JP5952701B2 - Motor stator structure, brushless motor, and method for manufacturing motor stator structure - Google Patents

Description

  The present invention relates to a motor stator structure, a brushless motor, and a method for manufacturing a motor stator structure, and more specifically, a motor stator structure including a plurality of core pieces arranged in a ring shape along the circumferential direction of the motor, The present invention relates to a brushless motor and a method for manufacturing a motor stator structure.

  A stator core of a conventional inner rotor type motor includes an annular portion, a core having a plurality of teeth portions extending in a radial direction from the annular portion, and a coil wound around each of the plurality of teeth portions in the core. . In this motor, since the tips of each of the plurality of tooth portions face the inner diameter side, it is difficult to wind the coil around the teeth portion, and the coil space factor is low. For this reason, a manufacturing method is proposed in which a plurality of core pieces each having a shape obtained by dividing the core in the circumferential direction are prepared, winding processing and crossover processing are performed on each of the core pieces, and then the plurality of core pieces are assembled in an annular shape. ing.

  By configuring the core with a plurality of core pieces, the space around the tooth portion is widened, so that the coil wire diameter can be increased, the space factor can be increased, and as a result, the motor efficiency is improved. In addition, since the number of cores that can be created from one laminated steel sheet increases, the material cost of the motor can be reduced.

  The following Patent Documents 1 to 3 disclose techniques for forming a core with a plurality of core pieces. For example, in Patent Document 1 below, the split cores held by the connection holding jig are arranged in a straight line, the coil is wound around the teeth portion of the split core, and the connecting wire spanned between the coils is connected to the insulator. A motor disposed on the outer peripheral surface of the wire holding wall is disclosed. In this technique, a pressing portion is provided between the connecting wire holding wall portions of the insulators adjacent to each other in the circumferential direction to press the connecting wire radially outward in a state where the split core is annularized.

  Patent Document 2 listed below discloses a motor including a stator formed by shaping a split core into a substantially cylindrical shape. At both ends of the annular portion of the split core or the insulator, a connecting portion that connects the split cores so as to be rotatable is provided.

  Patent Document 3 listed below discloses a motor including a unit core composed of a plurality of stator pieces connected to each other by thin connection portions.

JP 2011-234562 A JP 2003-164080 A JP-A-9-191588

  In the techniques of Patent Documents 1 to 3, in a state where a plurality of core pieces are connected to each other and arranged in a straight line, a coil is wound around the tooth portion of each core piece, and then the plurality of core pieces are assembled in an annular shape. However, when the stator is formed by winding the coil with the core piece deployed in a straight line and rounding it into a circular shape after carrying out the crossover process, slack is generated on the crossover line inside the fulcrum at the time of rounding. However, since there is a problem in that excessive tension is generated in the connecting wire outside the fulcrum, in Patent Document 1, the insulator is provided with a pressing portion that presses the connecting wire radially outward, and the core piece is developed linearly. When the adjacent pressing portions are brought into contact with each other when the wire is rounded, the connecting wire is pressed outward in the radial direction by the deformation of the pressing portion. However, when the core piece is rounded, the structure that presses the connecting wire due to the deformation of the pressing part when the pressing part abuts on the core piece, so that the deformation amount of the pressing part changes depending on the part accuracy, and the suppression of sagging becomes incomplete. There was a problem that excessive tension might be applied to the crossover.

  In Patent Document 2, the stator is composed of a plurality of independent core pieces, provided with connecting portions that connect the core pieces so as to be pivotable at both ends of the annular portion of the core piece or the insulator. Since the rolling operation is performed, if the connecting wire passes right above the fulcrum, no slack or excessive tension is generated on the connecting wire. However, there is a problem that the outer diameter of the stator is increased because a space for providing the connecting portion is required in the annular portion of the core piece, and the outer diameter of the motor is increased because the magnetic resistance is increased at the connecting portion, so that the motor characteristics are deteriorated. there were.

