JPH0311965A - Electrical rotary machine - Google Patents

Abstract

PURPOSE:To facilitate accurate positioning of a Hall element by forming magnetic path sections radially and then arranging a pole section on the outer end side, a gap between magnetic poles adjoining in circumferential direction, a main substrate on the counter rotor side in axial direction and an auxiliary substrate on the rotor side thereafter making lead wire connection of both substrate through a spacer penetrating in the axial direction. CONSTITUTION:Magnetic path sections 13 are formed radially and radially outermost end of each magnetic path 13 is projected axially to provide a pole section 14, then a gap 40 is formed between pole sections 14 adjoining in circumferential direction. Main substrate 28 for drive circuit is arranged on counter rotor side of a stator 6 and an auxiliary substrate 30 is arranged on the rotor side of the stator 6, then the main substrate 28 and a Hall element H are connected electrically through a lead wire 51 contained in a spacer 50 thus positioning the Hall element H by means of the auxiliary substrate 30. By such an arrangement, the Hall element can be positioned easily and accurately.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to rotating power machines such as electric motors and generators.

(Prior Art) For example, in the indoor unit of an air conditioner described in Japanese Utility Model Application Publication No. 61-178095, a DC brushless motor is used as the electric motor to drive the internal cross-flow fan, and the stator is Attempts have been made to downsize the device by fixing it to the frame of the indoor unit and directly connecting the rotor to the side surface of the fan rotor of the crossflow fan.

By the way, there are two types of DC brushless morphs: the so-called outer rotor method, in which the rotor surrounds the outer periphery of the stator, and the so-called axial gap method, in which the rotor and stator face each other in the axial direction. In this type of motor, the rotor has a large shape and therefore a large weight, so there is a problem that large vibrations occur even if the axis of the fan rotor is slightly misaligned with the fan rotor. On the other hand, in an axial gap type motor, for example, when the stator is composed of an iron core and a coil wound around the iron core, the iron core faces the rotor with a predetermined air gap therebetween, and The rotor is configured to have a shape including a plurality of magnetic pole portions provided in a shape, and a plurality of magnetic path portions extending in the axial direction from each magnetic pole portion toward the opposite side of the rotor and around which coils are wound. In such an axial air gap type motor, there is a hole for detecting the magnetic field that changes as the rotor rotates.
- It is necessary to arrange the rotor element so as to face the rotor.

Therefore, conventionally, a driving circuit such as a power transistor is provided on a circuit board provided on the opposite rotor side of the iron core, while a Hall element installed vertically on the circuit board has a long lead that passes through the gap in the iron core in the axial direction. It was placed at a predetermined position facing the rotor via a wire.

(Problem to be Solved by the Invention) However, with the conventional Hall element fixing structure as described above, the positioning of the Hall element tends to be inaccurate, and in the event that the position of the Hall element becomes inaccurate, the rotation There is a problem in that changes in the magnetic field due to the rotation of the child cannot be detected accurately. That is, the Hall element is connected to the tip of a long lead wire that is easy to bend, and is positioned by connecting the base end of the lead wire to the circuit board.

The present invention was made in view of the above-mentioned circumstances, and an object of the present invention is to provide a rotating power source that can accurately and easily position a Hall element located axially away from the circuit board. The aim is to provide the opportunity.

(Means for Solving the Problem) Therefore, in the rotating electric machine according to the first aspect, the magnetic pole portions of the rotor 3 and the stator 6 are made to face each other in the axial direction, and the rotor 3 and the stator 6 are made to face each other in the axial direction. A rotary power machine comprising an iron core 11 and coils 12 . . . 12 respectively wound around a plurality of magnetic path portions 13 . The portions 13...13 are formed in a shape extending radially in the radial direction, and each magnetic path portion 13...1
Each of the radially outer ends of 3 is provided with magnetic pole portions 14 .
．． A main board 28 for a drive circuit is provided on the side opposite to the rotor in the axial direction of the iron core 11, and a Hall element H is fixed to the rotor side in the axial direction of the iron core 11. An auxiliary board 30 is provided for connecting the two boards 28, 30, and spacers 50, . 28.30 is connected.

