JPH09261925A - Manufacture of stator of inner rotor type rotating electric machine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To place the coils of an inner rotor type rotating electric machine at normal positions without using a stator core. SOLUTION: A winding frame 36 which has winding cores 24 protruding from its outer circumference is made of resin containing magnetic powder. Coils 25 are wound on the winding cores 24. Then the outer circumferential side end parts of the winding cores 24 are heated, softened and fitted to the trenches 22 of a housing 21. After that, the center base part 37 of the winding frame 36 is removed by cutting, etc., to secure a space in which a rotor is provided.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a stator manufacturing method suitable for a small-sized inner rotor type rotary electric machine.

[0002]

2. Description of the Related Art An inner rotor type motor has a structure in which a rotor is arranged inside a stator.
As shown in FIG. 11, usually, the coil 3 is attached to the winding core 2a of the stator core 2 formed by stacking punched sheets of electromagnetic steel sheets.
And is fitted inside the housing 4. The rotor 5 is arranged in the inner space of the stator core 2, and the shaft 8 of the rotor 5 is supported by the bearings 7, 7 provided on the brackets 6, 6 at both ends of the housing 4.

Also, in the small-sized inner rotor type motor, unlike the above-mentioned ordinary one, a stator core is not used as shown in FIG. 12, and a plurality of coils 9 are made of magnetic metal, for example, an inner peripheral surface of a steel plate housing 10. It is fixed by direct bonding or the like. Then, the rotor 11 is arranged in the space surrounded by the coil 9, and the shaft 14 of the rotor 11 is supported by the bearings 13, 13 of the brackets 12, 12 attached to both ends of the housing 10.
Note that FIGS. 11 and 12 show the rotors 5 and 11 as permanent magnet type rotors.

[0004]

In the normal inner rotor type motor shown in FIG. 11, the magnetic circuit is formed by the stator core 2, so that the motor is efficient. However, in the stator core 2, the stator core 2 is provided outside the winding core 2a. Since the annular yoke 2b is present and the diameter of the housing 4 is increased by that amount, there is a limit to downsizing. For these reasons, the coil 9 is directly bonded to the inner peripheral surface of the housing 10 in the ultra-small inner rotor type motor, in which miniaturization is more important than motor efficiency, and the stator core is omitted. .

However, in the ultra-small inner rotor type motor, since both the coil 9 and the housing 10 are very small, the small coil 9 is used for the housing 1 having a small diameter.
It is very difficult to insert into 0 and adhere correctly to the preset position. To facilitate this work, a stator core may be used, but this hinders miniaturization as described above, and the coil is wound around the teeth protruding from the inner peripheral side of the stator core having a small diameter. The work becomes very difficult.

The present invention has been made in view of the above circumstances, and an object thereof is to provide an inner rotor type rotary electric machine in which a coil or a housing can be easily arranged in a regular position even if the coil or the housing is small. It is in.

[0007]

In order to achieve the above object, the present invention is a method for manufacturing a stator of an inner rotor type rotary electric machine, wherein a winding frame formed by projecting a plurality of winding cores on the outer periphery of a central base portion. A coil is wound around the winding core of the winding frame to dispose the winding frame inside the housing, and then to form a space for disposing the rotor inside the coil, At least a part of the central base is removed (Claim 1).

Further, a winding frame formed by projecting a plurality of winding cores is formed on the outer periphery of a cylindrical central base having a space for arranging the rotor inside, and a coil is wound around the winding core of the winding frame. The winding frame may be arranged inside the housing by rotating (claim 2).

According to the above construction, the coil is wound around the winding core projecting from the outer periphery of the central base, so that the winding operation can be easily performed. Further, the positional relationship of the plurality of coils can be attached to the housing in a state where the positional relationship is fixed by the central base.

In the above structure, in order to eliminate the work of winding the magnet wire around the winding core to form the coil and facilitate the work of winding the coil around the winding core, the coil is wound with a sheet material made of an electric conductor. It is composed of a slice coil formed by cutting a coil material which is rotated and resin-molded to a desired thickness (Claim 3), or the coil is formed by etching an electric conductor layer attached to an electric insulating sheet. It can be composed of a sheet coil (claim 4).

In order to form a good magnetic circuit,
The reel can be made of a magnetic material (claim 5),
Further, in order to reduce the cogging torque, the winding frame may be made of non-magnetic resin (claim 6). Further, in order to prevent the generation of eddy currents due to the high frequency magnetic field during operation as much as possible, the winding frame may be formed of resin mixed with a fine magnetic material (claim 7).

