequency vibrating. The microphone is coupled to a feedback control circuit 119, which controls the amplifier 11
4 determines both the frequency and the amplitude of the drive signal supplied to the drive coil.

The transducer 117 has a horn 1 shaped to provide a V-shaped groove parallel to the axis of rotation.
22. This groove is dimensioned as shown in FIG.
４ to ２ are located above a plane passing through the lower horizontal plane of the horn.

In the raised position shown in FIG. 9, the V-shaped groove
It is about 0.25 inches (6.35 mm) above the lower surface. When the ultrasonic horn moves down, line 1
10 is captured in the V-shaped groove and urged downwardly toward the surface of the mandrel. The amount of ultrasonic energy delivered is empirically determined to be sufficient to heat the adhesive to an active state. The downward force controls the conductor to contact the surface of the mandrel or to a previously attached conductor so that ultrasonic energy can activate the contact surface. The downward force of the horn must not be large enough to move the previously deposited conductor or to compromise the integrity of the layer. This ultrasonic energy is shut off for about 1/3 second before raising the horn to allow the adhesive to set before the V-groove rises.

After bonding the linear conductors, the guide pins 107 and 108 are temporarily removed. As the wires are supplied, the mandrel is rotated to form a turn at the end. Next, the guide pins are reset and the bobbin 11
2 continues to supply wires to form the next working conductor. Alternatively, the linear process portion is glued by applying tension and then applying ultrasonic waves to press the conductor into contact with the underlying surface. The winding structure is manufactured by repeating this process and alternately forming linear conductors and end-turned portions. At least the straight working conductor or a part thereof is glued before the next end turn or working conductor.

In the ultrasonic horn 122 shown in FIG. 9, the entire linear active conductor portion is bonded in one step.

FIG. 12 shows another alternative structure in which the horn 128 intermittently contacts the working conductor and achieves stitch-type bonding in a single step. FIG. 13 shows another alternative embodiment in which insulated wires are similarly intermittently bonded using a narrow ultrasonic horn 129 that is movable with respect to the longitudinal axis of the mandrel. In this case, the horn is moved longitudinally to the desired bonding point and then moved down to activate the adhesive. Typically, the working conductor is glued at the ends and at some point between the ends.

A preferred technique for forming a multi-phase winding, such as a three-phase winding, is to use a spool of multiple insulated conductors. The device first forms a first layer of a first coil as a first phase on the face of the mandrel. Next, another line spool is used to form the first layer of the second coil in the second phase. Next, a first layer of a third coil is formed in a third phase using a third wire spool. Once the first layer of each phase has been formed on the face of the mandrel, the apparatus again uses the first spool to form the second layer of the first coil in the first phase. The second and third spools are used sequentially to form a second layer in the second and third phases. In this way, the winding process is continued until a three-phase, multilayer winding is completed. The apparatus is computer controlled so that virtually any desired type of winding is produced. The computer controls not only the rotational position of the mandrel, but also the position of the guide pins and the operating conditions and operation of the ultrasonic horn. This device can form windings as small as the pole span of two conductors.

Another alternative device for producing three-phase windings is to have three complete winding stations offset from one another by 120 °.

FIG. 14 shows a stator of a linear motor that can be manufactured using the present invention. The winding structure of this stator has a suitable flat forming surface 130,
Or, desirably, back iron for the stator (back iro)
n) can be formed on the surface that provides n). If the windings of the self-supporting stator are first formed and then moved to the back metal stator structure, the forming surface should be Teflon (Te
It is desirable to coat a material such as flon) or cover a film material such as Kapton.

The winding structure can be in any form suitable for the desired linear motor, and is preferably formed using an insulated conductor coated with an adhesive. The winding shown in FIG. 14 is a single-layer winding, and here, the coil 13
4, 135 and 136 are attached in a single shape. Although shown as a single layer of windings for convenience, the actual windings are typically multi-layered. Using a scribing head similar to that shown in FIG.
Alternatively, it can be attached and adhered to a previously attached line. The scribing head is designed to allow for controlled movement in X and Y coordinates. In addition to or as an option for the adhesive coating of the conductor, an adhesive layer can be applied to the forming surface or between the conductor layers. The working conductor portions of the winding are perpendicular to the direction of movement and parallel to each other.

