JP3741091B2 - DC brushless motor and sealless pump using it - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a DC brushless motor having a long life and high efficiency, and a sealless pump using the same, by laying out, fixing and assembling a board on which a magnetic pole position sensor and a driver IC for driving a motor are mounted.
[0002]
[Prior art]
Conventionally, a DC brushless motor that uses a magnetic pole position sensor such as a Hall element to detect a magnetic pole position and controls a driver IC so as to switch a current direction based on this position signal has an armature of a motor core (stator). It has been difficult to shorten the coil end length because of the need to arrange a coil and a magnetic pole position sensor. Recently, however, there is an increasing demand for downsizing and thinning.
[0003]
Hereinafter, a conventional thinned DC brushless motor will be described with reference to a configuration diagram of a conventional thinned DC brushless motor shown in FIG. 6 (see, for example, Patent Document 1).
[0004]
As shown in FIG. 6, the conventional DC brushless motor is configured by arranging a magnet rotor 106 around the armature 108. A driver IC 113 that drives the motor by switching a current flowing through the winding coil 110 of the armature 108 is provided on the substrate 112, and is disposed at the center of the armature 108. The substrate 112 on which the driver IC 113 is mounted is placed on the shield plate 114 and fixed to the armature 108. The magnet rotor 106 on the rotation side is held by the rotor frame 107 and is disposed at a position facing the armature 108.
[0005]
A magnetic pole position sensor 115 for detecting the magnetic pole position of the magnet rotor 106 is also disposed on the substrate 112, and the driver IC 113 receives an output signal from the magnetic pole position sensor 115, and the current passed through the winding coil 110 of the armature 108. To control. As a result, the armature 108 becomes an electromagnet and is attracted and repelled with the magnetic poles of the magnet rotor 106, and rotational torque is generated in the magnet rotor 106.
[0006]
With this configuration, the conventional DC brushless motor can easily perform pattern wiring from the driver IC 113, and the area of the pattern wiring with respect to the substrate 112 can be reduced, so that the outer shape of the substrate 112 can be reduced. The DC brushless motor can be miniaturized. Further, there is no restriction received from the winding coil 110 wound around the armature 108, and a thin DC brushless motor can be obtained.
[0007]
[Patent Document 1]
Japanese Patent No. 3106582 [0008]
[Problems to be solved by the invention]
However, in the conventional DC brushless motor, since the board on which the magnetic pole position sensor and the driver IC are mounted is arranged with an appropriate gap from the coil end of the stator core constituting the armature, the position of the coil end The thickness of the motor is determined by the thickness of the substrate. Due to this limitation, there has been a limit to reducing the thickness of the DC brushless motor.
[0009]
Moreover, when fixing the board | substrate which mounts a magnetic pole position sensor, the variation in attachment generate | occur | produced with respect to an armature, Therefore, it had the subject that the performance of a motor varied.
[0010]
Furthermore, when a DC brushless motor is used in a sealless pump, the stator core is fixed to a separation plate for isolating the pump operating part of the sealless pump from the electric part on the drive side. There were also problems such as fluctuations in the position and direction of the motor, resulting in variations in motor performance, and increased vibration and noise levels.
[0011]
In order to solve the above-mentioned conventional problems, the present invention ensures a stable motor performance and vibration / noise level, can improve motor efficiency, and can reduce the number of parts and assembly man-hours. An object is to provide a DC brushless motor.
[0012]
It is another object of the present invention to provide a sealless pump that can secure motor performance and stability of vibration and noise levels, and can reduce the number of parts and the number of assembly steps.
[0013]
[Means for Solving the Problems]
In order to solve the above problems, a DC brushless motor according to the present invention has a substrate fixed to the central portion of a stator core, the central substrate portion extending from the central substrate portion to the salient pole, and a winding coil. And an arm substrate part that is interposed between them, a driver IC is mounted on the central substrate part, and a magnetic pole position sensor is mounted on the arm board part.
[0014]
As a result, the stability of the motor performance and vibration / noise values can be achieved, the motor efficiency can be improved, and a thin DC brushless motor capable of reducing the number of parts and the number of assembly steps can be realized. .
