JP4718383B2 - Claw pole DC brushless motor - Google Patents

Description

  The present invention relates to an improvement in productivity of a claw pole DC brushless motor composed of a molded yoke.

  In a claw-pole type stepping motor having a shape in which one substantially cylindrical rotor having a central axis is wrapped by two cup-shaped stators from both end face directions of the rotor, each of the two stators includes at least one magnetic coil, In a structure in which both stators are joined in a face-to-face state with two pairs of pole teeth that are magnetically coupled and the magnetic phase difference at the tip of the pole teeth is 180 ° in electrical angle. A claw pole type stepping motor is disclosed in Patent Document 1 in which both stators are coupled to each other by a hollow fixing pipe passing through in the axial direction in a face-to-face state. In this claw pole type stepping motor, the number of parts can be reduced to reduce the labor of assembly.

JP 2005-33977 A

  An object of the present invention is to provide a claw pole DC brushless motor having a structure in which the number of parts and productivity are improved in a claw pole DC brushless motor using a molded yoke.

  According to the present invention, in order to reduce the types of molding die of the molding yoke, the positioning of the molding yoke constituting the phase and the positioning used in configuring each phase are configured by the molding die of one type of molding yoke. The productivity of electrical work was improved by reducing the types of molds and making the lead part a terminal and resin molding.

  According to the present invention, since the molding die of the molding yoke can be constituted by one type, there are the effects that the number of parts of the molding yoke can be reduced and the productivity of the electrical work can be improved by forming the lead portion as a terminal and resin molding.

  Embodiments of the present invention will be described below with reference to the drawings.

  FIG. 1 is a developed view of an inner diameter side of a stator 1 of a claw pole DC brushless motor. In the stator 1, a tooth 3 a formed integrally with the forming yoke 2 a and a tooth 3 b formed integrally with the forming yoke 2 b are formed via a gap 4. The gap 4 here is a gap between the teeth, which is a slit in a normal stator.

  The molding yoke 2a and the molding yoke 2b are made of resin powder coated with iron powder and molded with an injection molding machine. In this case, the saturation magnetic flux density is reduced, but the productivity is improved. Further, the bending strength and compressive strength of the molded product can be increased.

  Further, when the molding yoke 2a and the molding yoke 2b use only iron powder or resin-coated iron powder as a material, the molding yoke is produced by pressure molding. However, as an advantage, the saturation magnetic flux density can be increased. As the mechanical strength, the compressive strength is large, but the bending strength is small. Therefore, as a reinforcing method, the part where the bending strength is applied is fixed with a mold, and the injection pressure is applied to the molding yoke so that bending stress is not applied to the molded yoke. The gate position is placed from the inside to the mold side so as to be on the side, and the interior is resin-molded to leave a space for the winding, so that the resin part can have a structure that has both insufficient bending strength and insulation. .

  As another method, the bending strength can be improved by sintering at a high temperature of several hundred degrees, and the bending strength can be improved by securing the accuracy by sizing, but the loss due to high frequency magnetic flux increases so the low frequency region That is, it can be used at 150 Hz or less because the influence of loss reduction is small.

  These formed yokes are used properly according to the application.

  A front view and a longitudinal sectional view of the forming yoke 2 of this embodiment are shown in FIG. The number of teeth 3 is 18 on one side and 36 on both sides. Since the forming yoke 2 of the claw pole DC brushless motor has a three-dimensional shape, it cannot be laminated by punching a steel plate, and is therefore formed with iron powder.

  FIG. 2 shows an AA cross section of the portion including the terminal portion of the stator 1. The forming yoke 2a and the forming yoke 2b have a mating structure at the center of the outer peripheral surface 5. The terminal 6 is drawn out from a hole portion 7 formed by a notched portion of the forming yoke 2a and the forming yoke 2b provided on the outer peripheral surface 5, and is formed and fixed to the terminal portion by the resin mold 8, and wound around the winding bobbin 9. Inner diameter portions of the forming yoke 2a and the forming yoke 2b including the winding 10 are molded. The terminal 6 is fixed by winding an insulating tape 11 in the circumferential direction for temporary fixing until the resin mold 8 is performed. For this reason, the terminal 6 can be moved up and down to a certain degree to facilitate fixing the terminal 6 to the mold. As shown in FIG. 8, the terminal 6 and the winding are connected to each other by cutting and raising a part of the terminal 6 to temporarily crimp the winding 10 and using fusing to make it easy to automate the height direction. Since the connection can be reduced, the space between the winding 10 and the forming yokes 2a and 2b can be narrowed, and the size can be reduced.

