JP4974482B2 - Flat coreless motor, armature in flat coreless motor, and manufacturing method thereof - Google Patents

Description

  The present invention relates to a flat coreless motor suitable for use in general industrial equipment, home appliances, electrical equipment, etc., so-called flat motors, and in particular, using an armature that is formed by mixing magnetic powder into a molding resin. The present invention relates to a flat coreless motor, an armature in a flat coreless motor, and a method for manufacturing the same, and further relates to a flat coreless motor whose output shaft can be easily connected to an external driven body.

  In recent years, flat coreless motors have been widely used as various drive sources, taking advantage of their thinness, small size, and light weight, from general industrial equipment and home appliances to electrical equipment (for automobiles). Recently, there has been a strong demand for higher efficiency of devices due to the trend toward energy saving, and miniaturization of motors as drive sources has been increasingly demanded. At the same time, demand for high efficiency and high torque has been increasing. In particular, the coreless motor is excellent in torque ripple because it has no iron core, but on the other hand, there is a limit to the increase in torque because of its fast magnetic saturation and poor output characteristics.

Examples of conventional flat coreless motors are disclosed in Patent Document 1, Patent Document 2, and the like. Patent Document 1 discloses a flat motor formed by integrally molding a flat coil into a disk shape with a resin molding material mixed with magnetic powder (soft iron powder). As a result, when an armature current flows through the single coil group of the rotor, the magnetic circuit resistance composed of the field part, the air gap, the rotor disk, the air gap, and the stator frame is reduced, and the output characteristics are improved. ing.
Patent Document 2 discloses a technique in which a rectangular copper wire is wound around an armature coil to eliminate a gap between adjacent coils and improve the coil space factor.
JP 61-46879 JP 60-96985

However, when magnetic powder is mixed with a resin mold material, a magnetic path can be formed inside the armature, but magnetic flux amplification between the armature and the magnet cannot be expected, and it cannot contribute to improvement of output characteristics. Similarly, even if the armature coil is formed by winding a rectangular copper wire, the space factor is improved, but a remarkable effect of output characteristics cannot be expected.
In addition, in a conventional flat coreless motor, in order to transmit the output to an external driven body (load), it is necessary to connect a coupling member such as a coupling member to the output shaft, which makes the structure complicated. At the same time, it is necessary to cause the motor output shaft to protrude from the motor body, which limits the miniaturization of the motor, and thus limits the degree of freedom in designing the driven body (loading means).

SUMMARY OF THE INVENTION The present invention has been made in view of the above-described conventional problems. A flat coreless motor capable of greatly improving output characteristics with a simple configuration without increasing the size of the motor, and an electric machine in the flat coreless motor. It aims at providing a child and its manufacturing method.
It is an object of the present invention to provide a flat coreless motor that can easily connect an output shaft to a load means with a simple configuration and that can be applied to various applications by taking advantage of the flat shape.

In order to solve the above-mentioned problems, a flat coreless motor according to claim 1 of the present invention has a plurality of single coils each wound in a round shape or a polygonal shape around the rotating shaft in the axial direction of the rotating shaft. A planar armature that is annularly disposed on a plane perpendicular to the surface and molded with a resin, and at least one surface side of the plane of the armature via a gap in the axial direction of the rotary shaft A flat coreless motor having a ring-shaped magnet disposed opposite to the one surface and rotatably supporting one of the armature or the magnet with respect to the other;
The resin for molding the armature is mixed with magnetic powder, and the magnetic powder is magnetized in the axial direction of the rotary shaft, thereby generating an electromagnetic force generated by passing a current through the armature coil, and a constant It is driven by superimposing the magnetic flux of the magnetic powder magnetized in the direction and the magnetic flux of the magnet.
According to a sixth aspect of the present invention, there is provided a method for manufacturing an armature in a flat type coreless motor, wherein a planar armature and at least one of the planes of the armature are arranged in the axial direction of a rotating shaft. An armature in a flat type coreless motor having a magnet annularly arranged on one surface through a gap and having one of the armature or the magnet rotatably supported with respect to the other A manufacturing method of
A plurality of single coils each wound in a round shape or a polygonal shape are annularly arranged on a plane perpendicular to the axial direction of the rotating shaft around the rotating shaft to create a planar armature,
Magnetic powder is mixed with resin for molding in advance.
The armature is molded with the resin in a state where a magnetic field is applied to the resin in a direction along the axial direction of the rotation axis, and thereby the magnetic powder is magnetized in the axial direction of the rotation axis. And

Preferably, each of the plurality of single coils is formed by winding a flat copper wire.
Preferably, the armature has a bent portion bent in the axial direction of the rotary shaft from a position outside the rotary shaft and on the inner side of the magnet not facing the magnet. And
Preferably, the surface of the magnetic powder powder is provided with an insulating film formed by an insulating treatment, and the mixing ratio of the magnetic powder in the resin is about 40 to 60% by weight.

