JPS6335151A - Manufacture of cored armature of inner rotor motor - Google Patents

Abstract

PURPOSE:To facilitate winding work, by winding an armature winding over winding insert slots of an armature core, and after fixing an armature cylindrical magnetic substance to its outside circumference, by enclosing resin containing magnetic powder into the winding insert slots. CONSTITUTION:An armature winding 21 is wound over a winding insert slot 20 formed by a winding salient pole 18 of an armature core 16. Then an armature cylindrical magnetic substance 24 with the diameter approximately agreed with the outside diameter of the armature core 16 is fixed to the outside circumference of the armature core 16. After that, the magnetic powder, resin containing magnetic powder, or resin 25-27 is enclosed into the winding insert slot 20.

Description

Detailed Description of the Invention (Industrial Application Field of the Invention) The present invention provides a DCC brushless motor for an inner rotor motor.
ta (also called AC nana-B-yu) and stepping e-
Regarding the method for manufacturing iron-core type armatures, according to the present invention, the iron-core type of the inner rotor motor can be formed very easily and inexpensively, and the cog-type armature with almost no cogging can be obtained. Things can be done.

By eliminating air gaps in the slot, the magnetic circuit performance ε
Not only is it possible to improve C, but it is also possible to suppress vibration ε of the armature winding. In particular, magnetic powder-containing resins, such as iron powder-containing resins, etc.
(:- If it is hardened and solidified, the above-mentioned effect ε can be further enhanced.

(Prior Art and its Problems) Although the iron core type six-wheel drive unit can obtain a larger torque than the coreless six-wheel drive unit, it has the disadvantage of causing large cogging.

A motor that generates such a large amount of cogging is not only unable to perform smooth servicing, but also has various disadvantages.

For this reason, the conventional iron core stacker C is formed by e-skewing the salient poles (cores) for the winding, or the DCC brushless motor C is magnetized by e-skewing the magnetic poles of the field magnet. In addition to employing the pinhole method ε, the restraint circuit E was constructed to be complicated and expensive, and twisted pairing was performed using electric circuit means. It is also cogging ε in the iron-centered product e-evening.
Not only is it difficult to eliminate, but also the steel core type [
- It was inexpensive and not easy to mass produce.

Such drawbacks occur regardless of whether the iron core type is an outer rotor type or an inner rotor type.

In addition, types of iron-core stacked motors include DCC brushless motors (AC nervous motors), stepping motors, etc., which have a salient pole for the winding, and the armature winding is attached to the salient pole for the winding. This includes any type of e-mail that is wrapped.

There are two types of iron core type rotors, one is an outer rotor type and the other is an inner rotor type, as shown in the above example.
In terms of performance, the inner rotor type is more desirable than the outer rotor type.

However, the inner rotor type iron core armature C is
Winding salient poles extending in the inward @η direction are formed on the inner periphery of the annular (cylindrical) stator yoke, and armature winding ε windings are formed in the slots between the winding salient poles. need to be equipped.

For example, as an inner rotor type DCC brushless type 1, there is one shown in FIG.

In this DCC brushless motor 1, reference numeral 2 denotes a stator armature C1 formed in an annular shape.A magnet rotor 4 as a rotor is rotatably supported in the same space B of the stator armature 2. The stator armature 2 is fixed to an e-ta casing 5 forming a stator e. The stator armature 2 has a large number of T-shaped winding salient poles 7ε extending inwardly formed on the inner circumference of the stator yoke 6 along the IRH direction. A winding insertion slot 8ε is formed between the winding salient poles 7.

This slot 8 has a narrow entrance for the winding and a wide interior. This is to obtain a large torque ε and to rotate the rotor (magnet rotor 4) six times in one night as smoothly as possible. Further, the armature winding 9 wound between the slots 8 is wound around two or more salient winding poles 7 in a loop. Accordingly, the DCC brushless motor 1'c of FIG. 1 is different from a motor in which the armature windings 9 overlap each other in the .eta. direction.

