JP6866319B2 - Stator, rotary machine and vehicle - Google Patents

Description

Embodiments of the present invention relate to stators, rotary machines and vehicles.

As an example of a rotary electric machine, an axial gap motor in which a rotor connected to a shaft and a stator are arranged to face each other in the axial direction of the shaft with a gap is known. For example, as a stator of this type of motor, there is a configuration in which a plurality of cores are arranged in the circumferential direction about the rotation axis of the shaft, and a coil that individually surrounds each core is arranged.

On the other hand, as a configuration of the axial gap motor, it is conceivable to provide an annular coil surrounding the shaft and arrange a plurality of cores around the coil. Each core faces the coil in the radial direction about the axis of rotation of the shaft. When such an annular coil is used, the coil is present in any of the radial directions. Therefore, it is necessary to devise a structure for fixing the coil and the core to the frame.

Japanese Unexamined Patent Publication No. 2017-55556

An object to be solved by the present invention is to provide a stator capable of suitably fixing a core and a coil, a rotary electric machine having the stator, and a vehicle equipped with the rotary electric machine.

The stator according to one embodiment includes a first support plate, an annular coil, and a plurality of cores. The first support plate has a first surface, a second surface opposite to the first surface, and a plurality of openings penetrating from the first surface to the second surface. The coil is supported by the first surface. The plurality of cores are aligned with the coil in the radial direction of the coil, are supported by the first surface, and are exposed from the opening to the second surface side.

FIG. 1 is a perspective view showing an external configuration of the motor according to the first embodiment. FIG. 2 is a schematic exploded perspective view of the motor. FIG. 3 is a schematic cross-sectional view of the motor. FIG. 4 is a schematic exploded perspective view of the stator included in the motor. FIG. 5 is a schematic perspective view of the core included in the stator. FIG. 6 is a schematic perspective view showing a manufacturing process of the stator. FIG. 7 is a schematic perspective view showing a manufacturing process of the stator. FIG. 8 is a schematic perspective view showing a manufacturing process of the stator. FIG. 9 is a schematic plan view of the assembled stator. FIG. 10 is a schematic cross-sectional view of the stator along line F10 of FIG. FIG. 11 is a schematic cross-sectional view of the stator along line F11 of FIG. FIG. 12 is a schematic cross-sectional view of the stator along line F12 of FIG. FIG. 13 is a diagram showing an application example of the motor. FIG. 14 is a schematic cross-sectional view of a part of the stator according to the second embodiment. FIG. 15 is a schematic cross-sectional view of a part of the stator according to the third embodiment.

Some embodiments will be described with reference to the drawings.
In each embodiment, an axial gap motor is disclosed as an example of a rotary electric machine. However, a part of the structure shown in each embodiment can be applied to other types of rotary electric machines.

[First Embodiment]
FIG. 1 is a perspective view schematically showing an example of an external configuration of an axial gap motor M (hereinafter, referred to as a motor M) according to the first embodiment.
The motor M includes four housings 10A, 10B, 10C, 10D, three rectangular frames 20A, 20B, 20C, and a shaft S.

The frame 20A is arranged between the housings 10A and 10B. The frame 20B is arranged between the housings 10B and 10C. The frame 20C is arranged between the housings 10C and 10D. The housing 10A has a bottomed tubular shape, and one end of the opening is connected to the frame 20A. The housing 10B has a tubular shape, one end of which is connected to the frame 20A and the other end of which is connected to the frame 20B. The housing 10C has a tubular shape, one end of which is connected to the frame 20B and the other end of which is connected to the frame 20C. The housing 10D has a bottomed tubular shape, and one end of the opening is connected to the frame 20C.

The shaft S is passed through the housings 10A to 10D and the frames 20A to 20C. For example, the shaft S is rotatably supported by housings 10A and 10D via bearings.

Through holes H are provided at the four corners of the frames 20A to 20C. The motor M can be fixed at the installation location by utilizing these through holes H. FIG. 1 shows a state in which the through holes H below the frames 20A and 20C are connected to the fixture F at the installation location, but the installation method of the motor M is not limited to this.

FIG. 2 is a schematic exploded perspective view of the motor M.
Here, the illustrations of the housings 10A to 10D are omitted. The motor M includes a rotor 1A housed in the housing 10A, a rotor 1B housed in the housing 10B, a rotor 1C housed in the housing 10C, and a rotor 1D housed in the housing 10D. There is. Further, the motor M includes a stator 2A fixed to the frame 20A, a stator 2B fixed to the frame 20B, and a stator 2C fixed to the frame 20C.

The shaft S is passed through the center of the rotors 1A to 1D and the stators 2A to 2C. The rotors 1A to 1D are attached to the shaft S. As a result, the rotor 1A, the stator 2A, the rotor 1B, the stator 2B, the rotor 1C, the stator 2C, and the rotor 1D are arranged in order along the rotation axis AX of the shaft S through the gap.

The rotors 1A to 1D include a disk-shaped support plate 11, a plurality of permanent magnets 12, and a plurality of cores 13. The core 13 is a dust core obtained by compressing and solidifying a ferromagnetic powder such as iron. The permanent magnets 12 and the core 13 have a long shape extending radially around the rotation axis AX, and are arranged alternately in the circumferential direction around the rotation axis AX. In the rotor 1A, the permanent magnet 12 and the core 13 are arranged only on one surface of the support plate 11 facing the stator 2A. In the rotors 1B and 1C, the permanent magnets 12 and the core 13 are arranged on both sides of the support plate 11. In the rotor 1D, the permanent magnet 12 and the core 13 are arranged only on one surface of the support plate 11 facing the stator 2C.