In order to solve the above-mentioned other problems, a flat coreless motor according to claim 9 of the present invention has a plurality of single coils wound in a round shape or a polygonal shape around the rotation shaft. A planar armature that is annularly disposed on a plane perpendicular to the axial direction and molded with resin, and a gap is formed in the axial direction of the rotary shaft on at least one surface side of the plane of the armature. A flat coreless motor having a magnet annularly disposed on one surface of the armature and having one of the armature or the magnet rotatably supported with respect to the other,
The resin for molding the armature is mixed with magnetic powder, and the magnetic powder is magnetized in the axial direction of the rotary shaft, thereby generating an electromagnetic force generated by passing a current through the armature coil, and a constant Driven by superposition of the magnetic flux of the magnetic powder magnetized in the direction and the magnetic flux of the magnet, a hole is disposed on the rotating shaft concentrically with the axis, and the hole is provided from the outside. One end side of the screw member can be fitted.

Preferably, an actuator of an automobile, for example, is coupled to, connected to or abutted with the rotating shaft via the screw member, and is used as a drive source for the actuator of the automobile.
Preferably, the screw hole is a bottomed hole that is screwed into a nut shape at an axial center portion of the rotating shaft.
Preferably, further, on the other surface side of the plane of the armature, the other surface is annularly opposed to the other surface through a gap in the axial direction of the rotation shaft, and the armature is interposed between the armature and the armature. And having another magnet arranged so as to face each other.

  According to the first and sixth aspects of the present invention, magnetic powder is mixed into the armature mold resin, and molding is performed in a state where a magnetic field is applied to the resin during molding. The magnetism can be generated in the armature itself. Therefore, the electromagnetic force generated by passing an electric current through the armature coil, the magnetic flux generated by the magnetic powder magnetized in a certain direction, and the magnetic flux of the magnet are superposed to generate a stronger torque rotational force. Can be greatly improved.

Furthermore, it is preferable to wind a single coil of the armature with a flat copper wire. In the case of a flat copper wire, the space factor is improved as compared to a round copper wire, so that the efficiency is improved and it is possible to contribute to a reduction in thickness and weight.
Further, the armature is configured to have a bent portion that is bent in the axial direction of the rotating shaft from a position that is outside the rotating shaft and not facing the magnet on the inner side of the magnet. preferable. The portion near the rotation axis of the armature coil is not affected by the magnetic flux of the magnet (the magnetic flux density of the magnet is low), so it does not contribute to the torque characteristics. By bending this portion, the armature diameter can be reduced. As a result, the inertia can be kept small. In particular, when a flat copper wire is used as a single coil, it becomes thin and easy to bend, and the flatness of the armature after bending is excellent, and there is no problem in the resin mold.

  According to the ninth aspect of the invention, since the rotating shaft can function as a fixing member for the screw member, the output shaft can be easily connected to the load means with a simple configuration, and the merit of the flat shape is achieved. It can be applied to various uses by utilizing That is, since the rotating shaft does not protrude from the motor body, the manufacturing efficiency of the motor can be improved, and the degree of freedom of design such as the length and diameter of a coupling means such as a ball screw that is coupled (screwed) to the rotating shaft is increased. be able to. In addition, since it is thin and does not take up space, it can be a small and high torque motor, so it is suitable as a drive source for various actuators for automobiles and the like.

Further preferably, an automobile actuator is coupled to, connected to or abutted with the rotating shaft via the screw member, and is used as a drive source for the automobile actuator. Therefore, for example, it is possible to function as a thin, lightweight, highly mountable and highly efficient drive source for a valve timing opening / closing actuator of an internal combustion engine of an automobile.
Preferably, the screw hole is a bottomed hole that is threaded into a nut shape at the axial center of the rotating shaft. Accordingly, it is possible to easily couple (screw) the coupling means such as a ball screw to the rotating shaft.
Preferably, further, on the other surface side of the plane of the armature, the other surface is annularly opposed to the other surface through a gap in the axial direction of the rotation shaft, and the armature is interposed between the armature and the armature. And another magnet arranged to face each other. Therefore, by configuring as a so-called double magnet in this way, the magnetic flux generated from the magnet can be made stronger, so that the output characteristics can be further improved.

