JP5255996B2 - Armature core, motor using the armature core, and manufacturing method thereof - Google Patents

Description

  The present invention relates to an armature core, a motor using the armature core, and a manufacturing method thereof.

  In recent years, rotating machines with high efficiency and low cost have been demanded from the viewpoints of fuel shortage, environmental pollution and economy. And it is considered that an amorphous metal is used in this rotating electric machine. Amorphous metal is a material with excellent magnetic and mechanical properties such as low loss, high magnetic permeability, high strength, and corrosion resistance. Therefore, it is expected to be used as a motor core for improving motor efficiency and cost.

A normally used amorphous metal is in the form of a thin continuous ribbon having a certain width. Regarding the method of manufacturing the core from the ribbon-like amorphous metal, the conventional techniques are roughly divided into three types. As a first method, a core wound and laminated in a ring shape is used. For example, Patent Document 1 describes an example in which a magnetic material formed after winding and cutting a continuous amorphous metal ribbon is used as a core. Here, since the wound core is used as it is, a loop circuit is formed with respect to the current, so that the eddy current loss is large.
Furthermore, since there is nothing to protect the outside of the core, it is difficult to arrange the windings.

  In addition, there is a problem that the manufacturing process becomes complicated because an insert for stopping between the cores is necessary.

As a second method, a part of the amorphous metal wound body is cut and used as a core.
For example, in Patent Document 2, an outer periphery of an iron core wound with an amorphous thin body is formed by holding a shape maintaining material such as a silicon steel plate and mounting it on a forming jig. In this state, heat treatment and annealing are performed. Thereafter, the silicon steel plate is removed, and an adhesive is applied to the cut surface after cutting. According to this method, since the wound iron core cannot be cut completely, there is a problem that the utilization rate is low, and there is a high possibility of rusting when cutting. And there was a problem that it was difficult to design the shape and dimensions of the core.

  As a third method, an adhesive is applied to an amorphous metal strip, and a plurality of amorphous strips are overlapped and thermocompression bonded. As an example, Patent Document 3 describes a technique for manufacturing an amorphous laminated material. However, there has been a problem that the space factor of the iron core is lowered by applying the adhesive.

US Pat. No. 6,407,466 Japanese Patent Laid-Open No. 5-114525 JP 2007-311652 A

  Amorphous metal has the characteristics of energy saving and high magnetic permeability, so it can contribute to higher motor efficiency. Since amorphous metal is thin, hard, and brittle, it is difficult to perform stamping and cutting, and the conventional techniques cannot produce the optimum shape suitable for motors, resulting in complicated manufacturing processes. .

  In view of these problems, the present invention provides, as a first object, an amorphous iron core that can be used as a rotating electrical machine.

  Further, as a second object, a method for processing these amorphous iron cores is provided.

  A third object is to provide an axial gap motor using these amorphous iron cores.

  In order to solve the above problems, the present invention provides an armature core used in a rotating electric machine, including an iron core portion in which a plurality of amorphous metal foil strips are laminated, and a resin that fixes the amorphous metal foil strips. It has at least two cross sections with respect to the laminated surface.

  Furthermore, the present invention is characterized in that the amorphous metal foil strip is made of an amorphous material.

  Furthermore, the present invention is characterized in that the cross section is perpendicular to the laminated surface of the amorphous metal foil strip.

  Furthermore, the present invention is characterized in that the gap side resin portion of the armature core when used as a motor has a thickness of 0.3 mm to 0.5 mm.

  In order to solve the above-mentioned problems, the present invention provides an armature core used for a rotating electrical machine for fixing an amorphous metal foil strip to an iron core portion in which a plurality of amorphous metal foil strips are laminated. Means are provided.

  In order to solve the above problems, the present invention provides an armature core used in a rotating electrical machine, wherein a plurality of amorphous metal foil strips are laminated and the amorphous metal foil strips are connected between layers. It is characterized by that.

