JP5480741B2 - Surface-facing resolver insulator and surface-facing resolver - Google Patents

Description

  The present invention relates to an insulator of a surface-facing type resolver and a resolver using the insulator.

  Patent Document 1 discloses a face-to-face resolver in which a stator winding is provided on a winding magnetic core. Here, the stator winding is merely described as being composed of any one of a well-known sheet coil, printed circuit board coil, alignment winding, and the like, and there is no detailed description of the alignment winding. Usually, when manufacturing a surface facing type resolver, a separation type bobbin is prepared in advance, this bobbin is attached to an insulator, and a magnet wire is wound around this bobbin. However, in this method, it is necessary to prepare a bobbin separately, or it is necessary to attach the bobbin to an insulator, and the process becomes complicated. In addition, there is a method of integrally molding an insulator having a shape with a bobbin attached thereto. In this case, however, the parting structure is complicated and expensive. In particular, it is difficult to integrally form a plurality of bobbins in a shape in which the ridges of the bobbin portion are connected in an annular shape. Further, a structure is also conceivable in which a magnet wire is wound around a winding jig to create a coil, the coil is solidified, and then removed from the jig and placed on the magnetic pole of the stator. However, this method requires a jig and takes time to harden the coil.

JP 2008-29069 A

  In such a background, an object of the present invention is to provide a technique for obtaining an insulator of a surface-facing resolver that can be obtained by integral molding with an inexpensive mold.

  According to a first aspect of the present invention, there is provided an insulator for a face-facing resolver for insulating a stator core and a coil, a substantially disk-shaped disk-shaped part having a hole in the center, and a shaft extending from the disk-shaped part. A plurality of bobbin portions extending in a direction and having a cylindrical shape for winding a coil, and each of the plurality of bobbin portions extends in a direction perpendicular to the rotation axis from the tip of the bobbin portion, A plurality of flanges having a structure separated from each other, and a plurality of openings provided at positions overlapping with the plurality of flanges of the disk-shaped part when viewed from the rotation axis direction. And a plurality of bobbin portions and a plurality of flange portions, wherein the insulator is a surface facing resolver.

  According to the first aspect of the present invention, the opening provided at a position overlapping with the flange as viewed from the axial direction becomes a gap for removing the mold in the axial direction when the insulator is integrally formed. For this reason, an insulator with an integrated bobbin can be obtained by integral molding with an inexpensive mold without using an expensive and labor-intensive mold such as a split mold.

  According to a second aspect of the present invention, in the first aspect of the present invention, the disk-shaped portion is characterized in that the divided portions having the plurality of bobbin portions are connected via thin-walled connecting portions. . According to invention of Claim 2, it changes between the bobbin which adjoins compared with the case where it is set as a disk shape (state before expand | deploying) by deform | transforming into the structure which expand | deployed the disk-shaped part linearly. The interval can be widened. That is, when a coil is wound using a winding device in a narrow place where a plurality of bobbins are densely packed, the outer shape of the coil takes into account the gap into which the nozzle of the winding device (nozzle for routing the wire) enters. There is a need and the size of the coil is limited. According to the second aspect of the present invention, the spacing between adjacent bobbins can be increased compared to the case where the insulator has a disk shape (the state before deployment), so that a coil having a larger diameter can be wound. And the winding occupation ratio can be increased.

  According to a third aspect of the present invention, there is provided a stator core having the insulator of the surface facing resolver according to the first or second aspect, a coil wound around the plurality of bobbin portions, and a portion inserted inside the bobbin portion. And a rotor disposed at a position facing the stator core.

  According to the present invention, the flange portion of the bobbin is separated into a plurality of portions, and further, an opening is provided at a position overlapping the plurality of separated flange portions in the axial direction. It becomes a part of the escape necessary for pulling out the mold to be formed integrally. For this reason, the insulator of the surface facing type | mold resolver which can be obtained by integral molding with an inexpensive metal mold | die can be obtained.

It is a perspective view of the insulator bobbin of an embodiment. It is a perspective view which shows the state which isolate | separated the insulator bobbin and stator core of FIG. 1 up and down. It is a perspective view of the stator of an embodiment. FIG. 4A is a conceptual diagram showing a molding process, and FIG. 4A is a diagram of a state in which an upper mold 401 and a lower mold 402 for molding the insulator bobbin 100 are combined, and FIG. Fig. 4C is a view showing a state in which a gap between the upper mold 401 and the lower mold 402 is filled with a resin 404. Fig. 4 (C) shows that the upper mold 401 and the lower mold 402 are moved up and down. It is a figure of the state which isolate | separated. It is a perspective view of the insulator bobbin of a comparative example. It is the top view (A) of the insulator bobbin of other embodiment, and the perspective view (B) of the unfolded state.