Embodiments of the present invention will be described below with reference to the drawings.
FIG. 1 is a cross-sectional view of an essential part showing an embodiment of a flat coreless motor according to the present invention. FIG. 1 shows a plurality of flat single coils around a rotary shaft 10 on a plane perpendicular to the axial direction of the rotary shaft 10. An armature that is annularly arranged and molded (solidified) with a thermosetting resin (for example, phenol resin), 2 is a gap in the axial direction of the rotary shaft 10 on at least one of the planes of the armature 1. The magnet is arranged in an annular shape so as to face the armature 1 via, and is composed of, for example, four or more even poles alternately with N and S poles. Each magnet may have any shape such as a sector shape or an annular shape. Reference numeral 3 denotes a cover A made of a steel plate, to which a magnet 2 is fixed by adhesion or the like. 4 is a cover B which is also made of a steel plate and forms a magnetic path of the armature 1 and the magnet 2, and a plurality of brushes 6 which are in contact with the commutator 5 are attached thereto. Reference numerals 7 and 8 denote bearings for rotatably supporting the rotary shaft 10 of the armature 1, and are fixed to the cover A3 and the cover C9, respectively. Reference numeral 10a denotes an output shaft end of the rotary shaft 10, which is connected to load means such as a fan and a pulley (not shown).

FIG. 2 is a perspective view showing the armature 1 before resin molding, and shows a state in which each single coil is connected to the commutator 5. FIG. 3 is a perspective view showing the armature 1 after being resin-molded.
FIG. 4 is a schematic diagram showing an example of the shape of a single coil constituting the armature winding of the flat coreless motor of the present invention, where (A) is a substantially pentagonal polygonal shape, and (B) is a substantially square shape. Wound, (C) is wound in a substantially circular shape, and shows a state in which the winding start line and winding end line are extended. In addition, (B) is an example wound with a flat copper wire, and (A) and (C) are examples wound with a round copper wire. The winding shape of the single coil may be a substantially hexagonal shape or the like, and may be formed in a round shape or a polygon shape within a range that receives the effective magnetic field of the field magnet. The flat copper wire eliminates the gap between adjacent copper wires and improves the space factor of the coil. For example, a copper wire rolled into a flat angle by rolling a coil having a circular cross section may be used. The winding direction of the flat copper wire is preferably such that the flatness is increased by overlapping a wide surface in the axial direction. In other words, the winding direction of the copper wire may be configured by a so-called edgewise (vertical winding) method in which a wide surface is turned in an axial direction so as to turn. FIG. 4D shows an example of a single coil wound in an edgewise (vertically wound) manner. FIG. 2 shows an example in which a substantially pentagonal single coil is used.

  FIG. 5 is a plan view schematically showing the positional relationship between the single coil 1a and the field magnet 2, and as described above, the rotation axis of the rotary shaft is set so that the single coil is positioned within the range receiving the effective magnetic field of the field magnet. It is preferable to arrange the field magnet 2 so as to be located in the inner peripheral surface of the single coil 1a in the direction perpendicular to the axial direction (the arrow direction in the figure).

  Next, a method and apparatus for resin molding an armature coil will be described with reference to FIGS. FIG. 6 is a sectional view of an example of an apparatus for performing resin molding, and FIG. 7 is an exploded perspective view thereof. In these figures, reference numeral 1 denotes an armature in which each of a plurality of single coils is arranged in a ring shape on a commutator 5 and a winding start line and a winding end line of each single coil are respectively connected to predetermined commutator pieces. 12 is a lower mold for performing resin molding, and 13 is an upper mold. 14a is a guide pin (invitation pin) provided at the lower part of the upper mold in order to form the cavity 11 by clamping either one of the lower mold 12 and the upper mold 13 to be movable, and 14b is provided at the upper part of the lower mold. It is a hole for receiving a guide pin. Reference numeral 21 denotes a replaceable sprue bush in which a sprue 16 for guiding resin into a mold from a plurality of nozzles 17 (here, three nozzles) and a gate 15 for injecting a molten resin material into the cavity 11 are formed. A plurality (for example, three) of the sprue 16 may be provided corresponding to the nozzle 17, and the sprue bush 21 may be provided detachably on the side (side wall) of the upper mold 13 or the lower mold 12.

