KR100845850B1 - Motor - Google Patents

Abstract

The present invention relates to a motor, and more particularly, to a motor that reduces manufacturing costs and improves manufacturing and reliability.

According to the present invention, a stator having a stator core and an insulator provided in the stator core and wound around a coil; A rotor rotatably provided with respect to the stator; It includes a tab terminal provided in the insulator is positioned the end of the coil, the coil provides a motor comprising a core wire made of aluminum.

Motor, Aluminum, Core, Tap Terminal

Description

Motor

1 is an exploded perspective view showing a stator of a motor according to the present invention;

2 is a perspective view of a rotor of a motor according to the present invention;

3 is an exploded perspective view of the tab terminal and the magmate;

4 is a perspective view of the mating tab terminal, coil, and magmate;

FIG. 5 is a schematic diagram schematically showing the coupling of the coil and magmate shown in FIG. 4; FIG.

6 is a schematic diagram schematically illustrating a state in which an insulation part is included in a coupling portion of the coil and the magmate illustrated in FIG. 4;

7 is a perspective view showing an embodiment of the insulator according to the present invention;

8 is a perspective view of a tab terminal cover according to the present invention;

9 is a perspective view showing another embodiment of the insulator according to the present invention;

10 is a partial plan view showing one embodiment of the coil rolling prevention structure according to the present invention;

11 is a partial plan view showing another embodiment of the coil rolling prevention structure according to the present invention;

12 is a cross-sectional view taken along line II of FIG. 1.

<Explanation of symbols for the main parts of the drawings>

100: stator 110: stator core

120: upper insulator 128: tap terminal for power connection

129: neutral tap terminal 130: lower insulator

150: Magmate 160: Coil

170, 270: resin 180: tab terminal cover

121, 131: winding section

The present invention relates to a motor, and more particularly, to a motor that reduces manufacturing costs and improves manufacturing and reliability.

The motor according to the present invention may be a motor applied to a washing machine, but the application example is not limited thereto.

In general, the motor transmits the rotational force of the rotor to the rotary shaft, the rotary shaft drives the load. For example, the rotating shaft may be connected to the drum of the washing machine to drive the drum, and may be connected to the fan of the refrigerator to drive the fan so that cold air is supplied to the required space.

On the other hand, in such a motor, the rotor is rotated by electromagnetic interaction with the stator. To this end, a coil is wound around the stator, and as the current is applied to the coil, the rotor rotates with respect to the stator.

The coil is generally formed of a copper material. This is because the copper material has excellent electrical conductivity and excellent ductility, so that the damage of the winding is small.

However, the copper material generally has a very high cost and accordingly a manufacturing cost of the motor increases. In addition, international demand for copper has soared, preventing stable supply of raw materials.

Therefore, it is necessary to reduce the manufacturing cost of the motor by using a coil of a material other than the copper coil and to ensure a stable supply and demand of raw materials. In addition, it is necessary to manufacture a motor of at least equivalent quality than using a copper coil, even if a coil of another material is used.

On the other hand, when replacing a coil of copper material with a coil of another material, it is preferable not to greatly change the conventional configuration. This is because, even if the cost of the coil itself is reduced, initial capital investment costs may be excessively increased if other necessary components must be newly designed and manufactured.

The present invention basically aims to solve the above problems.

More specifically, an object of the present invention is to reduce the cost of the coil to reduce the overall manufacturing cost of the motor.

In addition, an object of the present invention is to provide a motor that reduces the manufacturing cost of the motor, but is easy to manufacture and improved reliability and product durability.

In addition, it is an object of the present invention to provide a motor having a quality equal to or greater than that of a conventional motor without significantly changing the conventional essential components.

In order to achieve the above object, the present invention, a stator core and a stator having an insulator provided in the stator core is wound coil; A rotor rotatably provided with respect to the stator; It includes a tab terminal provided in the insulator is positioned the end of the coil, the coil provides a motor comprising a core wire made of aluminum.

Here, the tap terminal may be a tap terminal for power connection. In the power terminal tap terminal, two or three coil ends may be located at the tap terminal for power connection, depending on the type of power applied. The tab terminal may be integrally formed with the insulator.

The tap terminal may also be a neutral tap terminal. That is, when the coils are wound to have u, v, and w phases, respectively, the coil ends of the u, v, and w phases are electrically connected to each other to form a neutral point, which may be formed through the tab terminal. have. Thus, three coil ends are located at the neutral tap terminal.

On the other hand, the end of the coil may be fixed to the tab terminal through a magmate inserted into the tab terminal. The end of the coil may be electrically connected to the magmate while the magmate is inserted into the tab terminal.