After forming the stator windings, the windings are:
It is firmly adhered to the back metal 130 of the stator. This can be done by curing the two-stage adhesive or by using or adding a thermosetting encapsulant.

As shown in FIG. 15, the linear motor includes a movable permanent magnet 140 mounted on a carriage (not shown) so as to move linearly with respect to the stator winding 132. The weak magnetic pole pieces 142 and 144 are
The dimensions are such that the distance between the pole surfaces is equal to the coil span of the stator winding. Back metal 130 completes the magnetic path for the movable magnet. Coil 134 to 136
Are connected to a suitable array of switches that can continuously excite the coil to achieve the desired linear operation.

A method of manufacturing a motor winding structure according to a preferred embodiment of the present invention comprises the following steps.

(A) attaching the insulated wire to the mandrel or to the cylindrical support according to the desired winding pattern; The surface of the support, or one or both of the insulated conductors,
Cover with heat-sensitive adhesive. A further adhesive can be applied between the conductor layers. The coil of the winding pattern is
It has a working part to be placed in the cavity and a turn at the end between the continuous working parts. The working part is preferably straight and parallel with respect to the axis.

(B) Applying energy, preferably ultrasonic, while depositing at least a portion of the insulated conductor so that the working portion is adhered parallel to the axis of rotation.
Other energy sources that can be selected include infrared and laser energy. The winding structure having the bonded portions is substantially rigid and self-supporting.

(C) The self-supporting winding structure is removed from the mandrel and placed inside the cylinder of the back metal of the motor stator. Next, the winding is sealed, and the winding is firmly fixed to the back metal cylinder. Separate encapsulation (encapsulant)
ing) A resin can be used, but it is desirable that the heat-sensitive adhesive also contains a thermosetting resin which can be cured to exhibit an encapsulating function. Another preferred alternative that can be used is to use an encapsulant in addition to the heat-sensitive adhesive containing the thermosetting resin.

(D) Once the winding structure is in place, the motor assembly can be completed, preferably including rotating high energy permanent magnets.

(E) In the case of a linear motor, the insulated wire is
Attached on a flat portion forming surface which can be a backing of the stator. Preferably, the active part of the winding is parallel and perpendicular to the direction of movement. The winding structure is encapsulated after manufacture to firmly secure the winding to the backing metal.

(F) When distributing the windings or activating the windings one portion at a time, the adhesive can be activated continuously. The insulated conductor can be adhered by activating the adhesive to the active portion of the winding or only a portion thereof. Further, the insulated conductive wire can be bonded in an intermittent stylus shape.

(G) To facilitate removal of the self-supporting winding structure, the mandrel or forming surface can be wrapped with a film material such as Mylar or coated with a material such as Teflon.

(H) In order to facilitate the insertion of the back metal of the self-supporting winding structure into the cylindrical body (that is, the outer shell of the stator), the end folded portion at one end is displaced inward, The diameter of the folded portion at the end of the winding structure may not exceed the diameter of the active portion. The winding structure can then be inserted with the inwardly displaced end turn first. Also, after the winding structure has been completed, before applying it into the outer shell of the stator, re-activate the adhesive and apply enough heat and pressure to displace the folded portion of the end inward. Thereby, it is also possible to displace the folded portion at the end inward.

(I) When the substantially rigid winding structure is disposed in the outer shell of the backing metal, the winding is compressed outwardly with respect to the outer shell to increase the mounting density of the conductor, and the encapsulant is used. The void space that needs to be filled can be reduced. This outward compression can be accomplished using an inflatable balloon, an inflatable split roller, a drawing process, or other known techniques. Heat may be applied so that compression and heat temporarily change the adhesive to a plastic state. Alternatively, it is also possible to perform a compression step before inserting the winding structure into the shell of the backing metal and while inserting it into the holder.

(J) The adhesive and / or encapsulant is a resin composition using powder particles of a weak magnetic material such as iron or Metglass instead of the filler usually present in the composition. It is possible to include things.
These particles are desirably coated in advance with an insulating layer. These particles are used to improve the magnetic and thermal properties of the motor. Instead of fillers, ceramic particles, industrial diamond chips, or other materials with high thermal conductivity can also be used.

