JPH07245895A - Rotary motor and manufacture thereof - Google Patents

Abstract

PURPOSE:To perform the aligned winding of a coil simply and to utilize the slot part effectively as the occupying space of the coil. CONSTITUTION:A stator core l is divided into a ring-shaped outer yoke 3 and a plurality of magnetic pole teeth 2, which are fixed to the inner-diameter side. Coil bobbins 5, which are coupled with the magnetic, pole teeth 2, respectively, are linked in the non-ring shape with thin parts 15a, which can be freely bent, at the outer-diameter side of the magnetic pole teeth 2. The interval between the neighboring coil bobbins 5 can be formed as large as possible when the thin parts 15a are bent to the opposite side in this constitution.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a rotary electric motor such as an AC servo motor and a method for manufacturing the same.

[0002]

[Prior art]

Conventional example 1. FIG. 22 is an exploded perspective view showing a conventional rotary electric motor disclosed in Japanese Patent Laid-Open No. 63-299734. In the figure, the stator core 1 is divided into a radial magnetic pole tooth 2 integrated on the inner diameter side and a ring-shaped outer yoke 3 fixed to the outer diameter side of the magnetic pole tooth 2. In this electric motor, the coil bobbins 5 around which the coils 4 are wound are individually mounted individually on the magnetic pole teeth 2, and then the outer diameter side end portions of the magnetic pole teeth 2 are fitted and fixed to the inner diameter portion of the outer yoke 3. The stator 8 is configured by soldering the pin terminals 6 of the coil bobbin 5 with the ends of the coil 4 twisted to the printed circuit board 7.

Conventional example 2. Fig. 23 shows the actual exploitation Sho 57-1804.
It is an exploded perspective view which shows the conventional rotary electric motor shown by the 48th publication. In the figure, a stator core 1 includes a radial magnetic pole tooth 2 integrated on the inner diameter side and a magnetic pole tooth 2
Is divided into a ring-shaped outer yoke 3 fixed to the outer diameter side. In this electric motor, the coil 4 is wound around the coil bobbin 5 whose inner diameter side is connected by the connecting plate portion 5a, the coil bobbin 5 is attached to the magnetic pole teeth 2, and then the magnetic pole teeth 2 are fitted to the outer yoke 3, whereby the stator 8 is formed.
Are configured.

Conventional example 3. FIG. 28 shows Japanese Patent Laid-Open No. 5-16818.
It is a sectional side view of the conventional rotary electric motor shown by the 1st publication. In this figure, 1 is a stator core, 4 is a coil,
Reference numeral 10 is a rotor, and 34 is a rotor magnet. In this electric motor, the rotor magnet 34 is provided with a skew angle so as to eliminate uneven rotation due to cogging torque.

Conventional example 4. FIG. 29 shows JP-A-1-27075.
It is a cross-sectional view of the conventional rotary electric motor shown by the gazette No. 7. In this drawing, the stator core 1 is divided into a ring-shaped outer yoke 3 and a plurality of independent magnetic pole teeth 2, and the rotor facing portion 2a of the magnetic pole teeth 2 is inclined with respect to the axial direction as shown in FIG. The skew angle (skew S) is given.

[0006]

As described above, since the coil bobbins 5 are constructed independently of each other in the rotary electric motor of the conventional example 1, the winding start and the winding end of the coil 4 can be changed for each coil bobbin 5. It was necessary to process the terminals one by one and connect them to the printed circuit board 7 via the pin terminals 6. Although the coils 4 of the same phase can be continuously wound by connecting at a portion called a crossover wire, in this conventional example, the coils 4 are once cut and then connected again via the printed circuit board 7. Therefore, there is a problem that an extra process is added.

Further, since the rotary electric motor of the conventional example 2 has the coil bobbin 5 connected thereto, continuous winding is possible without cutting the connecting wire. However, since the coil bobbin 5 is connected at the inner diameter side, the coil 4 It is not possible to secure a large working space for winding the coil, and the coil 4 cannot be wound in a line. Further, there is a problem that the slot portion cannot be effectively used as an occupied space of the coil.

This point will be described in detail with reference to the drawings. In the aligned winding, as shown in FIG. 24, the winding wire 12 is sequentially wound from one end in the width direction of the coil bobbin 5 to the other end, and from the other end to one end.
Is a winding method for laminating. In FIG. 24, the winding 12
The numbers in the section of indicate the winding order. This aligned winding can increase the winding density in a limited space and can realize a stable winding shape. Therefore, it contributes to increase the output of the rotary motor, stabilize the characteristics, and further reduce the size.

As shown in FIG. 25, in the aligned winding, the winding nozzle 13 is rotated while being relatively moved in the width direction of the coil bobbin 5, so that the winding 12 is fed out from the winding nozzle 13 and wound. However, when the coil bobbins 5 are connected and provided as shown in FIG. 26, due to the influence of the adjacent coil bobbins 5, it is difficult to secure a sufficient space for the winding nozzles 13 and it may not be possible to perform the aligned winding. Then, as shown in FIG. 27, the windings 12 are disturbed, the gaps between the windings 12 increase, and the winding density decreases,
There is a limit to the improvement of characteristics.

In the rotary motor of the second conventional example, the inner side of the coil bobbin 5 radially arranged during assembly is connected to the connecting plate portion 5a.
Since the adjacent coil bobbins 5 and 5 are connected with each other, the space between the adjacent coil bobbins 5 and 5 is narrow (this corresponds to the slot portion at the time of assembly), it is difficult to secure a sufficient space for winding the winding nozzle 13, and aligned winding cannot be performed. The space in the slot could not be effectively occupied by the coil.