The coil includes an aluminum core wire, and a coating film for insulation is formed outside the core wire. On the other hand, the coating film serves to reinforce the ductility of the aluminum core as well as insulation. That is, without such a coating film, the aluminum core wire can be easily broken even by a small external force.

Therefore, the coating film is preferably a double coating film for the necessary insulation function and ductile reinforcement.

Meanwhile, a magmate formed of a conductive material is inserted into the tab terminal. The end of the coil is connected to a power source through the magmate, or a neutral point is formed.

In the present invention, the coating film is removed so that the core end of the coil is first exposed to the core terminal, and then the magmate is inserted to electrically connect the end of the coil and the magmate.

In addition, in the present invention, the end of the coil is positioned in the tab terminal in the state where the coating film is not removed, and then the coating film is removed by inserting the magmate to electrically connect the end of the coil and the magmate. In this case, a slot corresponding to the core outer diameter of the coil end is formed in the magmate so that the coating film is removed as the end of the coil is inserted into the slot.

In the present invention may be formed on one side of the tab terminal further comprises a strength reinforcement for reinforcing the strength of the tab terminal. Here, the strength reinforcement may be integrally formed with the tab terminal, and likewise, the strength reinforcement may also be integrally formed with the insulator.

Here, the strength reinforcement may perform a function of reinforcing the strength of the coil terminal as well as the strength of the tab terminal. That is, the end of the coil may be inserted into the tab terminal after being inserted into the strength reinforcing portion. Therefore, the coil located in the strength reinforcing portion is in a state where the core wire is not exposed. Therefore, when an external impact is applied, the impact or external force is first transmitted to the strength reinforcing portion, thereby minimizing the impact transmitted to the core portion.

On the other hand, in the present invention, it is preferable that the insulating portion for electrically insulating the end of the coil exposed core wire from the outside is formed. In addition, the insulation is preferably configured to reinforce the strength of the end of the coil as well as insulation. This is because the exposed core wire is made of aluminum, so that the core wire may be easily disconnected by external impact.

In addition, aluminum materials are generally vulnerable to water, in particular brine. That is, a problem may arise in that the brine contacts the aluminum core wire so that the end of the coil is easily corroded. Since the insulation may be easily disconnected due to such corrosion, it is preferable that the insulation part also performs a function of blocking water, especially salt water, from contacting the core wire.

As an example of the insulator, the insulator may be a resin to be applied. That is, after the ends of the magmate and the coil are coupled to the tab terminal, a resin material may be applied to the tab terminal. Since the resin material is applied not only to the coupling portion of the magmate and the coil, but also to the outside of the exposed core wire, it is possible to secure insulation and strength reinforcement functions.

On the other hand, the strength reinforcement is preferably formed with a pocket. That is, a predetermined space is formed through the pocket. Thus, the end of the coil is fixed to the tab terminal across the pocket.

Here, the pocket and the tab terminal inside are preferably in communication with each other. Therefore, even if the resin material applied to the tab terminal overflows, it overflows into the pocket. Therefore, the resin is also applied to the pocket. Therefore, it is possible to reinforce the end strength of the coil double through this resin. In addition, since there is an advantage that the resin can be applied in a fixed amount through such a pocket, it is possible to automatically apply the resin to simplify the production process.

In order to achieve the above object, the present invention also provides a coil wound on the stator core including an aluminum core wire, an insulator for maintaining insulation between the stator core and the coil; A tab terminal provided in the insulator and at which an end of the coil is located; A magmate inserted into the tab terminal and exposed to the core wire of the coil to be electrically connected to the coil and fixing the coil to the tap terminal; And it provides a motor comprising an insulating portion formed in the core wire exposed portion of the coil.

Here, the insulating portion is preferably formed in the magmate exposed to the outside.

In order to achieve the above object, the present invention also includes a stator having a stator core and an insulator provided on the stator core to which a coil is wound; A permanent magnet provided inside and rotatably provided outside of the stator; And a tab terminal provided at the insulator and positioned at an end of the coil, and the end of the coil is fixed to the tap terminal to expose an aluminum core wire, and thereafter, to prevent corrosion and strength reinforcement of the end of the coil. In order to provide a motor having an insulation part in the tab terminal.

Meanwhile, according to the present invention, a tab terminal cover may be provided as another example of the insulating part. Of course, the insulating part may include the above-described resin material and the tab terminal cover.

The tab terminal cover is formed of an insulating material to perform a function of isolating the tab terminal from the outside. That is, the tab terminal cover may prevent corrosion of the core wire exposed portion and reinforce the strength of the coil end. That is, it is possible to prevent the external shock is directly transmitted to the core wire through the tab terminal cover. In addition, insulation of the core wire may be maintained through the tab terminal cover.