Further, the rotary power machine according to the second claim is the rotary power machine according to the first claim, in which a mold layer 60 made of resin is formed around the coils 12.

(Function) In the rotating power machine according to the first aspect, the main board 28 for the drive circuit is arranged on the side opposite to the rotor of the stator 6, and the auxiliary board 30 is arranged on the side of the rotor of the stator 6. Then, the Hall element H is attached to this auxiliary substrate 30, and the position of the Hall element H is determined at 3 degrees from the auxiliary substrate. In other words, the main substrate 28 and the Hall element H are connected to the spacers 50...50.
The Hall element H is electrically connected by lead wires 51 and 51 built into the main board 28, and is positioned relative to the main board 28 via the spacers 50, . . . 50 and the auxiliary board 30. Therefore, the Hall element H is
This facilitates electrical connection with the drive circuit of the main board 28.

Further, in the rotary power machine according to the second aspect, the coils 12...12 are covered with a mold layer 60, and the coils 12...12 are covered with a mold layer 60.
...Reducing electromagnetic vibration noise generated from 12.

(Example) Next, regarding a specific example of the rotating electric power machine of the present invention,
This will be explained in detail with reference to the drawings.

FIG. 1 is an assembled cross-sectional view of the main parts of a cross-flow fan installed in an indoor unit of an air conditioner. A fan motor of one embodiment is connected. That is, the yoke 4 made of a ring-shaped iron plate that constitutes the rotor 3 of the DC brushless morph and the permanent magnet 5 made of magnetic powder hardened with resin are combined into a rotor body 7 made of resin, and the rotor body 7 is attached to the side plate 2. By fixing, the rotor 3 is directly connected to the fan rotor l, and a stator 6, which will be described later, is placed at a position facing the permanent magnet 5 in the axial direction.
has been set up.

A rotation support shaft 9 is provided at the axial center of the side plate 2 and extends through the rotor main body 7 to the right. The base end of the rotation support shaft 9 is knurled, and this base end is embedded and connected to the side plate 2.

The permanent magnet 5 that constitutes the magnetic pole portion on the rotor 3 side is
On the right end surface, four poles N, S, N, and S are arranged in the circumferential direction.

On the other hand, the stator 6 is composed of an iron core 11 formed by laminating electric iron plates and a coil 12 wound around the iron core 11. As shown in FIGS. 2 and 3, the iron core 11 includes a magnetic path portion 13 extending in the radial direction and around which the coil 12 is wound, and a permanent magnet on the radially outer peripheral side of the magnetic path portion 13. The stator magnetic pole part (hereinafter abbreviated as magnetic pole part) 14 protrudes toward the permanent magnet 5 side and has a tip end face facing the permanent magnet 5. This iron core 11 is constructed by combining a first element 11a on the right side and a second element 11b on the left side, as shown in FIG.

FIG. 4 shows one sheet of the first element constituting the first element 11a.
The first rope plate 15 has a ring-shaped portion 16 on the center side, and six magnetic path forming portions 17 extending radially outward from the ring-shaped portion 16.・17
and the salient pole portion 18 on the tip side of each magnetic path forming portion 17.
・Created by punching with a press into a shape consisting of 18.

The first element 11a is formed by laminating a plurality of these first steel plates 15. The salient pole portion 18...18
The circumferential width of is set to Wi.

On the other hand, FIGS. 5 to 7 show the shape of the second additional plate 19 constituting the second element 11b. This second additional board 1
The second element 11b described above is composed of a predetermined number of laminates of 9. The second steel plate 19 includes a ring-shaped portion 32 at the center and six magnetic path forming portions 33 extending radially from the ring-shaped portion 32.
. . 33 and bent portions 34 . . . 34 that are continuous with the tips of the magnetic path forming portions 33 .

The circumferential width of the base end of each of the bent portions 34 is −i, which is the same as the salient pole portion 18, and the circumferential width of the tip portion is 10. The outer shape of the second steel plate 19 is turned on, and the bent portion 34 is turned on.
If the height of 34 is Ln, the developed view is shown in FIG.