  FIG. 3 shows a partial cross section when resin molding is performed with a mold. A molding die is constituted by a lower die 30 which is a fixed die and an upper die 31 which is a movable die. Although not shown, the terminal 6 is partially pressurized and fixed so that a resin burr is not stretched by a middle piece with a spring action. Further, a plurality of gates 32 for injecting resin are provided in a hole 7 provided in the terminal 6 for drawing out. Further, in the case of a dust core, the bending strength is weak, so that the end surface 33 of the teeth 3a and the end surface 34 of the teeth 3b are reversely tapered so as not to be deformed to the inner diameter side by the resin during resin molding. Also, by fixing with a molding die on the inner diameter side, deformation due to pressure during injection can be prevented, and an accurate resin molded stator can be obtained. Further, the pressure at the time of molding by the resin mold determines the gate position so that the molding die is formed from the inside of the molding yoke 2a and the molding yoke 2b.

  FIG. 4 relates to the position example of the present invention, and shows a partial view of the forming yoke 2a as seen from the outer peripheral side. The interval between the teeth 3a is 360 degrees in electrical angle. The combination of the concave 40, convex 41, and concave 42 provided on the outer peripheral portion has an interval of θ1, that is, an electrical angle of 180 degrees. The electrical angle depends on the number of poles of the rotor. That is, since the electrical angle between the same poles is 360 degrees, the actual mechanical angle changes when the number of poles changes, so it is necessary to prepare the mold according to the number of poles. Note that the convex and concave portions can be easily aligned because the fitting tolerance is a gap fitting.

  FIG. 5 relates to the position example of the present invention, and shows a partial view seen from the outer peripheral side in which two identical molded yokes 2a are combined vertically. The upper and lower molding yokes have concave and convex positioning for the first from the left, the concave molding 42 for the lower molding yoke, the upper molding yoke has no irregularity, the second molding for the lower molding yoke 41, the upper molding yoke for the concave 40, and three The lower forming yoke is concave 40, the upper forming yoke is convex 41, the fourth is the lower forming yoke without unevenness, and the upper forming yoke is concave 42, with the same uneven shape and alignment at the interval of θ1. it can. Note that θ1 is an electrical angle of 180 degrees. Thus, by combining the same molded yoke, it is possible to configure a claw pole stator in which teeth at an electrical angle of 180 degrees are alternately arranged. This combination can achieve the same effect by a combination of one convex and two concaves, and each interval being θ1.

  FIG. 6 relates to a position embodiment of the present invention, and shows a partial view of a stator in which terminals 6 are formed by a resin mold 8. There are four intervals between the terminals as θ2. θ2 is an electrical angle of 120 degrees. Further, in the stator 1, the interval between the upper surface convex 61 and the upper surface concave 62 is 2θ2, the interval between the upper surface convex 61 and the lower surface concave 63 is θ2, and the interval between the lower surface concave 63 and the lower surface convex 64 is 2θ2. . Thereby, the positioning unevenness between the four terminal hole portions 7 and the stators of the respective phases can be configured by the same upper and lower molds.

  FIG. 7 relates to a position embodiment of the present invention. When the stator 1 is combined with three phases of the U phase 71, the V phase 72, and the W phase 73, the arrangement of the terminals 6 and the positioning irregularities of the stator of each phase are shown. The partial figure showing the relationship of is shown.

The terminals 6 of the U phase 71 are arranged in the hole 71a and the hole 71d. The terminals 6 of the V phase 72 are arranged in the hole 72a and the hole 72c. The terminals 6 of the W phase 72 are disposed in the hole 73a and the hole 73b. The terminal 6 arranged in the hole 71d, the hole 72c, and the hole 73b is a neutral point of the Y connection. On the power supply side, the hole 71a in the U phase, the hole 72a in the V phase, and the hole 72a in the W phase The terminal 6 arranged in the hole 73a is a power supply terminal. Further, the hole 71d, the hole 72c, and the hole 73b, which are neutral points, are arranged in a straight line and are short-circuited by a connector 75. In each phase of the stator, the upper surface protrusion 61 and the upper surface recess 62 are fitted to the lower surface recess 63 and the lower surface protrusion 64 provided on both end faces. The terminals 6 are fixed by resin molding from the holes arranged in a straight line. Since the connector 75 has a different thickness and the distance between the terminals is different, the connector 75 is required for each thickness. However, two shorts between the terminals are caulked with a conductor and short-circuited so that the distance between the terminals is increased. Can also be connected. Further, in order to prevent the terminal incorporated in the connector from being detached, the terminal of the positive block is used, so that even if a force is applied to the conductor with a small insertion force, the reliability and workability are improved.