Such a tab terminal cover can be inserted from above the tab terminal to receive the tab terminal. Therefore, the above-mentioned resin application can be deleted through the tab terminal cover. Of course, by inserting the tab terminal cover after the resin coating, the insulation of the core wires, corrosion protection, and strength reinforcement may be doubled.

Meanwhile, the tab terminal may be integrally formed with the above-described magmate. That is, the magmate may be inserted into the tab terminal to be electrically connected to the end of the coil and simultaneously inserted into the tab terminal to accommodate the tab terminal cover.

Such a tab terminal and a magmate may be integrally formed when the tab terminal of the insulating material is injected and formed to insert a magmate of a conductive material.

Therefore, according to the present embodiment, it is possible to provide a more reliable motor while at the same time simplifying the process by preventing corrosion of the core wire and reinforcing strength by the tab terminal cover at the same time as the insertion of the magnet.

In addition, the present invention further comprises a coil rolling prevention structure for preventing winding failure of the coil.

The coil rolling prevention structure is preferably formed in the winding portion of the coil of the insulator is wound. Through the coil rolling prevention structure, the coil is wound while being self-aligned and fixed, thereby minimizing winding failure caused by the coil being pushed.

In addition, the winding portion is preferably formed with a coil support for supporting the coil so that the coil is gently wound while forming an arc.

The coil support is preferably formed on the upper surface of the winding of the upper insulator and the lower surface of the winding of the lower insulator.

The coil rolling prevention structure and the coil support are particularly preferable in a motor to which a coil including a core wire made of aluminum is applied. This is because there is a possibility that the core wire made of aluminum may be easily damaged by an abrupt change in shape and an external impact.

Hereinafter, with reference to the accompanying drawings will be described in detail with respect to the present invention. The accompanying drawings show a motor for a washing machine. However, the present invention is not necessarily limited to the motor for a washing machine.

First, the motor structure according to the present invention will be described in detail with reference to FIGS. 1 and 2.

1 is an exploded perspective view of a stator of a motor according to the present invention.

The stator 100 includes a stator core 110, an upper insulator 120, and a lower insulator 130.

The stator core 110 includes an annular back yoke 111 and a tooth 112 protruding radially outward along an outer circumference of the back yoke. FIG. 1 illustrates a stator of an outer rotor type motor which is provided with a rotor described later outside the stator core 110 and rotates. Accordingly, the teeth 112 may protrude radially inward along the inner circumference of the back yoke. In this case, the stator will be the stator of the inner rotor type motor.

On the other hand, the stator core 110 may be formed by laminating a steel sheet. However, in the case of using such a method, the steel sheet fragments, etc., generated in a circular shape inside are not necessary, and there is much room for waste of materials. Therefore, the strip-shaped yoke and the teeth vertically protruding from the back yoke are preferably bent and spirally stacked to form a spiral core. This spiral core form is shown in FIG. 1.

In addition, the stacked annular back yoke 111 is formed with a caulking portion 113 such that each layer is coupled to each other to form a stator core integrally.

A coil (not shown) is wound around the tooth 112. However, since the tooth is generally a conductor material, an insulator for insulation is generally provided between the tooth and the coil. Therefore, in the present invention, the insulators 120 and 130 are provided on the upper and lower portions of the stator core 110, respectively. That is, the upper insulator 120 and the lower insulator 130 are combined with the stator core 110 to surround the stator core. At this time, a coil is wound around the windings 121 and 131 surrounding the teeth 112.

However, unlike FIG. 1, the insulators 120 and 130 may be integrally formed with the stator core 110. For example, it is possible that the stator core is insert injection molded and formed integrally with the insulator.

Meanwhile, fastening bosses 125 and 135 protruding in the radial direction are formed inside the insulators 120 and 130, and the stator 100 is positioned on the rear wall surface of the tub of the drum washing machine (not shown). Fastening holes 126 and 136 are formed to be fixed. Of course, the fastening bosses 125 and 135 may not necessarily be configured to be fixed to the tub, and may be fixedly coupled to a bracket (not shown) or a motor housing (not shown) forming the outer shape of the motor according to the application example. It may be a configuration for.

That is, the fastening hole 126 of the upper insulator and the fastening hole 136 of the lower insulator correspond to each other when the upper insulator, the stator core, and the lower insulator are combined to form one fastening hole. The entire stator is fixed to the tub or the like through a bolt (not shown) in the fastening hole.

In addition, a positioning protrusion 127 may be formed near the fastening hole 126 of the upper insulator. That is, the positioning protrusion may be first inserted into a groove (not shown) formed in a tub or the like to determine the position of the stator 100, and then the stator 100 may be fixed by using the above-described bolt.