In order to obtain even smoother brushless windings, two or more of the Wa child windings 9 may be wound in one slot 8 in an overlapping manner. Such a stator [VA element 2] is fixed to the inner surface of a tubular-shaped muchita casing 5.

At the bottom of the inner surface of the e-ta casing 5, a printed WL board 10 having a printed power distribution pattern is fixedly installed. A position detection element 12 such as a Hall element or a Hall IC is disposed on the printed power distribution board 10, and is soldered to the power distribution pattern 11 for electrical connection. The lead wire 16 is connected to the printed power distribution pattern 11 of the printed wiring viewing board 10 by soldering, and is electrically connected.

In addition, the reference numeral 14 indicates that the terminal C115 of the armature winding 9 is the rotating shaft.

In this way, the conventional inner rotor type DCC brushless motor IC' has a stator yoke (1 is a vertical iron core).
Forming multiple salient winding poles 7e on the inner part of 6C
A slot 8ε for inserting a winding is formed, and an armature winding 96 is superimposed on the slot 8 to form a C stator armature 2ε.

Such a slotted iron core type DC Gracilless e-1 has the salient pole 7 for the winding, so it has the drawback that large cogging occurs as described above, and the inner rotor as shown in FIG. Type of iron core type DC Gracilless e
- For example 1C, it is necessary to wind 92 armature windings in the slot 8 from the direction 1η of the stator yoke 6, but this winding η
The drawback is that the process is very troublesome and does not lend itself to mass production. However, if such inner rotor type n-iron core DC brushless [-1] has a shorter diameter, or if you add one with a longer length in the direction opposite to the axis, Furthermore, the armature winding 96 is wound in slot 8.
There is a drawback that it is not suitable for mass production.

For this reason, in the case of a steel-core DC wireless e-type with a large inertia and good knaf resistance, a plurality of salient poles for the winding extending in the radially outward direction of the annular stator yoke should be formed.C slots for inserting the winding. An actor-rotor type iron-core DC brushless electric motor is used.

However, in order to obtain the iron core type DC Graciles e-ta 2 which can obtain large torque and has good low inertia C response, it is necessary to use the inner rotor type iron core type DC Graciles e-ta, which has a thick winding and is not good in CFI productivity. - There is no choice but to adopt 2.

[To briefly explain, in a conventional inch-rotor type FF iron core armature, the slot and rotor (e.g., magnet rotor) face each other with a radial gap in between, and cannot rotate. The influence of mutual attraction is clearly visible. In other words, this becomes a big problem when there is cogging C and you try to rotate the e-ta at low speed C.

The conventional η method to solve this problem is as follows:
The η method has been adopted in which the magnetic poles of the slot or magnet rotor are skewed by the ε force to soften the attraction.

However, with the above U method, machining and assembly are sometimes time-consuming, and the cogging force depends on the skew angle, which not only makes it impossible to achieve complete cogging E1m, but also causes a decrease in torque. .

Also, if you are using an inner rotary motor with slots facing inward on the stator yoke, it will be a little harder to wind the wire 6 times around the slots! Items that are not suitable for mass production.

Furthermore, the conventional slot type e-tater C requires insulation measures and an armature coil holder, that is, a winding frame (F-bin), which has the drawback that it cannot be mass-produced at low cost.

(Problem of the present invention) The present invention mainly solves the problem of cogging rx<s? ! ! It is extremely easy to wind the winding into the winding insertion slot of the machine winding.
Inner rotor type iron core type armature winding can be mass-produced at low cost, insulation measures ε can be easily installed, and winding frame ε is not required. If you are given the task of manufacturing method El), there is 7) c.