Although the rotary motor of Conventional Example 3 is constructed so that the skew angle is provided to the rotor magnet 34, the method of giving the skew angle by magnetizing the rotor magnet 34 requires that the skew angle be highly accurate. I can't
There are problems that the characteristics cannot be stabilized and that the cogging torque cannot be sufficiently reduced.

The rotary motor of Conventional Example 4 has magnetic pole teeth 2
The cogging torque is reduced by giving a skew angle (skew S) to the rotor facing portion 2a of the above. However, in the press working of the stator core 1, changing the shape of each laminated iron core requires a great deal of setup time. However, there is a problem in that it is not preferable in terms of processing efficiency.

The inventions of claims 1 to 3 have been made in order to solve the above-mentioned problems, and it is possible to continuously wind coils of the same phase without cutting the connecting wire, and to wind the coils in line. It is an object of the present invention to provide a rotary electric motor capable of effectively utilizing the slot portion as an occupied space of the coil.

It is an object of the present invention to provide a method of manufacturing a rotary electric motor, in which the coils can be easily aligned and wound, and the space of the slot portion of the stator can be effectively occupied by the windings. .

It is an object of the present invention to provide a rotary electric motor capable of reducing the rotational unevenness due to the generation of cogging torque without lowering the machining efficiency.

[0016]

According to a first aspect of the present invention, there is provided a rotary electric motor in which a stator core is divided into a ring-shaped outer yoke and a plurality of the magnetic pole teeth fixed to an inner diameter side of the outer yoke. The coil bobbins to be fitted are connected in a non-annular shape by a bendable thin portion on the outer diameter side of the magnetic pole teeth.

A rotary motor according to a second aspect of the present invention is a connector for connecting a neutral point terminal portion for connecting a neutral point side terminal of a coil and a connector side terminal to the outer diameter side of the coil bobbin of the first aspect of the invention. And a terminal portion.

A rotary electric motor according to a third aspect of the present invention is obtained by resin-molding the stator of the first aspect of the invention.

A method of manufacturing a rotary electric motor according to a fourth aspect of the present invention is the method of manufacturing a rotary electric motor according to the first aspect, wherein the coil bobbin is bent so that the thin portion is located on the inner diameter side, which is the opposite of the assembling time. The coil bobbin is placed in an annular shape, and the coil is wound around the coil bobbin in that state.After the coil is wound, the coil bobbin is inverted so that the thin portion is on the outer diameter side, and the coil bobbin is fitted to the coil bobbin before or after winding the coil. The inserted magnetic pole teeth are fixed to the outer yoke to form a stator.

According to a fifth aspect of the present invention, in a rotary electric motor, a stator core is divided into a ring-shaped outer yoke and a plurality of magnetic pole teeth fixed to an inner diameter side of the stator core, and a rotor facing portion facing a rotor of each magnetic pole tooth. Is composed of a combination of a plurality of rectangular portions that are displaced stepwise in the circumferential direction of the rotor from one end side to the other end side in the axial direction of the rotor, and the portion around which the coil of magnetic pole teeth is wound is formed in a rectangular cross section. It was done.

According to a sixth aspect of the present invention, a rotary electric motor according to the fifth aspect is such that the side surfaces of the rectangular portions of the adjacent magnetic pole teeth are in contact with each other at a plurality of points.

According to a seventh aspect of the present invention, in the rotary electric motor, a gap is provided between the rotor shaft and the rotor core, and concavities and convexities are provided on the facing surfaces of the rotor core and the rotor shaft so that the coaxiality between the rotor shaft and the outer circumference of the rotor magnet is adjusted. In this state, the rotor shaft, the rotor core, and the rotor magnet are integrated by a resin molding material.

According to an eighth aspect of the present invention, there is provided a rotary electric motor in which a stepped portion for positioning a rotor bearing is integrally formed with the resin molding material according to the seventh aspect.

[0024]

In the rotary motor according to the present invention, since the coil bobbin fitted to the magnetic pole teeth of the stator core is non-annularly connected by the thin wall portion on the outer diameter side of the magnetic pole teeth, the thin wall portion can be extended or opposed. By bending the coil bobbin to the side, the coil bobbins can be arranged in a straight line shape or an inside out annular shape. In this case, since the coil bobbins are radially arranged following the magnetic pole teeth during assembly, the distance between the adjacent coil bobbins on the outer diameter side is wider than the distance between the adjacent coil bobbins on the inner diameter side. Therefore, the pitch between the coil bobbins when the coil bobbins are linearly arranged is longer and the space between the coil bobbins is wider when the coil bobbins are connected in a straight line than when the coil bobbins are connected on the inner diameter side. In the case where the coil bobbins are bent in the opposite direction and arranged annularly, the distance between the adjacent coil bobbins becomes wider. For this reason, the winding space of each coil bobbin is widened, and aligned winding can be easily performed, and the winding nozzle that sends out the winding is easily handled, and the slot space is effectively occupied by the winding. Will be able to. Further, since the coil bobbins are connected and integrated, the coils can be continuously wound without cutting the connecting wire between the coils of the same phase, and the number of times of connecting the coil terminals can be minimized.

In the rotary electric motor according to the invention of claim 2, in addition to the operation of claim 1, since the neutral point terminal portion and the connector terminal portion are provided on the outer diameter side of the coil bobbin, the start of winding at the time of winding And the end can be directly drawn to the neutral point terminal part and the connector terminal part by an automatic machine.

In the rotary electric motor according to the third aspect of the present invention, since the stator of the first aspect is integrally molded with resin, the heat dissipation becomes good.