  Reference numeral 18 denotes a thermosetting resin (for example, phenol or the like) injected from a nozzle 17 of a molding machine (not shown), in which a predetermined ratio of soft magnetic powder is mixed. The soft magnetic powder is easily anisotropically magnetized. For example, soft ferrite powder is used, and the electric resistance between the powders is increased to reduce eddy current loss. What formed the film is used. The mixing ratio of the soft magnetic powder to the resin is about 40 to 90% by weight, preferably about 40 to 60% by weight. FIG. 13 shows the correlation between the mixing ratio of the soft magnetic powder to the resin, the motor torque, and the armature breaking strength. The higher the mixing ratio of magnetic powder, the greater the torque characteristics, but the mold material flow at the time of molding becomes worse and the moldability becomes inferior, and the fracture strength of the resin part after the armature resin molding gradually decreases to 90 weight. If it exceeds 50%, the binding strength of the magnetic powder by the resin is reduced and the brittleness is increased. If it is less than 40% by weight, the influence on the armature fracture strength is small, but it cannot contribute to the torque characteristics. Therefore, the mixing ratio of the magnetic powder to the resin is preferably about 40 to 60% by weight.

  In the present invention, a so-called molding is performed in a magnetic field in which a magnetic field is applied to the armature 1 during molding with a resin to control the orientation of the magnetic powder in the resin. For this reason, the magnetic field generating coils 19 and 20 are housed in enclosures (not shown), respectively, and are installed in the upper mold 13 and the lower mold 12 in advance. The magnetic field generating coils 19 and 20 are arranged so that their inner peripheral surfaces are positioned substantially outside the outer edge (outer peripheral surface) of the armature 1. Furthermore, the magnetic field generating coils 19 and 20 are electrically connected to an external power source (not shown) so that they can be energized.

  When the armature is resin-molded, first, the armature 1 in a state where the winding is completed and a predetermined number of single coils are mounted is placed in the receiving hole of the lower die 12 with the commutator 5 facing downward, and the upper die 13 is lowered so that the pin 14a fits into the hole 14b, and the cavity 11 is formed. Next, the nozzle 17 of the molding machine is brought into contact with the sprue 16 inlet of the sprue bush 21 set in the upper mold 13 in advance. The molten resin 18 formed of a thermosetting resin is filled into the cavity 11 from the gate 15 through the nozzle 17 and the sprue 16, and the armature 1 is fixed with the resin.

  Here, in order to perform the molding in the above-described magnetic field, a predetermined current is applied in advance to the magnetic field generating coils 19 and 20 mounted on the upper mold 13 and the lower mold 12 before the resin is injected, and the magnetic field Is generated. FIG. 8 is a schematic diagram showing the current flowing through the magnetic field generating coils 19 and 20 and the flow of magnetic flux generated from the coils 19 and 20. In addition, the direction of the current of the coils 19 and 20 is also indicated by symbols. Here, the symbol x (cross) in the circle indicates that the current flows from the front to the back of the paper, and the symbol (dot) in the circle indicates that the current flows from the back to the front. By performing molding while applying a magnetic field to the armature 1 in this way, the magnetic flux generated by the coils 19 and 20 is almost perpendicular to the surface of the armature 1 from the same direction as shown in FIG. Therefore, the magnetic powder in the resin is magnetized, and the armature 1 having a magnetic flux oriented along the axial direction as shown by an arrow in FIG. 9C can be completed. 9A and 9B are diagrams showing the armature after resin molding, FIG. 9A is a plan view of a state in which the armature coil is partially exposed, FIG. 9B is a side view, and FIG. 9C is a view in FIG. It is an enlarged view of the part enclosed with a circle, and shows the orientation direction (magnetization direction) of the armature as a partial detailed view.

FIG. 10 is a schematic diagram for explaining the crystal arrangement of the ferrite-based magnetic powder. (D) shows the easy magnetization direction and the hard magnetization direction of the magnetic powder 30. The easy magnetization direction of the powder 30 is shown randomly, (B) shows the state in which the magnetic powders 30 in the resin 18 are magnetized in a certain direction after application of the magnetic field, and (C) shows the state after application of the magnetic field. The orientation direction of magnetic powder is shown. Thus, even with a relatively small amount of fine powder, the easy magnetization direction can be aligned in one direction, so that the armature can be magnetized with a simple configuration and the magnetic force can be increased.
Depending on the arrangement position of the field magnet 2, the orientation direction of each magnetic powder 30 may be reversed. For example, when the magnet 2 of FIG. 1 is arranged on the left side of the armature 1, The orientation direction of FIG. 9 (C) may be reversed.