[0015]
The sealless pump of the present invention includes the above-described DC brushless motor, and is characterized in that a core press-fitting stopper and a substrate fixing stopper are provided on a separation plate provided in a gap between the magnet rotor and the armature.
[0016]
As a result, the motor performance and vibration / noise level stability can be secured, and the number of parts and the number of assembly steps can be reduced.
[0017]
DETAILED DESCRIPTION OF THE INVENTION
According to a first aspect of the present invention, there is provided a stator iron core provided with salient poles at the tips of a plurality of teeth, an armature provided with winding coils wound around the teeth, and salient poles. A DC provided with a magnet rotor arranged opposite to each other, a plurality of magnetic pole position sensors for detecting the magnetic pole position of the magnet rotor, and a driver IC for controlling a current flowing through the winding coil in accordance with an output signal from the magnetic pole position sensor A brushless motor, in which a substrate is fixed to the central portion of the stator core, and the substrate includes a central substrate portion disposed inside the winding coil, and a space between the winding coil from a predetermined location of the central substrate portion. And an arm substrate portion fixed at a predetermined position of the salient pole through,
Since it is a DC brushless motor characterized in that a driver IC disposed on the armature side of the central substrate portion is housed in the hole and a magnetic pole position sensor is disposed on the armature side of the arm substrate portion . Unlike conventional DC brushless motors, the height of the board and mounting parts and the gap are not added to the thickness of the motor with reference to the coil end, and the board is attached based on the stator core. The thickness can be made approximately the coil end length (the thickness of the winding coil), and the DC brushless motor can be dramatically reduced in thickness.
[0018]
According to a second aspect of the present invention, there is provided a DC brushless motor according to the first aspect, wherein a positioning projection is formed on the stator iron core, and a hole is formed in the substrate for fitting with the positioning projection. As a result, the mounting accuracy of the substrate is improved, thereby suppressing variations in the magnetic pole position detection of the magnetic pole position sensor among individual motors and improving the stability of the motor performance.
[0019]
Invention according to claim 3, claim stator core, laminated steel plate, along with being integrally caulked by the caulking portion, wherein the positioning projections by the caulking portion is formed 2 Since the DC brushless motor is described , the caulking portion serves as a positioning protrusion, the number of protrusions can be reduced, the magnetic resistance of the stator core is increased, and the iron loss of the stator core is thereby increased. Therefore, the motor efficiency is not reduced.
[0020]
According to a fourth aspect of the present invention, the pitch angle between two teeth adjacent to the arm substrate portion of the substrate is different from each other by widening the angle θ1 in directions away from each other on the basis of the equiangular pitch angle. The DC brushless motor according to any one of claims 1 to 3, wherein the pitch between the winding coils is widened, and the substrate area on which the magnetic pole position sensor is arranged is enlarged. The degree of freedom of the advance position of the sensor is increased, and the motor efficiency can be improved. In addition, a sufficient width can be secured even in the minimum width portion of the substrate, and the strength of the substrate can be improved.
[0021]
The invention according to claim 5 is characterized in that the pitch angle between the teeth other than the two teeth adjacent to the arm substrate portion of the substrate is narrowed by an angle θ2 on the basis of the equiangular pitch angle. Since it is a DC brushless motor according to claim 4, the pitch between the substrate, the winding coil and the coil can be set to the minimum, and the motor efficiency can be improved.
[0022]
Invention of claim 6, a seal-less pump with a DC brushless motor according to any one of claims 1 to 5, the core pressed stoppers separation plate provided in the gap between the magnet rotor and the armature And a board-fixing stopper. Therefore, the number of board-fixing parts can be reduced and the number of assembling steps can be reduced. Furthermore, since the press-fitting position of the stator core can be accurately determined with respect to the pump, the occurrence of variations in the magnet center force with the magnet rotor can be suppressed, and the stability of the vibration and noise values of the individual motors can be achieved.