In the method for manufacturing a rotary electric motor according to the invention of claim 4, the coil bobbin is wound around the coil bobbin with the thin portion of the coil bobbin being on the inner diameter side, and after the coil is wound,
Since the resin coil bobbin is inverted so that the thin part is on the outer diameter side, the space between the adjacent coil bobbins during winding can be made quite large, and the degree of freedom in the winding nozzle layout is increased. Thus, aligned winding can be easily performed, and the space of the slot portion can be effectively occupied by the winding.

In the rotary motor according to the invention of claim 5, the stator core is divided into magnetic pole teeth and a ring-shaped outer yoke, and the rotor facing portion of the magnetic pole teeth facing the rotor is formed by a rectangular portion having a staggered shape. Therefore, when the stator core is pressed, the shape of the laminated core can be efficiently processed only by performing necessary and sufficient setups. In addition, since the magnetic pole teeth have a stepped shape, a skew effect is provided, so that the rotor magnet can be formed in a straight shape with good magnetization accuracy, the characteristics are stabilized, and the cogging torque is improved. It is possible to reduce uneven rotation due to. Further, since the coil winding portion is formed in a rectangular cross section, aligned winding can be easily performed, and the cross sectional area of the coil winding portion can be minimized.

In the rotary electric motor according to the invention of claim 6, in addition to the effect of claim 5, since the side surfaces of the rectangular portions of the adjacent magnetic pole teeth are in contact with each other at a plurality of points, one of the magnetic fluxes generated by the coil is reduced. The parts will leak to the adjacent magnetic pole teeth. The leakage magnetic flux in this case affects the reduction of the driving torque, but also affects the reduction of the cogging torque. Therefore, combined with the skew effect, the effect of reducing the cogging torque becomes large.

According to a seventh aspect of the present invention, in a rotary electric motor, a gap is provided between the rotor shaft and the rotor core, and the rotor shaft, the rotor core, and the rotor magnet are resin-molded with the outer circumference of the rotor magnet and the rotor shaft being coaxial with each other. Since they are integrated by the material, a rotor having good coaxiality can be easily manufactured at low cost. Further, since the opposing surfaces of the rotor core and the rotor shaft are provided with concavities and convexities, even though they are components joined by resin, the integrity of the two is increased. Moreover, the resin in the gap between the rotor shaft and the rotor core serves as a damper to absorb the vibration caused by the generation of the cogging torque.

In addition to the function of the seventh aspect, the rotary motor according to the eighth aspect of the invention has the stepped portion for positioning the rotor bearing integrally formed of resin. It is no longer necessary to perform the groove machining on the rotor shaft.

[0032]

【Example】

Example 1. An embodiment of the present invention will be described below with reference to the drawings. 1 is a front view showing a rotary electric motor (this example is an AC brushless motor) according to an embodiment of the present invention. In this figure, 1 is a stator core, 4 is a coil,
Reference numeral 5 is a resin coil bobbin, 8 is a stator including the stator core 1, the coil bobbin 5, and the coil 4, and 10 is a rotor. The coil bobbin 5 need only be insulative and need not necessarily be made of resin.

FIG. 2 is a front view showing the stator core 1. The stator core 1 includes the same number (6 in this example = 3 phases × 2 times) of separate magnetic pole teeth (pole teeth) 2 as the number of the slot portions 14, and a substantially ring-shaped outer yoke arranged on the outer diameter side thereof. It is divided into three parts. Magnetic pole teeth 2
The outer yoke 3 is composed of a laminated iron core. That is, a thin plate made of a magnetic material is punched out by a press and is crimped to form a block-shaped laminated body. The outer yoke 3 has a regular hexagonal hole 3a in the center, and the outer end of each magnetic pole tooth 2 is fitted into a fitting recess 3b provided at the center of each side (straight line portion) of the inner periphery of the hexagonal hole 3a. The (outer diameter side end) is fitted. Before assembly, each magnetic pole tooth 2 is independent. The rotor facing portion 2a of the magnetic pole teeth 2 that faces the rotor 10 on the inner diameter side during assembly is formed in a flange shape.

FIG. 3A shows a correspondence relationship between the coil bobbin connecting body 15 formed of resin and each magnetic pole tooth 2.
The coil bobbin connecting body 15 connects the six coil bobbins 5 that are respectively fitted to the six magnetic pole teeth 2 in a non-annular shape (non-annular means that one point is not connected and is interrupted). The outer yoke 3 has a size that fits exactly into the hexagonal hole 3a of the outer yoke 3 during assembly. If the resin material is, for example, polypropylene resin, nylon resin, or ABS resin, it has good moldability,
A softness that can withstand several bendings is obtained. Figure 3 (b)
Shows the state in which the magnetic pole teeth 2 are attached to each coil bobbin 5 of the coil bobbin coupling body 15. Thin portions 15a are provided at the connecting portions of the coil bobbins 5, respectively. The thin portion 15a is a portion formed thin so as to be bendable and soft. As shown in FIG. 4, the thin portion 15a is formed to have a length from one end to the other end in the width direction of the coil bobbin 5 (= the axial direction of the coil bobbin 5).

As shown in FIG. 5, projections 16 for hooking a connecting wire or the like may be provided on both sides of the thin portion 15a. Further, as another example of the thin portion 15a, a hole 17 may be formed in the central portion of the thin portion 15a as shown in FIG.
As shown in FIG. 7, notches 18 may be provided at both ends of the thin portion 15a. In this way, holes 17 and notches 18 are formed in the thin portion 15a.
With the provision of, the thin portion 15a is more likely to bend.
A crossover may be hooked on the notch 18 shown in FIG. 7 to replace the protrusion 16 shown in FIG.