FIG. 8 shows a developed view of the - second steel plate 19, that is, the shape before bending the bent portions 34, . . . , 34. N sheets of this second tl [19 are stacked, and the second
As shown in the drawings and FIG. 3, the shape of the magnetic pole parts 14, . - When configuring so that
The bending radius Dn and the radial length L of the bent portion 34 are shown in the figure.
It is necessary to sequentially change the width -n at the leading edge position of the bending part 34, and in the n-th (n is an integer from 1 to N) second #I plate 19 from the right end in FIG. is, Dn=Do -2X n X tl, n=Lo -n
Regarding n, the shape obtained by bending with a curvature along the circumference of diameter Dn is the width of the magnetic pole part 14 -0 (Fig. 2)
Therefore, the width of the bent portion 34 of the n-th second steel plate 19 is Wn, and the central angle 2 corresponding to this width - n is θn.
Then, Wn-20nXθn x (π/360)...
(1) (However, θn = arcsin (ladle 10n)
) to determine the shape of each of the first steel plates 15...19. In addition, as shown in FIG. 2, the second W4 on the inner circumferential side
The circumferential width of the bent portion 34 in the plate 19 is set so as to ensure the minimum gap required between the circumferentially adjacent magnetic pole portions 14, 14, that is, the slot open So.

As for the shape of the bent portion 34, as shown in FIG. I'm keeping it small. That is, in the case of the above embodiment, when the width of the magnetic path forming portion 33 is T,
2, and the length d of the leading edge region of the width Wn is, for example, 1 mm.
The outer circumferential shape is made as short as possible, and extends from this region to the proximal region of width Wn' in a curved line along the circumference of radius R-.(Wn-T)/4. In this way, the gap between the mutually adjacent magnetic pole parts 14 and 14 is So + on the anti-fan side.
2R, so that the leakage magnetic flux can be reduced and the permanent magnet 5 can be made smaller.

As shown in FIG.
Since the magnetic pole parts 14.14 adjacent in the circumferential direction have a large gap on the proximal end side except for the distal end side, leakage magnetic flux between the adjacent magnetic pole parts 14.14 is greatly reduced,
Therefore, cogging during rotational drive is reduced, resulting in low noise and
Able to operate with low vibration. Furthermore, a gap 40 is formed between the magnetic pole parts 14 and 14 of the iron core 11 for passing a spacer 50 which will be described in detail later.

Furthermore, in the above, in each of the second steel plates 19, the bending portions 34 constituting the magnetic path forming portion 33 and the magnetic pole portion 14 are
Since it is constructed integrally in the direction of magnetic flux flow,
Eddy currents, which cause iron loss, are less likely to occur, and as a result, the effective magnetic flux density that induces rotational force increases, which further improves rotational force and provides a highly efficient motor.

As shown in FIG. 4, approximately the center position of each salient pole portion 18...18 on the first M plate 15, and six locations on the same circumference within the ring-shaped portion 16 of the second steel plate 19. At the positions, protrusions 20 having a V-shaped cross section as shown in FIG. 9 are formed by pressing a ■-shaped punch with a press. When the first and second steel plates 15 and 19 are stacked, each V-shaped protrusion 20 passes through the adjacent 7-shaped protrusion 20 through the opening as the uncut mark of the 7-shaped protrusion in the adjacent steel plate, as shown by the imaginary line in the figure. They will be brought into close contact with the protrusions 20 one after another, and at this time they will be caulked at the opening position and fixed to each other. Note that no V-shaped protrusion is formed in the first steel plate 15 located at the rightmost end in FIG. It is drilled at the position of the protrusion.

After configuring the iron core 11 as described above, each magnetic path section 13...
The stator 6 is constructed by winding the coils 12 . . . 12 around each of the coils 13 . Winding on the stator in conventional axial gap motors required a special winding machine because the electric circuit section for winding extends in the axial direction. Since it can be wound using the same method as the stator of Furthermore, as mentioned above, since each coil 12...12 is wound around the magnetic path section 13 that extends radially inward from the magnetic pole section 4,
The coil does not protrude further outward than the outer circumferential shape of the stator core, and the occupied space is further reduced, thus making it possible to further downsize.