Meanwhile, a coil corresponding to each of u, v, and w phases may be wound in the stator illustrated in FIG. 1. One coil may be wound around one tooth such that one tooth has one magnetic pole. This is called the concentration zone. The more stator stimulation, the lower the maximum rotation speed of the rotor. Therefore, it is easy to control the motor, and the maximum torque can also be relatively large.

First, when the winding of the u-phase coil is terminated in one tooth, the coil is wound around the coil winding ribs 122 formed in the upper insulator and fixed, and then wound again in the next tooth after crossing two neighboring teeth. The start and end of this coil are located at the tap terminal 128 and the neutral tap terminal 129 for power connection, respectively.

Here, the connector 140 is coupled to the tap terminal for power connection, and power of three phases is applied to the coils of each of u, v, and w phases. In addition, the ends of the coils of each phase are all electrically connected to each other at the neutral point terminal terminal 129 to form a neutral point.

Here, the tab terminals 128 and 129 are formed of an insulating material, preferably, integrally with the insulator.

Meanwhile, the hall sensor assembly 141 is fixed to one side of the tap terminal, that is, the tap terminal 128 for power connection and the neutral tap terminal. Through the Hall sensor assembly, the rotation speed and torque of the rotor can be controlled by sensing the position and / or speed of the rotor to be described later and adjusting the phase and current strength of the applied voltage.

Insulator ribs 123 are formed in the radially inner side of the coil winding rib 122 along the circumferential direction. Of course, such insulator ribs 123 are formed in the lower insulator as well as the upper insulator. The insulator rib 123 is formed to a predetermined height or more to perform a function of blocking the flow of moisture inside the insulator to the windings 121 and 131.

In addition, the insulator rib 123 is preferably formed to be higher than the height of the coil winding. This is because the coil may be damaged when the stator 100 is handled or the like. That is, when placed on the floor, only the insulator rib 123 is in contact with the floor, and the coil is not in contact with the floor, thereby preventing damage to the coil in advance.

Figure 2 is a perspective view of the rotor of the motor according to the present invention.

The rotor 200 according to the present invention includes a rotor frame 210 and a permanent magnet 216.

The rotor frame 210 includes a base 212 and side wall portions 211 formed on the outer side of the base, which may be formed by pressing a single iron plate. Here, a plurality of permanent magnets are provided inside the sidewall portion along the circumferential direction. These permanent magnets are magnetized to the north pole and the south pole alternately along the circumferential direction.

The side wall portion 211 performs a back yoke function of forming a magnetic path.

Of course, the rotor frame described above may be formed by injection, in which case the annular magnetic back yoke should be provided separately.

In addition, the center portion of the base 212 is formed with a hub portion 213 protruded upward for rigid reinforcement of the base. The hub portion 213 has a through hole 219 is formed in the center, the rotation axis (not shown), for example, the rotation axis of the washing machine is located. In addition, the rotation shaft and the hub portion 213 are connected to each other using a connector, not shown. Therefore, as the rotor is rotated, the rotational force of the rotor is transmitted to the rotating shaft.

In addition, the hub portion 213 may be provided with a coupling hole 214 for coupling the aforementioned connector, or a positioning groove 215 for determining the position of the connector first.

The rotor 200 accommodates the stator 100 therein, and rotates with respect to the stator 100 through the interaction of the stator 100. Of course, the rotational force of the rotor is coupled to the rotor frame 210 to be transmitted to a rotating shaft (not shown) to rotate integrally.

In the present invention, it is characterized by using a coil made of an aluminum core wire instead of a conventional copper coil. Aluminum has a higher internal resistance than copper. Therefore, in order to reduce such internal resistance, the outer diameter needs to be increased as compared with the conventional copper coil.

In addition, the aluminum material is weaker than the copper material. Therefore, there is a fear that the wire is easily disconnected by an external impact during winding. In addition, the aluminum material is susceptible to water, in particular, brine, so there is a high risk of being easily corroded and disconnected when it comes in contact with the brine.

Therefore, in the motor according to the present invention, the aluminum coil is preferably formed with a double coating film formed outside the core wire of the aluminum material to reinforce strength and ductility. In addition, it is possible to further increase the reliability of the insulation of the coil through the double coating film.

Meanwhile, as described above, the end of the coil is positioned at the tab terminal. In order to electrically connect the ends of the coils, the coating layer must be removed to expose the core wires to the outside. Therefore, as described above, the end portion of the coil to which the core wire is exposed is weak in strength and ductility, and thus may be easily disconnected. In addition, there is a problem that can be easily corroded when in contact with water, especially brine.