The coil bobbin coupling body 15 is housed in the hexagonal hole 3a of the outer yoke 3 as shown in FIG. The coil bobbins 5 of the coil bobbin connecting body 15 are connected to each other at the outer diameter side when housed in the holes 3a of the outer yoke 3, that is, when assembled as the stator 8. Since the coil bobbins 5 are arranged radially at the time of assembly, when they are connected to each other on the outer diameter side, as shown in FIG. 3, they are thinner than when they are connected to each other on the inner diameter side. When 15a is extended and opened linearly, the space between the adjacent parts becomes wide.

FIG. 15 shows a case in which the coil bobbin 5 is wound, but such a thin portion 15a is bent in the direction opposite to the normal state (state during assembly), and the coil bobbin connecting body 15 is turned upside down. When rounded, the spacing between the adjacent coil bobbins 5 becomes even larger. Therefore, in any case, the space between the adjacent coil bobbins 5 is widened, so that the coil 4 can be easily wound around the coil bobbin 5, and the winding nozzle of the winding machine is used to easily perform the aligned winding. Will be able to.

As shown in FIG. 1, each coil bobbin 5 of the coil bobbin connecting body 15 is fitted to the magnetic pole teeth 2 in a state where the coils 4 are concentratedly wound. Since the outer ends of the magnetic pole teeth 2 are fitted and fixed to the outer yoke 3, the hexagonal holes 3 of the outer yoke 3 are formed.
It is housed in a and is held by the magnetic pole teeth 2, and thereby the stator 8 is configured.

FIG. 8 shows the connection state of the coil 4, and FIG. 9 shows the winding direction and arrangement relationship of the coil 4. Coil 4
Has three phases of U phase, V phase and W phase, and in this example, Y connection is performed. Of course, the Δ connection may be used instead of the Y connection. P in FIG. 8 indicates a neutral point, and Q1, Q2, and Q3 indicate the terminals on the connector side of each coil of U, V, and W phases. There are two U-phase coils, Ua and Ub, two V-phase coils, Va and Vb, and two W-phase coils, Wa and Wb. The coils of the same phase are arranged at positions facing each other by 180 degrees and are connected in series. The coils of the same phase facing each other by 180 degrees are connected by a crossover wire and are not cut in the middle but continuously wound. This is possible because the coil bobbins 5 are connected to each other. The winding direction of each coil is as shown in FIG. In FIG. 9, YA is the arrow head,
YS represents the tail of the arrow, and the direction of the arrow is the winding direction.

Next, the operation will be described. FIG. 15 shows a state in which the coil 4 is wound around the coil bobbin 5.
Since this FIG. 15 is shared with other embodiments, the details are slightly different from those of this embodiment. When the coil 4 is wound around the coil bobbin 5, as shown in FIG. 15, the coil bobbin connecting body 15 is rolled into a substantially annular shape on the side opposite to the assembled state (that is, the side facing the rotor is outside and the thin portion 15
(a is made into an inner diameter side and rounded into an annular shape), and the space between the adjacent coil bobbins 5 is widened. Coil bobbin 5 in advance
If the magnetic pole teeth 2 are attached to the respective magnetic pole teeth 2 and the work is performed while holding the coil bobbin coupling body 15 using the magnetic pole teeth 2, the winding can be efficiently performed. In this case, the windings of the coils 4 having the same phase can be continuously wound without cutting the crossover wire because all the coil bobbins 5 are connected. Further, the crossovers are not obstructed during assembly by being hooked on the projections 16 shown in FIG.

After the coil 4 is wound, the coil bobbin connecting body 15 is inverted and rounded to a normal state, and each magnetic pole tooth 2 is fitted and fixed to the outer yoke 3, thereby forming the stator 8. The coil bobbin 5 may not be mounted on the coil bobbin 5 at the time of winding, but the coil 4 may be wound and the magnetic pole teeth 2 may be mounted on the coil bobbin 5 immediately before fitting with the outer yoke 3.

Example 2. 10 is a front view of a rotary electric motor according to an embodiment of the invention of claim 2, FIG. 11 (a) is a view showing the relationship between the coil bobbin connecting body 15 and the magnetic pole teeth 2, FIG.
1 (b) is each coil bobbin 5 of the coil bobbin connecting body 15.
It is a figure which shows the state which attached the magnetic pole teeth 2 to. The difference of the second embodiment from the first embodiment is that the neutral point terminal portion 21 for connecting the neutral point side terminal of the coil 4 to the outer diameter side of the coil bobbin coupling body 15 and the connector terminal for connecting the connector side terminal. The point is that the part 22 is integrally provided. Other than that is the same as that of the first embodiment.

The neutral point terminal portion 21 and the connector terminal portion 22 are arranged at positions opposed to each other by 180 degrees, and are integrally formed so as to project to the outside of the coil bobbin 5, respectively.
The neutral point terminal portion 21 has three connecting terminals 21a, 21b, and 21c that join the coil terminals and are electrically connected to each other. Further, the connector terminal portion 22 has three independent connection terminals 22a, 22b, 22c, each of which has connector terminals 23a, 23b, 23b on the tip side.

Next, the operation will be described. When winding the coil 4, as shown in FIG. 12, continuous winding is performed without cutting the connecting wire between the coils of the same phase, and the winding start and the winding end of the coil of the same phase are respectively the connector terminal portion 22 and the neutral point terminal portion. 21 is automatically peeled off with a winding machine and joined. As a result, all windings of the coil can be automatically processed by the winding machine, and it is possible to obtain an inexpensive rotary motor with no connection failure.