As shown in FIG. 1, the stator 6 configured as described above is fixed within a fixed case 23 that is fixed to a frame 22 of an indoor unit of an air conditioner. At this time, the stator side vibration isolating member 2 made of an elastic body surrounding the radial outer peripheral surface of the stator 6
4 and a housing 41 which will be described in detail later. Furthermore, a bearing 25 is provided in the axial center through hole of the stator 6.
A bearing case 26 is provided which houses the bearing case 26. The bearing case 26 is supported by the iron core 11 via a vibration isolating member 42 made of an elastic material such as synthetic rubber. By inserting the rotating support shaft 9 extending from the side plate 2 side of the fan rotor l into the bearing 25, the fan rotor l side is rotatably supported, and the left end surface of the inner ring of the bearing 25 and the Due to the contact with the rotor body 7, an assembled state is established in which a predetermined air gap is provided between the permanent magnets 5 and the stator 6, which face each other in the axial direction.

The housing 41 will be explained with reference to FIGS. 10 and 11. In FIG. 10, when the housing 41 is viewed from the fan side in FIG. 1, the housing 41 includes a cylindrical portion 43 and a rectangular cylindrical portion 44. The magnetic pole part 14 of the iron core 11 is press-fitted into the cylindrical part 43, and the circuit board 28 and the like are accommodated inside the square cylindrical part 44. In addition, the cylindrical portion 43 and the rectangular cylindrical portion 4
The first element 11 of the iron core 11 is located at the interface 45 between the iron core 11 and the
The end faces of a are pressed against each other. Boss portions 46...46 are formed at the four corners of the rectangular tube portion 44, and screw holes 47 of each boss portion 46...46 are opened.

Next, as shown in FIG. 1, a circuit board 28 (main board) having a drive circuit for the DC brushless motor is disposed in a space surrounded by the iron core 11 and the square tube part 44. In addition to the power transistor Q, electronic components such as a capacitor, a resistor, and a control IC are mounted on this circuit board 28. Among these electronic components, tall ones such as the power transistor Q and the capacitor are laid down horizontally. By mounting it, we minimize the storage space.

Further, a heat sink 29 is disposed facing the circuit board 28, and the heat sink surface of the power transistor Q, which generates a large amount of heat, is brought into close contact with the heat sink 29.

Furthermore, the circuit board 28 is fixed by screwing screws 48 into the tapped holes 47 of the housing 41. On the other hand, at the position on the rotor 3 side of the iron core 11,
In a space radially inward of each magnetic pole portion 14, an auxiliary substrate 30 to which a Hall element H as a magnetic field detection element is attached is disposed. The Hall element H detects the rotational position of the rotor 3 based on changes in the magnetic field intensity from the permanent magnet 5.

By the way, as shown in FIG. 12, the auxiliary board 30 for the Hall element H and the circuit board 28 for the drive circuit are spacers 50 passing through the gaps 40 of the iron core 11.
50 is connected. As shown in FIGS. 15 and 16, these spacers 50...50 are made of resin and are molded into a substantially triangular column shape, and have two lead wires 5L5 in the longitudinal direction.
1 is built-in. Both ends of the lead wires 51.51 protrude from both ends of the spacer 50 in the longitudinal direction.

And both the above-mentioned substrates 2 by the above spacers 50...50
8.30 connections are made as follows. That is,
As shown in the silk diagram of FIG. 13, on the circuit board 28 for the drive circuit, the power transistors Q...Q, the capacitor C, etc. are arranged, and a through hole is provided for passing the ends of the lead wires 51 and 51. Six holes 52, 52 are drilled in pairs, twelve in total. These six through holes 52
．． 52 are arranged corresponding to the positions of the lead wires 51 and 51 of the spacers 50, . . . 50, respectively.

On the other hand, as shown in FIG. 14, the auxiliary substrate 30 for the Hall element H is molded from resin into a substantially disk shape, and has substantially triangular protrusions 53 formed at six locations on its outer periphery. There is. These protrusions 53...53 are the spacers 50...5.
0, and each protrusion 53...53 has two through holes 54, 54, respectively.
is perforated. In addition, twelve through holes 55...55 are bored in the inner peripheral part of the auxiliary board 30, and these through holes 5
4.55 are electrically connected by printed wiring 56...56. Further, the terminals of the Hall elements H, which are provided at three locations in pairs, six in total, are similarly soldered to the through holes 55. Therefore, the spacer 50
. . 50 through the gaps 40 . . . 40 of the iron core 11, and both ends of the lead wires 51.
30 and soldered to connect both substrates 28, 30 and to electrically conduct the drive circuit and Hall element F1.