[0023]
(Embodiment 1)
Hereinafter, Embodiment 1 of the present invention will be described with reference to FIGS. FIG. 1A is a configuration diagram in the case where the board mounting component of the DC brushless motor according to Embodiment 1 of the present invention is mounted on the board surface opposite to the armature, and FIG. 1B is the DC of FIG. FIG. 2A is a cross-sectional view of the brushless motor, FIG. 2A is a configuration diagram of the DC brushless motor according to Embodiment 1 of the present invention mounted on the board surface on the armature side, and FIG. 2 is a cross-sectional view of the DC brushless motor of FIG. When mounting a board-mounted component on the board surface opposite to the armature as shown in FIG. 1, it is preferable to use it when the mounted component is large, and as shown in FIG. When mounted on a substrate surface, the motor can be made thinner if it is used when the mounted parts are small.
[0024]
First, in FIGS. 1A and 1B, 1 is a stator core constituting an armature, 2 is a salient pole provided at the tip of an arm extending from the stator core 1, and 3 is from the center of the stator core 1. Teeth, which are radially extending arm portions, 4 is a winding coil wound around the teeth 3, 5 is a magnet rotor, and 6 is an armature. The armature 6 includes a stator core 1 (including salient poles 2 and teeth 3), a winding coil 4 and the like. As the stator core 1, a silicon steel plate having a large magnetic permeability and a thickness of about t = 0.2 to 0.5 mm is generally used in order to reduce iron loss and improve motor efficiency. Is formed by laminating a plurality of sheets. Windings are wound around the teeth 3 of the stator core 1 to form a winding coil 4 that forms a rotating magnetic field. The winding material wound as the winding coil 4 is obtained by applying a thin insulating film to a copper wire. A hole 301 is formed in the center portion of the stator core 1.
[0025]
The salient pole 2 disposed opposite to the magnet rotor 5 takes in the magnetic flux of the magnet into the stator core 1 as much as possible, and secures as much as possible the portion of the winding coil 4 that can be wound. It has a wide shape. The magnet of the magnet rotor 5 is preferably a ferrite that can be a permanent magnet or a metal-based magnetic material (SmCo or the like). The magnet rotor 5 generates torque in the rotational direction due to attraction and repulsion due to the magnetic force with the electromagnetic magnet generated by passing a current through the winding coil 4 applied to the stator core 1, and rotates the magnet rotor 5.
[0026]
7 is a magnetic pole break used to indicate the magnetic pole position of the magnet rotor 5, 8 is a magnetic pole position sensor such as a Hall element, 9 is a driver IC, 10 is a substrate, and 11 is a coil end length. In order to efficiently generate rotational torque in the magnet rotor 5, it is necessary to switch the direction of the current flowing through the winding coil 4 with good timing. To generate this timing signal, the magnetic pole of the magnet rotor 5 is detected by the magnetic pole position sensor 8. A break 7 is detected. The timing signal generated by the magnetic pole position sensor 8 is input to the driver IC 9, and the current direction that the driver IC 9 flows to the winding coil 4 is switched. Polarity switches. Here, the magnetic pole position sensor 8 and the driver IC 9 are mounted on the same substrate 10.
In the case of FIGS. 1A and 1B, the driver IC 9 is larger than the diameter of the hole 301 in the middle part of the stator core 1, so that the driver IC 9 is mounted on the opposite side to the armature 6. 10 also includes a magnetic pole position sensor 8. However, in this case, the thickness of the board 10 fixed to the stator core 1 and the height of the mounted component are larger than the coil end length 11 that determines the thickness of the armature 6. However, even if the thickness is reduced, the thickness may be slightly larger than the coil end length.
[0027]
The most characteristic configuration of the C brushless motor according to the first embodiment of the present invention is the shape of the substrate 10 and the layout performed on the armature 6. As can be seen from FIGS. 1A and 1B, the shape of the substrate 10 is a virtue shape composed of a central substrate portion 10a and an arm substrate portion 10b. This is due to the following reason. The magnetic pole position sensor 8 must be as close to the magnet rotor 5 as possible in order to detect the magnetic pole position (magnetic pole break 7). Further, since the driver IC 9 requires a mounting area several times that of the magnetic pole position sensor 8, the driver IC 9 needs to have a layout mounted on the central portion of the stator core 1. For this reason, the magnetic pole position sensor 8 is mounted on the arm substrate portion 10b, and the driver IC 9 is mounted on the central substrate portion 10a. In order to fix the substrate 10 on the stator core 1, it is necessary to fix the substrate 10 while avoiding the winding coil 4. Therefore, the base of the arm substrate portion 10 b is a dimension having a minimum width B or less between the winding coils 4. Thus, the arm substrate portion 10b is securely fitted between the two winding coils 4 so that the substrate 10 is mounted on the stator core 1. For this reason, the shape of the substrate 10 is a virtue shape.