(Means for Achieving the Object of the Invention) The object of the present invention is to integrally form two or more salient winding poles protruding in the radially outward H direction on the outer periphery of a cylindrical body made of a magnetic material. An armature core ε is formed with a winding insertion slot formed between the poles, and two windings of the armature winding are placed in the winding insertion slot formed by the above-mentioned salient poles for the convex wire of the armature core. An electric cylindrical magnetic body ε having an inner diameter approximately equal to the outer diameter of the armature core is fixed to the outside of the armature core, and magnetic powder is applied to the winding insertion slot, or magnetic powder-containing resin or magnetic powder is applied to the winding insertion slot. Encapsulating the resin C is accomplished.

Other means for achieving the objects of the present invention will become clear in the following description.

(Effects of the Invention) According to the present invention, (1) Since the rotor, for example, the magnet rotor, has a rotorless structure on the a#c core type armature surface, large cozening, which is a problem at low speeds, does not occur. In other words, it is necessary to obtain an inner rotor e-rotor with a slotless structure and good C5 performance.

(2) In the process of forming the iron core armature, the slot for inserting the winding of the armature core becomes an open type on the outside, so the armature winding can be easily wound in the slot of the iron core type. The armature can be easily and inexpensively mass-produced. (3
) The radial gap between the C1 rotor and the iron-core armature (stator armature j) where it is possible to carry out grinding or other processing ε in the inner diameter η direction of the inner surface ε of the cylindrical magnetic body in the same part of the armature core. It is possible to obtain a large torque with C1 of length 6, which can be turned to the minimum. (4
) Seed iron core ε is formed by integrally forming a plurality of salient poles e for winding protruding outwardly and radially outward of the magnetic cylinder to form slots 8 for inserting the winding between the salient poles for winding; The cylindrical magnetic body e is fixed to the outside of the armature core with the armature winding ε wound. Not only does the armature winding holding member become unnecessary, but the shape of the salient pole for the winding of the armature core becomes simpler, and the machining of the salient pole for the winding becomes easier. Iron core type armatures can be mass-produced easily and inexpensively. When (5) is integrally formed with a seed core made of a mixture of magnetic material and resin, for example, a mixture of resin containing iron powder,
Since the hysteresis loss and eddy current loss are small, and there is no cozening loss as described above, it is possible to obtain an iron core type inner rotor motor with good performance. (6) In addition, when forming iron powder-containing resin C'g1 machine iron seeds as described above, processing of this inner cylindrical magnetic material is extremely easy. C can be further improved. (7) Forming a salient pole for the winding of the armature core oriented in the diameter H direction, and forming an outward cylindrical magnetic body of the armature core oriented in the q direction. Magnetic circuit configuration for desirably passing the magnetic flux E. It is possible to obtain a large torque ε of C1. (8) In addition, if the winding insertion slot of the iron core type 1JLF11 child is coated with magnetic powder or filled with iron powder ε containing magnetic powder and solidified, a winding frame (bobbin) for suppressing the vibration e of the armature winding can be formed. There is an effect that the iron core type armature can be mass-produced in a safe field. (9) In addition, by filling the slot for inserting the winding with magnetic powder or magnetic powder-containing resin ε, the gap ε of the slot can be completely eliminated by C% magnetic saturation f: a desirable magnetic circuit configuration. It is possible to obtain a cored armature ε of C. (10) If the winding insertion slot is filled with magnetic powder-containing resin or resin T, not only can the winding frame E be eliminated as described above, but it can also serve as an insulation measure.

αυ Due to the above effects (1) to 00), it is possible to achieve high precision, low cost and easy mass production.

(Embodiment of the invention) In addition, in the embodiment C shown below, salient poles for winding (
Although an example ε is shown in which the number of winding insertion slots is small, in reality, the present invention functions more effectively as the number of slots increases.

In addition, in Example C shown below, one armature winding has six windings on one winding salient pole, but two armature windings may be wound across multiple slots. I'll tell you what, there's no C.

Hereinafter, with reference to FIGS. 2A and 2B, a method for manufacturing a core type armature for an inner rotary vehicle as an embodiment of the present invention will be described.