In the fan device having the above configuration, upon receiving a detection signal of the rotational position of the rotor 3 by the Hall element H, a drive signal is generated by the control IC at a predetermined timing, and this causes the energization of each coil 12 . A rotating magnetic field is generated on the stator 6 side under periodic control. The rotor 3 and the fan rotor 1 are rotationally driven by this rotating magnetic field.

In such a rotational driving state, cogging is particularly reduced in the above device, and therefore an operating state with less vibration can be maintained. This is because the magnetic flux distribution characteristic acting from the permanent magnet 5 to the stator 6 is improved compared to the conventional one due to the shape of the magnetic pole portion 14 described above.

Furthermore, since the fan rotor 1 as described above has a long axial length and is made of a synthetic resin material whose rigidity is lower than that of a metal material, the fan rotor 1 has a warp that causes the central portion to be eccentric outward. Rotational runout is likely to occur, and in the past, vibrations due to this rotational runout were propagated to the frame of the indoor unit, causing vibrations of the entire device. , bearing 25, stator 6
, the fixed case 23, and the frame 22 are interposed with vibration isolating members made of elastic bodies, the vibration isolating member 42 and the stator side vibration isolating member 24, and thereby the frame The amount of vibration propagated to 22 is reduced, and further low-noise and low-vibration operation can be achieved.

Furthermore, in the above embodiment, the circuit board 28 for the drive circuit, which is located on the right side of the iron core 11 in FIG.
The auxiliary board 30 fixed to the housing 41 by the spacers 50, . The six Hall elements H... can be accurately positioned on the substrate 30 in the circumferential direction. Moreover, the drive circuit and the Hall element I" can be electrically connected easily and reliably by the lead wires 51 and 51.

FIG. 17 shows an assembled cross-sectional view of a main part of a cross flow fan connected to a fan motor according to a second embodiment of the present invention. The device of this second embodiment is similar to the first embodiment except for the structure of the mold layer 60 covering the coil 12, so the same functional parts will be given the same numbers and explained. Omitted.

Iron core 11 in the device of the second embodiment shown in FIG.
The coil 12 portion, the auxiliary substrate 30 portion, and the spacer 50 portion are covered with a resin mold layer 60. This mold layer 60 prevents electromagnetic vibration noise generated from the coil 12, and also functions to fix the auxiliary substrate 30, the Hall element H, the spacers 50, etc. In addition, the inner peripheral surface 61 of the mold layer 60 on the left side of the magnetic path section 13 is formed so as to be in close contact with the outer peripheral surface of the vibration isolating member 42, so as to prevent the vibration of the rotating shaft 9 transmitted to the vibration isolating member 42. By supporting the inner circumferential surface 61 which has a large diameter and a wide area, the vibration damping effect can be further improved. Furthermore, an annular resin film 62 is interposed between the right end surface of the vibration isolating member 42 in FIG. 17 and the left end surface of the inner peripheral portion of the iron core 11. The vibration isolating effect of the vibration isolating member 42 is improved by making the right end surface of the vibration isolating member 42 easier to slide.

The mold 7 for the mold layer 60 is shown in FIGS. 18 and 19.
Explain 0. The mold 70 has a cylindrical portion 71 in the center, and a rectangular cylindrical outer wall portion 73 surrounding the cylindrical portion 71 with a substantially annular cavity 72 in between. More than 70 molds
As shown in FIG. 20, the stator 6 is fitted into the housing 41, and the mold layer 60 is formed by filling the inside of the stator 6 with a thermoplastic resin mixed with a filler. After the mold layer 60 is heated and cured, it is removed from the mold 70. As the filler, it is preferable to use an inorganic powder that has good insulation properties, has a specific gravity close to that of resin, and has a particle size of 50 μm or less. Further, the opening lower part 4 in the mold 70 is used for removing the stator 6.