Example 3. 13 is a front view of a rotary electric motor according to an embodiment of the invention of claim 3, and FIG. 14 is a side sectional view of the rotary electric motor. In the figure, 30 is a molding resin (resin), 31 is a motor flange, 32 is a rotor shaft, 33 is a rotor core arranged outside the rotor shaft 32, 34 is a rotor magnet arranged on an outer peripheral portion of the rotor core 33, and 35 is a rotor magnet.
Is a rotor bearing that rotatably supports the rotor shaft 32. In the rotary electric motor according to the third embodiment, after the stator 8 is configured in the same manner as the first or second embodiment, the outer shell of the stator 8 excluding the rotor 10 and the inside of the slot portion 14 including the coil 4 are made of epoxy resin or the like. Mold resin 3
Molded at 0. Thus, when the stator 8 is resin-molded, the heat dissipation of the coil 4 is improved.

Example 4. FIG. 15 is an explanatory view of an embodiment of the invention of claim 4, and FIG. 16 is an explanatory view showing the winding order.
In FIGS. 15 and 16, 40 is a winding flyer of an automatic winding machine, 41 is an index portion, 12 is a winding, and 13 is a winding nozzle. The winding flyer 40 is driven to rotate around a reference line 45, and has a winding nozzle 13 at its tip. The winding nozzle 13 has a tip oriented in the reference line 45 direction, and sends the winding 12 from the tip in the reference line 45 direction. The index portion 41 is made of a cylindrical body or a cylindrical body, and has a center of rotation 4 orthogonal to the reference line 45.
It is designed to be rotated around 6. Positioning recesses 41a are provided on the outer circumference of the index portion 41 at equal positions in six positions in the circumferential direction.

When the stator 8 of the first or second embodiment is constructed, the coil 4 is wound around the coil bobbin 5 as shown in FIG. That is, first, the magnetic pole teeth 2 are attached to each coil bobbin 5 of the coil bobbin coupling body 15. After that, the rotor facing portion 2 of the magnetic pole teeth 2 facing the rotor
Bending the thin portion 15a so that a is on the outside, and rolling the outer end of the magnetic pole teeth 2 (which is located on the inner peripheral side in this case) into the index portion while rounding the thin portion 15a into an annular shape opposite to the normal assembled state. It is fitted into the positioning recess 41 on the outer periphery of 41.
In this state, the coil bobbins 5 are projected radially outward, and the distance between the adjacent coil bobbins 5 is considerably widened. This is because the coil bobbin 5 is not connected on the inner diameter side but is connected on the outer diameter side.

Then, the coil bobbin 5 to be wound is positioned on the reference line 45 by turning the index portion 41, and the winding flyer 40 is moved around the reference line 45 while the winding 12 is being sent out from the winding nozzle 13. To orbit,
In synchronization with this, the winding flyer 40 is moved in parallel along the reference line 45. As a result, the winding 12 is connected to the coil bobbin 5
Can be aligned and wound. In addition, since the space between the coil bobbin 5 that is wound and the adjacent coil bobbin 5 can be increased, the stacking height of the windings can be freely controlled.
The coil 4 can be wound in the shape of a truncated cone in which the winding diameter on the base end side is increased. Therefore, as shown in FIGS. 1 and 10, the space of the slot portion 14 can be effectively occupied by the coil 4. In this embodiment, the winding 12
Since the coil bobbin can be wound right beside the coil bobbin 5, it is possible to secure an unlimited winding space and form the coil 4 of high density with high accuracy.

FIG. 16 shows a state where the winding is carried out. As shown in this figure, in-phase coils such as U
A and Ub are wound continuously without cutting the connecting wire 50. When the neutral point terminal portion 21 and the connector terminal portion 22 are provided, the terminals at the beginning and the end of the winding are respectively connected to the terminal portions 21, 2
Connect to the corresponding connection terminal of 2.

When the winding is completed, the coil bobbin connecting body 15 is removed from the index portion 41 and the coil bobbin connecting body 15 is inverted. That is, the thin portion 15a is bent so that the rotor facing portion 2a of the magnetic pole tooth 2 is on the inside, and the coil bobbin coupling body 15 is rolled into an annular shape. And
The magnetic pole teeth 2 and the coil bobbin connecting body 15 are housed in the hexagonal holes 3 a of the outer yoke 3, and the magnetic pole teeth 2 are fitted into the fitting recesses 3 a of the outer yoke 3. In this way, the stator 8 shown in FIG. 1 or 10 is configured.

In the fourth embodiment, since the coils of the same phase can be continuously wound without cutting the connecting wire 50, an extra manufacturing process is unnecessary. In addition, the coil 4 can be wound in a line and the slot portion 14 (see FIGS. 1 and 10).
Is effectively used as the space occupied by the coil 4,
It is possible to increase the output of the rotary motor, stabilize the characteristics, and further reduce the size.

Incidentally, the coil bobbin 5 may not be fitted with the magnetic pole teeth 2 during winding, but the coil 4 may be formed, and the magnetic pole teeth 2 may be fitted to the coil bobbin 5 immediately before the magnetic pole teeth 2 are fitted to the outer yoke 3. .

Example 5. FIG. 17 is a perspective view of the stator core 1 in the rotary electric motor according to the fifth embodiment of the invention. In this rotary electric motor, the stator core 1 is divided into a plurality of separate and independent magnetic pole teeth 2 and a ring-shaped outer yoke 3, and the shape of the rotor facing portion 2a of the magnetic pole teeth 2 is set in the axial direction of the stator core 1 (of the rotor 10). A plurality of rectangular portions 60 having the same shape, which are shifted stepwise in the circumferential direction of the stator core 1, are formed in a combined manner from one end side to the other end side (which is the same as the axial direction). In this case, the rectangular portions 60 are combined in a staircase pattern with the same amount offset. Reference numeral 61 is a stepped portion between the rectangular portions 60.