(Constitution)
(Insulator bobbin)
Hereinafter, a first embodiment using the invention will be described. FIG. 1 shows a resolver insulator bobbin 100 utilizing the present invention. The insulator bobbin 100 is an insulator in which a bobbin around which a stator side coil is wound is integrated. The insulator bobbin 100 is molded by integral molding using a resin material as a raw material. The insulator bobbin 100 includes a disk portion 103, a cylindrical portion 104, and eight bobbins 101 that are integrally formed by molding. The disc portion 103 has a substantially disc shape in which a hole 102 through which a rotation shaft (not shown) passes is provided at the center. The cylindrical portion 104 has a structure extending from the outer peripheral portion of the disc portion 103 in the axial direction (Z-axis method in the figure).

  In the disk portion 103, eight bobbins 101 are arranged on the same circumference with an equal angular position. The eight bobbins 101 are bobbins around which an excitation coil or a detection coil (the selection of two coils is determined depending on the location) is wound, and is molded integrally with the disk portion 103 (insulator bobbin 100) by molding. Has been. The bobbin 101 has a cylindrical shape and includes flanges 105a, 105b, and 105c extending from the top of the bobbin 101 in a direction perpendicular to the axis (a direction perpendicular to the Z axis). The flange portions 105 a, 105 b, and 105 c have a structure separated from each other, extend in three equal directions, and are integrally formed with the bobbin 101. The structure of these ridges is the same for all eight bobbins.

  When viewed from the axial direction (Z-axis direction), openings 106a and 106b having the same shape and the same dimensions as the flange are provided in portions overlapping the flanges 105a, 105b, and 105c of the disc portion 103. In addition, although the same opening part is provided also in the part of the disc part 103 which overlaps with the collar part 105c, it is hidden behind the bobbin 101 in the figure. This opening is designated as 106c. That is, when viewed from the axial direction, an opening 106a is provided in a portion of the disc portion 103 that overlaps with the flange portion 105a, and an opening 106b is provided in a portion of the disc portion 103 that overlaps with the flange portion 105b. An opening 106 c is provided in the overlapping disk portion 103. The relationship between the flange and the opening overlapping with the flange in the axial direction is the same for the other bobbins.

(Resolver stator structure)
FIG. 2 shows a stator core 200 coupled to the insulator bobbin 100 of FIG. The stator core 200 is made of a magnetic material and includes a columnar magnetic pole 201 formed by machining or pressing. Eight magnetic poles 201 are provided corresponding to the bobbin 101. The stator core 200 and the insulator bobbin 100 are joined by pressing the stator core 200 toward the insulator bobbin 100 from below in FIG. 2 and fitting the magnetic pole 201 inside the cylindrical bobbin 101.

  FIG. 3 shows a resolver stator 300. The stator 300 has a structure in which the stator core 200 of FIG. 2 is coupled to the insulator bobbin 100 of FIG. 1 and magnet wires are wound around eight bobbins 101 to form coils.

  Hereinafter, eight coils will be described. Since the eight coils have the same structure, only one coil will be described here as a representative. In FIG. 3, a coil 302 is shown. The coil 302 is an excitation coil for supplying a resolver excitation signal and a detection coil for receiving a detection signal from the rotor. The coil 302 is wound around the bobbin 101. Inside the cylindrical bobbin 101, the magnetic pole 201 protruding in the axial direction of the stator core 200 is positioned in a state of being inserted. The coil 302 is wound between the flange portions 105 a, 105 b, and 105 c of the bobbin 101 and the openings 106 a, 106 b, and 106 c of the disc portion 103.

  Although not shown, the resolver using the present invention has a rotor arranged opposite to the surface of the stator 300 on which the coil is provided, that is, in the Z-axis direction. This rotor is made of a magnetic material having a rotation axis passing through the hole 102 fixed to the rotation center portion, and is rotatable with respect to the stator 300. When the rotor rotates with an excitation signal supplied to the excitation coil of the stator 300, the gap permeance changes, and a detection signal corresponding to this change is detected from the detection coil of the stator 300. The detection signal is processed by the RD converter, so that information on the rotation angle of the rotor can be obtained. This is the same as a normal face-to-face resolver.