  Further, in Patent Document 3, a stator is manufactured in a straight line shape in which a plurality of core pieces are connected by a connecting portion, and is rounded with the connecting portion as a fulcrum. Therefore, if the connecting wire passes directly above the connecting portion, the connecting wire No slack or excessive tension is generated. However, a space for providing a connecting portion that serves as a fulcrum for bending and a hole for preventing interference between the core pieces is required in the annular portion of the core piece, so that the outer diameter of the stator is increased, and the stator is manufactured in a straight line. Further, since it is difficult to bend the core piece into a perfect circle, there is a problem that the assembly accuracy is lowered and the motor characteristics are deteriorated.

  The present invention is for solving the above-described problems, and an object of the present invention is to provide a motor stator structure, a brushless motor, and a method for manufacturing the motor stator structure that can improve the characteristics of the motor. .

  A stator structure of a motor according to one aspect of the present invention is a stator structure of a motor including a plurality of core pieces arranged in an annular shape along the circumferential direction of the motor, and each of the plurality of core pieces has an arc shape. Including an arc-shaped portion and a tooth portion protruding from the arc-shaped portion toward the inner diameter side, and the arc-shaped portion is a contact portion provided at an end portion on the circumferential side of the core piece and is in contact with an adjacent core piece And a cutout portion formed on the outer diameter side of the contact portion, the cutout portion is formed in a dimension that does not contact each other when a plurality of core pieces are linearly expanded, The coil further includes a coil wound around a tooth portion of each of the core pieces, and an insulator that insulates the plurality of core pieces from each other, and the insulator covers each of the plurality of core pieces. A coil wound around one core piece of a plurality of core pieces, and a coil wound around another core piece, including a covering portion that extends from the covering portion along the rotation axis of the motor Is connected to the outer diameter side of the extending portion of the one insulator, and passes through a position that substantially overlaps the boundary between the contact portion and the notch portion of the core piece.

  Preferably, in the stator structure of the motor, each of the plurality of core pieces further includes a holding groove formed on the outer peripheral surface of the arcuate portion.

  Preferably, the stator structure of the motor has a cylindrical shape, and further includes a frame in which each of the plurality of core pieces is press-fitted inside, and exposes a contact portion of an adjacent core piece by notching a circumferential end portion of the insulator. Thus, when the plurality of core pieces are press-fitted into the frame, the contact portions of the adjacent core pieces can be pressed.

  A brushless motor according to another aspect of the present invention includes the above-described stator structure of the motor and a rotor that is rotatably disposed on the inner diameter side of the stator structure of the motor.

  A manufacturing method of a stator structure of a motor according to still another aspect of the present invention provides a preparation step of preparing a plurality of core pieces including an arc-shaped portion having an arc shape and a teeth portion protruding from the arc-shaped portion toward the inner diameter side. And a plurality of jig pieces, and a fulcrum arranged slightly on the outer diameter side from the boundary between the notch and the contact portion of the core piece that connects adjacent jig pieces among the plurality of jig pieces, And an attachment step of arranging the plurality of core pieces in a straight line by deploying each of the plurality of core pieces in a straight line on a jig in which each of the plurality of jig pieces is relatively rotatable around a fulcrum. After the mounting process, a winding process in which a coil is wound around each of the teeth of each of the plurality of core pieces, and after the winding process, each of the plurality of jig pieces is rotated around a fulcrum. Missing part And the assembly step of assembling each of the plurality of core pieces in a ring shape in a state where the contact portions provided on the inner diameter side are in contact with each other, and wound around one core piece of the plurality of core pieces in the winding step The connecting wire connecting the coil and the coil wound around the other core piece is arranged at a position substantially overlapping with the fulcrum when viewed in plan.

  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of the stator structure of a motor which can improve the characteristic of a motor, a brushless motor, and the stator structure of a motor can be provided.