The portion of each magnetic pole tooth 2 around which the coil is wound is formed in a rectangular cross section. When the coil winding section has a rectangular cross section, the cross-sectional area is minimized and the winding density can be increased, and there is the advantage that aligned winding can be easily performed, stabilizing characteristics, downsizing, and high output. Can be achieved.

In producing each magnetic pole tooth 2, the shape of the press die is set up in accordance with the number of steps of the rectangular portion 60, and punching and caulking are sequentially performed to sequentially stack the blocks in a block shape. It is also possible to first form the blocks for each step of the rectangular portion 60 and then stack the blocks to form the magnetic pole teeth 2. In any case, by shifting the rectangular portions 60 in a stepwise manner and combining them, while improving the processing efficiency,
The magnetic pole teeth 2 can have a skew effect. Therefore, it is possible to stabilize the characteristics of the rotary motor and reduce the uneven rotation due to the cogging torque without giving a skew angle to the rotor magnet.

It should be understood that the stator core 1 of this embodiment can be applied to the rotary electric motors of Embodiments 1 to 4. When the stator 8 is constituted by the stator core 1, for example, each magnetic pole tooth 2 is attached to the coil bobbin connection body of the first embodiment.
By inserting, the stator 8 can be manufactured as in the first embodiment.

Example 6. FIG. 18 shows the rotor facing portion 2 of the magnetic pole teeth 2 of the rotary motor according to the sixth embodiment of the invention.
FIG. 6 is a development view of a viewed from the rotor 10 side. This Example 6
In the example 5, the side surfaces of the adjacent rectangular portions 60 of Example 5 are brought into contact with each other at a plurality of points. In the figure, 62 is a contact portion. It can be manufactured by the same method as in the fifth embodiment. When the side surfaces of the rectangular portion 60 are brought into contact with each other in this way, a leakage magnetic flux is generated between the adjacent magnetic pole teeth 2, and the leakage magnetic flux reduces the cogging torque. In addition, since the number of contact points and contact area of the rectangular portion are easy to manage, there is little variation in the performance of individual products and the characteristics are stable.

Example 7. 19 is a side sectional view showing a rotor portion of a rotary electric motor according to an embodiment of the invention of claim 7, and FIG. 20 is a sectional view taken along the line XX-XX of FIG.
In these drawings, 32 is a rotor shaft, 33 is a rotor core, 34 is a rotor magnet, 35 is a rotor bearing, and 36 is a rotor bearing.
Is a retaining ring for positioning the rotor bearing 35, and 37 is a retaining ring 3
It is a groove into which 6 is fitted.

In the rotor 10 of the rotary electric motor according to the seventh embodiment, a gap 71 is provided between the outer circumference of the rotor shaft 32 and the inner circumference of the rotor core 33, and a plurality of irregularities 72 are provided on the inner circumference of the rotor core 33. A cutout (unevenness) 73 is provided on a part of the outer circumference of the rotor shaft 32, a rotor magnet 34 is arranged on the outer circumference of the rotor core 33, and the resin shaft and the outer circumference of the rotor shaft 32 and the outer circumference of the rotor magnet 34 are aligned with each other. 70 is integrally molded to fix the rotor shaft 32, the rotor core 33, and the rotor magnet 34.
Examples of the resin molding material 70 include PPS resin and PB
T resin is used and integrated by injection molding. In this case, an injection mold is manufactured so that the outer circumference of the rotor magnet 34 and the rotor shaft 32 can be constrained, and then injection molding is performed. With this configuration, the rotor magnet 3
Even if there is a thickness error of 4, the error can be absorbed by the gap 71, and a rotor having a good coaxiality can always be obtained at a low cost. Further, since the resin molding material 70 in the gap 71 between the rotor shaft 32 and the rotor core 33 serves as a damper to absorb the vibration caused by the generation of the cogging torque, it is possible to obtain a rotary motor with less vibration.

It should be noted that the rotor 10 of this embodiment can be incorporated in the rotary electric motors of the first to fourth embodiments. Further, it is of course possible to combine the sixth and seventh embodiments with the seventh embodiment.

Example 8. 21 is a side sectional view of a rotary electric motor according to an embodiment of the present invention. In Example 7,
Although the rotor bearing 35 is positioned by using the retaining ring 36, in the eighth embodiment, the stepped portions 75 for positioning the rotor bearing are integrally projected at both axial ends of the resin molded portion made of the resin molding material 71. Then, the rotor bearing 35 is positioned by bringing the end surface of the stepped portion 75 into contact with the rotor bearing 35. In this way, the snap ring 36
The positioning means can be omitted. The stepped portion 75 can be easily constructed by simply changing the shape of the injection molding die and can be easily implemented.

[0062]

As described above, according to the first aspect of the present invention, the coil bobbin fitted to the magnetic pole teeth of the stator core is configured to be non-annularly connected by the thin portion on the outer diameter side of the magnetic pole teeth. The space for winding each coil bobbin can be increased. For this reason, the degree of freedom in handling the winding nozzle of the winding machine is increased, and aligned winding can be easily performed, and the slot space can be occupied by the winding, and the coil density is high.
It is possible to obtain a stable and small rotary electric motor having good characteristics. In addition, the coils can be continuously wound without cutting the connecting wire between the coils of the same phase, and the number of times of connecting the coil terminals can be minimized. As a result, no extra connecting step is required and the cost is low. Moreover, there is an effect that it is possible to obtain a rotary electric motor without connection failure.

