JP5181827B2 - Axial gap motor and fan device using the same - Google Patents

Description

  The present invention relates to an axial gap motor using an amorphous metal and a fan device using the same.

  In recent years, higher efficiency of motors has been demanded from the viewpoint of energy saving and environmental problems. Higher efficiency of motors has been achieved with improved material properties such as electrical steel sheets and magnet materials. Among them, amorphous metal is characterized by high magnetic permeability and low loss, and can be expected to contribute to higher motor efficiency. As a form in which amorphous metal is used for a motor, a simple structure that does not perform machining with high productivity and a structure that improves motor efficiency are required.

  Patent Documents 1 and 2 disclose forming a stator core by laminating amorphous metals.

  Patent Document 3 discloses an example of an axial gap motor using a stator core that is not processed as much as possible, and proposes a method of forming a stator core by winding an electromagnetic steel sheet.

JP 2006-516877 A Special table 2002-518975 gazette JP 2007-104795 A

  The application of amorphous metal, which is characterized by low loss and high magnetic permeability, is effective for improving the motor efficiency. However, since amorphous metal has a low saturation magnetic flux density, application to a location where the magnetic flux density is extremely high, such as a tooth tip portion of a slot tooth motor, may adversely deteriorate the motor characteristics. In addition, since amorphous metal is thin, hard, and brittle, it is difficult to process by punching like an electromagnetic steel sheet.

  Therefore, in the present invention, a structure that does not have a portion where the magnetic flux density is extremely high, such as a tooth tip portion of a slot tooth motor, and a simple stator core structure that is not subjected to machining as much as possible are used to achieve high efficiency and production. It is to provide a good and low cost axial gap motor.

Axial gap motor of the present invention, the stator core formed by winding a ribbon-like amorphous metal, a stator the stator winding is wound on both sides of the stator have a permanent magnet In the axial gap motor including the rotor disposed on the stator core, the stator core has one slit provided in the radial direction from the winding core portion to the outer peripheral surface of the stator .

According to the present invention, it is possible to provide an axial gap motor having high efficiency by reducing iron loss, low cost by a simple structure, low noise by reducing cogging torque and torque ripple, and a high efficiency, low cost, low noise fan device.

  The axial gap motor of the present invention has a stator in which a stator winding is wound around a stator core formed by winding a ribbon-like amorphous metal, and a rotor having a permanent magnet. It is characterized by.

  In that case, the stator iron core has a slit, and the slit is provided on the outer periphery of the stator.

  In addition, an insulator is sandwiched between ribbon-like amorphous metals, and a magnetic material is provided in a gap in the winding core portion of the stator core.

  Further, when the ribbon-like amorphous metal is wound, the radius of the bent corner portion of the ribbon-like amorphous metal is 1 mm or less.

  Further, the axial gap motor of the present invention includes a stator core formed by cutting a wound ribbon-shaped amorphous metal, a stator wound with a stator winding, and a rotor having a permanent magnet. It is characterized by having.

  At that time, the radius of the bent corner of the stator winding is 1 mm or less, and the stator winding is a thin plate.

  Furthermore, the axial gap motor of the present invention has a plurality of rotors, and the permanent magnets of the plurality of rotors have different residual magnetic flux densities. The interval between and is different.

  As described above, according to the present invention, the stator core of an axial gap motor is formed by winding a ribbon-like amorphous metal, and the motor is highly efficient, the productivity is improved by a simple structure, and the cost is reduced. It is also possible to form the stator core by winding the amorphous metal ribbon and then cutting it. In addition, after the stator core is formed, an increase in loss can be prevented by providing eddy current prevention slits in the stator core, making it possible to increase the efficiency of the motor by taking advantage of the high permeability and low loss that are the characteristics of amorphous metal. Become.

  In addition, when winding an amorphous metal, eddy current loss can also be prevented by sandwiching an insulator between the amorphous metals. Furthermore, the shape of the stator core can be easily made flat, and the flat shape makes it possible to reduce the cogging torque and torque ripple of the motor.

  Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings.

  FIG. 1 shows an axial gap motor according to a first embodiment of the present invention. The axial gap motor of the present embodiment includes a plurality of stator cores, a stator 100 having a stator winding, and a rotor 200 having a permanent magnet 3. As illustrated in FIG. 1, the rotor 200 may be disposed on both upper and lower sides of the stator 100 or may be disposed only on one side.

  The stator core 1 is formed by winding a ribbon-like amorphous metal as shown in FIG. 2, and has a fan-like shape as shown in FIGS. 3 (a) and 3 (b). Thereafter, the stator winding 2 is wound around the outer periphery of the stator core 1 as shown in FIG. In addition, insulation between the stator core 1 and the stator winding 2 is maintained between the stator core 1 and the stator winding 2 by a resin coil bobbin or an insulating tape.

  In this embodiment, an eddy current prevention slit 6 is further provided as shown in FIG. When amorphous metal that is not coated is used as a stator core of a motor, eddy current loss increases. However, by providing an eddy current prevention slit 6, generation of eddy current can be suppressed and a low-loss iron core can be provided. . Moreover, the flat shape as shown in FIG. 6 can be provided with a simple winding structure, and the cogging torque and torque ripple of the motor can be reduced and a low noise motor can be provided.

  In this embodiment, a cavity 5 is formed in the stator core core when the stator core is wound. By filling the cavity with a magnetic material such as a dust core, the cross-sectional area through which the magnetic flux of the stator core passes is increased. Motor efficiency can be improved.

  Moreover, the ratio of the stator core in the stator region is increased by setting the radius of the bending corner portion 7 of the stator core 1 formed by winding the ribbon-like amorphous metal to 1 mm or less, and the motor efficiency Can be improved.

