JP5146077B2 - Motor and manufacturing method thereof - Google Patents

Description

  The present invention relates to a motor that is operated in a high temperature environment such as an engine room environment of a car or a high vibration environment.

  In the inner rotor motor as shown in FIG. 7A, the motor casing 24 includes a casing body 24a and a casing lid 24b. A stator 22 with a winding 22a is fixed inside the casing body 24a. A rotor 21 having an output shaft 21a coaxial with the inner center of the stator 22 is rotatably attached to a motor casing 24 via bearings 28a and 28b.

  The core shape of the stator 22 is such that the outer ends (base ends) of the teeth 90 are connected to each other as shown in FIG. 7B, and a gap 100 is formed between the tips of the adjacent teeth 90 inside the stator 22. A magnetic steel plate is punched into a shape, the punched magnetic steel plates are stacked, a winding nozzle (not shown) of a winding machine is inserted from the gap 100, and the winding nozzle is rotated around the teeth 90 to rotate the teeth. The winding process to 90 is implemented.

However, in such a winding process, it is difficult to process and it is difficult to improve the winding occupancy rate. Therefore, in Patent Document 1, as shown in FIG. A stator core 22b in which a gap 200 is formed is used. As shown in FIG. 8 (b), the stator core 22b is formed by dividing the teeth blocks 116a, 116b,..., And the teeth blocks 116a, 116b,. It is arranged in an annular shape and is formed by casting with an insulating synthetic resin 30. Thereafter, the winding nozzle is inserted into the outer peripheral side from the gap 200 and the winding process is performed. The stator core 22b after the winding process is press-fitted inside the casing body 24a. Are connected by a casing body 24a to form a magnetic circuit.
JP-A-3-235629

  The use of the stator core 22b shown in FIG. 8 can realize the workability of the winding process and the improvement of the winding rate, but the stress generated when the stator core 22b is press-fitted into the casing body 24a and the difference in cylindricity between the two. As a result, a non-uniform gap is generated between the inner wall of the casing body 24a and the outer peripheral surface of the stator core 22b, and the magnetic resistance is partially increased, or the inner peripheral surface of the stator core 22b is distorted and the roundness accuracy is reduced. Since the cogging torque is likely to increase due to the non-uniform magnetic resistance of the magnetic paths connecting the teeth, the motor using the stator core having the shape shown in FIG. There was the subject that performance was inferior compared with.

  In particular, in the high temperature environment, the insulating synthetic resin 30 that casts the teeth blocks 116a, 116b,... Tends to creep, and the holding force for connecting the teeth blocks 116a, 116b,. There is a problem that the inner peripheral surface of the motor may be greatly distorted to hinder the rotation of the motor, or the stator core 22b may move when vibration is applied because the stress holding the stator core 22b is reduced.

An object of this invention is to provide the motor which can implement | achieve the workability | operativity of a winding process, and the improvement of a winding occupancy, and can implement | achieve smooth rotation performance and high reliability.

  According to a first aspect of the present invention, a winding-processed stator is disposed inside a motor casing, a rotor is disposed on the inner periphery of the stator, and energization of the stator winding is switched to rotate a rotating magnetic field. In the motor that rotationally drives the rotor by generating a tooth block, the stator has an inner peripheral side end of a plurality of teeth close to each other, and is divided into each tooth and arranged annularly, and an axial direction of the teeth block The teeth block has one end plate disposed on both sides, and one end of the teeth block on the outer peripheral side of the teeth block is formed so as to form a magnetic path through the motor casing between one end of the teeth block adjacent to the other. Abutting on the inside of the casing, the end plate is made of non-magnetic metal or low-magnetic metal, and a plurality of teeth having the same shape as the teeth block are placed in front. As well as arranged in the same sequence as the tooth block, the inner circumferential side end of each tooth is formed are connected, via the end plate, wherein the teeth block is connected.