  As shown in the sectional view of FIG. 11A and the partial perspective view of the armature coil 1a in FIG. 11B, the armature coil 1a of the armature 1 is near the outer periphery of the commutator 5, preferably a field magnet. You may comprise so that it may have the bending part 40 bent and formed from the part which is not opposite to 2. Since the bent portion 40 is not opposed to the magnet 2 and therefore does not contribute to the output characteristics, the outer diameter of the armature is reduced by bending. Bending is performed by a coil forming machine after winding the coil copper wire and before forming in a magnetic field. By providing the bent portion in this manner, the armature diameter can be reduced, and consequently, the inertia can be suppressed to be small. In particular, when a flat copper wire is used as a single coil, it becomes thin and easy to bend, and the flatness of the armature after bending is excellent, and there is no problem in the resin mold.

  Next, the operation of the flat coreless motor configured as described above will be described. First, when a current is supplied from a DC power source (not shown), the armature coil 1a is energized through the brush (positive electrode brush) 6 and the commutator piece of the commutator 5 with which the brush is in contact. The current that has passed through the armature coil 1a sequentially passes through the plurality of armature coils 1a connected to the same commutator piece, returns to the DC power source again through the commutator 5 and the other brush (negative electrode brush) 6. At this time, as shown in the partial cross-sectional view of the flat coreless motor of the present invention in FIG. 12, the electromagnetic force generated by the current flowing from the magnet 2 to the magnetic path formed on the cover B4 side and the armature coil. The armature 1 rotates in a predetermined direction according to the so-called left-hand rule, but since the armature 1 itself has a magnetic flux, the magnetic flux from the armature disk is superimposed on the magnetic flux of the magnet 2, and a stronger magnetic flux is passed through the magnetic path An attempt is made to push out the armature 1 generated inside. In this way, the output characteristics can be greatly improved without increasing the motor size. Since the soft magnetic powder is individually insulated (see FIG. 10C), the eddy current generated in the armature is closed inside the powder, and the powder itself has a fine particle size (several μm to several tens μm). Therefore, the individual eddy current is small and the output characteristics are hardly affected.

  Although the above embodiment has been described as a flat coreless motor with a brush, the armature windings are connected in three phases, the energization direction of the windings is switched according to the position of the field magnet, and the field magnet side is rotated. For example, the present invention can be appropriately applied to a brushless motor such as a rotary yoke type.

  According to the flat type coreless motor configured as described above, a plurality of single coils each wound in a round shape or a polygonal shape are annularly arranged around a rotation axis on a plane perpendicular to the axial direction of the rotation axis. A planar armature that is disposed on and molded with resin, and at least one of the planes of the armature is annularly formed on the one surface through a gap in the axial direction of the rotating shaft. A flat coreless motor having one of the armature and the magnet rotatably supported with respect to the other, wherein magnetic powder is mixed in the resin, When the child is molded with the resin, since the magnetic field is applied to the resin, the magnetic force is generated in the armature itself, and the electromagnetic force generated by passing a current through the armature coil. And constant A synthetic magnetic flux magnetic flux of the magnetic flux of the field magnet generated by the magnetization array of the magnetic powder is superimposed on the direction, it is possible to greatly improve the output characteristics because it tends to rotate with a stronger torque.

Furthermore, since the armature coil is wound with a flat copper wire, the space factor is improved as compared with a round copper wire, which can contribute to an improvement in efficiency and can be reduced in thickness and weight.
Furthermore, since the portion of the armature winding that does not face the field magnet is bent, the armature diameter can be reduced, and the inertia can be reduced. In this case, the use of a flat copper wire makes it thinner so that it is easy to bend, and the flatness of the armature after bending is excellent, so that the balance is not lost.

  FIG. 14 is a cross-sectional view of an essential part showing a second embodiment of the flat coreless motor of the present invention. The present embodiment is suitable for actuator applications such as cylinder head valve driving (opening / closing) and window opening / closing of an internal combustion engine of an automobile. In FIG. 14, 28 is a cover A for fixing and supporting the magnet 33 and the yoke 34, 31 is a cover B for fixing and supporting the brush holder 37 and the upper yoke 34, and the brush holder 37 has a plurality of brushes 36 in contact with the commutator 35a. Is provided. The cover A28 and the yoke 34 are fixed by spot welding or the like, and the magnet 33 is fixed to the yoke 34 by adhesion or the like. Reference numeral 32 denotes a cover C which is integrally fixed together with a yoke 34 and a cover B31 by means of a plurality of screws 42 arranged at substantially equal intervals in the circumferential direction. In FIG. 6, only one screw 42 is shown for convenience. Reference numerals 43 and 44 denote bearings, which are fixed to the cover C32 and the cover A28, respectively, and rotatably support the rotary shaft 45 of the armature 35. The yoke 34 is not necessarily provided when the thickness of the cover A28 and the cover B31 can be increased to ensure the necessary magnetic flux.