Therefore, the present invention is characterized in that it comprises an insulating portion for strength reinforcement, corrosion protection and insulation of the end portion of the coil. Such an insulation part may be formed in various ways, and the insulation part will be described in detail with reference to FIGS. 3 to 9.

3 is an exploded perspective view of a tab terminal and a magmate inserted into the tab terminal, and FIG. 4 is a perspective view illustrating a state in which an end of a coil is positioned at the tab terminal and electrically connected to the tab terminal.

The tap terminal may be a tap terminal 128 for power connection or a neutral tap terminal 129. However, only the neutral tap terminal is described for convenience of description, and the same may be applied to the tap terminal for power connection.

As shown in FIGS. 3 and 4, the tab terminal is formed with a space 161 into which the magmate 150 can be inserted. In addition, the slit 162 is formed at the front and the rear of the space, respectively, so that the end of the coil is caught on the slit 162 of both sides. On the other hand, it is preferable that the chamfer 163 or round is formed in the upper portion of the slit so that the coil can be easily inserted.

Meanwhile, one side of the tab terminal may be connected to the insulator rib 123 described above.

The magmate is formed in a 'c' shape, as shown in Figure 3, the slit 151 is formed on the front and rear, respectively. The width of the slit 151 is preferably formed corresponding to the core thickness of the coil. That is, it is preferable that the core wire of the coil is forcibly inserted into the slit 151 and is electrically connected to the magmate 150 at the same time. Therefore, the magmate should be formed of a conductive material.

Here, the electrical connection between the magnet 150 and the coil end is, as described above, after the end of the coil is located in the slit 162 of the tab terminal, the magnet 150 is the space portion of the tab terminal ( 161 may be inserted and simultaneously exposed to the core wire. However, the cores may be exposed first and then electrically connected as soon as the magmate is inserted.

Meanwhile, FIG. 4 illustrates a state in which a neutral point is formed by inserting a coil end and a magmate into the tab terminal, respectively.

5 and 6 schematically show how the magmate and coil ends are electrically connected.

First, the magmate and the ends of the coil 160 are electrically connected inside the tab terminal, which is in direct contact with the core 162 of the coil and the magmate made of a conductive material. Therefore, the specific portion of the coil 160 in direct contact with the magmate is a state in which the coating film, in particular the double coating film 161 is removed.

Therefore, when the coil 160 is shaken or an external impact is applied, the core wire 162 of the coil which is in direct contact with the magmate may be disconnected as described above. Moreover, there exists a possibility that corrosion may generate | occur | produce in this part.

In order to prevent this problem in advance, it is preferable that an insulation part is formed at a portion where the core wire 162 of the coil and the magmate are in contact. As an example of such an insulating part, a state in which the resin material 170 is applied is illustrated in FIG. 6.

The resin material 170 is formed of an insulating material, and is coated and cured to maintain insulation in the core wire 162 and protect the core wire from the outside. Of course, the external force is directly prevented from being transmitted to the core wire 161 to perform the function of reinforcing the strength of the core wire 161.

On the other hand, Figure 7 shows a state in which the resin material 170 is applied to the entire tab terminal. That is, a state in which the resin material 170 is coated to cover not only the exposed portion of the core 150 and the core 162 of the coil 150 but also a part of the coil 160 in which the coating film 161 is not removed is illustrated.

In this case, the amount of resin applied can be increased, but it is possible to more firmly fix the end of the coil to the tab terminal, it is possible to achieve insulation and corrosion protection more reliably.

In this case, the tap terminal is preferably a neutral tap terminal 129 rather than a tap terminal 128 for power connection. This is because the neutral tap terminal does not need to be electrically connected to another portion other than the coil 160.

On the other hand, when the tap terminal is a tap terminal 128 for power connection, the magmate 150 should be connected to a power source. Therefore, it will be desirable to prevent the resin material 170 from being applied to at least a portion for such a connection.

Hereinafter, another embodiment of the insulator according to the present invention will be described in detail with reference to FIG. 8.

In the above-described embodiment, the insulating portion for performing a function such as reinforcing the strength of the core wire exposed portion, insulation, anti-corrosion, etc. was made including the resin material to be applied.

In this embodiment as well, the insulating portion may include the resin material. However, in this embodiment, it is possible to form an insulating portion having the above-mentioned function even if such resin material is deleted.

8 shows a tab terminal cover 180 as another embodiment of this insulator. That is, the tab terminal cover 180 is another embodiment of the insulator according to the present invention, and functions to insulate a portion where the core wire 162 of the coil is in contact with the outside from the outside.

The tab terminal cover 180 is inserted from the top of the tab terminal to accommodate the tab terminal therein. That is, the tab terminal cover 180 surrounds all the outer appearance of the tab terminal to block the outside and the tab terminal.