FIG. 3 is a schematic cross-sectional view of the motor M.
Here, only a part of the rotors 1A and 1B and the stator 2A and the shaft S are shown, and the illustration of other elements is omitted. The stator 2A includes a first support plate 3 and a second support plate 4. The support plates 3 and 4 are preferably formed of a non-magnetic and non-conductive material. For example, each of the support plates 3 and 4 can be made of fiber reinforced plastic (FRP). Further, each of the support plates 3 and 4 can also be formed of a ceramic material. Since the ceramic material has excellent thermal conductivity, heat can be easily dissipated from the stators 2A to 2C, which contributes to the reduction in size and weight of the motor M and the increase in output.

Further, the stator 2A includes a first core 81, a second core 82, a third core 83, a first coil 91, and a second coil 92 arranged between the support plates 3 and 4. ing. The first core 81, the second core 82, and the third core 83 are arranged in order toward the rotation axis AX. The first coil 91 is arranged between the first core 81 and the second core 82, and the second coil 92 is arranged between the second core 82 and the third core 83. Both side surfaces of the cores 81 to 83 are exposed from the support plates 3 and 4, respectively, and face the rotors 1A and 1B.

When a current is passed through the coils 91 and 92, magnetic flux is generated around the coils 91 and 92 as shown by the broken line and the arrow. The magnetic flux passing through each of the cores 81 to 83 is substantially parallel to the rotation axis AX. These magnetic fluxes act on the permanent magnets 12 of the rotors 1A and 1B, and the rotors 1A and 1B and the shaft S rotate.

Similar magnetic flux is generated in the stators 2B and 2C. That is, the motor M of the present embodiment has three layers of structures in which a stator is arranged between two rotors. Three-phase alternating current is supplied to the coils 91 and 92 of the stators 2A to 2C, respectively.

Subsequently, the details of the stator 2A will be described with reference to FIGS. 4 to 12. Since the stators 2B and 2C have the same structure as the stator 2A, the description thereof will be omitted.
FIG. 4 is a schematic exploded perspective view of the stator 2A.
The stator 2A includes the above-mentioned first support plate 3, second support plate 4, a plurality of first cores 81, a plurality of second cores 82, a plurality of third cores 83, a first coil 91, and a second coil 92. I have. Further, the stator 2A includes first pressing members 5A and 5B, second pressing members 6A and 6B, and third pressing members 7A and 7B. These pressing members are preferably formed of a non-magnetic and non-conductive material, and can be formed of, for example, various plastics.

In the present embodiment, the first pressing members 5A and 5B constitute the first fixing member 5 for fixing the plurality of first cores 81. Further, the second pressing members 6A and 6B form a second fixing member 6 for fixing the plurality of second cores 82. Further, the third pressing members 7A and 7B constitute a third fixing member 7 for fixing the plurality of third cores 83.

The plurality of first cores 81 are arranged along the first circumference C1 centered on the rotation axis AX. The plurality of second cores 82 are arranged around the rotation axis AX and along the second circumference C2 having a radius smaller than that of the first circumference C1. The plurality of third cores 83 are arranged around the rotation axis AX and along the third circumference C3 having a radius smaller than the second circumference C2. The arrangement interval of the first core 81 in the circumferential direction may be constant, or may be different at least in part. The same applies to the second core 82 and the third core 83.

The first coil 91 and the second coil 92 are annular and are arranged concentrically around the rotation axis AX. The radius of the second coil 92 is smaller than the radius of the first coil 91. The first coil 91 and the second coil 92 are configured by winding a wire in the circumferential direction about the rotation axis AX. In each of the first coil 91 and the second coil 92, for example, the strands are flat in the axial direction, and are stacked in a plurality of stages in the axial direction parallel to the rotation axis AX and in the radial direction centered on the rotation axis AX.

The first support plate 3 has a circular shape centered on the rotation axis AX, and has a first surface F1, a second surface F2 on the opposite side of the first surface F1, and a circular central opening 30 for passing the shaft S. , A plurality of first core openings 31 corresponding to the first core 81, a plurality of second core openings 32 corresponding to the second core 82, and a plurality of third core openings 33 corresponding to the third core 83. doing. Further, the first support plate 3 has a plurality of holes 34 provided along the outer peripheral edge, a plurality of holes 35 provided along the central opening 30, and at least two positioning holes 36. .. Each of the openings 30 to 33 and each of the holes 34 to 36 penetrates from the first surface F1 to the second surface F2.

The second support plate 4 has substantially the same shape as the first support plate 3, and has a third surface F3 facing the first surface F1, a fourth surface F4 on the opposite side of the third surface F3, and a central opening 40. , A plurality of first core openings 41, a plurality of second core openings 42, and a plurality of third core openings 43. Further, the second support plate 4 has a plurality of holes 44 provided along the outer peripheral edge, a plurality of holes 45 provided along the central opening 40, and a slit for drawing out the wire of the second coil 92. It has 46 and at least two positioning holes 47. The openings 40 to 43 and the holes 44, 45, 47 all penetrate from the first surface F1 to the second surface F2.

The first pressing members 5A and 5B are, for example, annular, and have a plurality of first holding portions 50 arranged at the same pitch as the plurality of first cores 81 on the inner peripheral side. Further, the first pressing members 5A and 5B have a plurality of holes 51 provided in each of the first holding portions 50, a plurality of holes 52 provided along the outer peripheral edge, and at least two positioning holes 53. Have. A female screw is provided in the hole 51 of the first pressing member 5A.