  Reference numeral 38 denotes an annular sensor magnet arranged concentrically with respect to the rotating shaft 45, and a plurality of magnets (pole pieces) are arranged annularly so that different magnetic poles are alternately adjacent to each other. The sensor magnet 38 is fixed to the sensor magnet cover 29 fixed to the rotation shaft 45 by adhesion or the like, and the rotation amount (rotation angle) of the armature 35 is monitored by a sensor IC 39 connected to a control board (not shown). That is, when the sensor magnet 38 rotates with the rotation of the armature 35, the magnetic pole pieces of the sensor magnet 38 sequentially pass through the sensor IC 39, and thereby, a pulse signal is generated from the sensor IC 39 constituted by, for example, a Hall IC. The rotation amount (rotation angle) of the armature 35 is detected. Reference numeral 41 denotes a spacer for properly positioning the opposing position of the sensor magnet 38 and the sensor IC 39 and adjusting the thrust.

  The armature coil of the armature 35 has a bent portion 49 (corresponding to the bent portion 40 in FIG. 11A) formed by bending from the vicinity of the outer periphery of the commutator 35a, preferably from the portion not facing the field magnet 33. is doing. Similar to the bent portion 40 in FIG. 11A, the bent portion 49 is a portion that does not face the magnet 33 and does not contribute to the output characteristics, so that the outer diameter of the armature is reduced by bending. Bending is performed by a coil molding machine after coil copper wire is wound and before molding in a magnetic field.

  One feature of this embodiment is the configuration of the rotating shaft 45. That is, for example, a square or cylindrical bottomed opening 45a is provided at the axial center of the rotating shaft 45, and a screw member, for example, a pinion shaft 46 shaft, which is a coupling (or connection or abutment) means composed of a ball screw or the like A portion (for example, a square or cylindrical shaft portion) 46b is fitted into the bottomed opening 45a. Thereby, the rotational movement by the armature 35 is transmitted to the load means (the actuator of the automobile) to be driven. Reference numeral 46 a denotes a fixing member for the rotation shaft 45 for the pinion shaft 46, which is fixed to the rotation shaft 45 with a screw or the like and rotates integrally with the rotation shaft 45.

  For example, the case where the present embodiment is applied for driving an actuator for an injection valve of an automobile will be described. When a throttle (accelerator) pedal (not shown) of the automobile is depressed, a motor drive current having a value corresponding to the depression amount is supplied from a control board (not shown) to the motor of this embodiment. Then, the rotation shaft 45 rotates by an angle corresponding to the motor drive current, the pinion shaft 46 fixed to the rotation shaft 45 rotates and acts as a worm gear, and the rotation of the motor is reduced on the pinion gear (worm wheel) 47. introduce. Then, a camshaft as load means of an internal combustion engine (not shown) supported by a cam 48 provided on the shaft of the pinion gear 47 is driven to open and close the injection valve. At this time, the rotation angle of the motor, that is, the opening / closing amount of the valve is read by the monitoring means comprising the sensor magnet 38 and the sensor IC 39 and given to the control board, and the motor driving current is controlled from the control board, and the throttle pedal is depressed. Appropriate valve opening / closing amount is controlled. With such a configuration, it is possible to function as a thin, lightweight, highly mountable and highly efficient drive source as an actuator for opening and closing a valve timing of an internal combustion engine of an automobile.

As described above, since the rotary shaft 45 can function as a fixing member for the screw member, the output shaft can be easily connected to the load means with a simple configuration, and the advantages of the flat shape can be utilized for various applications. Can be applied. That is, since the rotating shaft does not protrude from the motor body, the production efficiency of the motor can be improved, and the degree of freedom in designing the length and diameter of the coupling means such as a ball screw can be increased. In addition, since it is thin and does not take up space, it can be a small and high torque motor, so it is suitable as a drive source for various actuators for automobiles and the like.