Thus, even if there is an exposed portion of the core wire 162, this portion is only inside the tab terminal, and the inside of the tab terminal is completely isolated from the outside by the tab terminal cover 180. Thus, insulation and corrosion protection of the core exposed portion can be performed.

In addition, referring to FIG. 4, the tab terminal cover 180 illustrated in FIG. 8 may be covered with an upper portion of the tab terminal to which the magmate 150 and the coil exposed with the core wire are coupled. At this time, a portion of the coil not exposed to the core is positioned in the slot 162, and the lower portion 181 of the tab terminal presses the coil portion. Therefore, external shocks and the like are not directly transmitted to the core wire exposed portion, but are transmitted only to the coil portion located in the slot portion. Therefore, there is an effect that the core wire portion can be prevented from being disconnected.

In addition, the tab terminal cover 180 is preferably inserted to receive the tab terminal deeper than the slot 162 portion of the tab terminal. That is, when the tab terminal cover is completely inserted to receive the tab terminal, it is preferable that the position of the lower portion 181 of the tab terminal cover is positioned below a predetermined height than the slot 162.

This is to prevent the penetration of external moisture through the slot 160 in advance.

Meanwhile, the tab terminal cover 180 may be formed separately from the magmate 150, but may be integrally formed as shown in FIG. 8. That is, while the mat 150 is inserted into the tab terminal, the tab terminal is inserted into the tab terminal cover 180. This has the advantage that it is possible to form the electrical connection and the insulation in the tab terminal through a single operation.

For example, the tab terminal may be formed of a conductive metal, whereas the tab terminal cover may be formed of an insulating material, that is, a resin-based material. Therefore, it will be possible for the tab terminal cover to be inserted in the injection molding of the tab terminal cover so that both are integrally formed.

Here, the tab terminal cover 180 performs a function of completely insulating the magmate from the outside. Therefore, the magmate 150 is difficult to be electrically connected to other parts other than the coil. Therefore, it is preferable that the tab terminal to which the tab terminal cover 180 is applied is a neutral tap terminal 129, but is not necessarily limited thereto.

Hereinafter, another embodiment of the insulating part of the present invention will be described in detail with reference to FIG. 9.

The present embodiment further includes a strength reinforcement 239 for reinforcing the strength of the tab terminal.

The strength reinforcement 239 is formed at one side of the tab terminal. More specifically, the strength reinforcement 239 may be formed in the radially inner side and / or outer side of the tab terminal. However, in consideration of the convenience of fixing the coil end, it is preferable to be formed on the radially outer side of the tab terminal. In addition, the tab terminal is preferably formed integrally with the insulator.

Meanwhile, the slit 241 is preferably formed in the strength reinforcing portion 239 as in the tab terminal. Accordingly, the end of the coil is fixed to the slit 241 of the strength reinforcing portion and the slit 162 of both of the tab terminal to further secure the fixed strength.

In addition, the widths of the slits 241 and 162 may be formed to correspond to the outer diameter of the coil 160. That is, unlike shown in Figure 9 it is preferable to form a narrower to some extent than the outer diameter of the coil 160 including the coating film to be forced to the coil at the same time to be fixed to the coil. However, in this process, it will be more preferable not to be too narrow so that the coating film is not damaged.

This width of the slit will be the same in this embodiment as well as the other embodiments described above.

In addition, the strength reinforcing portion 239 is preferably formed with a pocket 240 is formed a predetermined space inside. This pocket is preferably in communication with the inside of the tab terminal through the slit 162. Thus, the coil 160 is secured to the tab terminal across the pocket 239.

In this embodiment, the resin 270 may be applied as the insulating part. In this case, it is not preferable that the amount of resin applied on the tab terminal is excessive and leaks out of the tab terminal. Therefore, it is preferable to overflow the pocket 240 of the strength reinforcement 239 even if the resin overflows. Through this, it is possible to apply a quantitative resin material, and thus, it is possible to simplify the production process because the resin material application can be performed automatically rather than manually.

In addition, since the resin is applied to many parts, the strength of the coil ends, insulation, and corrosion protection will be more effective.

On the other hand, in the present embodiment it will be possible to apply the tab terminal cover 180 shown in Figure 8 by deleting the resin material 270. Of course, it will also be possible to insert the tab terminal cover after resin application. In this case, the shape of the tab terminal cover will have to be changed to some extent.

According to the present invention described above, a coil including a core wire made of aluminum, not conventional copper, is applied. In addition, it characterized by an insulating portion for strength reinforcement, insulation and corrosion protection for the core wire of the aluminum material. Here, the insulation is not limited to the above-described embodiment, various modifications are possible, but such modifications will also belong to the present invention as long as they belong to the technical spirit of the present invention.