(Example of assembly method)
Hereinafter, an example of the assembly procedure of the stator 300 of FIG. 3 will be described. First, a mold for obtaining the insulator bobbin 100 of FIG. 1 is prepared. This mold is composed of a set of molds on the upper side (Z-axis positive direction side) and the lower side (Z-axis negative direction side) in the state shown in FIG. What is important here is that the structure is provided with openings 106a, 106b, and 106c that overlap the flanges 105a, 105b, and 105c in the axial direction, so that a mold that separates up and down in a normal manner without requiring a special mold. The structure illustrated by the mold is obtained by molding.

  That is, the flanges 105a, 105b, and 105c and the openings 106a, 106b, and 106c are separated in the axial direction but overlap each other in the axial direction, which contributes to the formation of the flanges 105a, 105b, and 105c. The portion of the mold located on the lower side of FIG. 1 passes through the openings 106a, 106b, and 106c when the mold is separated. For this reason, the operation | work which matches an upper and lower metal mold | die, and the operation | work which isolate | separates can be performed without trouble.

  Hereinafter, the significance of providing the flange and the opening overlapping in the axial direction in the mold forming will be described. FIG. 4 is a cross-sectional process diagram illustrating a molding process of the present embodiment. FIG. 4 shows a state where the bobbin 101 of FIG. 1 is cut in the Z-axis direction and the cross section is viewed from the negative X-axis direction.

  FIG. 4A shows a state in which an upper mold 401 and a lower mold 402 for molding the insulator bobbin 100 are combined. Here, molding is performed by filling the gaps 403a and 403b, which are internal spaces of the mold, with resin. FIG. 4B shows a state in which the gap between the upper mold 401 and the lower mold 402 is filled with the resin 404.

  After obtaining the state of FIG. 4 (B), as shown in FIG. 4 (C), the upper die 401 and the lower die 402 are separated vertically to obtain the insulator bobbin 100. Here, FIG. 4C shows the disk portion 103, the bobbin 101, the flange portion 105a, and the opening portion 106a of the insulator bobbin 100. As is apparent from FIG. 4, in order to form the flange portion 105a, a portion denoted by reference numeral 402a of the lower mold 402 is necessary, but since this portion falls downward from the opening portion 106a, Separation of molds can be performed without any problem. If there is no opening 106a, the flange 105a cannot be formed by the lower mold 402, and it is necessary to adopt another method that causes an increase in cost such as using a divided mold.

  When the insulator bobbin 100 of FIG. 1 is obtained as described above, magnet wires (coil windings) are wound around the eight bobbins 101 using the winding device to obtain the coil 302. Then, the end portion of the exciting coil and the end portion of the detection coil are bound to the terminal pins of the insulator bobbin 101 (not shown). Thereafter, the stator core 200 and the insulator bobbin 100 are fitted together (see FIG. 2), and varnish is further dropped to fix the winding and the stator core and the insulator. In this way, the stator 300 shown in FIG. 3 is obtained.

(Superiority)
As described above, the insulator bobbin 100 coupled to the stator core 200 has a structure in which the bobbin 101 is integrally formed. Here, the bobbin 101 includes flange portions 105a, 105b, and 105c separated in the circumferential direction for holding the end portions of the coils, and the disc portion 103 of the insulator bobbin 100 overlaps with the flange portions when viewed from the axial direction. Are provided with openings 106a, 106b, 106c. According to this structure, the insulator bobbin in which the collar part and the bobbin are integrated with an inexpensive mold by retracting the mold for forming the collar parts 105a, 105b, 105c from the openings 106a, 106b, 106c. 100 can be obtained.

  For example, in the case of the disc-shaped flange portion 501 as shown in FIG. 5, in the normal vertical mold as illustrated in FIG. 4, a part of the disc portion 502 that overlaps the flange portion 501 in the axial direction The mold does not enter the portion between the two, and the shape shown in FIG. 5 cannot be obtained. This problem can be solved by adopting a method in which a mold of another member (divided mold) is mounted on a portion where the above-described mold does not enter. However, in the case of split molds, cost increases due to an increase in mold alignment operations and an increase in molds. In particular, in a structure in which a plurality of bobbins having ridges are erected as shown in FIG. 1, the mold division structure is complicated, resulting in a large cost increase.