[0028]
By laying out the board 10 on which the mounting components are mounted on the armature 6 in this way, in the conventional technique, the coil end length 11 and the thickness of the board 10 and the height of the mounting parts (driver IC 9 or magnetic pole position sensor 8) are increased. In the first embodiment, on the other hand, the thickness of the substrate 10, the height of the mounted component, and half of the coil end length 11 are determined by the thickness of the stator core 1. Therefore, the thickness of the motor or the coil end length 11 determines the thickness of the motor, so that the motor can be made thinner. As an example, a motor having a power supply voltage of 5 V and a motor output of 200 mW can be made to have a thickness of 4 mm by the stator core 1 having an outer diameter of 20 mm. In addition, in the conventional technology for the same motor, what was realized at 7.5 mm is 4 mm, so that the thickness of the motor can be reduced to almost half. According to the first embodiment, the thickness can be significantly reduced. It can be seen that it can be realized.
[0029]
Next, when the mounting component shown in FIGS. 2 (a) and 2 (b) is mounted on the armature side substrate surface, it is almost the same as FIGS. 1 (a) and 1 (b). This means that the mounting surfaces of the magnetic pole position sensor 8 and the driver IC 9 on the substrate 10 are mounted on the armature 6 side. This is particularly effective when the driver IC 8 has a small capacity and a small size, whereby only the coil end length 11 determines the thickness of the motor, and the DC brushless motor can be surely made thinner.
[0030]
(Embodiment 2)
Next, a second embodiment of the present invention will be described with reference to FIG. FIG. 3A is a positioning and fixing diagram of the stator core and substrate of the DC brushless motor according to the second embodiment of the present invention, and FIG. 3B is a positioning and fixing cross section of the stator core and substrate of the DC brushless motor of FIG. FIG. Here, the description of the same reference numerals as in the first embodiment will be omitted to the description of the first embodiment.
[0031]
As shown in FIGS. 3A and 3B, positioning protrusions are provided so that the laminated steel sheets of the stator core 1 are not separated one by one. In the second embodiment, the positioning projection is configured as a crimping portion, and a projection 12a is formed on each steel plate. The steel plates are stacked and pressed by a press machine and crimped. The projections 12a form the positioning projections, and the stator core 1 itself is crimped and integrated. However, in the conventional general stator iron core 1, the uppermost steel plate (A side) is not provided with a protrusion so that the upper surface of the stator iron core 1 (A side in the sectional view in the figure) is flat. A round hole that is inserted through the pin of the lower steel plate is provided and positioned. On the other hand, in the second embodiment, a projection 12b, which is one of the projections 12a, is provided on the uppermost surface side (A side), and a notch 13 corresponding to the projection 12b is formed on the substrate 10 to form the projection 12b. The substrate 10 is positioned and fixed by engaging the notch 13 with the notch 13. In the second embodiment, three protrusions 12b and three notches 13 are formed on each steel plate, respectively. However, the number may be one, and if a plurality of protrusions 12 are formed, positioning is performed with higher accuracy. Moreover, the notch 13 formed in the board | substrate 10 may be hole shape.
[0032]
In the conventional DC brushless motor, since the board 10 is fixed by soldering by inserting a pin standing on the armature 6, the pin installation accuracy is poor, and the positional accuracy is 2.5 ° (physical angle). Corner)) and more than 5% variation in motor output. On the other hand, in Embodiment 3 of the present invention, positioning is performed by the plurality of protrusions 12a and 12b and the notch 13, so that the positional accuracy is an angle in the rotational direction and is suppressed by a deviation within 1 ° (physical angle). Can do. In the case of the 4-pole DC brushless motor shown in FIG. 3, this corresponds to an electrical angle of 2 ° or less, and a stability of 1% or less can be obtained as a variation in motor output.