First, in the present invention C, an armature core 162 made of a magnetic material as shown in FIG. 2 is integrally formed.

This armature core 16 has a cylindrical magnetic body 17ε inside it,
A magnetic body cC extending in the radial direction on the outer circumference of this cylindrical magnetic body 17
A plurality of salient winding poles 18, four in FIG. 2C, are integrally formed with the two cylindrical magnetic bodies 17. In this armature core 16, the cylindrical magnetic body 17 in the inward portion is connected between the salient poles 18 for each winding, so it becomes a coin press 7) armature core 16 as described later, but the performance e. In order to increase the magnetic short-circuit ε caused by the cylindrical magnetic body 11 between the adjacent winding salient poles 8, it is necessary to make it as thin as possible (optimally). For this purpose, it is necessary to make the radial thickness of the cylindrical magnetic body 17 extremely thin.

For this reason, the cylindrical magnetic body 17 has a radial thickness of el mm (1 mm is the allowable range C1, which is actually 1 mm).
There are some cases where the thickness is less than or equal to that, but in this case, there is something that can be processed to make it optimal. Also, the thickness e is thinner T
In practice, the thickness of the cylindrical magnetic material is desirably 1 mm or less, but it may be 1 mm or more (1 mm or less) or less. .

Further, it is desirable that the armature core 16, especially the winding salient poles 18, be oriented in the viewing direction so that the magnetic path passes in a desired direction. In this case, the portion of the cylindrical magnetic body 17 of the armature core 16 other than the winding salient pole 18 portion e (horizontal 11iZ) does not need to be oriented in the radial plane, but since this portion is very thin, There is no problem even if the armature core 16E is formed to have a diameter or plane orientation.

1! When the machine core 16 is formed of laminated steel plates,
When integrally forming the cylindrical magnetic body 17 and the winding salient pole 18f, it is easy to form them by laminating and fixing a large number of them in the direction of the laminated steel plate E41 extending in the radial direction. In addition, if the armature core 16ε laminated steel plate C is not integrally formed, (1)
! (2) The H method, in which a mixture C of at least a magnetic material and a resin is integrally formed, such as the iron powder-containing resin C radially oriented. It is very convenient to form the armature core 168 by using the H method, such as by using a plastic %-t lead means to form the armature core 168 integrally. In this way, according to the η method of forming the C armature core 16E without using laminated steel plates ε, the processing of the cylindrical magnetic body 17 is extremely easy. becomes very easy. As a result, lfi, child and cylindrical magnetic body 1
When the radial gap length E between the inner rotor and the inner rotor is kept to a minimum, the inner rotor tie can be configured with an iron-core type e-coupler that can handle a large torque ε even at low speeds.

In addition, an example of a mixture of armature core 16E magnetic material and resin,
In the case of an integrally formed sheet made of resin containing iron powder,
The hysteresis loss and eddy current loss are small, and the presence of the cylindrical magnetic body 17 makes it a coin press. Therefore, it is possible to obtain a core type armature for an inner rotor e-tor with good performance. Child core 16ε magnetic powder-filled resin C
When integrally formed, method C such as two-color molding method will be described later. The surface on which the iEn child winding is wound, for example, the cylindrical magnetic body 17
By forming the outer Q part and the surface part ε of the winding salient pole 18 (to be described later) from resin, it is possible to provide insulation measures ε to the inner surface of the winding insertion slot 20 (to be described later). If Efa-containing resin C is not formed on the armature core 16, it is necessary to insulate the armature core 16 by applying a non-conductive paint e to the portion that comes into contact with the armature winding.

Incidentally, although the present invention C has the feature that the winding frame can be made unnecessary, this does not mean that the winding frame e must not be used. Note that if a non-conductive winding frame is used, the above-mentioned insulation treatment measures are not required. However, this embodiment C shows the case where the winding frame ε is not used.