Further, by forming a groove into which the outer peripheral side end of the winding core is fitted on the inner peripheral surface of the housing, positioning of the winding core with respect to the housing or securing of the winding core can be ensured. Good (Claim 8). In this case, in order to prevent the winding core from coming off from the groove of the housing, the groove of the inner peripheral surface of the housing is made wider on the bottom side than on the opening side (Claim 9), or on the outer peripheral side end of the winding core. The part can be formed in a shape with a wider width at the tip (claim 10).

Further, by fixing the housing and the winding core by melting or softening, the fixing of the both can be made more reliable (Claim 11).
Further, in order to facilitate the fixing work, the housing and the core may be fixed by adhesion (claim 12). At least a part of the central base portion of the reel can be removed by melting (claim 13).

In order to reinforce the winding core, the central base portion of the winding frame can be removed so that a holding portion for keeping the plurality of winding cores in a connected state remains. ). In this case, the holding portion may be present on a part of the winding core in the axial direction (claim 15).

[0015]

FIG. 1 shows a first embodiment of the present invention.
This will be described with reference to FIG. First, the whole inner rotor type motor is shown in FIG. 5, and in FIG. 5, the housing 21 constituting the motor case has a cylindrical shape with both end surfaces open, and the inner peripheral surface of the housing 21. For example, three grooves 22 are formed at an angular interval of 120 ° up to an intermediate portion from one opening end of the housing 21 to the other opening end.

As shown in FIG. 4, the housing 21 is made of a resin containing a fine magnetic material, for example, a powdery or granular magnetic material 23 (hereinafter, magnetic powder) 23 such as ferrite or iron. In this case, the surface of the magnetic powder 23 is covered with the insulating layer 23a made of iron oxide or resin.

Inside the housing 21, as shown in FIG. 2, three winding cores 24 each having one end fitted in the groove 22 are arranged at an angular interval of 120 °. A coil 25 is wound around each of the winding cores 24. Like the housing 21, the core 24 is made of a resin mixed with magnetic powder, and functions as a magnetic core of the coil 25 like the core of a stator core in a normal motor. And
Housing 21 and winding core 2 that function as a stator yoke
The stator core 26 and the coil 25 form a stator core 26.

On the other hand, the rotor 28 is constructed as a permanent magnet type rotor, and is provided with a shaft 29 and a permanent magnet 30 mounted on the outer circumference of the shaft 29. This rotor 2
8 is arranged inside the housing 21 so that the permanent magnet 30 faces the winding core 24 in the radial direction with a predetermined gap.

With respect to the rotor 28, the housing 21
Aluminum brackets 31 and 32 are fitted to both ends of the. A shaft 29 of the rotor 28 has one tapered end rotatably supported by a bearing mounted on the bracket 31, for example, a pivot bearing 33 made of a jewel bearing, and the other end mounted on the bracket 32 by a bearing. For example, it is rotatably supported by a plain bearing 34. In addition, for example, three notches 35 are formed on one end side of the housing 21, and both ends of the coil 25 wound around each winding core 24 are outwardly passed through the notches 35 for connection with an external drive circuit. Have been derived to.

The stator 27 of the inner rotor type motor as described above is manufactured by winding the coil 25 around the winding core 24 and then fixing the winding core 24 inside the housing 21. That is, the three winding cores 24 are
Although they are separated from each other as shown in FIG. 2, they were originally formed as a part of the winding frame 36 shown in FIG. 1, and the winding frame 36 has, for example, a cylindrical base portion 37 at the center. The three cores 24 are radially and integrally projected on the outer periphery of the central base 37 at an angular interval of 120 °. Further, in this embodiment, the thickness W1 of the winding core 24 is set to be slightly larger than the width W2 of the groove 22 of the housing 21.

Then, the winding frame 36 is set in a winding machine (not shown), and a magnet wire is wound around each winding core 24 to form a coil 25. In this case, the magnet wire used is one having a heat-adhesive coating.
The magnet wire is wound while being heated, or after being wound, the magnet wire is heated. This heating is performed by magnet wire (coil 25), for example.
This is performed by applying a current to the coil to generate heat, and this heating causes the coatings of the magnet wires to adhere to each other and hardens the coil 25 so as not to fall apart.

After this, the outer peripheral end of each winding core 24 is heated and softened. Then, the outer peripheral side end of each winding core 24 is press-fitted into each groove 22 of the housing 21 so that the housing 2
Insert into 1. At this time, the thickness W1 of the winding core 24 is
By setting the width W2 to be larger than the width W2, a part of the outer peripheral side end of the heat-softened core 24 protrudes from the groove 22 and covers a part of the coil 25 as shown in FIG. Become. Then, the protruding portion 24a of the winding core 24
Thus, the coil 25 is fixed to the winding core 24 so as not to move.