It is sectional drawing which shows typically the structure of the brushless motor in one embodiment of this invention. 3 is a plan view schematically showing a configuration in the vicinity of one core piece 3. FIG. It is a perspective view which shows typically the lamination process which laminates | stacks the several plate 11a. It is a top view which shows typically the process of forming the insulator. It is a perspective view which shows typically the process of forming the insulator. FIG. 5 is a plan view schematically showing an attaching process for attaching each of a plurality of core pieces 3 to a jig J. FIG. 5 is a perspective view schematically showing an attachment process for attaching each of a plurality of core pieces 3 to a jig J. 3 is a plan view schematically showing a winding process for winding a coil around a core piece 3. FIG. 3 is a perspective view schematically showing a winding process for winding a coil around a core piece 3. FIG. It is a top view which shows typically the assembly process which assembles each of the several core piece 3 cyclically | annularly. It is a perspective view which shows typically the assembly process which assembles each of the several core piece 3 cyclically | annularly. 3 is a perspective view schematically showing a press-fitting process for press-fitting a plurality of core pieces 3 into a motor frame 2. FIG.

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

  In the following description, “outer diameter side” means the outer diameter side when the rotation axis of the motor is the center, and “inner diameter side” means the inner diameter when the rotation axis of the motor is the center. Means the side. "Outer peripheral surface" means the outer peripheral surface when the rotation axis of the motor is the center, and "Inner peripheral surface" means the inner peripheral surface when the rotation axis of the motor is the center. Yes.

  FIG. 1 is a cross-sectional view schematically showing a configuration of a brushless motor according to an embodiment of the present invention.

  Referring to FIG. 1, an inner rotor type brushless motor as a motor in the present embodiment mainly includes a stator 1 (an example of a stator structure of a motor) and a rotor 5. The rotor 5 is disposed on the inner diameter side of the stator 1 and is rotatably supported with respect to the stator 1 by a bearing (not shown).

  The stator 1 includes a motor frame 2, a plurality of (here, nine) core pieces 3, and a coil 4. The motor frame 2 has a cylindrical shape. Each of the plurality of core pieces 3 is arranged in an annular shape along the circumferential direction of the brushless motor, and is press-fitted into the motor frame 2 (inner diameter side). Each of the plurality of core pieces 3 is independent and not connected to each other. The coil 4 is wound around each of the plurality of core pieces 3. The diameter of the stator is, for example, 20 to 70 mm.

  The rotor 5 includes a shaft 6 that is a rotating shaft and a magnet 7. The shaft 6 extends in a direction perpendicular to the paper surface in FIG. 1 so as to penetrate the central portion of the rotor 5. The magnet 7 is attached to the outer peripheral surface of the shaft 6 so as to face the stator 1. The magnet 7 has an annular shape, and regions magnetized in the N pole and regions magnetized in the S pole are alternately provided in a constant cycle along the circumferential direction.

  FIG. 2 is a plan view schematically showing a configuration in the vicinity of one core piece 3. (A) is a figure which shows the structure of the core piece 3 whole, (b) is an enlarged view of the edge part by the side of the circumferential direction of the circular arc-shaped part 31 of the core piece 3 in (a). In FIG. 2A, the portion of the core piece 3 hidden by the coil 4 is indicated by a dotted line, and the insulator 12 is indicated by a thick line.

  With reference to FIG. 2A, the core piece 3 includes a core piece main body 11, an insulator 12, and a terminal 13. The core piece body 11 includes an arc-shaped portion 31 (divided annular portion) having an arc shape, a teeth portion 32 protruding from the inner peripheral surface of the arc-shaped portion 31 toward the inner diameter side (lower side in FIG. 2), and a circular shape. And a holding groove 33 formed on the outer peripheral surface of the arc-shaped portion 31. A coil 4 is wound around the tooth portion 32. An insulator 12 made of an insulator is formed in a part of the core piece main body 11 including the tooth portion 32. The core piece body 11 and the coil 4 are insulated from each other by an insulator 12. The holding groove 33 is used when the core piece 3 is fixed to the jig.

  The insulator 12 includes a covering portion 21 that covers each of the core piece bodies 11, two extending portions 22 that extend from the covering portion 21 along the rotation axis direction (a direction perpendicular to the paper surface in FIG. 2), and a terminal 13. And a terminal holding part 23 that insulates and holds them. The covering portion 21 is notched so that the end of the split annular portion of the core piece 3 is exposed. The insulator 12 is preferably made of a flexible material such as a resin material.