  In order to solve the above-mentioned problems, the present invention provides an armature core used in a rotating electrical machine, in which an iron core portion in which a plurality of amorphous metal foil strips are laminated, and a resin layer on the outermost surface of the lamination. It is characterized by having.

  Furthermore, the present invention is characterized in that the resin layer has an angle R at the edge of the resin layer.

  In order to solve the above other problems, the present invention provides a method for manufacturing an armature core used in a rotating electric machine, the step of laminating a plurality of amorphous metal foil strips, and the laminated amorphous metal foil The method includes a step of placing the band in a mold and a step of injecting a resin into the mold, and the amorphous metal foil band is fixed by the resin.

  Furthermore, the armature core manufacturing method of the present invention is characterized in that a plurality of the amorphous metal foil strips are stacked in a ring shape and then placed in the mold.

  Furthermore, the method for manufacturing an armature core of the present invention is characterized in that when the amorphous metal foil strip is fixed with the resin, a recess is provided in the resin layer covering the fixed amorphous metal foil strip. It is what.

  In order to solve the above-mentioned other problems, the present invention provides an armature core used in a rotating electric machine, including an iron core portion in which amorphous metal foil strips are laminated in a ring shape, and a resin layer covering the iron core portion. The resin layer is provided with a recess.

  Furthermore, the present invention is characterized in that the iron core is exposed in the concave portion of the resin layer.

  In order to solve the above other problems, a stator having a plurality of stator cores extending in the axial direction and provided in the circumferential direction, and windings wound around the stator core, and the amorphous iron core In an axial gap motor including a rotor having a magnet opposed to the core, an amorphous laminated cut iron core is used as the stator core.

  Furthermore, the present invention is characterized in that the magnet has a substantially rhombus shape.

  Furthermore, the present invention is characterized in that the magnet has a skew shape.

  ADVANTAGE OF THE INVENTION According to this invention, it can implement | achieve providing the amorphous iron core which prevented the peeling prevention applicable to a rotary electric machine, and the rust of the gap surface.

  In addition, according to the present invention, it is possible to process a cut core whose shape and dimensions can be changed by applying amorphous metal to a motor, and therefore, it is expected that the performance of the motor using the amorphous core is improved. Further, since the processing steps from the ribbon-like amorphous metal to the cut core can be simplified and reduced in cost, an economical motor can be obtained.

  Further, according to the present invention, it is possible to provide a thin, high-efficiency motor having an axial gap structure using an amorphous iron core.

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

  Hereinafter, an embodiment of the present invention will be described with reference to FIGS.

  FIG. 1 shows an overall view of an amorphous iron core 102 according to a first embodiment of the present invention.

  The iron core portion 104 of the amorphous iron core 102 uses a ribbon-like (foil strip) amorphous metal (amorphous metal) 110 as an iron base (iron base), and an insulating resin material (hereinafter referred to as a resin) 112. The ribbon-like amorphous metal 110 is fixed by a resin.

  Further, the iron core portion 104 has a fan shape when viewed from above and below.

  The gap surface 106 of the iron core portion 104 is formed of a resin portion 108 made of a very thin resin of 0.3 mm to 0.5 mm to prevent the gap surface 106 from being rusted. A resin layer 108 made of resin is also formed on the surface in the main direction of the fan and on the outer surface to prevent rust.

  In order to arrange windings, which will be described later, around the amorphous iron core 102, a contact portion between the winding and the amorphous iron core 102, that is, an end portion of the amorphous iron core 102 has a chamfered structure with an angle R.

  Hereinafter, a method for manufacturing the amorphous iron core 102 will be described.