FIG. 15 shows a modification of the second embodiment. In the modification, the same components as those in FIG. As shown in the drawing, a bottomed opening 45a ′ threaded into a nut shape is provided in the axial center portion of the rotating shaft 45, and a screw member which is a coupling (or connecting or abutting) means made of, for example, a ball screw or the like. One end 53b of 53 is screwed together. The screw member 53 is further screwed into an inner surface of a cover (nut) 53a whose inner surface is threaded for the screw member 53, and the cover 53a is fixed to the rotating shaft 45 with a screw or the like and rotates integrally with the rotating shaft 45. The cover 53a may not be provided. For example, a cover (nut) 54 is provided on the other end side of the screw member 53. The screw member 53 is screwed to the inner surface of the cover 54, and the cover 54 is fixed to the housing (cover) 52 on the driven member 50 side. Has been. In addition, a driven member 50 (for example, an eccentric cam) is provided as a load means (an actuator of an automobile) below the screw member 53 in the axial direction of the screw member 53 (extension direction on the other end side of the screw member).
With such a configuration, when the armature 35 rotates, the screw member 53 rotates in the bottomed opening 45a ′, and according to the rotation direction, the upward or downward direction indicated by the arrow in the drawing (the direction along the axis of the screw member). ) Perform a linear motion. Therefore, the other end portion of the screw member 53 is brought into contact with the load means 50 according to the rotation of the armature 35, and the load means is driven upward or downward in the drawing according to the rotation direction of the armature 35. That is, when the load means 50 is a cam, it rotates about the shaft 51.

  FIG. 16 is a cross-sectional view of an essential part showing a modification of the flat coreless motor of FIG. 14, and the difference from the second embodiment is that the field magnets 33 are arranged on both sides of the armature. That is, the field magnets 33 are arranged on both sides of the armature so as to face each other in a ring shape with a gap and the armature 35 in the axial direction of the rotating shaft. By configuring as a so-called double magnet in this way, the magnetic flux generated from the magnet can be made stronger than that in the second embodiment, so that the output characteristics can be further improved. In this case, since the armature winding is bent from the vicinity of the outer periphery of the commutator as in the second embodiment, a double magnet is formed with the same axial height h as the single-sided magnet (single magnet) in the second embodiment. Can be configured.

  FIG. 17 is an external perspective view showing an example of a flat coreless motor according to the present invention. The power connector 72 for supplying the drive current from the control board to the armature and the output of the sensor IC are transmitted to the control board. A sensor connector 71 is provided on the cover (C) 32. These connectors are not particularly fixed, and may be provided, for example, on the side surfaces in the axial direction depending on the application. The output of the sensor connector 71 is connected to the control board.

  Although the above embodiment has been described as a flat coreless motor with brushes, a so-called rotary yoke type brushless in which the winding is three-phased and the energizing direction is switched according to the position of the field magnet to rotate the field magnet side. The present invention may be applied to a motor, and even in this case, it can be configured as a small, light, and high torque motor.

It is principal part sectional drawing which shows the 1st Example of the flat type coreless motor of this invention. It is a perspective view which shows the armature before resin mold shaping | molding in the flat type coreless motor of FIG. FIG. 2 is a perspective view showing an armature after resin molding in the flat coreless motor of FIG. 1. FIG. 4 is a schematic diagram showing an example of the shape of a single coil constituting the armature winding of the flat coreless motor of the present invention, where (A) is wound in a substantially pentagonal polygon, and (B) is wound in a substantially square. , (C) shows a substantially circular winding, and (D) shows a flat copper wire wound in an edgewise manner (vertical winding). In this invention, it is a top view which shows typically the positional relationship of a single coil and a field magnet. In this invention, it is sectional drawing of an example of the apparatus for resin-molding an armature. It is a disassembled perspective view of the apparatus shown in FIG. FIG. 8 is a schematic diagram showing a current flowing through a magnetic field generating coil and a flow of magnetic flux generated from the coil in the apparatus shown in FIGS. It is a figure which shows the armature after resin molding, (A) is a top view of the state which exposed a part of armature coil, (B) is a side view, (C) is the part enclosed by the circle of (B) FIG. 2 is an enlarged view of the armature, in which the armature orientation direction (magnetization direction) is partially shown in detail. It is a schematic diagram explaining the crystal arrangement of the ferrite magnetic powder, (A) shows the state of each magnetic powder in the resin in the initial stage of resin filling, (B) is a direction in which each magnetic powder in the resin after a magnetic field application in a certain direction (C) shows the orientation direction of the magnetic powder after application of the magnetic field, and (D) shows the easy magnetization direction and the hard magnetization direction of the magnetic powder. It is a figure which shows the modification of an armature in this invention, (A) is sectional drawing of the armature, (B) is the fragmentary perspective view of an armature coil. It is a fragmentary sectional view of a flat type coreless motor for explaining operation of the present invention. It is a figure which shows the correlation of the mixing ratio with respect to resin of magnetic powder, motor torque, and armature fracture strength. It is principal part sectional drawing which shows the 2nd Example of the flat type coreless motor of this invention. It is principal part sectional drawing which shows the modification of the 2nd Example of the flat type coreless motor of this invention. It is principal part sectional drawing which shows the modification of the flat type coreless motor shown in FIG. It is an external appearance perspective view which shows an example of the flat type coreless motor of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Armature 1a Single coil 2 Magnet 5 Commutator 10 Rotating shaft 11 Cavity 12 Lower mold 13 Upper mold 17 Nozzle 18 Resin 19, 20 Coil for magnetic field generation 30 Magnetic powder
40 Bending part 38 Sensor magnet
39 Sensor IC
40, 49 Bent part 45a, 45a 'Open hole with bottom 46, 53 Screw member 47 Pinion gear 48, 50 Cam 54 Nut