  The coil 4 includes a crossover wire 4a. The connecting wire 4a is a conductive wire that connects the coil 4 wound around one core piece 3 and a coil wound around another core piece (here, the core piece on the right side of the core piece 3 shown in FIG. 2A). It is. The connecting wire 4 a passes through the outer diameter side of the extending portion 22 of the insulator 12 in the core piece 3.

  The terminal 13 is provided in a part of the holding groove 33, and the coil 4 is electrically connected at a position not shown. Thereby, electric power is supplied to the coil 4. The terminal 13 is insulated and held from the core piece body 11 by the terminal holding portion 23.

  Referring to FIG. 2B, a contact portion 34 that contacts the core piece body 11 of the adjacent core piece 3 and a contact portion 34 are disposed at both ends of the arc-shaped portion 31 of the core piece body 11 in the circumferential direction of the brushless motor. And a notch 35 formed on the outer diameter side.

  Then, the manufacturing method of the stator 1 in this Embodiment is demonstrated.

  FIG. 3 is a perspective view schematically showing a laminating process for laminating a plurality of plates 11a.

  With reference to FIG. 3, the core piece main body 11 is created by laminating | stacking the several plate 11a first. Each of the plurality of plates 11a is made of an electromagnetic steel plate and is laminated in the direction of the rotation axis so as to contact each other. The number of plates 11a constituting the core piece body 11 is arbitrary. Each of the plates 11a has the same planar shape and includes an arcuate portion 31 and a tooth portion 32.

  4 and 5 are diagrams schematically showing a process of forming the insulator 12. 4 is a plan view, and FIG. 5 is a perspective view when viewed from the outer diameter side.

  4 and 5, next, an insulator 12 is formed on the core piece body 11. Further, when the insulator 12 is formed, the terminal 13 insulated and held by the terminal holding portion 23 is provided at, for example, the upper end portion of the holding groove 33. Thereby, the core piece 3 is prepared.

  6 and 7 are diagrams schematically showing an attaching process for attaching each of the plurality of core pieces 3 to the jig J. FIG. 6 is a plan view, and FIG. 7 is a perspective view when viewed from the tooth portion 32 side. 6 and 7, the extending portion 22 is omitted.

  Next, referring to FIGS. 6 and 7, each of the plurality of core pieces 3 is attached to the jig J. The jig J includes a plurality of jig pieces JT and a plurality of fulcrums PT. Adjacent jig pieces JT are connected to each other at a fulcrum PT, and can be relatively rotated (oscillated) around the fulcrum PT. The fulcrum PT is provided in the immediate vicinity of the position directly above the boundary between the contact portion 34 and the notch 35 in the core piece 3 (a position slightly on the outer diameter side from the boundary).

  Subsequently, the jig piece JT is rotated around the fulcrum PT to adjust the orientation of the core piece 3, thereby arranging (developing) the plurality of core pieces 3 in a straight line. Each of the plurality of jig pieces JT is inserted into the holding groove 33 in each of the plurality of core pieces 3 from the lower end side of the core piece 3 toward the upper end side (in the direction indicated by the arrow AR1 in FIG. 5).

  In a state of being arranged in a straight line, each of the plurality of core pieces 3 is adjacent to each other at the adjacent core piece 3 and the cutout portion 35. The core piece 3 can be stabilized when the core pieces 3 are arranged in a straight line by pressing the adjacent cutout portions 35 in the direction of the teeth portion 32 with another jig (not shown).

  By arranging the plurality of core pieces 3 in a straight line, the interval between the teeth portions 32 is widened, and the coil 4 can be easily wound. Moreover, since the core piece 3 is arrange | positioned stably, the coil 4 can be wound with sufficient precision.

  The surface constituting the notch 35 may be a curved surface.

  FIG. 8 and FIG. 9 are diagrams schematically showing a winding process for winding a coil around the core piece 3. FIG. 8 is a plan view, and FIG. 9 is a perspective view when viewed from the tooth portion 32 side. 8 and 9, three core pieces 3 are extracted and shown, and the jig J is omitted.