  The motor according to a second aspect of the present invention is the motor according to the first aspect, wherein first teeth and first holes are alternately formed in the teeth on the end plate, and the teeth block includes the end plate. A recess is formed at a position corresponding to the first protrusion, a protrusion is formed at a position corresponding to the first hole of the end plate, and the first protrusion of the end plate is formed into the recess of the teeth block. The teeth blocks are connected and fixed by press-fitting the protrusions of the teeth blocks into the first holes of the end plates.

  According to a third aspect of the present invention, in the motor according to the first aspect, the second protrusions sandwiched between the inner peripheral side ends of the adjacent tooth blocks are formed on each of the teeth connecting portions of the end plate. And

  A motor according to a fourth aspect of the present invention is the motor according to the third aspect, wherein the space between the inner peripheral side ends of adjacent tooth blocks is formed in a shape expanding in the inner diameter direction, and the second protrusion interposed in the space. The shape of the part is also formed in a shape spreading in the inner diameter direction.

  According to a fifth aspect of the present invention, in the motor according to the first to fourth aspects, an extension portion extending from the central portion to both sides along the inner side of the motor casing is formed at one end on the outer peripheral side of the teeth block. The overhanging portion is deformed by contacting the inner side of the motor casing, and a gap is formed between the central portion and the inner side of the motor casing.

  According to a sixth aspect of the present invention, in the method of manufacturing a motor according to the present invention, a plurality of teeth blocks are arranged in an annular shape with one end on the inner peripheral side approaching, and a plurality of teeth having the same shape as the teeth blocks are the same as the teeth blocks. Arranged in an array, end plates made of non-magnetic metal or low-magnetic metal formed by connecting one end of each tooth on the inner peripheral side are arranged on both sides in the axial direction of the teeth block, and through the end plate The teeth block is connected to form a teeth block connecting body, a winding is applied to the tooth portion of each tooth block of the teeth block connecting body, and a magnetic path is formed between one end on the outer peripheral side of the adjacent tooth block. As described above, the tooth block coupling body is press-fitted inside the motor casing.

According to a seventh aspect of the present invention, there is provided a motor manufacturing method according to the sixth aspect, wherein when the connecting body of the teeth block is formed via the end plate, the first protrusion and the first hole portion are formed on the end plate. Are alternately formed on each tooth, and the tooth block has a recess at a position corresponding to the first protrusion of the end plate and a protrusion at a position corresponding to the first hole of the end plate. Form and connect the teeth block by crimping the first protrusion of the end plate into the recess of the teeth block and press-fitting the protrusion of the teeth block into the first hole of the end plate. The second protrusion is fixed and connected in a state of being sandwiched between adjacent tooth blocks.

  According to this configuration, the workability of the winding process and the improvement of the winding occupancy can be realized, and the connection of the one end on the inner peripheral side of the tooth block is made through the end plate made of nonmagnetic metal or low magnetic metal. Because it is connected, there is less deformation due to creep compared to the conventional structure connected via synthetic resin, it can maintain smooth rotation performance, and it is reliable even when used in high temperature and high vibration environment Can be maintained.

  In addition, since a gap is formed between the center of the outer peripheral end of the teeth block and the inside of the motor casing, the roundness of the inner peripheral circle of the stator core after the teeth block coupling body is press-fitted into the motor casing. There is very little decline, and smooth rotation performance can be realized.

  Hereinafter, the motor of the present invention is explained based on an embodiment.

  1 to 5 show a motor of the present invention. The motor shown in FIG. 1A is a cross-sectional view taken along line A-AA in FIG.

  The motor casing 4 includes a metal casing body 4a and a metal casing lid 4b. Inside the casing body 4a, the rotor 1, the stator 2, and part of the first and second wiring boards 3a and 3b are housed. The stator 2 is disposed coaxially with the output shaft 1 a of the rotor 1. The first wiring board 3 a is disposed at the end of the rotor 1 and the stator 2 in the opposite direction of the output shaft 1 a of the rotor 1. A control circuit 6 and a power element 7 are mounted on the first wiring board 3a.