[0033]
(Embodiment 3)
Next, a third embodiment of the present invention will be described with reference to FIG. FIG. 4 is an armature diagram in the case where the teeth of the DC brushless motor according to the third embodiment of the present invention are at unequal intervals.
[0034]
In a conventional DC brushless motor, a tooth 3 is arranged in the center of the salient pole 2. However, in the third embodiment, the two adjacent teeth 3a and 3b at the position where the substrate 10 is inserted are not located at the center position of the salient pole 2, but at positions where the teeth 3a and 3b are separated by an angle θ1. . In other words, the teeth 3a are arranged at an angle that is delayed by θ1 and the teeth 3b are advanced by θ1 from the case of the equal pitch angle, and the angle between the teeth 3a and 3b is widened. Thereby, the width of the portion B having the minimum width can be secured sufficiently in the shape of the bottle-like shape of the substrate 10, and the strength is improved. In addition, the installable width C indicating the degree of freedom of the layout position of the magnetic pole position sensor 8 is 2 to 3 ° (physical angle) in the past. The advance angle can be adjusted, and the motor efficiency can be improved by 2%.
[0035]
Further, in FIG. 4, the teeth 3 c and the teeth 3 d are also shifted from the center of the salient pole 2 by θ 2. That is, the pitch angle is narrowed by θ2 with reference to the case where all teeth are provided at an equal pitch angle. If the teeth 3a, 3b and the teeth 3c, 3d are not shifted, the distance between the teeth 3a, 3c and the teeth 3b, 3d is shortened, the space factor of the winding is reduced, and the motor efficiency is reduced. To do. However, in the fourth embodiment, a decrease in the space factor is suppressed by shifting the teeth 3a and 3b and the teeth 3c and 3d by θ1 and θ2, respectively. Here, in the case of a 4-slot motor as shown in FIG. 4, it is preferable that θ2 = θ1 / 3. In general, in the case of n slots, θ2 changes for each tooth, so the angle θ between teeth other than between teeth shifted by θ1 is
θ = (360 / n) −2θ1 / (n−1)
It is good to set it to a degree.
[0036]
(Embodiment 4)
Next, a sealless pump according to Embodiment 4 of the present invention will be described with reference to FIG. FIG. 5 is a configuration diagram in which the DC brushless motor according to Embodiment 4 of the present invention is used as a sealless pump motor.
[0037]
In FIG. 5, reference numeral 60 denotes a separation plate for isolating the pump operating unit that sends out the liquid that forms the sealless pump and the electrical unit on the driving side (mounting parts of the armature 6 and the substrate 10). If it is a normal pump, it has a shaft seal, but in a sealless pump, the separator plate 13 is interposed to seal the electric machine as a whole. In the fourth embodiment, the armature 6 is fixed by press-fitting while the inner peripheral surface of the separation plate 13 and the outer peripheral surface of the salient pole 2 are brought into contact with each other. As shown in FIG. 5, a core press-fit stopper 14 that is in contact with the upper surface of the salient pole 2 and determines the press-fit position when being press-fitted into the separation plate 13 from below the pump is integrated with the separation plate 13. Reference numeral 15 denotes a substrate fixing stopper that contacts the upper surface of the substrate 10 and determines the press-fitting position. At the time of press-fitting the substrate 10, the substrate 10 is sandwiched between the salient pole 2 and the substrate fixing stopper 15 positioned above the core press-fitting stopper 14 by the thickness of the substrate 10 and fixed accurately. This press-fitting can reduce the number of assembly steps. Further, there is no variation in the mounting direction that occurs when press-fitting and fixing, there is no vibration / noise caused by this, and the vibration / noise value is stabilized.
[0038]
(Embodiment 5)
Next, a sealless pump according to Embodiment 5 of the present invention will be described with reference to FIG. FIG. 7 is a configuration diagram in which the DC brushless motor according to Embodiment 5 of the present invention is used as a sealless pump motor.
[0039]
The same reference numerals as those in the first to fourth embodiments basically indicate the same configuration, and a description thereof will be omitted.
[0040]
The DC brushless motor according to the fifth embodiment is used as a motor for a sealless pump, and has the same configurations as those of the first to fourth embodiments. Further, the armature 6 is provided on the salient pole 2 side wall of the separation plate 13. A protrusion 310 is formed between the adjacent salient poles 2 for positioning.