  Since the U-phase 71, V-phase 72, and W-phase 73 stators have different terminal exit positions, the resin mold is provided with a movable middle piece with springs at the positions of the four terminal exits. Since molding can be performed regardless of the presence or absence of the stator, U-phase 71, V-phase 72, and W-phase 73 stators can be produced using the same molding die only at the position where the winding terminal is attached. Can be eliminated and the operating rate can be increased. In addition, since one type each of the molding die of the molding yoke and the mold of the resin mold can be produced, the production can be performed with a small investment, and the operating rate of the molding die is improved, so that the production cost can be reduced.

FIG. 4 is a developed view of the inner diameter side of the stator of the claw pole DC brushless motor according to the embodiment of the present invention. The AA cross section of the part which concerns on the Example of this invention and contains the terminal part of a stator is shown. It concerns on the Example of this invention, and the partial cross section when resin-molding with a shaping | molding die is shown. FIG. 4 is a partial view of the forming yoke as viewed from the outer peripheral side according to the embodiment of the present invention. The partial view seen from the outer peripheral side which concerns on the Example of this invention and combined two shaping | molding yokes is shown. The partial view of the stator which concerns on the Example of this invention and the terminal was shape | molded by the resin mold is shown. FIG. 4 is a partial view showing the relationship between the arrangement of terminals and the positioning irregularities of the stator of each phase when the stator is combined with three phases of the U phase, the V phase, and the W phase according to the embodiment of the present invention. The partial figure which concerns on the Example of this invention and wound the coil | winding to the terminal is shown. The front view and longitudinal cross-sectional view of a shaping | molding yoke are based on the Example of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Stator, 2a, 2b, 2c ... Molding yoke, 3a, 3b, 3c ... Teeth, 6 ... Terminal, 8 ... Resin mold, 9 ... Winding bobbin, 10 ... Winding, 40, 42 ... Concave, 41 ... Convex 61 ... convexity on the upper surface, 62 ... concave on the upper surface, 63 ... concave on the lower surface, 64 ... convex on the lower surface.

Claims (7)

Teeth are alternately arranged on the inner diameter or outer diameter so as to sandwich the winding bobbin, and the winding bobbin is surrounded by each forming yoke constituting the teeth in the opposite direction to the teeth in the same direction, and magnetically integrated. Claw pole DC brushless motor
A claw pole DC brushless motor characterized in that a positioning unevenness is provided by a combination of two concave portions and one convex portion at an electrical angle interval of 180 ° at the mating portion for positioning both yokes.   2. The claw pole DC brushless motor according to claim 1, wherein the number of holes in the joints of the terminal drawing hole forming yoke of the stator constituting each phase is four, and each interval is 120 degrees in electrical angle. The claw pole DC brushless motor is characterized in that the terminal arrangement of each phase is shifted every 120 degrees as 360 degrees, 240 degrees, and 120 degrees. 3. The claw pole DC brushless motor according to claim 1 or 2, wherein a convex portion and a concave portion for alignment are provided on the front and back sides of the yoke end surface constituting the stator of each phase, and the electrical angle is set to 240 degrees relative to each other. Claw pole DC brushless motor.   The claw pole DC brushless motor according to any one of claims 1 to 3, characterized in that the claw pole DC brushless motor comprises a single mold for forming a molding yoke by sharing positioning irregularities. .   5. The claw pole DC brushless motor according to claim 1, wherein a winding bobbin in which a winding is wound around an insulating bobbin and a winding is connected to a terminal is resin-molded. Claw pole DC brushless motor.   The claw pole DC brushless motor according to any one of claims 1 to 5, wherein the gate position of the resin mold is a hole position of a molding yoke joint. The claw pole DC brushless motor according to any one of claims 1 to 6, wherein the claw pole DC brushless motor is used in a washing machine or a washing / drying machine as its application.

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