(K) As an example of selecting an embodiment using a cylindrical outer shell, a weak magnetic wire coated with an adhesive can be wound around the winding structure. Usually, five or six layers of iron wire are sufficient. Wrapping with this wire allows for the back metal to minimize the spacing between the windings and the back metal and to minimize the encapsulant and subsequent insulation barrier. A further advantage associated with the use of wrapped iron shells is the detection of the position of the rotor, or the complex multi-turn structure, including the windings used to control the motor to weaken the magnetic field. It is easy to use the body.

(L) Instead of the mandrel, the actual rotor of the motor can be used. The rotor may be wrapped in one or more layers of a thin film material, such as mylar, to provide a working space between the rotor and the stator. Care must be taken in the preferred embodiment to provide a uniform surface forming the windings. This winding structure is formed of mylar, as in the case of using a mandrel.

[Brief description of the drawings]

FIG. 1 is a sectional end view of a motor of the present invention.

FIG. 2A is a side view of a rotor portion of the motor of the present invention, and 2B is an end view of the rotor portion of the motor of the present invention.

FIG. 3 is a sectional view of a stator of the motor of the present invention.

FIG. 4 is a schematic diagram of a wire scribing head and related apparatus for manufacturing the self-supporting wound structure of the present invention.

5A is a cross-sectional view showing a line scribing stylus for a single conductor, and FIG. 5B is a cross-sectional view showing a modified example of an ultrasonic probe for three conductors.

FIG. 6 is a schematic diagram of an apparatus employing three scroll type heads for manufacturing a three-phase winding structure.

FIG. 7 is an illustration of a tapered mandrel used with the device shown in FIG.

FIG. 8 is an illustration of a tapered “drag cup” mandrel used with the device shown in FIG.

FIG. 9 is a perspective view of another optional device for manufacturing a winding structure, which allows simultaneous bonding of the entire working line portion.

10 is a partial schematic view of an ultrasonic transducer used in the apparatus of FIG. 9 and a related apparatus.

FIG. 11 is a cross-sectional view of the ultrasonic horn when capturing an insulated conductor.

FIG. 12 is a perspective view of another alternative embodiment in which the ultrasonic horn is configured to allow insulated conductors to be stitched together.

FIG. 13 is a perspective view of another alternative embodiment where the ultrasonic horn is narrow and moves with respect to the mandrel so as to be able to make a stitch-type bond as well.

FIG. 14 is a schematic perspective view of a stator of a linear motor manufactured according to the present invention.

FIG. 15 is a diagram showing a movable permanent magnet combined with a stator winding of a linear motor.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 10 Steel shaft 12 Back metal sleeve 14, 15, 16, 17, 18, 19 Permanent magnet 20 Strip 30 Outer shell 32 Housing 40 Winding structure 50 Scribing head 51 Winding pattern 52 Mandrel 54 Z drive 56 L drive Device 58 R drive device 60 Head direction control device 62 Frame 66 Spool 68 Drive roller 70 Idler roller 72 Ultrasonic stylus 81 Conductor 84 Ultrasonic stylus 85, 86, 87 Conductor 90 Mandrel 91, 92, 93 Conductor 94, 95 , 96
Spool 100 Mandrel 101 Enlarged diameter section 102, 103 End of mandrel 105 Rotational position drive 107, 108 Guide pin 110 Insulated conductor 112 Wire distribution bobbin 114 Amplifier 116 Drive coil 117 Ultrasonic transducer 119 Feedback control circuit 120 Microphone 122, 128 129 Horn 126 Insulated conductor 130 Forming surface 132 Stator winding 134, 135, 136 Coil 140 Permanent magnet 142, 144 Weak magnetic pole piece

Continued on the front page (73) Patent holder 591132025 Advanced Interconnection Technology Inc. ADVANCED INTERNECTION TECHNOLOGY, INCORPORATED 11751, New York, United States 11751, Izrip, Freeman Avenue 181 (72) Inventor Richard J. Forge, 240 United States, 240 Blacksburg, Highland Circle 151 (72) Inventor Mohammad Khandan-Balani 24141, Virginia, United States of America 241, Radford, Mountain View Lane 104 (72) Inventor Raymond E. S. Cage 11735, New York, USA Mindale, Laurel Street 45 (56) References JP-A-6-165446 (JP, A) JP-A-2-3171 ( P, U) (58) investigated the field (Int.Cl. ^7, DB name) H02K 15/08 H02K 3/00