  On the other hand, according to this embodiment, an insulator bobbin provided with a bobbin collar can be obtained by a single molding process using a mold that is separated and coupled vertically. For this reason, the insulator of the surface facing type | mold resolver which can be obtained by integral molding with an inexpensive metal mold | die can be obtained.

(Modification)
FIG. 6 shows a second embodiment of an insulator bobbin using the present invention. FIG. 6A shows an insulator bobbin 601. The insulator bobbin 601 is made of resin and has a structure that can be developed linearly as shown in FIG. 6B. That is, the insulator bobbin 601a in a linearly expanded state has a structure in which a plurality of substantially deformed quadrangular divided portions 602 having a fan shape are connected by a thin connecting portion 603. The thin connecting portion 603 has a circular shape functioning as an insulator bobbin having a hole in the center shown in FIG. 6 (A), from a state where the thin-wall connecting portion 603 is developed in a linear shape shown in FIG. 6 (B) due to the flexibility of the resin material. (Or vice versa). Note that the structure of the bobbin portion is the same as that of the embodiment described with reference to FIG.

  The insulator bobbin 601 is molded in a state where the insulator bobbin 601 is expanded in a straight line as shown in FIG. 6B, and the coil 605 is wound around each bobbin 604 in this state. Thereafter, the state is changed to the state shown in FIG. 6A, and the ends 606a and 606b are joined. Then, a stator core (not shown) is fitted, varnish is applied to fix the wire, and the insulator bobbin 601 and the stator core (not shown) are fixed.

  Compared to the first embodiment, in the state shown in FIG. 6B, the interval between adjacent bobbins is widened. That is, the gap into which the winding device nozzle (nozzle for drawing the wire) enters is increased. For this reason, compared with the case where a wire is wound around a bobbin in the first embodiment, a coil having a larger diameter can be wound.

(Other)
The number of coils 302 (the number of bobbins 101) is not limited to the eight illustrated, and other numbers may be used. The number of separation of the buttock is not limited to the case of three illustrated. The aspect of the present invention is not limited to the individual embodiments described above, and includes various modifications that can be conceived by those skilled in the art, and the effects of the present invention are not limited to the contents described above. That is, various additions, modifications, and partial deletions can be made without departing from the concept and spirit of the present invention derived from the contents defined in the claims and equivalents thereof.

  The present invention can be used for an insulator structure of a surface-facing resolver.

DESCRIPTION OF SYMBOLS 100 ... Insulator bobbin 101 ... Bobbin 102 ... Hole 103 ... Disk part 104 ... Cylindrical part 105a, 105b, 105c ... Gutter 106a, 106b ... Opening part 200 ... Stator core 201 ... Magnetic pole 300 ... Stator 302 ... Coil 401 ... Upper die 402: Lower mold 403a, 403b: Mold gap (internal space of the mold)
404 ... Resin material 501 filled in the mold ... 鍔 part 502 ... Disk part 601 ... Insulator bobbin 601a ... Expanded insulator bobbin 602 ... Divided part 603 ... Thin-walled connecting part 604 ... Bobbin 605 ... Coils 606a, 606b ... End

Claims (3)

In the insulator of the surface facing type resolver for insulating the stator core and the coil,
A substantially disk-shaped disk-shaped part with a hole in the center;
A plurality of bobbin portions extending in the axial direction from the disk-shaped portion and having a cylindrical shape for winding a coil;
Each of the plurality of bobbin portions extends in a direction perpendicular to the rotation axis from the tip of the bobbin portion, and has a plurality of flange portions separated from each other.
A plurality of openings provided at positions overlapping with the plurality of flanges of the disk-shaped portion when viewed from the rotation axis direction,
An insulator for a surface-facing resolver, wherein the disk-shaped portion, the plurality of bobbin portions, and the plurality of flanges are integrally formed.   The insulator of a surface facing resolver according to claim 1, wherein the disk-shaped portion is connected to the divided portions having the plurality of bobbin portions via thin-walled connecting portions. The insulator of the surface facing type resolver according to claim 1 or 2,
A coil wound around the plurality of bobbin portions;
A surface-facing resolver comprising: a stator core having a portion inserted inside the bobbin portion; and a rotor disposed at a position facing the stator core.

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