According to the invention of claim 2, since the neutral point terminal portion and the connector terminal portion are provided on the outer diameter side of the coil bobbin of the invention of claim 1, winding start and winding end are performed at the time of coil winding. Can be directly routed to the neutral point terminal part and the connector terminal part by an automatic machine. Therefore, in addition to the effect of the first aspect of the invention, all windings of the coil can be automatically processed by the winding machine, and there is an effect that it is possible to obtain an inexpensive rotary electric motor with no connection failure.

According to the third aspect of the invention, since the stator of the first aspect of the invention is integrally molded with resin, the heat dissipation is good, and in addition to the effect of the first aspect of the invention, magnetic noise is reduced. There is an effect that a low rotary motor can be obtained.

According to the invention of claim 4, the coil is wound around the coil bobbin with the thin portion of the coil bobbin on the inner diameter side, and after winding the coil, the coil bobbin is inverted so that the thin portion is on the outer diameter side. Since it is configured as described above, the space between the adjacent coil bobbins at the time of winding can be considerably increased, and the aligned winding can be easily performed.
The space of the slot can be effectively occupied by the winding. Therefore, there is an effect that a compact and high torque motor having a high coil density can be obtained at low cost.

In the rotary electric motor according to the invention of claim 5, the stator core is divided into magnetic pole teeth and a ring-shaped outer yoke, and the rotor facing portions of the magnetic pole teeth facing the rotor are formed by stepwise rectangular portions. With this configuration, it is possible to reduce the number of setups for pressing the stator core and improve the processing efficiency. Further, since the magnetic pole teeth have the skew effect, it is possible to stabilize the characteristics and reduce the rotation unevenness due to the cogging torque. Further, since the coil winding portion is formed in a rectangular cross section, the coils can be easily aligned and wound, and the cross sectional area of the coil winding portion can be minimized, which also stabilizes the characteristics. At the same time, there is an effect that miniaturization and high output can be achieved.

According to the invention of claim 6, the side surfaces of the rectangular portions of the adjacent magnetic pole teeth are in contact with each other at a plurality of points. Therefore, in addition to the effect of the invention of the fifth aspect, the space between the adjacent magnetic pole teeth is increased. There is an effect that the cogging torque can be reduced by the leakage magnetic flux. Further, since it is easy to manage the number of contact points and the contact area of the rectangular portion, it is possible to reduce variations in the performance of manufactured products and to provide a product with stable characteristics.

According to the invention of claim 7, a gap is provided between the rotor shaft and the rotor core, and the rotor shaft, the rotor core and the rotor magnet are made of a resin molding material in a state where the outer circumference of the rotor magnet and the rotor shaft are coaxial. Since the rotor is integrated, it is possible to easily and inexpensively manufacture a rotor having good coaxiality. In addition, the vibration due to the generation of the cogging torque is absorbed by the resin in the gap between the rotor shaft and the rotor core serving as a damper, so that there is an effect that it is possible to provide a rotary motor with less vibration.

According to the invention of claim 8, in the invention of claim 7, the stepped portion for positioning the rotor bearing is integrally formed of resin. Therefore, in addition to the effect of the invention of claim 7, in order to fix the bearing. Since it is not necessary to form a retaining ring or a groove for the retaining ring on the rotor shaft, there is an effect that the bearing can be accurately positioned at low cost.

[Brief description of drawings]

FIG. 1 is a front view of a stator of a rotary electric motor according to a first embodiment of the present invention.

FIG. 2 is a front view of the stator core of the rotary motor according to the first embodiment of the present invention.

3A and 3B are front views of the magnetic pole teeth of the stator core and the coil bobbin coupling body of the rotary electric motor according to the first embodiment of the present invention, FIG. 3A is a front view showing a state before the two are combined, and FIG. It is a front view which shows the state after it stood.

FIG. 4 is a perspective view showing an example of a thin portion that connects the coil bobbins of the rotary electric motor according to the first embodiment of the present invention.

FIG. 5 is a perspective view showing an example in which a protrusion is provided on the thin portion.

FIG. 6 is a perspective view showing another example of the thin portion.

FIG. 7 is a perspective view showing still another example of the thin portion.

FIG. 8 is a diagram showing an example of a wire connection state of coils in the stator of the rotary electric motor according to the first embodiment of the present invention.

FIG. 9 is a front view of a stator showing a combination of coil windings in the rotary motor according to the first embodiment of the present invention.

FIG. 10 is a front view of a stator of a rotary electric motor according to a second embodiment of the present invention.

FIG. 11 is a front view of a magnetic pole tooth of a stator core and a coil bobbin coupling body of a rotary electric motor according to a second embodiment of the present invention, (a) is a front view showing a state before the two are combined, and (b) is a combination of the two. It is a front view which shows the state after it stood.

FIG. 12 is a schematic diagram showing a wire connection relationship of coils of a stator of a rotary electric motor according to a second embodiment of the present invention.

FIG. 13 is a front view of a stator of a rotary electric motor according to Embodiment 3 of the present invention.

FIG. 14 is a side sectional view of a rotary electric motor according to Embodiment 3 of the present invention.

FIG. 15 is an explanatory diagram of a method of manufacturing a rotary electric motor according to a fourth embodiment of the present invention.

FIG. 16 is an explanatory diagram of a winding order in the manufacturing method.

FIG. 17 is a perspective view of a stator core of a rotary electric motor according to Embodiment 5 of the present invention.