  The second wiring board 3b on which the magnetoelectric conversion element 5 is mounted is disposed between the rotor 1 and the first wiring board 3a. The magnetoelectric conversion element 5 is disposed close to the rotor 1, and a detection signal or the like detected by the magnetoelectric conversion element 5 detecting the magnetic pole of the rotor 1 is transmitted from the second wiring board 3 b to the control circuit 6 of the first wiring board 3 a. And the control circuit 6 switches the energization to the winding 2a of the stator via the power element 7 mounted on the same first wiring board 3a to generate a rotating magnetic field to drive the rotor 1 to rotate. Yes.

  2 to 6 show details of the stator 2 and the casing body 4a.

  The stator core of the stator 2 includes a plurality of tooth blocks 16 shown in FIG. 2A and two end plates 17 shown in FIG.

  The teeth block 16 is formed by stacking magnetic steel plates by known means such as caulking, bonding, laser welding, etc., and the outer periphery of the rotor 1 is assembled at one end of the inner peripheral side 18 as shown in FIG. Overhanging portions 19b and 19c that face each other with a gap are formed on both sides from the central portion 19a. In addition, projecting portions 21 b and 21 c extending from the central portion 21 a to both sides along the inner side of the motor casing are formed at one end of the outer peripheral side 20.

In this embodiment, as shown in FIG. 3, twelve teeth blocks 16 are arranged in an annular shape with one end on the inner peripheral side being close to each other. As shown in FIG. 2B, the end plate 17 has a plurality of teeth 17a having the same shape as the teeth block 16 arranged in the same arrangement as the teeth block 16, and one end on the inner peripheral side of each tooth 17a is connected. Is formed. In addition, first protrusions 17b and first hole portions 17d are alternately formed in the circumferential direction for each tooth 17a on the surface of the end plate 17 that contacts the tooth block 16 of each tooth 17a in the axial direction. Yes. Further, twelve second protrusions 17 c are formed at equal intervals on each tooth connecting portion of the end plate 17.

  As shown in FIG. 3, recesses 16a or protrusions 16b are alternately formed for each tooth block at positions corresponding to the first protrusions 17b or the first holes 17d of the end plate 17 of the tooth block 16. The first protrusion 17b of the end plate 17 is pressed into the recess 16a of the teeth block 16, and the protrusion 16b of the teeth block 16 is pressed into the first hole 17d of the end plate 17 from above and below. By performing, the adjacent tooth block 16 is connected and the teeth block coupling body 23 shown to Fig.4 (a) is comprised. At this time, as shown in FIG. 5, the second protrusion 17c is sandwiched between the overhanging portions 19b and 19c of the adjacent tooth block 16, and the overhanging portions 19b and 19c of the adjacent tooth block 16 are It is contact | abutted in the circumferential direction via the 2 protrusion 17c.

  The teeth block 16 has a convex portion on one surface in the stacking direction, and the other surface has a plurality of magnetic steel plates formed with concave portions by forming convex portions. When the sheet block 16 is formed by laminating and caulking in a so-called pack method in which layers are stacked and integrated while being pressed into the recess, a protrusion is formed on one end surface of the teeth block 16 in the stacking direction, and a recess is formed on the opposite end surface. Is formed. Therefore, the concave portion can be used as the concave portion 16a and the convex portion can be used as the protruding portion 16b. That is, if the tooth blocks 16 created by the above-described pack method are alternately inverted and arranged in an annular shape, the recesses 16a and the protrusions 16b can be alternately arranged on the surface in contact with the end plate 17. According to the above method, the tooth block coupling body 23 can be formed with a small number of parts including one type of tooth block 16 and one type of end plate 17.

  When the material of the teeth block 16 is a silicon steel plate, it is desirable to use SUS304 or the like as the material of the end plate 17 which is a nonmagnetic material or a low magnetic material and has a thermal expansion coefficient very close to that of the teeth block 16. .