(1) Iron core molding process FIG. 2 shows a mold for molding an iron core. The mold includes an upper cover 202, a lower cover 204, a center core 242 and an out core 244. The upper and lower bars 202 and 204 are provided with a hole 206 for injecting resin and a protrusion 208 for forming a groove in the gap surface. The center core 242 is provided with a protrusion 210 for forming a groove on the tape surface of the iron core, and the outer core 244 is provided with a protrusion (not shown) on the inside thereof. In this embodiment, since the projections 208 having a width of 2 degrees are provided every 24 degrees, the groove of the mold having a concave shape is formed by 22 degrees. Further, it is preferable that the protrusion 208 is in the entire peripheral range from 0 to 360 degrees. Since the amount of the resin injected from the hole 206 can be controlled, a thin and uniform thin film can be formed. Therefore, rusting of the gap surface 106 can be prevented by forming a very thin resin of 0.3 mm to 0.5 mm on the gap surface 106 side of the iron core portion 104.

  The protrusion 208 can form an armature core having a structure in which the surface of the amorphous wound core 120 is exposed with the groove of the mold having a concave shape as a cut portion.

  As the mold, it is preferable to use a circular shape or a substantially circular shape. As a method for bonding the ribbon-like amorphous metal 110, an adhesive method such as an adhesive or welding can be applied.

  An amorphous wound iron core 120 as shown in FIG. 3 is put in a mold and closed, and a resin is injected from the hole 206. After that, vacuum impregnation was performed, and the groove 130 of the amorphous resin-coated core 122 was cut by impregnating a large amount of resin into the gap between the ribbon-shaped amorphous core 120 and the mold as shown in FIG. The mechanical strength can be ensured.

(2) Cutting process FIG. 5 shows the cutting process of the resin-coated iron core 122. Cut from the groove 130 where the iron core surface is exposed in the cooling water. The core portion 122 with resin and the groove 130 of the core portion where the core surface is exposed can relieve stress during cutting, and the laminated core can be prevented from being scattered. In addition, with this method, the heating before cutting described in Patent Document 2 is not necessary. Furthermore, a preferable shape and size of the cut core can be manufactured by setting the groove 130. In order to arrange winding around the amorphous iron core 102, the contact portion between the winding 160 and the amorphous iron core 102 has a chamfered structure with an angle R.

  FIG. 6 shows an axial gap motor using the amorphous iron core 102 core of the first embodiment. The motor using the amorphous core of this embodiment includes a plurality of stator amorphous cores 102, a stator 304 having a stator winding 160, and rotors 302 and 304 having a substantially rhomboid ferrite magnet 310. . The two rotors 302 and 304 have a structure sandwiching the stator 304, and in the motor of this embodiment, the stator has 9 poles and the magnet has 6 poles. Other combinations of the number of magnet stations are possible. In some cases, the rotor in this embodiment can be set to rotate on the stationary side and the stator side can be rotated.

  FIG. 7 shows detailed shapes of the ferrite magnet 310, the amorphous iron core 102, and the winding 160. FIG. 7 shows the shape of the motor of FIG. 6 as viewed from above. In order to reduce the cogging torque, the magnet 310 is provided with a skew of a predetermined angle in the circumferential direction and the radial direction. When the rotation direction of the magnetic pole of the magnet 310 is defined, an N pole is arranged in the traveling direction and an S pole is arranged in the opposite direction. The winding 160 is wound around the amorphous iron core 102 along a plane perpendicular to the motor axis. Note that the motor of this embodiment can be rotated in both directions by controlling the flowing current.

  Further, as the shape of the magnet 310, the member shape of the magnet 310 shown in FIG. 7 is θ1: 25 ° with respect to the center line, and the angles of the member apexes are θ2: 65 °, θ3: 115 °, The angles are θ4: 109 ° and θ5: 71 °.

  The motor windings 160 of these motors are connected to a power converter (not shown), and the power is supplied and controlled from the power converter so that the motor is rotationally controlled at the required rotational speed. It has become.

  FIG. 8 shows the waveform of the cogging torque of an embodiment of a motor in which the magnet of the present invention has a substantially rhombic skew shape. FIG. 9 shows the waveform of the cogging torque of the motor when a conventional all-around magnet is used as the rotor.