The plurality of second pressing members 6A and 6B are arranged in an annular shape at the same pitch as the plurality of second cores 82. The second pressing members 6A and 6B have holes 61. A female screw is provided in the hole 61 of the second pressing member 6A.

The third pressing members 7A and 7B are, for example, annular, and have a plurality of second holding portions 70 arranged at the same pitch as the plurality of third cores 83 on the outer peripheral side. Further, the third pressing members 7A and 7B have a plurality of holes 71 provided in each of the second holding portions 70, and a plurality of holes 72 provided along the inner peripheral edge. A female screw is provided in the hole 71 of the third pressing member 7A.

The frame 20A has a circular opening 21 having a diameter smaller than the outer diameter of each of the support plates 3 and 4. Further, the frame 20A has an annular step portion 22 on the peripheral edge of the opening 21. The step portion 22 is provided on both the side of the first support plate 3 and the side of the second support plate 4. Further, the frame 20A has a plurality of holes 23 provided in the step portion 22 and at least two positioning holes 24.

The circumferences C1 to C3, the outer circumferences of the support plates 3 and 4, the central openings 30 and 40, the opening 21 of the frame 20 and the coils 91 and 92 and the like are concentric circles centered on the rotation axis AX. ..

FIG. 5 is a schematic perspective view of the first core 81.
The second core 82 and the third core 83 have the same shape as the first core 81. In FIG. 5, the reference numerals of the respective parts of the first core 81 and the corresponding codes of the respective parts of the second core 82 and the third core 83 are written in parentheses. In the figure, X is an axial direction parallel to the rotation axis AX, R is a radial direction centered on the rotation axis AX, and C is a circumferential direction centered on the rotation axis AX.

The first core 81 has a core main body 81a and a pair of collar portions 81b. The core body 81a is, for example, a rectangular parallelepiped. The pair of flange portions 81b project from both side surfaces F11 and F12 in the circumferential direction C of the core main body 81a. In the example of FIG. 5 , each of the pair of collar portions 81b is provided over the entire space between both ends of the side surfaces F11 and F12 in the radial direction R. That is, the width of the collar portion 81b in the radial direction R and the width of the core main body 81a in the radial direction R coincide with each other. The width of the flange portion 81b in the circumferential direction C is smaller than the width of the core main body 81a in the circumferential direction C.

The first core 81 can be composed of a plurality of electromagnetic steel sheets 810 laminated in a direction perpendicularly intersecting the rotation axis AX (diameter direction R). The electrical steel sheet 810 has a first portion 810a corresponding to the core main body 81a and a pair of second portions 810b corresponding to each flange portion 81b. The electrical steel sheet 810 is a grain-oriented electrical steel sheet having excellent electromagnetic characteristics in the rolling direction (direction in which magnetization is easy) D. The rolling direction D is, for example, parallel to the axial direction X. In this case, the rolling direction D coincides with the direction of the magnetic flux passing through the first core 81 shown in FIG.

The laminated electromagnetic steel sheets 810 can be fixed to each other at each flange portion 81b (each second portion 810b). For example, each electrical steel sheet 810 may be fixed by caulking or tacking at a pair of fixed positions 81c that overlap with each flange portion 81b. If the electromagnetic steel plate 810 is fixed to each flange portion 81b, the core main body 81a is not deformed, so that the electromagnetic characteristics of the core main body 81a can be kept good.

The laminated electromagnetic steel sheet 810 may be fixed by an adhesive, or may be fixed by impregnating the resin and then curing the resin. In these cases, the electromagnetic steel sheet 810 is not deformed, so that the electromagnetic characteristics of the first core 81 are generally good. Further, the laminated electromagnetic steel sheets 810 can be fixed by welding. In this case, the first core 81 can be easily manufactured.

Like the first core 81, the second core 82 has, for example, a rectangular parallelepiped core body 82a and a pair of collar portions 82b protruding from both side surfaces F21 and F22 in the circumferential direction C of the core body 82a. Each of the pair of flange portions 82b is provided over the entire space between both ends of the side surfaces F21 and F22 in the radial direction R. That is, the width of the collar portion 82b in the radial direction R and the width of the core main body 82a in the radial direction R coincide with each other. The width of the flange portion 82b in the circumferential direction C is smaller than the width of the core main body 82a in the circumferential direction C.

Like the first core 81, the second core 82 can be composed of a plurality of electromagnetic steel sheets 820 laminated in the radial direction R. The electrical steel sheet 820 has a first portion 820a corresponding to the core main body 82a and a pair of second portions 820b corresponding to each flange portion 82b. The electrical steel sheet 820 is a grain-oriented electrical steel sheet, and its rolling direction D is parallel to the axial direction X. The laminated electromagnetic steel sheet 820 can be fixed by caulking or tacking at a pair of fixing positions 82c that overlap with each flange portion 82b, for example. In addition, various methods described above for the electromagnetic steel sheet 810 can be applied to the fixing of the electrical steel sheet 820.

Like the first core 81, the third core 83 has, for example, a rectangular parallelepiped core main body 83a and a pair of collar portions 83b protruding from both side surfaces F31 and F32 in the circumferential direction C of the core main body 83a. Each of the pair of flange portions 83b is provided over the entire space between both ends of the side surfaces F31 and F32 in the radial direction R. That is, the width of the collar portion 83b in the radial direction R and the width of the core main body 83a in the radial direction R coincide with each other. The width of the collar portion 83b in the circumferential direction C is smaller than the width of the core main body 83a in the circumferential direction C.