In FIG. 2, reference numeral 19 denotes an inward space S, and by housing the rotor ε rotatably in this space 19, an inner rotary shaft is formed.

Reference numeral 20 indicates the winding insertion slot C1.
The electric winding (Naruko winding) described later is stored.

As is clear from FIG. 2, the armature core 16 of the present invention has an open outer cap type winding insertion slot 20ε formed in which the armature winding ε can be easily stored. C Become something that can be done.

First, after forming the armature core 16ε of the outside q open type as shown in FIG. It is inserted into the winding salient pole 18 from the outer diameter H direction and fixed.

Note that the salient pole 18 for the N and A child windings 21E windings is wound in a cylindrical shape.
If it is not inserted into the winder, use an appropriate winding machine to directly
C armature winding 21 to be wound around salient pole 18 for 6 windings of conducting wire
It is preferable to fix the windings to the salient poles 18 for eight windings.

As shown in FIG. 3 above, the armature winding 216 is wound around the winding salient pole 18 C1, thereby completing the second step of the manufacturing method of the present invention.

After forming as shown in Figure 3, it is necessary to prevent the armature winding 21 from escaping and close the magnetic circuit.
1 As shown in FIG. 4, a cylindrical magnetic body 23ε is fixed to the outside of the winding salient pole 18 by suitable means C.

Note that it is desirable that the inner surface of the cylindrical magnetic body 26 be subjected to insulation treatment.

When this cylindrical magnetic body 26 also serves as a heater casing, it becomes unnecessary to use a rJi machine seed presser, for example, a winding frame.

Further, the cylindrical magnetic body 26 is desirably oriented in the circumferential direction in order to obtain a magnetic circuit configuration in which the magnetic flux ε is desirably ffl.

In this way, by fixing the cylindrical magnetic body 26ε to the outside of the armature core 16 provided with the armature winding 21ε shown in FIG. 3, an iron-core type armature 24e as shown in FIG. 4 can be formed.

This is the third process C1 of the manufacturing method of the present invention.This third process may be performed before or after the fourth process described later. In addition, if the cylindrical magnetic body 17 is very thick in the radial direction,
Will the cylindrical magnetic body 17 cause a short circuit between the salient poles 18? ? In this case, it is desirable to process the inner circumference 6 of the cylindrical magnetic body 17 as shown in FIG. 5 so that the thickness in the radial direction H becomes thinner.

This process in the present invention, including the above or the fourth process E to be described later, is preferably adopted in an appropriate process in the main process of the manufacturing method of the present invention C.
be.

Next, the fourth step of the manufacturing method U of the present invention will be explained. In this fourth process C, the armature winding 212 is firmly held on the winding salient pole 18, and the armature winding 21F is held firmly on the slot 20 of the armature core 16 held on the armature winding 21F as shown in FIG. 4
The resin 25, iron powder 27, or iron powder-containing resin 26 is being filled into the slot 20 of the iron-core armature 24 shown in the figure.

When the resin 25 or the iron powder-containing resin 26ε is to be sealed in the slot 20, it is sufficient that the molten resin 25 or 26ε is injected into the slot 20 and then solidified. J125.
When the cylindrical magnetic body 23 is sealed in the 26ε slot 20 by e-hardening, etc., there is an advantage that no insulation treatment is required on the inward surface of the cylindrical magnetic body 23, and the armature winding 16 of the slot 20
It is also possible to omit insulation treatment on the surface in contact with the surface. In addition, when injecting the magnetic powder-containing resin 26f into the slot 20,
Since there is an advantage that the cylindrical magnetic body 23ε can also be integrally formed with an e-rud C at the same time, there is an advantage that the armature core 168 can be mass-produced at low cost. Furthermore, magnetic powder-containing resin 26
Or when enclosing the magnetic powder 27e1 into the slot 20,
1! In addition to preventing the rotation of the rotor winding 21, there is no air gap in the slot 20, so magnetic saturation can be prevented, and the magnetic path 2 can be rationally closed.This is a desirable magnetic circuit. The composition is C. In addition, when the Q-type material 27ε is to be enclosed in the slot 20, it is desirable that the -H open end ε of the slot 20 in the axial direction is closed in advance by an appropriate means C, and the opening end ε of the slot 20 is closed in the axial direction.