  With reference to FIG. 8 and FIG. 9, the coil 4 is wound around the tooth portion 32 in each of the plurality of core pieces 3. In the first core piece 3A, the coil 4 is first held on the terminal 13 by a method such as provisional caulking, and then wound around the tooth portion 32 through the outside of the extending portion 22. It passes through the outer diameter side of the extending portion 22 of the insulator 12 (crossover processing) and is wound around the second core piece (in FIGS. 8 and 9, the second core piece is the core piece 3A). The case where it is the adjacent core piece 3B is shown). The crossover line 4a is arranged at a position overlapping the fulcrum PT of the jig J when viewed in plan (so that the fulcrum PT exists immediately below the crossover line 4a). The position of the crossover 4a is defined by the position of the extending portion 22, and the position of the fulcrum PT is defined by the shape of the jig J. After winding the coil 4, the terminal of the coil 4 and the terminal 13 are electrically joined by, for example, fusing joining.

  FIG. 10 and FIG. 11 are diagrams schematically showing an assembly process for assembling each of the plurality of core pieces 3 in an annular shape. FIG. 10 is a plan view, and FIG. 11 is a perspective view when viewed from the tooth portion 32 side. 10 and 11, the coil 4 and the extending part 22 are omitted.

  Referring to FIGS. 10 and 11, each of the plurality of jig pieces JT is rotated about the fulcrum PT to assemble (round) each of the plurality of core pieces 3 in an annular shape. In a state where each of the plurality of core pieces 3 is annularly assembled, each of the plurality of core pieces 3 is in contact with each other at the adjacent core piece 3 and the contact portion 34. By forming the contact portion 34, the core pieces 3 come into surface contact with each other when each of the plurality of core pieces 3 is annularly assembled, so that the core pieces 3 can be stabilized.

  In the assembly process, sagging occurs in the connecting wire on the inner diameter side of the fulcrum of the jig. In the present embodiment, the occurrence of sagging is suppressed by arranging the crossover wire 4a at a position substantially overlapping with the fulcrum PT when viewed in plan. This is because the distance between the fulcrum PT and the terminal 13 does not change before and after the assembly process.

  FIG. 12 is a perspective view schematically showing a press-fitting process for press-fitting a plurality of core pieces 3 into the motor frame 2.

  Referring to FIG. 12, motor frame 2 is inserted into the plurality of core pieces 3 assembled in an annular shape from the upper end side to the lower end side of core piece 3 (in the direction indicated by arrow AR2). When the motor frame 2 is inserted, the lower end portion of the motor frame 2 pushes the upper surface SF of the jig J, and the jig J is moved to the lower end side of the core piece 3 (in the direction indicated by the arrow AR3). Specifically, the motor frame 2 is pressed by supporting the contact portion 34 of the adjacent core piece with a jig (not shown). That is, since the portion of the contact portion 34 is cut out at the end in the circumferential direction of the insulator 12, the contact portion of the adjacent core piece is exposed, and by supporting the exposed core piece with a jig (not shown), By pressing the motor frame 2, it can be press-fitted with high accuracy. As a result, the plurality of core pieces 3 are press-fitted into the motor frame 2, and the jig J is removed from the plurality of core pieces 3. The stator 1 is completed through the above steps.

[Effect of the embodiment]
According to the present embodiment, when the core pieces 3 are rolled, the core pieces 3 are in surface contact with each other at the contact portion 34, so that the assembly accuracy of the stator can be improved and the magnetic resistance can be reduced.

  In addition, the occurrence of sagging is suppressed by arranging the crossover line 4a at a position overlapping the fulcrum PT when viewed in plan. Since it is not necessary to press the connecting wire by deformation of the pressing portion as in Patent Document 1, it is possible to suppress incomplete suppression of sagging due to the pressure of the pressing portion, and to prevent excessive tension from being applied to the connecting wire. .

  Further, since the plurality of core pieces 3 are fixed by press-fitting into the motor frame 2, it is necessary to provide a connecting portion for connecting the core pieces as in Patent Document 2, or the annular shape of the core piece as in Patent Document 3 This eliminates the need for a space for providing a hole portion for preventing interference between the connecting portion and the core piece as a fulcrum for bending. As a result, the width of the arc-shaped portion of the core piece can be reduced, and the outer diameter of the stator can be reduced. Moreover, it becomes easy to assemble the core piece into an annular shape. Furthermore, an increase in magnetic resistance and a decrease in assembly accuracy due to the connecting portion can be suppressed, and the characteristics of the motor can be improved.