Like the first core 81, the third core 83 can be composed of a plurality of electromagnetic steel sheets 830 laminated in the radial direction R. The electrical steel sheet 830 has a first portion 830a corresponding to the core main body 83a and a pair of second portions 830b corresponding to each flange portion 83b. The electrical steel sheet 830 is a grain-oriented electrical steel sheet, and its rolling direction D is parallel to the axial direction X. The laminated electromagnetic steel sheet 830 can be fixed by caulking or tacking, for example, at a pair of fixing positions 83c that overlap with each flange portion 83b. In addition, various methods described above for the electromagnetic steel sheet 810 can be applied to the fixing of the electrical steel sheet 830.

The rolling directions D of the electromagnetic steel sheets 810, 820, and 830 do not have to exactly coincide with the axial direction X, and may intersect the axial direction X at a constant acute angle. In FIG. 5, the rolling direction D parallel to the axial direction X is shown. For example, the rolling direction D can be determined within a range not exceeding the angle θ1 formed by the diagonal line L1 and the axial direction X of the first portion 810a and the angle θ2 formed by the diagonal line L2 and the axial direction X.

Further, the electromagnetic steel sheets 810, 820, and 830 may be non-oriented electrical steel sheets. Further, each core 81 to 83 may be a dust core obtained by compressing and solidifying a ferromagnetic powder such as iron. When a dust core is used as each of the cores 81 to 83, it is possible to reduce the iron loss when the motor M is driven by alternating current in a high frequency region, for example.

An example of the assembly procedure (manufacturing method) of the stator 2A will be described with reference to the perspective views of FIGS. 4 and 6 to 8.
FIG. 6 is a schematic perspective view showing the stator 2A during assembly.
First, at least two positioning pins P are passed through the positioning holes 36 (see FIG. 4) of the first support plate 3 and the positioning holes 53 of the first holding member 5A. At this time, each of the first core openings 31 of the first support plate 3 is located between the first holding portions 50 of the first pressing member 5A.

Next, the third pressing member 7A is arranged on the first supporting plate 3 so that the third core opening 33 of the first supporting plate 3 is located between the second holding portions 70 of the third pressing member 7A. To do. Further, a plurality of second pressing members 6A are arranged between the second core openings 32 of the first support plate 3.

Next, the core body 81a of the first core 81 is inserted between the first holding portions 50 of the first pressing member 5A and into the first core opening 31 of the first support plate 3. Further, the core body 82a of the second core 82 is inserted between the adjacent second pressing members 6A and into the second core opening 32 of the first support plate 3. Further, the core body 83a of the third core 83 is inserted between the second holding portions 70 of the third pressing member 7A and into the third core opening 33 of the first support plate 3.

Further, the second pressing member 6B is arranged between the adjacent second cores 82, respectively. Each flange portion 82b of the second core 82 is interposed between the second pressing members 6A and 6B. Further, the third pressing member 7B is arranged so that the core main body 83a is inserted between the second holding portions 70 of the third pressing member 7B. Each flange portion 83b of the third core 83 is interposed between the second holding portions 70 of both the third pressing members 7A and 7B.

FIG. 7 is a schematic perspective view showing an assembly procedure following FIG. 6 of the stator 2A.
The frame 20A is arranged through the positioning pin P in the positioning hole 24. The first pressing member 5A comes into contact with the stepped portion 22 on the back surface side of the illustrated frame 20A. The pressing members 6A, 6B, 7A, 7B and the cores 81 to 83 fit within the opening 21 of the frame 20A.

After arranging the frame 20A, the first coil 91 is arranged between the plurality of first cores 81 and the plurality of second cores 82. Further, the first pressing member 5B is arranged through the positioning pin P in the positioning hole 53. At this time, the core main body 81a is inserted between the first holding portions 50 of the first pressing member 5B. The first pressing member 5B comes into contact with the stepped portion 22 of the frame 20A.

After arranging the first pressing member 5B, the second coil 92 is arranged between the plurality of second cores 82 and the plurality of third cores 83. The two lead portions 91a of the strands of the first coil 91 and the two lead portions 92a of the strands of the second coil 92 are drawn out of the frame 20A through, for example, a hole provided in the frame 20A.

After arranging the coils 91 and 92, the screw S1 is inserted into each hole 51 of the first pressing member 5B, and the tip thereof is screwed into the female screw of each hole 51 of the first pressing member 5A to obtain the first pressing member 5A. , 5B are connected (see FIG. 11 described later). Further, the second pressing members 6A and 6B are connected by inserting the screw S2 into the hole 61 of the second pressing member 6B and screwing the tip thereof into the female screw of the hole 61 of the second pressing member 6A (see also FIG. 11). ). Further, the third pressing members 7A and 7B are connected by inserting the screw S3 into each hole 71 of the third pressing member 7B and screwing the tip thereof into the female screw of each hole 71 of the third pressing member 7A (also shown in the figure). 11). In FIG. 7, only one screw S1 to S3 is shown.

FIG. 8 is a schematic perspective view showing an assembly procedure following FIG. 7 of the stator 2A.
The second support plate 4 is arranged through the positioning pin P in the positioning hole 47. At this time, the core body 81a of the first core 81 is inserted into the first core opening 41, the core body 82a of the second core 82 is inserted into the second core opening 42, and the core body 83 of the third core 83 is inserted into the third core opening 43. The core body 83a is inserted. The lead portion 92a of the second coil 92 is housed in the slit 46.