  From this experimental result, the cogging torque of the embodiment of the motor of the present invention is smaller than the conventional cogging torque waveform. This is because, as shown in the present embodiment, the cogging torque can be suppressed by making the magnet 310 a substantially rhombic skew shape with respect to the shape of the stator 304 (amorphous iron core 102, winding 160). Show.

  FIG. 10 shows the detailed shape of the magnet, and FIG. 11 shows the detailed shape of the amorphous iron core.

  In the motor of the embodiment of the present invention, when the skew shape of the magnet 310 is the circle peripheral length L1 of the magnet 310 and the circle peripheral length L2 of the amorphous iron core 102, the relationship of L2 / L1 is 0.4-0. The cogging torque can be suppressed to be low by setting the range to 53.

  In the above-described embodiments, the configuration in which the ribbon-like amorphous metal is mainly fixed by the resin is shown. However, in addition to this fixing method, the ribbon-like amorphous metal is connected between the layers using an adhesive or an adhesive method such as welding. Therefore, it is possible to constitute an amorphous iron core as a whole.

  And since the amorphous cut core is used in the Example mentioned above, it has implement | achieved providing a motor with little eddy current loss and high efficiency. Moreover, since the ferrite magnet can be used, the cost of the motor is reduced.

  The amorphous iron core of the present invention can be applied to a brushless motor aiming at small size, high efficiency, and low noise. In addition, the motor having an axial gap structure using the amorphous iron core of the present invention can be applied to a general motor system such as a thin and high-efficiency fan system.

1 shows an amorphous armature core according to an embodiment of the present invention. 1 shows an amorphous iron core mold forming apparatus according to an embodiment of the present invention. 1 shows an amorphous iron core mold according to one embodiment of the present invention. The ring-shaped amorphous iron core concerning one Example of this invention is shown. The amorphous cut core concerning one Example of this invention is shown. 1 shows an axial gap motor using an amorphous iron core according to an embodiment of the present invention. The positional relationship between the magnet and the stator core of an axial gap motor according to an embodiment of the present invention is shown. The cogging torque waveform of the axial gap motor concerning one Example of this invention is shown. The cogging torque waveform of the prior art of this invention is shown. The detailed shape of the magnet of one Example of this invention is shown. The detailed shape of the amorphous iron core of one Example of this invention is shown.

Explanation of symbols

102 Amorphous iron core 104 Iron core portion 106 Gap surface 108 Resin portion 110 Amorphous metal 112 Insulating resin material

Claims (5)

In the armature core used for rotating electrical machines,
A wound iron core of an amorphous metal foil strip fixed and covered with a resin film is cut into a plurality of fan shapes to form an iron core portion.
The iron core portion is formed by laminating a plurality of amorphous metal foil strips with an insulating resin material in the radial direction of the wound iron core,
Other than the two cross-sections with respect to the laminated surface, the resin film is covered,
The armature core, wherein the amorphous metal foil strip is an Fe-based amorphous metal . The armature core according to claim 1,
2. The armature core according to claim 1, wherein the cross section is perpendicular to the laminated surface of the amorphous metal foil strip. The armature core according to claim 1,
When used as a motor, the gap side resin portion of the armature core is configured to have a thickness of 0.3 mm to 0.5 mm, and a groove provided in the resin film is used as a reference for cutting. Iron core. In the manufacturing method of the armature core used for the rotating electrical machine,
The process of placing the wound core of the amorphous metal foil strip into the mold,
Injecting resin into the mold and covering the wound core with a resin film;
Cutting the core with resin film into a plurality of fan shapes, and
A plurality of amorphous metal foil strips sandwiching an insulating resin material in the radial direction of the wound iron core,
A method for manufacturing an armature core , wherein the armature core is covered with the resin film except for two cross sections with respect to the laminated surface . 4. An axial gap type motor comprising the armature core according to claim 1 as a stator core.

Images