Next, the housing 21 is set on a processing machine such as a lathe, and the central base portion 37 of the winding frame 36 is cut and removed. By removing the central base portion 37, a space 38 for arranging the rotor 28 inside the winding core 24 is formed. After that, the rotor 28 is arranged in the housing 21, and
Brackets 31 and 32 are fitted to both ends of the housing 21, and the shaft 29 of the rotor 28 is supported by a pivot bearing 33 and a plain bearing 34. As described above, the inner rotor type motor shown in FIG. 5 is manufactured.

In the inner rotor type motor having the above structure, when the three coils 25 are sequentially energized, a rotating magnetic field is formed by these coils 25, and the rotor 28 is rotated by the rotating magnetic field. In this case, in the inner rotor type motor of the present embodiment, since a large amount of magnetic powder 23 is mixed in the housing 21 and the winding core 24, the coil 25 is formed by the housing 21 and the winding core 24.
Magnetic circuit is formed. Even if the high-frequency magnetic field acts on the magnetic powder 23 when the rotor 28 rotates, since the individual magnetic powders 23 are electrically insulated, the induction action of the high-frequency magnetic field causes the housing 21 and the winding core. There is no possibility that an eddy current will be generated in 24, and even if it is generated, it can be suppressed to a minute current. For this reason,
Compared to the case where the housing 21 and the winding frame 36 are made of a magnetic material, the loss due to the eddy current in the housing 21 and the winding core 24 can be suppressed.

According to the inner rotor type motor of this embodiment as described above, the stator 27 is constructed by fixing the winding core 24 around which the coil 25 is wound inside the housing 21 which also serves as the stator yoke. The motor can be made smaller than that of a structure in which a coil is wound around the teeth of the stator core and the stator core is fitted inside the housing.

Moreover, in the present embodiment, the winding core 24 is fixed to the inside of the housing 21 and then the coil 25 is not wound around the winding core 24, but the winding core 24 is wound around the central base portion 37. Since the frame 36 is formed separately from the housing 21 and the coil 25 is wound around the winding core 24 of the winding frame 36, the winding operation of the coil 25 around the winding core 24 can be easily performed.

In this case, in the structure in which the coil is wound around the teeth protruding from the inner circumference of the stator core, or in the structure in which the coil is wound around the winding core protruding in advance inside the housing, the motor is If the inner diameter of the stator core or the housing is reduced in order to reduce the size, it becomes very difficult to wind the coil around the teeth or the winding core projecting inside the small stator core or the housing. . On the other hand, in the present embodiment, in order to downsize the motor, even if the housing 21 is formed to have a small diameter and the winding frame 36 is also formed to have a small diameter accordingly, the winding core 24 has the outer circumference of the central base portion 37. Since it is projected on the part, the coil 25
Can be easily wound.

In addition, a portion of the winding frame 36 that interferes with the arrangement of the rotor 28, that is, the central base 37 connecting the three winding cores 24 in this embodiment, connects the winding core 24 to the inner circumference of the housing 21. The three cores 24 are fixed to the housing 21 by the central base portion 37 while maintaining an angular interval of 120 ° accurately because they are fixed after being fixed to the portion and removed. Therefore, the work of disposing the three winding cores 24 at the housing 21 at predetermined regular angular intervals can be easily performed.

By the way, in order to facilitate the winding operation of the coil 25 and the disposition of the winding core 24 at the regular position as described above, the housing 21 and the winding frame 36 are mixed with the magnetic powder 23. You may form with the resin which is not. However, in the present embodiment, in particular, since the housing 21 and the winding frame 36 are made of the resin in which the magnetic powder 23 is mixed, the magnetic circuit is formed by the housing 21 and the winding core 24 as described above. Therefore, the housing 21
Further, as compared with the case where the winding frame 36 is formed of resin in which the magnetic powder 23 is not mixed, the motor current is not wastefully increased, and the motor efficiency can be improved.

FIGS. 6 and 7 show the second and third aspects of the present invention.
However, the coil 25 is not formed by winding a magnet wire around the winding core 24, but a separately formed coil is attached to the winding core 24. It is in the place where it has been configured.

That is, in the second embodiment shown in FIG. 6, a strip-shaped conductive foil, which is a sheet material made of an electric conductor, for example, a strip-shaped copper foil 3 is used.
Coil block 40 having a hole 40a to be fitted in winding core 24 in the center portion by stacking 9 on a strip-shaped insulating film (not shown) and winding it in a rectangular spiral shape.
To form Then, this coil block (coil material) 40 is thinly sliced as shown by a chain double-dashed line to obtain a slice coil 41.
It is configured to be fitted on the winding core 24 of No. 6.