[Others]
The manufacturing method of the above-described embodiment is an example, and the stator structure of the motor of the present invention may be manufactured by other manufacturing methods. For example, regarding the method of fixing the plurality of core pieces 3, in addition to press-fitting the plurality of core pieces 3 into the motor frame 2, the outer peripheral portions of the plurality of core pieces 3 may be fixed by a method such as welding or brazing, or a binding band.

  The above-described embodiment is to be considered as illustrative in all points and not restrictive. The scope of the present invention is defined by the terms of the claims, rather than the description above, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.

DESCRIPTION OF SYMBOLS 1 Stator 2 Motor frame 3, 3A, 3B Core piece 4 Coil 4a Crossover 5 Rotor 6 Shaft 7 Magnet 11 Core piece main body 11a Plate 12 Insulator 13 Terminal 21 Covering part 22 Extension part 23 Terminal holding part 31 Arc-shaped part 32 Teeth part 33 Holding groove 34 Contact part 35 Notch J Jig JT Jig piece PT Jig fulcrum SF Jig upper surface

Claims (5)

A stator structure of a motor comprising a plurality of core pieces arranged in an annular shape along the circumferential direction of the motor,
Each of the plurality of core pieces includes an arc-shaped portion having an arc shape, and a teeth portion protruding toward the inner diameter side from the arc-shaped portion,
The arcuate portion is a contact portion provided at an end portion on the circumferential side of the core piece, a contact portion that contacts an adjacent core piece, and a notch portion formed on the outer diameter side of the contact portion. Including
The notch is formed in a dimension that does not contact each other when the plurality of core pieces are expanded linearly, and a coil wound around the teeth portion in each of the plurality of core pieces;
An insulator for insulating the plurality of core pieces and the coil from each other;
The insulator includes a covering portion that covers each of the plurality of core pieces, and an extending portion that extends from the covering portion along the rotation axis of the motor,
The connecting wire connecting the coil wound around one core piece of the plurality of core pieces and the coil wound around the other core piece is on the outer diameter side than the extending portion of the one insulator, and A stator structure of a motor that passes through a position that substantially overlaps a boundary between the contact portion and the notch portion of the core piece.   2. The stator structure of the motor according to claim 1, wherein each of the plurality of core pieces further includes a holding groove formed on an outer peripheral surface of the arc-shaped portion.   The frame further includes a frame in which each of the plurality of core pieces is press-fitted, and a circumferential end portion of an insulator is notched to expose a contact portion of an adjacent core piece, and the plurality of the core pieces are exposed to the frame. The stator structure of the motor according to claim 1, wherein the contact portion of the adjacent core piece can be pressed when the core piece is press-fitted. The stator structure of the motor according to any one of claims 1 to 3,
A brushless motor comprising: a rotor disposed rotatably on an inner diameter side of the stator structure of the motor. A preparation step of preparing a plurality of core pieces including an arc-shaped portion having an arc shape and a teeth portion protruding from the arc-shaped portion toward the inner diameter side;
A plurality of jig pieces, a contact portion of a core piece that connects adjacent jig pieces among the plurality of jig pieces, and a fulcrum arranged slightly on the outer diameter side from the boundary of the notch, and The plurality of core pieces are arranged in a straight line by attaching each of the plurality of core pieces to a jig in which each of the plurality of jig pieces is relatively rotatable about the fulcrum. Installation process;
After the attaching step, a winding step of winding a coil around the teeth portion in each of the plurality of core pieces;
After the winding step, by rotating each of the plurality of jig pieces around the fulcrum, the contact portions provided on the inner diameter side than the notch portions are in contact with each other. An assembly step of assembling each of the plurality of core pieces in an annular shape,
In the winding step, the fulcrum is substantially the same as the fulcrum when the connecting wire connecting the coil wound around one core piece of the plurality of core pieces and the coil wound around another core piece is viewed in plan view. A method for manufacturing a stator structure of a motor, which is arranged at an overlapping position.

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