The first support plate 3 and the second support plate 4 are fixed to each other by, for example, a plurality of sets of bolts B1 and nuts N1 and a plurality of sets of bolts B2 and nuts N2. In FIG. 8, only one set of each of the bolt B1 and the nut N1 and the bolt B2 and the nut N2 is shown. The bolt B1 is passed through the hole 34 of the first support plate 3, the hole 52 of the first holding member 5A, the hole 23 of the frame 20A, the hole 52 of the first holding member 5B, and the hole 44 of the second support plate 4 in this order. It is screwed into the nut N1 on the side of the second support plate 4 (see FIG. 10 described later). The bolt B2 is passed through the hole 35 of the first support plate 3, the hole 72 of the third pressing member 7A, the hole 72 of the third pressing member 7B, and the hole 45 of the second support plate 4 in this order, and the bolt B2 is passed through the hole 45 of the second support plate 4. It is screwed into the nut N2 on the side (also see FIG. 10).

The stator 2A assembled in this way may be impregnated with a thermosetting and insulating resin, for example, in a vacuum atmosphere. This resin enters between the first support plate 3 and the second support plate 4 from the vicinity of the central openings 30 and 40, for example, and fills the gap between the adjacent elements inside the stator 2A. Before the resin is completely cured, it is preferable to rotate the stator 2A in an upright state in the direction of gravity. As a result, the resin on the outer surface and the inside of the stator 2A flows and is made uniform, and excess resin can be removed.

FIG. 9 is a schematic plan view of the assembled stator 2A as viewed from the side of the second support plate 4. Here, only half of the stator 2A is shown, and a part of the second support plate 4 is broken.
The positions of the first core 81, the second core 82, and the third core 83 are displaced from each other in the circumferential direction about the rotation axis AX by, for example, an angle corresponding to 120 ° in terms of electrical angle.

The first core 81 is located between the first pressing members 5A and 5B and the first coil 91. The first holding portion 50 of the first pressing members 5A and 5B does not extend toward the first coil 91 from the first core 81. The second core 82 is located between the coils 91 and 92. The width of the second pressing members 6A and 6B in the radial direction R is equal to or less than the width of the second core 82 in the radial direction R. Therefore, the second pressing members 6A and 6B do not extend from the second core 82 to the first coil 91 side and the second coil 92 side. The third core 83 is located between the third pressing members 7A and 7B and the second coil 92. The second holding portion 70 of the third pressing members 7A and 7B does not extend toward the second coil 92 from the third core 83.

A part of each flange portion 81b of the first core 81 on the side of the first coil 91 is exposed from the first pressing member 5B (and the first pressing member 5A). The entire flange portion 82b of the second core 82 is in contact with the second pressing member 6B (and the second pressing member 6A). A part of each flange portion 83b of the third core 83 on the side of the second coil 92 is exposed from the third pressing member 7B (and the third pressing member 7A). The entire flange portion 81b may come into contact with the first pressing members 5A and 5B. Similarly, each flange portion 83b may come into contact with the third pressing members 7A and 7B as a whole. Further, a part of each flange portion 82b may be exposed from the second pressing members 6A and 6B.

FIG. 10 is a schematic cross-sectional view of the stator 2A along line F10 in FIG.
The support plates 3 and 4 and the first pressing members 5A and 5B are fixed to the frame 20A by the bolts B1 and nuts N1 described above. Further, the support plates 3 and 4 and the third pressing members 7A and 7B are fixed by the bolts B2 and the nuts N2 described above.

When the above-mentioned impregnation treatment is performed, an insulating resin layer 95 is formed inside the stator 2A. The resin layer 95 fills the gaps between the support plates 3 and 4, the pressing members 5A, 5B, 6A, 6B, 7A, 7B, the coils 81 to 83, and the coils 91, 92. Thereby, each element of the stator 2A can be firmly fixed. In FIG. 10, the resin layer 95 is shown only inside the stator 2A, but the resin is formed on the second surface F2 of the first support plate 3, the third surface F3 of the second support plate 4, the surface of the frame 20A, and the like. Layer 95 may be formed.

In the first core 81, since the core body 81a is fitted in the first core opening 31 of the first support plate 3 and the first core opening 41 of the second support plate 4, the support plates 3 and 4 are used to provide radial radius R and It is fixed in the circumferential direction C. Similarly, the second core 82 and the third core 83 are also fixed in the radial direction R and the circumferential direction C by the support plates 3 and 4. The core bodies 81a to 83a are exposed from the first core openings 31 to 33 on the second surface F2 side of the first support plate 3, respectively. Further, the core bodies 81a to 83a are exposed from the first core openings 41 to 43 on the fourth surface F4 side of the second support plate 4, respectively.

Each of the coils 91 and 92 is supported by a first surface F1 of the first support plate 3 and a third surface F3 of the second support plate 4. Specifically, the coils 91 and 92 are sandwiched between the first surface F1 and the third surface F3, and are thus fixed in the axial direction X.

Between the support plates 3 and 4, the first core 81, the first coil 91, the second core 82, the second coil 92 and the third core 83 are arranged in this order in the radial direction of the coils 91 and 92. There is. In this embodiment, since the coils 91 and 92 are concentric circles centered on the rotation axis AX, the radial direction of each coil 91 and 92 coincides with the radial direction R centered on the rotation axis AX.

FIG. 11 is a schematic cross-sectional view of the stator 2A along line F11 in FIG.
As described above, the first pressing members 5A and 5B are connected by the screw S1, the second pressing members 6A and 6B are connected by the screw S2, and the third pressing members 7A and 7B are connected by the screw S3. In the illustrated example, counterbore is provided in each of the hole 51 of the first pressing member 5B, the hole 61 of the second pressing member 6B, and the hole 71 of the third pressing member 7B, and the heads of the screws S1 to S3 are provided in the counterbore. Is housed.