In the third embodiment shown in FIG. 7, a film substrate 42 formed by attaching an electric conductor layer such as a copper foil to the surface of an electrically insulating sheet such as a thin resin sheet is prepared, and the copper foil of the film substrate 42 is prepared. Is etched to form a large number of unit coils 43. After that, the film substrate 42 is cut into each of the unit coils 43 as shown by a chain double-dashed line to obtain a large number of sheet coils 44, and a hole 44a fitted to the winding core 24 is formed at the center of each sheet coil 44. Is formed, and one or more of the sheet coils 44 are laminated and electrically connected to each other, and are fitted to the winding core 24 of the winding frame 36.

FIG. 8 shows a fourth embodiment of the present invention.
This is because the groove 46 of the housing 21 into which the winding core 24 is fitted is formed in, for example, a trapezoidal shape (a groove having a width) that is wider on the bottom side than on the opening side, and at the outer peripheral side end of the winding core 24. Is formed in a shape in which the tip is wide, for example, a trapezoidal shape. In this case, the trapezoidal portion of the winding core 24 is formed to be slightly larger than the groove 46. Then, the trapezoidal portion of the winding core 24 is softened by heating and fitted into the groove 46.

By thus forming the groove 46 and the outer peripheral side end of the winding core 24 fitted in the groove 46 in a trapezoidal shape, it is possible to prevent the winding core 24 from coming out of the groove 46.
In this case, the outer peripheral end of the winding core 24 does not necessarily have to be trapezoidal. The reason is that by heating and softening the outer peripheral side end of the winding core 24 and fitting it into the groove 46, the outer peripheral side end of the winding core 24 becomes a trapezoidal shape following the shape of the groove 46. is there.

FIG. 9 shows a fifth embodiment of the present invention.
This is because after the winding frame 36 is arranged in the housing 21, the central base portion 37 is formed to form a space for arranging the rotor 28.
When removing, the outer peripheral portion of the central base portion 37 is left in a cylindrical shape. If the tubular portion 37a as the holding portion is left in this manner, the three winding cores 24 remain connected to each other by the tubular portion 37a.
It is possible to prevent the swinging movement by being reinforced.

FIG. 10 shows a sixth embodiment of the present invention, which is arranged in the axial direction of the central base 37 when the central base 37 is removed after the winding frame 36 is arranged in the housing 21. A part, for example, the outer peripheral portion on one end side is left in a ring shape. By leaving the ring-shaped portion 37b in this way, the same effect as that of the ninth embodiment can be obtained, and the permanent magnet 30 of the rotor 28 is positioned at the portion where the central base portion 37 is completely removed. As a result, the diameter of the housing 21 can be reduced as compared with that in FIG.

The present invention is not limited to the embodiments described above and shown in the drawings, and the following expansions and modifications are possible. The shape of the central base portion 37 is not limited to the cylindrical shape, and may be a cylindrical shape. Further, when the central base portion 37 is formed in a tubular shape, the inner space is sized so as to accommodate the rotor 28, so that the central base portion 37 is disposed inside the housing 21, and then the central base portion 37 is formed as a space for disposing the rotor 28. Therefore, it does not have to be removed.

The winding core 24 and the housing 21 may be fixed by adhesion. In this case, if the outer peripheral side end of the winding core 24 is formed in a trapezoidal shape as shown in FIG.
Since the bonding area with the inner peripheral surface of the housing 21 is increased, it can be more firmly fixed.

The winding core 24 and the housing 21 may be fixed by melting one or both.

In order to secure a space for arranging the rotor 28, the process of removing a part of the winding frame 36 is not limited to cutting, but may be performed by melting with a heated mold, melting with laser light, or melting with chemicals. You can In order to secure a space for disposing the rotor 28, the inner peripheral side end of the winding core 24 may be removed.

The winding frame 36 may be formed of a magnetic material such as a silicon steel plate. By doing so, a sufficient magnetic circuit is formed, so that the motor efficiency is improved. Reel 36
The magnetic powder 23 may not be included, and the magnetic powder 23 may be formed of only resin. By doing so, the cogging torque can be reduced. The housing 21 may also be made of a magnetic material such as iron, or may be made of resin alone without the magnetic powder 23. The present invention can be applied to an inner rotor type generator.

[0042]

As described above, according to the present invention, in order to reduce the size of the inner rotor type motor as a whole, even if the coil and the housing are formed in a small size, the coil can be easily positioned in the regular position in the housing. Can be installed at Further, since the coil is wound around the winding core protruding to the outer circumference of the winding frame, the coil winding work can be easily performed even when the coil is formed by winding the magnet wire around the winding core. .