Particularly, when the iron powder-containing resin 26f is applied to the slot 20 in the succeeding position, the magnetic path can be further closed rationally, which is desirable.

[Brief explanation of drawings]

Figure 1 shows the conventional D inner rotor type iron core armature 2.
Explanatory diagram of developing DCC buteneless, Figures 2 to 6
The figure is an explanatory diagram of the manufacturing method of the present invention, Figure 2 is an explanatory diagram of the armature core, and Figure 3 is a case in which the armature winding is attached to the salient pole for the winding of the armature core in Figure 2. FIG. 4 is an explanatory diagram of the manufacturing method of the iron core type armature of the present invention. FIG. 5 is an explanatory diagram of the case where the iron core type electric seed ε of FIG. 4 is further processed. There is an explanatory diagram C of the η method in which resin or iron powder-containing resin is inserted into the winding slots of the iron-core armature. (Explanation of symbols) 1...DCC brushless motor, 2...Stator armature, 3...Inner subspace section, 4...Magnet rotor, 5...E-ta casing, 6...
・Stator yoke, 7... Salient pole for winding, 8...
- Winding insertion slot, 9...'ir: L armature winding, 10... Printed power distribution board, 11... Printed power distribution pattern, 12°゛. Position detection element, 16...Lead wire, 14...
・Terminal, 15... Rotating shaft, 16... Armature core,
17... Cylindrical magnetic body, 18... Salient pole for winding, 19... Inner peripheral space, 20... Slot for winding insertion, 21... Armature winding, 23... Cylindrical magnetic material, 24...K iron core armature, 25...Resin, 26...Resin containing iron powder, 27...Magnetic powder.

Claims (7)

[Claims] (1) An armature core in which a plurality of salient winding poles protruding radially outward are integrally formed on the outer periphery of a cylindrical body made of a magnetic material, thereby forming slots for winding insertion between the salient winding poles. and winding an armature winding in a winding insertion slot formed by the winding salient poles of the armature core, so that the outer periphery of the armature core substantially coincides with the outer periphery of the armature core. A method for manufacturing an iron core type armature for an inner rotor motor, wherein an armature cylindrical magnetic body having an inner diameter of (2) The inner rotor motor according to claim (1), wherein the cylindrical body and the winding salient poles integrally formed on the outer periphery are formed by laminating a large number of laminated steel plates extending in the radial direction in the axial direction. A method of manufacturing a iron-core armature. (3) The cylindrical body and the salient pole for winding integrally formed on the outer periphery of the cylindrical body are integrally formed from a magnetic material in a radial direction by means such as centrifugal casting, as described in claim (1). A method for manufacturing a cored armature for an inner rotor motor. (4) The method for manufacturing an iron-core armature for an inner rotor motor according to claim (1), wherein the armature core is integrally formed of a mixture of at least a magnetic material and a resin. (5) The armature winding according to any one of claims (1) to (4), wherein the armature winding is wound around one or more of the winding salient poles. A method of manufacturing a cored armature of the inner rotor motor described above. (6) The cylindrical body having the salient pole for winding on the outer periphery is formed so that its inner diameter has a thickness of 1 mm or less in the radial direction. ) A method for manufacturing a cored armature of an inner rotor motor according to any one of the above items. (7) In the above-mentioned iron core type armature, the inner cylindrical body having salient winding poles on the outer periphery has a thickness of 1 mm or less in the inner radial direction by processing the inner periphery. Become,
A method for manufacturing a cored armature of an inner rotor motor according to claim (6).