Claims (10)

Each round or polygonal shape and arranged in an annular a plurality of single coils wound on axially perpendicular plane of the rotary shaft around the axis of rotation to molded resin was planar Electric A magnet and a magnet disposed on the one surface of at least one of the planes of the armature so as to face the one surface annularly through a gap in the axial direction of the rotating shaft, In a flat coreless motor in which one of the magnets is rotatably supported with respect to the other,
The planar armature molded with the resin is formed on the rotating shaft from a position outside the outer peripheral surface of the rotating shaft and on the inner side of the inner peripheral surface of the magnet and not facing the inner peripheral surface of the magnet. Having a bent portion bent in the axial direction of
The resin for molding the armature is mixed with magnetic powder, and the magnetic powder is magnetized in the axial direction of the rotary shaft, thereby generating an electromagnetic force generated by passing a current through the armature coil, and a constant A flat coreless motor, which is driven by superimposing the magnetic flux of the magnetic powder magnetized in the direction and the magnetic flux of the magnet.   2. The flat coreless motor according to claim 1, wherein each of the plurality of single coils is formed by winding a flat copper wire. 3. Each round or polygonal shape and arranged in an annular a plurality of single coils wound on axially perpendicular plane of the rotary shaft around the axis of rotation to molded resin was planar Electric A magnet and a magnet disposed on the one surface of at least one of the planes of the armature so as to face the one surface annularly through a gap in the axial direction of the rotating shaft, In a flat coreless motor in which one of the magnets is rotatably supported with respect to the other,
The planar armature molded with the resin is formed on the rotating shaft from a position outside the outer peripheral surface of the rotating shaft and on the inner side of the inner peripheral surface of the magnet and not facing the inner peripheral surface of the magnet. Having a bent portion bent in the axial direction of
The resin for molding the armature is mixed with magnetic powder, and the magnetic powder is magnetized in the axial direction of the rotary shaft, thereby generating an electromagnetic force generated by passing a current through the armature coil, and a constant Driven by superimposing the magnetic flux of the magnetic powder magnetized in the direction and the magnetic flux of the magnet,
A flat-type coreless motor, wherein a hole is disposed concentrically with the axis of the rotary shaft, and one end of a screw member can be fitted into the hole from the outside.   The flat coreless motor according to claim 3, wherein each of the plurality of single coils is formed by winding a flat copper wire.   4. The flat coreless motor according to claim 3, wherein an actuator of an automobile is coupled to, connected to, or abutted with the rotating shaft via the screw member, and is used as a drive source for the actuator of the automobile.   Furthermore, on the other surface side of the plane of the armature, it is opposed to the other surface in a ring shape through a gap in the axial direction of the rotation shaft, and is opposed to the magnet via the armature. The flat coreless motor according to claim 3, further comprising another magnet arranged as described above.   The flat coreless motor according to claim 3, wherein one end side of the screw member is fitted and fixed in the screw hole.   The flat member according to claim 3, wherein the screw member is rotated together with the rotation shaft along with the rotation of the rotation shaft so that a driven member provided on the other end side of the screw member can be driven. Type coreless motor.   The screw hole is a bottomed opening threaded in a nut shape at an axial center portion of the rotating shaft, and one end side of the screw member is screwed into the opening. The flat coreless motor described.   The other end side of the screw member is provided with a cover whose inner surface is threaded. The screw member is screwed with the inner surface of the cover, and the cover is fixed to the housing on the driven member side, whereby the screw The member is linearly moved in the direction along the axis of the screw portion with the rotation of the rotating shaft, and the driven member provided in the extending direction on the other end side of the screw member can be driven. The flat coreless motor according to claim 9.

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