[Brief description of drawings]

FIG. 1 is a perspective view of essential parts showing a first embodiment of the present invention.

FIG. 2 is a perspective view showing a state after the central base portion of the reel has been removed.

FIG. 3 is a partial cross-sectional view.

FIG. 4 is an enlarged cross-sectional view showing a configuration of materials forming a housing and a reel.

FIG. 5 is a vertical sectional side view of an inner rotor type motor.

FIG. 6 shows a second embodiment of the present invention, and is a perspective view showing a procedure for manufacturing a slice coil.

FIG. 7 shows a third embodiment of the present invention and is a perspective view showing a manufacturing procedure of the sheet coil.

FIG. 8 is a partial view showing a fourth embodiment of the present invention.

FIG. 9 is a view corresponding to FIG. 2, showing a fifth embodiment of the present invention.

FIG. 10 is a view corresponding to FIG. 2 showing a sixth embodiment of the present invention.

11 is a view corresponding to FIG. 5 showing a conventional normal inner rotor type motor.

FIG. 12 is a view corresponding to FIG. 5 showing a conventional ultra-compact inner rotor type motor.

[Explanation of symbols]

In the figure, 21 is a housing, 22 is a groove, 23 is magnetic powder (fine magnetic material), 24 is a winding core, 25 is a coil, 27 is a stator, 28 is a rotor, 36 is a winding frame, 37 is a central base,
41 is a slice coil, 43 is a sheet coil, and 46 is a groove.

Claims (15)

[Claims] 1. A method for manufacturing a stator of an inner rotor type rotary electric machine, wherein a winding frame formed by projecting a plurality of winding cores on the outer periphery of a central base is formed, and a coil is wound around the winding core of the winding frame. After turning and arranging the reel inside the housing,
A method for manufacturing a stator of an inner rotor type rotary electric machine, comprising removing at least a part of a central base portion of the winding frame to form a space for arranging a rotor inside the coil. 2. A method of manufacturing a stator of an inner rotor type rotary electric machine, wherein a winding frame formed by projecting a plurality of winding cores on an outer periphery of a cylindrical central base portion in which a space for arranging a rotor is formed. Then, a coil is wound around the winding core of the winding frame to dispose the winding frame inside the housing. 3. The coil according to claim 1 or 2, wherein the coil is a slice coil formed by winding a sheet material made of an electric conductor and cutting the resin-molded coil material to a desired thickness. A method for manufacturing a stator of an inner rotor type rotary electric machine. 4. The method of manufacturing a stator for an inner rotor type rotary electric machine according to claim 1, wherein the coil is a sheet coil formed by etching an electric conductor layer attached to an electric insulating sheet. 5. The method of manufacturing a stator for an inner rotor type rotary electric machine according to claim 1, wherein the winding frame is made of a magnetic material. 6. The method of manufacturing a stator for an inner rotor type rotary electric machine according to claim 1, wherein the winding frame is made of non-magnetic resin. 7. The method of manufacturing a stator for an inner rotor type rotary electric machine according to claim 1 or 2, wherein the winding frame is formed of resin mixed with a fine magnetic material. 8. The method of manufacturing a stator for an inner rotor type rotary electric machine according to claim 1, wherein a groove into which the outer peripheral side end of the winding core is fitted is formed on the inner peripheral surface of the housing. 9. The method of manufacturing a stator for an inner rotor type rotary electric machine according to claim 8, wherein the groove on the inner peripheral surface of the housing is wider on the bottom side than on the opening side. 10. The method for manufacturing a stator of an inner rotor type rotary electric machine according to claim 1, wherein the outer peripheral end of the winding core is formed in a shape with a wider width at the tip. . 11. The method of manufacturing a stator for an inner rotor type rotary electric machine according to claim 1, wherein the housing and the core are fixed by melting or softening. 12. The method of manufacturing a stator for an inner rotor type rotary electric machine according to claim 1, wherein the housing and the winding core are fixed by adhesion. 13. The method for manufacturing a stator of an inner rotor type rotary electric machine according to claim 1, wherein at least a part of the central base portion of the winding frame is removed by melting. 14. The inner rotor type according to claim 1, wherein the central base of the winding frame is removed so that a holding portion for keeping the plurality of winding cores in a connected state without separating remains. A method for manufacturing a stator of a rotating electric machine. 15. The method of manufacturing a stator of an inner rotor type rotary electric machine according to claim 14, wherein the holding portion is present in a part of the winding core in the axial direction.