  Next, after an insulating layer is formed on the teeth block connector 23 by a method such as powder coating, electrodeposition coating, or dip coating, winding is performed on each of the teeth portions from the gaps 25, and FIG. Finish in the state shown in. As described above, the winding 2a is wound from the gap 25 on the outer periphery of the teeth block coupling body 23, so that the workability of the winding process and the improvement of the winding occupation ratio can be maintained.

  Next, as shown in FIG.4 (c), the teeth block coupling body 23 in which the winding process was completed is press-fitted inside the casing body 4a. The connection of the winding 2a of the teeth block 16 may be performed either in a pre-process or a post-process in which the teeth block coupling body 23 is press-fitted into the casing body 4a, and the corresponding teeth blocks 16 are continuously wound. It doesn't matter.

  FIG. 5 shows the details of the teeth block connector 23 after press-fitting. Here, the winding 2a is not shown.

  In the press-fitted tooth block connecting body 23, the protruding portions 21b and 21c at one end on the outer peripheral side 20 of the tooth block 16 are deformed from a wavy line position to a solid line position and press-fitted into the inside of the motor casing 4a. A magnetic path is formed between the outer peripheral side end of the block via the motor casing body 4a. At this time, the outer peripheral end of the teeth block and the motor casing body 4a are in close contact with each other, so that a uniform magnetic path with low magnetic resistance can be formed.

  Thus, in the state in which the tooth block coupling body 23 is press-fitted, a state in which a large force acts in the direction of reducing the inner diameter between the adjacent tooth blocks 16 on the inner peripheral side 18 of the teeth block 16 continues. In the state where only the synthetic resin 30 is interposed as in the conventional example illustrated in FIG. 8B, creep occurs in the interposed synthetic resin 30, and the arrangement of the magnetic poles on the inner periphery of the stator 22 is true. In this embodiment, the end plate 17 made of a low-magnetic metal having higher rigidity than the synthetic resin 30 is used. The tooth block 16 is connected with the second protrusion 17c of the plate 17 interposed, and a space between adjacent tooth blocks 16, that is, a space surrounded by the tip portions 19b and 19c is formed. It is formed in a shape that expands in the inner diameter direction, and the shape of the second protrusion 17c interposed therein is also formed in a shape that expands in the inner diameter direction, so that the second protrusion 17c functions as a wedge. A kind of wedge effect Therefore, even if a state in which a large force is applied in the direction of reducing the inner diameter and a large force is applied between adjacent teeth blocks 16 as indicated by an arrow F in FIG. There is no reduction in the roundness of the arrangement of the magnetic poles on the inner periphery of the stator 2. Therefore, smooth rotation performance can be maintained over a long period of time, and rotation performance and reliability can be maintained even when used in a severe environment of high temperature and high vibration.

  Furthermore, in this embodiment, the projecting portions 21b and 21c are in contact with the inner side of the motor casing body 4a at one end on the outer peripheral side of the teeth block 16 even when the protruding portions 21b and 21c are in contact with the inner side of the motor casing body 4a. There is no central portion 21a, and a gap 27 is formed between the central portion 21a at one end on the outer peripheral side of the teeth block 16 and the inside of the motor casing body 4a.

  It will be described with reference to the comparative example shown in FIG. 6 that the formation of the gap 27 as described above can more reliably prevent the roundness of the magnetic pole array on the inner periphery of the stator 2 from being lowered. .

  In the case of FIG. 6, the shape of one end on the outer peripheral side of the teeth block 16 is different from that of the above embodiment, the shape of one end on the outer peripheral side of the teeth block 16 is a part of an arc, and its radius of curvature is the casing. The radius of curvature of the inner periphery of the main body 4a is set to be approximately equal. In the state where the teeth block coupling body 23 is press-fitted inside the motor casing main body 4a, the central portion 21a abuts on the inner side of the motor casing main body 4a and the magnetic pole 29 is pushed out to the inner peripheral side as indicated by an arrow G. As the teeth block connector 23 is press-fitted inside the motor casing body 4a, the position of the magnetic pole on the inner peripheral side is deformed inward as indicated by the phantom line, and smooth rotation performance cannot be obtained.