In the second embodiment shown in FIG. 17, the mold layer 60 covers not only the coil 12 but also the auxiliary substrate 30, the Hall element H, the spacers 50, etc., so the fixing strength of these parts is also improved. do.

However, it is also possible to cover only the coil 12 with the mold layer.

Although specific embodiments of the rotary power machine of the present invention have been described above, the rotary power machine of the present invention is not limited to the above embodiments, and may be implemented with various modifications within the scope of the present invention. is possible.

For example, in the above embodiments, the case where the present invention is applied to a motor has been described, but the present invention is not limited to motors, but can also be applied to generators and the like.

(Effect of the invention) As mentioned above, in the rotating electric machine according to the first claim,
The main board for the drive circuit is placed on the side opposite to the rotor of the stator, the auxiliary board is placed on the rotor side of the stator, a Hall element is provided on this auxiliary board, and both boards are connected with a spacer. Therefore, the position of the Hall element can be accurately and easily determined using the spacer and the auxiliary substrate. Furthermore, the Hall element can be easily and reliably electrically connected to the drive circuit on the main substrate side using the lead wire built into the spacer.

Furthermore, in the rotary power machine according to the second aspect of the present invention, the coil is further covered with a mold layer to reduce electromagnetic vibration noise generated from the coil, thereby providing a rotary power machine with low noise.

[Brief explanation of the drawing]

FIG. 1 is an assembled sectional view of a main part of a fan device incorporating a fan motor according to a first embodiment of the present invention, FIG. 2 is a side view of an iron core constituting a stator, and FIG. Figure 2 is a sectional view taken along line I-III in Figure 2, Figure 4 is a side view of the first steel plate, Figure 5 is a side view of the second steel plate, Figure 6 is a sectional view taken along line A-A in Figure 5, and Figure 7. is a view in the direction of the ■ arrow in Fig. 5, Fig. 8 is a developed view of the second steel plate, Fig. 9 is a cross-sectional view showing the caulking part by the V-shaped protrusion, Fig. 10 is a side view of the housing, Fig. 11 is the 10th
A-A sectional view in the figure, Figure 12 is an assembled side view of the iron core,
Fig. 3 is a schematic diagram of the structure of the circuit board, Fig. 14 is a schematic diagram of the structure of the auxiliary board, Fig. 15 is a front view of the spacer, and Fig. 16 is a schematic diagram of the structure of the auxiliary board.
17 is an assembled sectional view of a main part of a fan device having a fan motor according to a second embodiment of the present invention, FIG. 18 is a side view of the mold, and FIG. 19 is a sectional view of the mold. A of
-A sectional view and FIG. 20 are structural diagrams showing a molding process using a metal mold. 3... Rotor, 6... Stator, 11... Iron core, 1
2...Coil, 2 days...Circuit board (main board), 30
...Auxiliary substrate, 50...Spacer, 51...Lead wire, 60...Mold layer, H...Hall element.

Claims (1)

[Claims] 1. The magnetic pole portions of the rotor (3) and stator (6) are made to face each other in the axial direction, and the rotor (3) and stator (6)
(6), and the coils (12)...(12) respectively wound around the core (11) and the plurality of magnetic path sections (13)...(13) of the core (11). A rotary power machine consisting of the magnetic path section (13)...(
13) are formed in a shape extending radially in the radial direction, and each radially outer end side of each magnetic path portion (13)...(13) is made to protrude in the axial direction to form a magnetic pole portion (14)... (14
), and gaps (40)...(40) are formed between the magnetic pole parts (14) (14) adjacent to each other in the circumferential direction.
) The main board for the drive circuit (
28), and an auxiliary board (30) for fixing the Hall element (H) on the rotor side in the axial direction of the iron core (11).
spacers (40, 40) that axially penetrate the gaps (40), (40), and have built-in lead wires (51, 51) that electrically connect the two substrates (28, 30).
50) A rotating power machine characterized in that both the substrates (28) and (30) are connected at (50). 2. The rotating power machine according to claim 1, characterized in that a resin mold layer (60) is formed around the coils (12) (12).