[0041]
【The invention's effect】
As described above, according to the present invention, the DC brushless motor can be drastically reduced in thickness. In addition, variations in motor performance and vibration / noise values of the DC brushless motor can be eliminated to achieve stability. Further, the motor efficiency can be improved. In addition, it is possible to reduce the number of parts for fixing the substrate and the number of assembly steps, thereby reducing the cost.
[Brief description of the drawings]
FIG. 1A is a configuration diagram in the case where a board mounting component of a DC brushless motor according to a first embodiment of the present invention is mounted on a board surface opposite to an armature. FIG. 1B is a block diagram of the DC brushless motor of FIG. Sectional view [FIG. 2] (a) Configuration diagram when mounting board mounting component of DC brushless motor of Embodiment 1 of the present invention on board surface on armature side (b) Section of DC brushless motor of (a) FIG. 3 (a) Positioning and fixing diagram of stator core and substrate of DC brushless motor according to Embodiment 2 of the present invention (b) Positioning and fixing sectional view of stator core and substrate of DC brushless motor of (a) FIG. 4 is an armature diagram when teeth of a DC brushless motor according to Embodiment 3 of the present invention are unevenly spaced. FIG. 5 shows a DC brushless motor according to Embodiment 4 of the present invention as a motor for a sealless pump. Configuration diagram using a DC brushless motor in the diagram FIG. 6 embodiment 5 of the conventional thinned configuration diagram of a DC brushless motor [7] The present invention was used as a motor sealless pump EXPLANATION OF REFERENCE NUMERALS
DESCRIPTION OF SYMBOLS 1 Stator iron core 2 Salient pole 3 Teeth 4,110 Winding coil 5,106 Magnet rotor 6,108 Armature 7 Magnetic pole break 8,115 Magnetic pole position sensor 9,113 Driver IC
DESCRIPTION OF SYMBOLS 10,112 Board | substrate 10a Central board | substrate part 10b Arm board part 11 Coil end length 12a, 12b Protrusion 13 Notch 14 Core press-fit stopper 15 Substrate fixing stopper 60 Separation plate 301 Hole 310 Protrusion

Claims (6)

A stator core in which salient poles are provided at the tips of a plurality of teeth and a hole having a predetermined diameter is formed in the center , and an armature including a winding coil wound around each of the teeth;
A magnet rotor disposed opposite to the salient poles;
A plurality of magnetic pole position sensors for detecting the magnetic pole position of the magnet rotor;
A DC brushless motor comprising a driver IC for controlling a current flowing through the winding coil in accordance with an output signal from the magnetic pole position sensor,
A substrate is fixed to the central part of the stator core,
The board includes a central board part disposed inside the winding coil , and an arm board part fixed between the winding coil from a predetermined place of the central board part to a predetermined position of the salient pole. Is provided,
A DC brushless motor characterized in that a driver IC disposed on the armature side of the central substrate portion is accommodated in the hole and a magnetic pole position sensor is disposed on the armature side of the arm substrate portion . 2. The DC brushless motor according to claim 1 , wherein a positioning projection is formed on the stator iron core, and a hole is formed in the substrate for fitting with the positioning projection. 3. The DC brushless motor according to claim 2 , wherein the stator iron core is integrated by caulking a laminated steel plate by a caulking portion, and the positioning projection is formed by the caulking portion. Claims pitch angle between two teeth adjacent to the arm board portion of the substrate, and the pitch angle of the equal angle to the reference, characterized in that it is a pitch angle different spread by respective angles θ1 away from each other Item 4. A DC brushless motor according to any one of Items 1 to 3 . 5. The DC brushless motor according to claim 4 , wherein a pitch angle between teeth other than two teeth adjacent to the arm substrate portion of the substrate is narrowed by an angle θ <b> 2 on the basis of an equiangular pitch angle. . A sealless pump comprising the DC brushless motor according to any one of claims 1 to 5 , wherein a core press-fitting stopper and a substrate fixing stopper are provided on a separation plate provided in a gap between the magnet rotor and the armature. A sealless pump characterized by that.

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