FIG. 18 is a partial detailed view of a stator core of a rotary electric motor according to a sixth embodiment of the present invention viewed from the rotor side.

FIG. 19 is a side sectional view of a rotary electric motor according to a seventh embodiment of the present invention.

20 is a cross-sectional view taken along the line XX-XX of FIG.

FIG. 21 is a side sectional view of a rotary electric motor according to Embodiment 8 of the present invention.

FIG. 22 is an exploded perspective view of a stator in the rotary electric motor of Conventional Example 1.

FIG. 23 is an exploded perspective view of a stator in a rotary electric motor of Conventional Example 2.

FIG. 24 is an explanatory diagram of how to wind a coil around a coil bobbin, and is a cross-sectional view showing aligned winding.

FIG. 25 is a cross-sectional view showing a state in which coils are aligned and wound around a coil bobbin by using an automatic winding machine.

FIG. 26 is a front view showing a state where a coil is wound around a coil bobbin by using an automatic winding machine.

FIG. 27 is an explanatory diagram of how to wind a coil around a coil bobbin, and is a cross-sectional view showing a state when the winding cannot be performed in an aligned manner.

FIG. 28 is a side sectional view of a rotary electric motor of Conventional Example 3.

FIG. 29 is a front view of a rotary electric motor of Conventional Example 4.

FIG. 30 is a partial perspective view of a magnetic pole tooth portion in the rotary electric motor of Conventional Example 4.

[Explanation of symbols]

 1 stator core 2 magnetic pole teeth 2a rotor facing part 3 outer yoke 4 coil 5 coil bobbin 8 stator 10 rotor 15a thin part 21 neutral point terminal part 22 connector terminal part 30 mold resin (resin) 32 rotor shaft 33 rotor core 34 rotor magnet 35 rotor bearing 60 Rectangular part 70 Resin molding material 71 Gap 72 Unevenness 73 Notch (unevenness) 75 Stepped part

 ─────────────────────────────────────────────────── ─── Continuation of front page (72) Inventor Yoichi Fujita 8-1-1 Tsukaguchihonmachi, Amagasaki City Mitsubishi Electric Corporation Production System Technology Center (72) Inventor Yoshimitsu Okawa 5-1-1 Yada Minami, Higashi-ku, Nagoya No. Mitsubishi Electric Co., Ltd., Nagoya Works (72) Inventor, Yoichi Ikeda, 5-1, 14 Yada Minami, Higashi-ku, Nagoya City (72) Mitsubishi Electric, Co., Ltd. (72) Inventor, Hiroki Matsubara 5--14, Yada Minami, Higashi-ku, Nagoya No. Mitsubishi Electric Co., Ltd. Nagoya Works (72) Inventor Yoshiyuki Kiyo 5-14 Yanda Minami 5-chome, Higashi-ku, Nagoya City Mitsubishi Electric Co., Ltd. Nagoya Works

Claims (8)

[Claims] 1. A rotary electric motor comprising: a stator having a coil bobbin fitted to the magnetic pole teeth of a stator core and the coil being concentratedly wound on the coil bobbin; and a rotor arranged on the inner diameter side of the stator. -Shaped outer yoke and a plurality of the magnetic pole teeth fixed to the inner diameter side of the outer yoke, and the coil bobbins fitted to the magnetic pole teeth are not bent by a thin portion that is bendable on the outer diameter side of the magnetic pole teeth. A rotary electric motor, which is connected in a ring shape. 2. A neutral point terminal portion for connecting the neutral point side terminal of the coil and a connector terminal portion for connecting the connector side terminal to the outer diameter side of the coil bobbin. The rotary electric motor according to 1. 3. The rotary electric motor according to claim 1, wherein the stator is molded with resin. 4. The coil bobbin is arranged in an annular shape opposite to that at the time of assembly by bending the thin portion so as to be positioned on the inner diameter side, and in that state, the coil is wound around the coil bobbin, and after winding the coil, The stator is configured by inverting the coil bobbin so that the thin portion is on the outer diameter side, and fixing the magnetic pole teeth fitted into the coil bobbin before or after winding the coil to the outer yoke. Method of manufacturing rotary motor. 5. A rotary electric motor comprising: a stator having a concentrated winding of a coil for each magnetic pole tooth of a stator core; and a rotor arranged on the inner diameter side of the stator, wherein the stator core has a ring-shaped outer yoke and an inner diameter thereof. A plurality of magnetic pole teeth fixed to the side, and the rotor facing portion of each of the magnetic pole teeth facing the rotor is arranged in the circumferential direction of the rotor as it goes from one end side to the other end side in the axial direction of the rotor. A rotary electric motor comprising a combination of a plurality of rectangular portions shifted in a stepwise manner, and further, a portion around which the coil of the magnetic pole teeth is wound is formed in a rectangular cross section. 6. The rotary motor according to claim 5, wherein the side surfaces of the rectangular portions of the adjacent magnetic pole teeth are in contact with each other at a plurality of points. 7. A rotary electric motor comprising a stator having a coil arranged therein, and a rotor having a rotor core on the outer peripheral side of a rotor shaft and having a rotor magnet arranged on the outer peripheral side of the rotor core, the rotor shaft and the rotor core. A gap is provided between the rotor core and the rotor shaft, and concavities and convexities are provided on the opposing surfaces of the rotor core and the rotor shaft, and the rotor shaft, the rotor core, and the rotor magnet are resin-molded in a state where the coaxiality between the rotor shaft and the rotor magnet outer periphery is matched. A rotary electric motor characterized by being integrated by materials. 8. The rotary electric motor according to claim 7, wherein a stepped portion for positioning the rotor bearing is integrally formed by the resin molding material.