FIG. 12 is a schematic cross-sectional view of the stator 2A along line F12 in FIG.
This cross-sectional view includes a first core 81 and first pressing members 5A, 5B. The cross section including the second core 82 and the second pressing members 6A and 6B and the cross section including the third core 83 and the third pressing members 7A and 7B are the same as the illustrated cross section. In FIG. 12, the symbols of the respective parts of the first core 81 and the pressing members 5A and 5B correspond to the symbols of the corresponding parts of the second core 82 and the second pressing members 6A and 6B, and the third core 83 and the third pressing member. The codes of each part of 7A and 7B are written in parentheses.

Each flange portion 81b of the first core 81 is sandwiched by the first holding portion 50 of each of the first pressing members 5A and 5B. As a result, the first core 81 is fixed in the axial direction X. Further, the first pressing members 5A and 5B are sandwiched by the support plates 3 and 4. That is, the first core 81 is supported by the first surface F1 and the third surface F3 via the first pressing members 5A and 5B.

Each flange portion 82b of the second core 82 is sandwiched by the second pressing members 6A and 6B. As a result, the second core 82 is fixed in the axial direction X. Further, the second pressing members 6A and 6B are sandwiched by the support plates 3 and 4. That is, the second core 82 is supported by the first surface F1 and the third surface F3 via the second pressing members 6A and 6B.

Each flange portion 83b of the third core 83 is sandwiched by the second holding portion 70 of each of the third pressing members 7A and 7B. As a result, the second core 82 is fixed in the axial direction X. Further, the third pressing members 7A and 7B are sandwiched by the support plates 3 and 4. That is, the third core 83 is supported by the first surface F1 and the third surface F3 via the third pressing members 7A and 7B.

FIG. 13 is a diagram showing an application example of the motor M according to the present embodiment.
The motor M can be applied to the traction motor of the railway vehicle 100. The railway vehicle 100 includes a vehicle body 110, a trolley 120 arranged below the vehicle body 110, a drive device 130, and a pantograph 140 arranged above the vehicle body 110. In the illustrated example, two bogies 120 and two pantographs 140 are provided for the vehicle body 110, and two drive devices 130 are provided for each bogie 120, but the present invention is not limited to this example.

The bogie 120 includes a bogie frame 121, a plurality of wheels 122 attached to the bogie frame 121, and an air spring 123 arranged between the bogie frame 121 and the vehicle body 110. The drive device 130 includes a motor M as a traction motor. Further, the drive device 130 includes a control device for controlling the motor M. Wheels 122 are directly connected to both sides of the shaft S of the motor M. The pantograph 140 is in contact with the overhead wire 150. The electric power taken from the overhead wire 150 via the pantograph 140 is supplied to the drive device 130, and the electric power causes the motor M to rotate.
In the configuration in which the wheels 122 are directly connected to both sides of the shaft S, the power transmission loss is suppressed and the energy efficiency is improved as compared with the configuration in which the wheels 122 are connected to the shaft S via a transmission device having a gear or the like. In addition, the railroad vehicle 100 can be miniaturized.
The motor M according to the present embodiment can be applied not only to railway vehicles but also to various vehicles. In addition to vehicles, the motor M can be applied to various devices that require rotational power.

In the stator 2 (2A to 2C) of the present embodiment described above, the cores 81 to 83 are formed on one surface of the first support plate 3 and the second support plate 4 fixed to the frame 20 (20A to 20C). And each coil 91, 92 is supported. With such a structure, the annular coils 91 and 92 and the cores 81 to 83 can be suitably fixed to the frame 20 in a state where the coils 91 and 92 are arranged in the radial direction. By arranging the coils 91 and 92 and the cores 81 to 83 in the radial direction of the coils 91 and 92, a magnetic flux is generated which passes through the cores 81 to 83 in parallel with the rotation axis AX as shown in FIG. Can be done.

More specifically, the cores 81 to 83 and the coils 91 and 92 are sandwiched by the first support plate 3 and the second support plate 4 along the rotation axis AX. As a result, in a structure in which the stator 2 is arranged between the two rotors 1, even if each core 81 to 83 and each coil 91, 92 receives a force from both rotors 1, each core 81 ~ 83 and the coils 91 and 92 can be suitably fixed.

Further, the cores 81 to 83 are exposed from the core openings 31 to 33 of the first support plate 3 and the core openings 41 to 43 of the second support plate 4. As a result, the magnetic flux around the coils 91 and 92 is less likely to be affected by the support plates 3 and 4, so that the magnetic characteristics can be improved.

Further, the support plates 3 and 4 sandwich the stepped portion 22 around the opening 21 of the frame 20 in the axial direction X. As a result, the support plates 3 and 4 and the frame 20 can be firmly fixed particularly in the axial direction X.

Further, the first core 81 has a pair of collar portions 81b protruding in the circumferential direction C, and these collar portions 81b are sandwiched by a pair of first pressing members 5A and 5B and fixed to the frame 20. With such a structure, the first core 81 can be suitably fixed in the axial direction X. Similarly, the second core 82 and the third core 83 can be suitably fixed in the axial direction X by the second pressing members 6A and 6B and the third pressing members 7A and 7B, respectively.