Claims (25)

(57) [Claims] 1. A rotary electromechanical system comprising a slotless stator having a preformed at least partially rigid winding structure inside a stator shell and a rotor provided with one or more permanent magnets. A method for manufacturing a converter includes the steps of: (1) placing an insulated conductor on a cylindrical support surface and activating the conductor and / or the surface by applying energy to either or both of the conductor and the surface; Providing a layer of adhesive that can be coated or provided, wherein: (a) the cylindrical support surface while a portion of the insulated conductor moves toward one end of the support surface; (B) being arranged in parallel with respect to the axis of the winding structure to form a working conductor portion of the winding structure; and (b) a part of the insulated conductor forming a loop of the conductor forming a folded portion at the end. This is placed in (C) subsequently distributing a portion of the insulated conductor while moving in opposite directions parallel to the axis to form another working conductor portion of the winding structure; (D) Next, a part of the insulated conductor is distributed to form a loop of another conductor constituting a folded portion of the end; and (e) all the winding coils of the winding structure. (A) repeating steps (a) to (d) until is completed, (2) before forming the next part constituting the working part of the winding structure, Attaching at least a portion of the active conductor portion with an adhesive one at a time, thereby forming a cylindrical winding structure having at least the working conductor portion adhered; and (3) a resin as the encapsulant. The structure is encapsulated using a composition, while the structure is Phase and, (4) to include at least one of the rotary permanent magnet rotor structure, a manufacturing method including the steps of completing the assembly of the electromechanical transducer, the adhering to the shell. 2. A slotless stator consisting of a metal structure having a preformed at least partly rigid winding structure inside a stator shell and a rotor provided with one or more permanent magnets. A method of manufacturing a rotary electric converter comprising: (1) distributing and attaching an insulated conductor while the scribing means of the conductor is on a cylindrical support surface; At least one of the supporting surfaces or both of them is provided with an adhesive layer that can be activated by applying energy, and (a) a part of the insulated conductive wire is provided on the supporting surface. (B) being disposed parallel to the axis of the cylindrical support surface while moving toward one end of the cylindrical support surface to form a working conductor portion of the winding structure; End wrap (C) thereafter distributing a portion of the insulated wire while moving in a reverse direction parallel to the axis, Forming another working conductor portion of the winding structure; and (d) then distributing a portion of the insulated wire to form another wire loop forming a folded portion at the end. (E) repeating the steps (a) to (d) until all winding coils of the winding structure are completed; and (2) forming the insulated conductor. Substantially simultaneously with distributing at least a portion, continuously attaching at least a portion of each working conductor portion with an adhesive to form a cylindrical winding structure to which at least the working conductor portion is bonded; Attach the winding structure of the stator shell with adhesive Enclosing the winding structure with a resinous composition during the operation, and (4) disposing a rotor having at least one permanent magnet in the winding structure to complete the assembly of the electromechanical converter. And a manufacturing method. 3. The method according to claim 1, wherein the winding structure is formed by applying a pressure or a pressure and a temperature sufficient to temporarily convert an adhesive into a plastic state. A manufacturing method comprising compressing. 4. The method according to claim 3, wherein the structure is compressed before enclosing the structure and firmly attaching it to the metal structure of the slotless stator. 5. The method according to claim 3, wherein the step of compressing is performed with encapsulation. 6. The manufacturing method according to claim 1, wherein at least one end of the winding structure has a folded portion displaced in a direction perpendicular to the axis of the cylindrical support. . 7. The manufacturing method according to claim 6, wherein the winding structure is inserted into the outer shell of the slotless stator with the inwardly displaced end turning portion first. Production method. 8. A method according to claim 1 or 2, wherein the expandable means is inserted into the interior thereof and an outwardly directed pressure or pressure and heat is applied to activate the adhesive. A method of manufacturing, comprising further compressing the winding structure outward by temporarily converting to a plasticized state. 9. The method according to claim 1, wherein the insulated conductor is coated with an adhesive and disposed between guides with respect to the cylindrical support surface, and substantially with respect to an axis of the cylindrical support. Forming a working conductor portion extending in parallel, tensioning the insulated conductor between the guides, and after applying the tension, forming at least a portion of the working portion on or before the support surface; Fixing to the surface of the conductor layer. 