  On the other hand, when the gap 27 is left as shown in FIG. 5, the positional deviation of the magnetic poles caused by press-fitting the teeth block coupling body 23 into the motor casing body 4a is compared with FIG. Therefore, smooth rotation performance can be obtained.

  Although the magnetic resistance increases in the gap 27, as described above, since the projecting portions 21b and 21c are in contact with the inner side of the motor casing body 4a to form a magnetic path, the magnetic flux does not decrease. It is configured.

  Further, when the teeth block coupling body 23 is press-fitted inside the motor casing body 4a, a deformation preventing jig is inserted into the inner circumference of the teeth block coupling body 23 in order to further reduce the deformation of the inner circumference of the teeth block coupling body 23. Press-fit in the state.

In the present embodiment, the tooth block coupling body 23 is inserted into the motor casing main body 4a by press-fitting. However, in addition to this method, after the casing main body 4a is heated and fitted with its inner diameter expanded, A method of cooling and holding the teeth block connector 23 under pressure (so-called shrink fitting) is also possible. According to this method, since there is no generation of wear debris due to sliding during press-fitting, a highly reliable motor can be manufactured. Further, as shown in FIG. 4 (d), after the teeth block connector 23 is inserted into the casing main body 4a in a gap-fitted state, another cylindrical member 4c is shrink-fitted to the outside of the casing main body 4a. A method of holding 23 under pressure is also effective. According to this method, there is no generation of wear debris due to sliding during press-fitting, and the cylindrical member 4c used for shrink fitting can be heated in advance, so that assembly can be performed in a short time. Further, when the cylindrical member 4c is formed of a magnetic material, a magnetic circuit can be formed together with the motor casing body 4a, so that the thickness of the motor casing body 4a can be reduced. Thereby, the diameter reduction of the motor casing main body 4a when the cylindrical member 4c is shrink-fitted on the outside of the motor casing main body 4a is facilitated, and the teeth block coupling body 23 can be held with pressure more reliably.

  The present invention can contribute to improving the reliability of various devices using a small motor.

(A) Vertical sectional view of the motor of the present invention, (b) Cross sectional view of the motor of the present invention (A) Perspective view of teeth block of same embodiment, (b) Enlarged perspective view of ring end plate The disassembled perspective view of the teeth block coupling body of the embodiment (A) The figure which shows the teeth block coupling body of the embodiment, (b) The figure which processed the teeth block coupling body, (c) The figure which press-fitted the teeth block coupling body which the winding process was completed to the casing main body, (D) The figure which hold | maintained the tooth block coupling body after a casing main body press-fit with a cylindrical member by pressurization. The enlarged view of the state which press-fitted the teeth block coupling body of the same embodiment to the casing main body Enlarged view of the comparative example (A) A longitudinal sectional view of a conventional motor, (b) a plan view of a stator core of a first conventional example. (A) The top view of the stator core of the 2nd prior art example, (b) The principal part enlarged view of the 2nd prior art example.

Explanation of symbols

1, 21 Rotor 1a, 21a Rotor 1 output shaft 2, 22 Stator 2a, 22a Winding 3a First wiring board 3b Second wiring board 4, 24 Motor casing 4a, 24a Casing body 4b, 24b Casing lid 4c Cylindrical Shaped member 5 Magnetoelectric conversion element 6 Control circuit 7 Power element 16, 116a, 116b Teeth block 180 Core inner peripheral side 16a Recess 16b Protrusion 17 End plate 17a End plate teeth 17b First protrusion 17c Second protrusion 17d 1st hole 18 Inner peripheral side of teeth block 19a Inner peripheral side of teeth block 19b, 19c Overhanging portion of teeth block on inner peripheral side 20 Outer side of teeth block 21a Outer peripheral side of teeth block 21b , 21c Projection portion on the outer peripheral side of the teeth block 22b Stator core 23 teeth block concatenation 25,27,100,200 gap 28a, an arrow indicating the direction of arrow G pole showing a direction 28b bearing 29 pole 30 of synthetic resin 90 teeth F shrinkage