Further, since each core 81 to 83 has a simple block-shaped shape that is fragmented, it can be composed of laminated electromagnetic steel sheets 810, 820, and 830, respectively. As a result, the saturation magnetic flux density, heat resistance, and strength of each core 81 to 83 are increased as compared with the case where each core 81 to 83 is a dust core. By increasing the saturation magnetic flux density, it is possible to realize a high output of the motor M. Further, by aligning the rolling direction (easy magnetization direction) D with the rotation axis AX as described above, the magnetic flux component passing through each core 81 to 83 becomes substantially parallel to the axial direction X, and the magnetic characteristics can be further improved.
In addition to the above, various suitable effects can be obtained from the present embodiment.

In the first embodiment, the structure in which the cores 81 to 83 and the coils 91 and 92 are supported by the first support plate 3 and the second support plate 4 is disclosed. However, as in the second and third embodiments shown below, each core 81 to 83 and the like can be supported by one support plate. In the second embodiment and the third embodiment, the structures not particularly mentioned are the same as those in the first embodiment.

[Second Embodiment]
FIG. 14 is a schematic cross-sectional view of a part of the stator 2A according to the second embodiment. The structures of the stators 2B and 2C are the same as those of the stator 2A, for example.
The stator 2A includes a support plate 200. The support plate 200 has the same configuration as the first support plate 3 in the first embodiment, and has a first core opening 31, a second core opening 32, and a third core opening 33. The support plate 200 can be fixed to the frame 20A with bolts and nuts, for example, as in the first embodiment. The stator 2A includes first pressing members 5A and 5B, second pressing members 6A and 6B, and third pressing members 7A and 7B as in the first embodiment, but is not shown in FIG.

The support plate 200 has a first surface F201 and a second surface F202 opposite to the first surface F201. The cores 81 to 83 and the coils 91 and 92 are arranged on the side of the first surface F201.

The stator 2A includes an insulating resin layer 201 that covers the cores 81 to 83, the coils 91 and 92, and the first surface F201. The resin layer 201 can be formed, for example, by the above-mentioned impregnation treatment. The thickness of the portion of the resin layer 201 that covers each of the cores 81 to 83 and each of the coils 91 and 92 is smaller than, for example, the thickness of the support plate 200.

The support plate 200 supports the cores 81 to 83 and the coils 91 and 92 by the first surface F201. Specifically, the first core 81 is fixed to the first surface F201 by the first pressing members 5A and 5B and the resin layer 201 (not shown). The second core 82 is fixed to the first surface F201 by the second pressing members 6A and 6B and the resin layer 201 (not shown). The third core 83 is fixed to the first surface F201 by the third pressing members 7A and 7B and the resin layer 201 (not shown). Each of the coils 91 and 92 is fixed to the first surface F201 by the resin layer 201. The stator 2A may further include a member for fixing the coils 91 and 92 to the support plate 200.

With the structure of the present embodiment, since one support plate can be omitted, the manufacturing cost of the stator 2 or the motor M can be reduced, and the stator 2 can be made thinner. Further, the insulating resin layer 201 can firmly fix the cores 81 to 83 and the coils 91 and 92, and can improve the insulating property of the stator 2.

Instead of using the pressing members 5A, 5B, 6A, 6B, 7A, and 7B, the cores 81 to 83 and the coils 91 and 92 may be fixed to the support plate 200 with the resin layer 201. In this case, the number of parts corresponding to these pressing members can be reduced.
In addition, the same effect as that of the first embodiment can be obtained from the present embodiment.

[Third Embodiment]
FIG. 15 is a schematic cross-sectional view of a part of the stator 2A according to the third embodiment. The structures of the stators 2B and 2C are the same as those of the stator 2A, for example.
The stator 2A includes a support plate 300. The support plate 300 has the same configuration as the first support plate 3 in the first embodiment, and has a first core opening 31, a second core opening 32, and a third core opening 33. The support plate 300 can be fixed to the frame 20A with bolts and nuts as in the first embodiment, for example.

The support plate 300 has a first surface F301 and a second surface F302 opposite to the first surface F301. The first core 81 is inserted into the first core opening 31 and protrudes from both the surfaces F301 and F302. The second core 82 is inserted into the second core opening 32 and protrudes from both the surfaces F301 and F302. The third core 83 is inserted into the third core opening 33 and protrudes from both the surfaces F301 and F302.

As an example, the length of the first core 81 protruding from the first surface F301 in the axial direction X is equal to the length of the first core 81 protruding from the second surface F302 in the axial direction X. However, the length of the first core 81 protruding from each of the surfaces F301 and F302 may be different. Similarly, the lengths of the second core 82 protruding from the surfaces F301 and F302 in the axial direction X are, for example, the same, but these lengths may be different. Further, the lengths of the third core 83 protruding from the surfaces F301 and F302 in the axial direction X are, for example, the same, but these lengths may be different.

The stator 2A includes a first coil 311 supported by the first surface F301, a second coil 312 supported by the second surface F302, a third coil 313 supported by the first surface F301, and a second surface. It is provided with a fourth coil 314 supported by F302. Each of these coils 31 to 314 is an annular shape surrounding the rotation shaft AX, and is configured by winding a wire in the circumferential direction C. The first coil 311 and the second coil 312 are electrically connected. The third coil 313 and the fourth coil 314 are electrically connected to each other. The first coil 311 and the second coil 312 have the same radius and are aligned in the axial direction X. The third coil 313 and the fourth coil 314 have the same radius and are aligned in the axial direction X. The radii of the third coil 313 and the fourth coil 314 are smaller than the radii of the first coil 311 and the second coil 312.

The first core 81 is arranged in the circumferential direction C on the outer peripheral side of the first coil 311 and the second coil 312. The second core 82 is arranged in the circumferential direction C between the first coil 311 and the second coil 312 and the third coil 313 and the fourth coil 314. The third core 83 is arranged in the circumferential direction C on the inner peripheral side of the third coil 313 and the fourth coil 314.