10. The method according to claim 1, wherein the winding structure is disposed in a plurality of conductor layers. 11. The manufacturing method according to claim 1, wherein the adhesive is applied to the attached conductor before the next winding layer is attached. 12. The method according to claim 1, wherein the adhesive is activated by applying ultrasonic, infrared, heat or laser energy. 13. The method according to claim 1, wherein the adhesive is in a solid and non-adhesive state when in an inactivated state, and by applying a certain level of energy. A manufacturing method in which the solid state is activated by the activity to a bondable plastic state, and when the application of energy is stopped, the solid state returns to the non-adhesive state. 14. The method according to claim 13, wherein:
The adhesive is activated to its adhesive state by applying a certain level of energy, and at a later stage is completely cured to its thermoset state by applying a higher level of energy. Manufacturing method. 15. The method according to claim 1, wherein the encapsulant and the adhesive for encapsulating the winding structure are almost completely cured at the same time. 16. The production method according to claim 1, wherein the encapsulant contains a filler having a high thermal conductivity. 17. The method according to claim 16, wherein:
A manufacturing method in which a part or all of the filler is composed of finely pulverized particles of a weak magnetic material. 18. The method according to claim 17, wherein
A production method wherein the particles are pre-coated with an electrical insulating layer. 19. The manufacturing method according to claim 1, wherein a part or all of the magnetic stator structure is made of a resin composition filled with finely ground particles of a weak magnetic material. A manufacturing method formed by an injection molding method and attached to an outer surface of the winding structure. 20. The method according to claim 1, wherein a conductor made of the weak magnetic material is applied to an outer surface of the formed winding structure to form a magnetic stator structure surrounding the winding. The method comprises: (a) disposing a wire coated with an adhesive made of a weak magnetic structure in a plurality of layers surrounding the winding structure; and (b) winding the wire made of the magnetic material into the winding. A manufacturing method, comprising: adhering to the outer surface of the structure and to each other with an adhesive; and (c) consolidating the formed structure by applying energy and pressure. 21. An apparatus for manufacturing a self-supporting winding structure for a slotless stator including an outer shell of a magnetic stator, comprising: (a) a cylindrical carrier mandrel providing a cylindrical support surface; (C) means for controlling the rotational position of the mandrel; and (c) means for distributing an insulated conductor coated with an adhesive which can be activated into a plastic adhesive state by applying energy. D) moving said distributing means so as to arrange the insulated conductor parallel to the axis of said cylindrical mandrel to form the working conductor portion of the winding structure and to distribute the wire to end portions between said working conductor portions; And (e) activating the adhesive coating to the plastic adhesive state and simultaneously bonding at least a portion of the working conductor portion one by one to form a self-supporting device. Means for forming a linear structure, and means for securing the (f) the insert a self-supporting winding structure into the outer shell of the stator, said winding structure therein,
An apparatus comprising: 22. Apparatus according to claim 21, further comprising a retractable guide pin provided in the area of the mandrel and forming a tip for the working conductor part. 23. An apparatus for manufacturing a self-supporting wound structure for a slotless stator including an outer shell of a magnetic stator, comprising: a cylindrical carrier mandrel providing a cylindrical support surface; and rotation of the mandrel. A driving device for controlling the position; a means for distributing an insulated wire coated with an adhesive which can be activated into a plastic adhesive state by applying energy; and moving the dispensing means to move the insulated wire. A drive device attached parallel to the axis of the cylindrical mandrel to form the working conductor portion of the wire structure and to distribute windings to form end turn portions between the working conductor portions; While the windings are being dispensed, the adhesive coating is continuously activated into the plastic adhesive state, and at least a portion of the working conductor portion is adhered to form a self-supporting winding structure. And means for forming a. 24. Apparatus according to claim 22 or claim 23, wherein the mandrel comprises a reduced diameter region corresponding to a turn at the end of a winding structure formed on the support surface. 25. Apparatus according to claim 22 or 23, comprising a plurality of means for simultaneously distributing insulated conductors at different radial positions on the cylindrical support.