Claims (8)

  A motor in which a stator subjected to winding is disposed inside a motor casing, a rotor is disposed on the inner periphery of the stator, and a rotating magnetic field is generated by switching energization to the winding of the stator to rotate the rotor. The stator includes a plurality of teeth that are close to each other on the inner peripheral side, divided into each tooth and arranged annularly, and end plates disposed on both sides in the axial direction of the teeth block. In addition, the outer peripheral ends of the teeth blocks are in contact with the inner side of the motor casing so that a magnetic path is formed between the adjacent outer peripheral ends of the teeth blocks via the motor casing. A plurality of teeth having the same shape as the teeth block are arranged in the same arrangement as the teeth block. As well as, the inner circumferential side end of each tooth is formed are connected, via the end plate, the teeth block is connected motor.   First teeth and first holes are alternately formed in the teeth on the end plate, and the teeth block has a recess at a position corresponding to the first protrusion of the end plate. Projecting portions are formed at positions corresponding to the first hole portions, the first projecting portion of the end plate is formed in the recess of the teeth block, and the projecting portion of the teeth block is projected in the first hole portion of the end plate. The motor according to claim 1, wherein the teeth blocks are connected and fixed by press-fitting portions and caulking.   The motor according to claim 1, wherein a second protrusion that is sandwiched between one end on the inner peripheral side of adjacent tooth blocks is formed on each tooth connecting portion of the end plate.   The space between one end on the inner peripheral side of adjacent tooth blocks is formed in a shape that expands in the inner diameter direction, and the shape of the second protrusion that intervenes in the space is also formed in a shape that expands in the inner diameter direction. The motor described.   At one end of the teeth block on the outer peripheral side, an overhanging portion extending from the center portion to both sides along the inside of the motor casing is formed, and the overhanging portion abuts on the inside of the motor casing and deforms, and the center portion The motor according to any one of claims 1 to 4, wherein a gap is formed between the motor and the inside of the motor casing.   One end of the teeth block divided into a plurality is arranged in an annular shape close to each other, a plurality of teeth having the same shape as the teeth block are arranged in the same arrangement as the teeth block, and one end on the inner periphery side of each tooth block End plates made of non-magnetic metal or low magnetic metal formed by being connected are arranged on both sides of the teeth block in the axial direction, and the teeth blocks are connected via the end plates to form a teeth block connector. And winding the teeth block of each tooth block of the teeth block coupling body so that a magnetic path is formed between one end of the adjacent teeth blocks and the inner side of the motor casing. Of manufacturing a motor press-fitted into   One end of the teeth block divided into a plurality is arranged in an annular shape close to each other, a plurality of teeth having the same shape as the teeth block are arranged in the same arrangement as the teeth block, and one end on the inner periphery side of each tooth block End plates made of non-magnetic metal or low magnetic metal formed by being connected are arranged on both sides of the teeth block in the axial direction, and the teeth blocks are connected via the end plates to form a teeth block connector. The teeth block of each tooth block of the teeth block coupling body is wound around the teeth block, the teeth block coupling body is held in a state of being fitted in a gap inside the motor casing, and a cylindrical member is shrink fitted on the outside of the motor casing. To reduce the diameter of the motor casing and form a magnetic path between one end of the adjacent teeth block Motor manufacturing method of that.   When forming the connection body of the tooth block through the end plate, the first protrusion and the first hole portion are alternately formed on the end plate, and the tooth block includes the first block of the end plate. Forming a recess at a position corresponding to the first protrusion, a protrusion at a position corresponding to the first hole of the end plate, and forming the first protrusion of the end plate into the recess of the teeth block, The teeth block is press-fitted into the first hole portion of the end plate and caulked to connect and fix the teeth block, and the second protrusion is sandwiched between adjacent tooth blocks. The method for manufacturing a motor according to claim 6, wherein the motors are connected in a state.

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