The stator 2A includes an insulating first resin layer 301 and a second resin layer 302. The first resin layer 301 covers the first surface F301, the first coil 311 and the third coil 313, and the cores 81 to 83 protruding from the first surface F301. The second resin layer 302 covers the cores 81 to 83 protruding from the second surface F302, the second coil 312, the fourth coil 314, and the second surface F302. The thickness of the portion of the first resin layer 301 that covers each of the cores 81 to 83 and each of the coils 311, 313 is smaller than, for example, the thickness of the support plate 300. Similarly, the thickness of the portion of the second resin layer 302 that covers each of the cores 81 to 83 and each of the coils 312 and 314 is smaller than, for example, the thickness of the support plate 300.

The cores 81 to 83 are fixed to the support plate 300 by the resin layers 301 and 302. The first coil 311 and the third coil 313 are fixed to the first surface F301 by the first resin layer 301. The second coil 312 and the fourth coil 314 are fixed to the second surface F302 by the second resin layer 302.

With the structure of the present embodiment, since one support plate can be omitted as in the second embodiment, the manufacturing cost of the stator 2 or the motor M can be reduced, and the stator 2 can be made thinner. Further, the cores 81 to 83 and the coils can be arranged in a well-balanced manner on both sides of the support plate 300 in the axial direction X. Further, the insulating resin layers 301 and 302 can firmly fix the cores 81 to 83 and the coils 31 to 314 and improve the insulating property of the stator 2.

In the above first to third embodiments, the motor M including four rotors 1A to 1D and three stators 2A to 2C is disclosed. However, the motor M may include a larger number of stators and rotors, or a smaller number of stators and rotors.

The flange portion 81b of the first core 81 is not limited to the one protruding from the core main body 81a in the circumferential direction C, and may protrude in another direction intersecting the axial direction X. For example, the collar portion 81b may protrude in the radial direction R from the core main body 81a. The same applies to the flange portion 82b of the second core 82 and the flange portion 83b of the third core 83.

When each of the support plates 3, 4, 200, 300 is formed of a non-magnetic and non-conductive material, the core opening does not necessarily have to be provided as long as the magnetic flux around each coil is not obstructed.

Although some embodiments of the present invention have been described, these embodiments are presented as examples and are not intended to limit the scope of the invention. These novel embodiments can be implemented in various other embodiments, and various omissions, replacements, and changes can be made without departing from the gist of the invention. These embodiments and modifications thereof are included in the scope and gist of the invention, and are also included in the scope of the invention described in the claims and the equivalent scope thereof.

M ... motor, S ... shaft, AX ... rotating shaft, 1A to 1D ... rotor, 2A to 2C ... stator, 3 ... first support plate, 4 ... second support plate, 5A, 5B ... first holding member, 6A, 6B ... 2nd presser member, 7A, 7B ... 3rd presser member, 10A-10D ... Housing, 20A-20C ... Frame, 31-33, 41-43 ... Core opening, 50, 70 ... Holding part, 81 ... 1st core, 82 ... 2nd core, 83 ... 3rd core, 91 ... 1st coil, 92 ... 2nd coil, 810-830 ... Electromagnetic steel plate, X ... axial direction, R ... radial direction, C ... circumferential direction, D ... Rolling direction.

Claims (8)

It is a stator of a rotary electric machine,
A first support plate having a first surface, a second surface opposite to the first surface, and a plurality of openings penetrating from the first surface to the second surface.
An annular coil supported by the first surface and
A plurality of cores that are aligned with the coil in the radial direction of the coil, are supported by the first surface, and are exposed from the opening to the second surface side.
Stator with. The core has a core body and a collar portion protruding from the core body.
A fixing member that holds the collar and
A second support plate having a third surface facing the first surface, a fourth surface on the opposite side of the third surface, and a plurality of openings penetrating from the third surface to the fourth surface. With more
The fixing member and the coil are sandwiched by the first surface and the third surface.
The core body is exposed from the opening of the first support plate to the second surface side and is exposed to the fourth surface side from the opening of the second support plate.
The stator according to claim 1. The first support plate holds the peripheral edge of the opening of the frame of the rotary electric machine.
The stator according to claim 1 or 2. The coil, the plurality of cores, and a resin layer covering the first surface are further provided.
The stator according to claim 1. It is a stator of a rotary electric machine,
A support plate having a first surface, a second surface opposite to the first surface, and a plurality of openings penetrating from the first surface to the second surface.
An annular first coil supported by the first surface and
An annular second coil that is supported by the second surface and faces the first coil via the support plate.
A plurality of cores, which are aligned with the first coil and the second coil in the radial direction of the first coil and the second coil, are passed through the opening, and project from the first surface and the second surface.
Stator with. A first resin layer that covers the first surface, the first coil, and the plurality of cores protruding from the first surface, and fixes the first coil and the plurality of cores to the support plate.
A second resin layer that covers the second surface, the second coil, and the plurality of cores protruding from the second surface, and fixes the second coil and the plurality of cores to the support plate.
The stator according to claim 5. A shaft that extends along the axis of rotation and
With the rotor attached to the shaft,
The stator according to any one of claims 1 to 6, which faces the rotor in an axial direction parallel to the rotation axis via a gap.
Rotating electric machine equipped with. The rotary electric machine according to claim 7 and
Wheels provided on both sides of the shaft of the rotary electric machine and
Vehicles equipped with.

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