[ Reference Example 1 ]
Next, a method for manufacturing a stator core as a reference example will be described. As shown in FIG. 8, a ribbon-like amorphous metal is wound. Thereafter, the wound core is impregnated and cut into an arbitrary number of divisions as shown in FIG. 9 to obtain a wound core cut-out stator core 9 shown in FIG. In addition, as shown in FIG. 11, the stator winding 2 is wound around the outer periphery of the wound core cut-out stator core 9 to form the stator 100. In the present embodiment, an increase in eddy current loss can be prevented by providing an eddy current prevention slit 6 as shown in FIG.

  Thus, the stator core can be obtained only by simple processing after winding, and the cavity of the stator core winding core that cannot be avoided when the core is obtained only by winding as in the first embodiment. 5 and a highly efficient stator core which does not have a bent corner portion of the stator core can be provided. Further, in this embodiment, as shown in FIG. 13, the number of divisions to be divided is cut twice, and the two pieces are used as a set as shown in FIG. 14, and the stator winding 2 is wound as shown in FIG. The stator 100 can be provided by turning. In this way, by using a set of two, it is possible to manufacture a stator core that can suppress eddy currents by machining only with one machining condition. A simple and low-cost, high-efficiency stator core can be produced. Can be provided.

  Also, as shown in FIG. 16, the flat stator core shown in FIG. 17 that can reduce cogging torque and torque ripple can be easily manufactured by cutting it into a flat fan shape.

In this reference example, the material of the stator core is not limited to amorphous metal, but can be changed to a thin magnetic body such as an electromagnetic steel plate.

[ Reference Example 2 ]
In the present embodiment, in the stator winding 2 of the first embodiment and the reference example 1 , the radius of the bending corner portion 10 of the stator winding 2 shown in FIG.

  Thus, by setting the bending angle portion 10 of the stator winding 2 to 1 mm or less, the ratio of the stator core in the stator region is increased, and the space factor of the stator winding 2 can be increased, The motor efficiency can be improved. Furthermore, by using a thin copper foil or the like for the stator winding 2, the space factor of the stator winding can be improved as compared with the case of using a round copper wire, and the number of turns in the stator winding region can be improved. Therefore, the stator winding can be formed with a small number of manufacturing processes.

  FIG. 19 shows a fan device using the axial gap motor of this embodiment. Since the axial gap motor of the present invention has a high output density due to the structure of the stator 100, a small and highly efficient motor can be provided even if the residual magnetic flux density of the permanent magnet 3 of the rotor 200 is low. Therefore, cost reduction can be realized by using an inexpensive permanent magnet such as a ferrite magnet. In addition, in the axial gap motor having two or more rotors 200 from which various permanent magnets can be selected, those having different residual magnetic flux densities of the permanent magnets 3 of the respective rotors 200 can be used for the shaft. A thrust force is generated and the thrust force generated by the rotation of the blades 13 can be canceled out, and a low noise fan device can be provided. Furthermore, in this embodiment, even if the gap distance between the stator 100 and the rotor 200 of the axial gap motor having two or more rotors 200 is different, a thrust force is generated on the shaft, and the blade 13 Thrust direction force generated by rotation can be canceled out, and a low noise fan device can be provided.

  In the present invention, the axial gap motor is small, highly efficient, and low in noise, so it can be used as a fan motor for indoor units and outdoor units for air conditioners in home appliances, and a flat structure is also possible because of the axial gap structure. Therefore, it can also be used for industrial fan devices and automotive auxiliary devices.

The figure which shows the structure of the axial gap motor in connection with one Example of this invention. The figure which shows the manufacturing method of the stator core in connection with one Example of this invention. The figure which shows the stator core in connection with one Example of this invention. The figure which shows the stator in connection with one Example of this invention. The figure which shows the eddy current suppression slit structure of the stator core in connection with one Example of this invention. The figure which shows the stator core in connection with one Example of this invention. The figure which shows the stator core in connection with one Example of this invention. The figure which shows the manufacturing method of the stator core in connection with one Example of this invention. The figure which shows the manufacturing method of the stator core in connection with one Example of this invention. The figure which shows the stator core in connection with one Example of this invention. The figure which shows the stator in connection with one Example of this invention. The figure which shows the eddy current suppression slit structure of the stator core in connection with one Example of this invention. The figure which shows the manufacturing method of the stator core in connection with one Example of this invention. The figure which shows the stator core in connection with one Example of this invention. The figure which shows the stator in connection with one Example of this invention. The figure which shows the manufacturing method of the stator core in connection with one Example of this invention. The figure which shows the stator core in connection with one Example of this invention. The figure which shows the stator in connection with one Example of this invention. The figure which shows the fan apparatus in connection with one Example of this invention.

DESCRIPTION OF SYMBOLS 1 Stator core 2 Stator winding 3 Permanent magnet 4 Rotor yoke 5 Cavity of stator core winding core part 6 Eddy current prevention slit 7 Bending corner part of stator core 1 Winding core 9 Winding core cutting stator core 10 Bending corner 11 of stator winding 2 Gap 12 between stator 100 and rotor 200 Shaft 13 Blade 100 Stator 200 Rotor

Claims (3)

Comprising a stator solid stator iron core formed by winding a ribbon-like amorphous metal stator winding is wound and a rotor disposed on both sides of the stator have a permanent magnet In the axial gap motor
The stator core has an axial gap motor having one slit provided in a radial direction from a winding core portion to a peripheral surface on the outer periphery side of the stator .   2. The axial gap motor according to claim 1, wherein an insulator is sandwiched between ribbon-like amorphous metals.   2. The axial gap motor according to claim 1, wherein a magnetic material is provided in a gap in a winding core portion of the stator core.

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