Hereinafter, the coil push preventing structure according to the present invention will be described in detail with reference to FIGS. 10 to 11.

In general, the coil is wound around the teeth, not directly through the teeth, but through the windings 121 and 131 of the insulator corresponding to the teeth.

In addition, the coil is not wound in only one layer, but wound in a plurality of layers. For example, it may be wound to have four layers in a washing machine motor. Thus, in this case the height of the ideal winding layer can be said to be four times the outer diameter of the coil. However, when the rolling occurs in the coil of the lower layer, the coil of the upper layer is partially recessed or vice versa. Thus, the protruding coils may cause the entire winding layer to be high, and may cause a problem in that the protruding coils are damaged in handling.

Therefore, it is desirable to minimize the occurrence of protruding coils, and for this purpose, it is important to prevent rolling of the coils.

The maximum number of turns that the coil wound around the windings 121 and 131 can be wound is determined by the length of the winding and the outer diameter of the coil. For example, if the length L of the winding is 20 mm and the outer diameter of the coil is 0.95 mm, the number of turns that can be wound is 21.

The form wound in this manner is represented by reference numeral 200 in FIG.

On the other hand, in this case, predetermined intervals are formed at the beginning and the end of the winding portion, i.e., both ends. This spacing will be smaller than the outer diameter of the coil. Therefore, the coils wound by the predetermined intervals are pushed together, and a predetermined interval is generated between the coils and the coils at portions other than both ends of the winding portion, resulting in a winding failure.

Therefore, it is important to prevent rolling of the coil, and for this purpose, it is important to fill a predetermined gap formed at both ends of the winding part.

To this end, the present invention prevents the coil push by the additional windings 210 and 211 to which one turn is forcibly added.

That is, the coil 202 is started to be wound and the coil 202 is formed. Then, the coil 203 and the coil 204 are formed, and the coil is wound around one tooth. In this case, for example, 21 turns are formed as described above.

However, in the present invention, one turn is forcibly added and wound through the coil 210 and the coil 211. The gaps formed at both ends of the winding part are filled through the coil 210 and the coil 211. Thus, as the coil is wound, the coils align themselves so that no rolling occurs.

And, this additional one turn is preferably formed on the opposite side of the portion where the winding starts and on the opposite side of the portion where the winding ends. That is, 1/2 turns from the coil 201 to the coil 202 and 1/2 turns from the coil 204 to the coil 211 are forcibly wound to add one turn as a whole.

On the other hand, the coil layer of one layer is formed through the structure through such a forced winding. Thereafter, the coil layer to be laminated is formed by the winding path formed by the coil formed in the coil layer of the first layer, so that the rolling of the coil is prevented even in the upper layer. That is, since the cross section of the coil is circular, a constant path is formed between the coil and the coil. The coil is rewound along this path. On the other hand, even if the coil is wound in this path, as described above, the coil is prevented from rolling, thereby preventing the coil layer from collapsing.

In addition, the additional one turn is preferably formed only in the coil layer of one layer, not formed in the upper layer. That is, since one turn is forcibly added, the additionally wound part protrudes more than the other coils, and if the winding is made again in this part, the coils protrude from both ends of the winding part in comparison with other parts.

In addition, according to the present invention, since the winding is again made along the path between the coil and the coil, even though four winding layers are formed, the thickness of the winding layer is lower than four times the outer diameter of the coil. In other words, the winding is tight and more stable winding can be achieved.

In addition, in the present invention, in addition to the structure that is additionally wound to fill the gap formed on both ends of the winding portion is possible other structures.

As shown in FIG. 11, the coil push preventing structure may be a protrusion protruding to reduce the length of the winding part. That is, the protrusions are formed at both ends of the winding part, particularly preferably on the opposite side of the portion where the winding starts and the portion where the winding ends. The protrusion height of the protruding portion reduces the length of the winding portion, and is preferably formed corresponding to the length of the outer passage of the winding so that no gap is formed between the coils to be wound.

In addition, when the protruding length of the protruding portion is larger than the outer diameter of the coil, a case in which one turn cannot be wound may occur. Therefore, the protruding length of the protrusion is preferably smaller than the outer diameter of the coil.

In addition, the protrusion may protrude in the longitudinal direction of the winding part, but may protrude in the radial direction. That is, it may be formed at the corner portions of both ends of the winding part. In this case, the length of the protrusion protruding in the radial direction is also preferably smaller than the outer diameter of the coil. This is to ensure that these protrusions do not interfere with winding the coil formed in the upper layer.

Therefore, the winding method wound by the protrusion may be the same as the conventional winding method. However, the protrusion prevents the coil from rolling and minimizes the winding failure.

According to the present invention through the above-described coil rolling prevention structures it is possible to minimize the winding failure. In addition, even if the outer diameter of the coil using an aluminum core wire is larger than when using a conventional copper coil, the conventional insulator can be used as it is or through a slight deformation.

Meanwhile, according to the present invention, since a coil including a core wire made of aluminum is applied, it is required to be wound to minimize damage of the coil during winding. That is, it is preferable that the coil is gently wound without a sudden bent portion.

To this end, according to the present invention, a coil support formed in the winding part is provided.

12 is a cross-sectional view taken along line II of FIG. 1. That is, it is a cross section of the winding part, which may be formed in the same way as the winding part of the upper insulator and the winding part of the lower insulator.

First, when the coil is wound on the winding, it is wound up on the side of the winding and on the top. Here, the coil may be bent rapidly at an angle of 90 degrees when winding from the side to the upper surface. In this case, there is a risk that the coil itself may be damaged, and the resistance may increase due to a sudden change in shape, which may lower the efficiency.

Therefore, it is preferable that a coil support part for supporting the coil is formed on the upper surface of the winding part so that the coil is gently wound.

Meanwhile, the coil support 190 may include a first coil support 191 protruding from both sides and a second coil support 192 formed between the first coil support.

In addition, the protruding height of the second coil support 192 may be higher than the protruding height of the first coil support 191. The coil is supported through the coil support 190 and may be gently wound while forming an arc.

On the other hand, the front end portion of the second coil support is preferably formed in a round shape. Of course, the same applies to the first coil support. This is to allow the supported coil to distribute the force to minimize damage by external force.

According to the present invention is to reduce the cost of the coil applied to the motor as a whole can reduce the manufacturing cost of the motor.

In addition, according to the present invention, while reducing the manufacturing cost of the motor, it is possible to provide a motor that is easy to manufacture and improved reliability and product durability.

In addition, according to the present invention, it is possible to provide a motor having a quality equal to or higher than that of a conventional motor without significantly changing the conventional essential components.

Claims (15)

A stator having a stator core and an insulator provided in the stator core to which a coil is wound;  A rotor rotatably provided with respect to the stator; It comprises a tab terminal provided in the insulator is positioned the end of the coil, The coil comprises a core wire made of aluminum. The method of claim 1, And the end of the coil is fixed to the tab terminal through a magmate inserted into the tab terminal. The method of claim 2, And the end of the coil is electrically connected to the magmate while the magmate is inserted into the tab terminal. The method of claim 3, wherein And a resin is applied to the tab terminal after the magmate and the end of the coil are coupled to the tab terminal. The method according to any one of claims 1 to 4, The coil is characterized in that it further comprises a double coating film formed on the outside of the core wire. The method of claim 1, And the tab terminal is integrally formed with the insulator. The method of claim 6, And the tap terminal is a tap terminal or a neutral tap terminal for power connection. An insulator provided on the stator core, the coil including a core wire made of aluminum, wound thereon, and maintaining insulation between the stator core and the coil; A tab terminal provided in the insulator and at which an end of the coil is located; A magmate inserted into the tab terminal and exposed to the core wire of the coil to be electrically connected to the coil and fixing the coil to the tap terminal; And A motor comprising an insulating portion formed in the core wire exposed portion of the coil. The method of claim 8, And the insulating part is formed on the magmate exposed to the outside. The method according to claim 8 or 9, And the insulating part is a resin material applied to the tab terminal. A stator having a stator core and an insulator provided in the stator core to which a coil is wound;  A permanent magnet provided inside and rotatably provided outside of the stator; It comprises a tab terminal provided in the insulator is positioned the end of the coil, The end of the coil is fixed to the tab terminal to expose the core wire made of aluminum, and then a resin is applied to the tab terminal to prevent corrosion and reinforcement of the coil end. The method of claim 11, And a magnet is inserted into the tab terminal and the core wire of the coil is exposed to electrically connect with the magnet. The method according to claim 11 or 12, The resin is a motor, characterized in that the coating to form an electrical insulation covering all the exposed portion of the core and the core of the coil exposed to the outside. The method of claim 13, And the tap terminal is a neutral tap terminal. A stator having a stator core and an aluminum coil wound around the stator core;  A rotor rotatably provided with respect to the stator; A tab terminal provided at the stator and having an end of the coil; A magmate inserted into the tab terminal to electrically connect with the core wire of the coil and fix the coil to the tap terminal; An insulation portion formed in the core wire exposed portion of the coil; And And a connector coupled to the tab terminal to apply power to the coil.

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