KR101372270B1 - motor and manufacturing method thereof - Google Patents

Abstract

The present invention relates to a motor and a method of manufacturing the same that can minimize the loss of the steel sheet during stator fabrication.

The configuration of the present invention includes a housing forming an exterior, a rotor rotatably supported inside the housing, and a stator positioned inside the housing and having stator core plates stacked thereon, wherein the stator core plates are interconnected to form an annular shape. It is provided with a plurality of split core plate, a groove is provided in the yoke portion of the stator core plate to be easily bent in an annular shape, characterized in that the one end of the divided core plate is provided with a projection portion, the other end is provided with a locking portion, respectively do.

Description

Motor and manufacturing method thereof

1 is a horizontal cross-sectional view of an embodiment according to the present invention.

2 is a vertical sectional view of an embodiment according to the present invention. (A-A ')

3 is an explanatory view of the coupling relationship between the magnetic torque and the reluctance torque of the embodiment according to the present invention.

4A and 4B are explanatory diagrams showing the occurrence of a cut-steel sheet in the stator core punching process of the embodiment according to the prior art.

Figure 5 is an explanatory view showing the generation of a scavenger steel sheet in the stator core punching process of the embodiment according to the present invention.

Figure 6 is an explanatory view showing the manufacturing process of the outer and inner stator core of the embodiment according to the present invention.

7 is a plan view and vertical cross-sectional view (B-B ') of the coil wound on the stator of the embodiment according to the present invention.

8 is a plan view and a perspective view of a fixing frame of the embodiment according to the present invention.

9 is a detailed view of the split core plate of the inner rotor of the embodiment according to the present invention.

10 is a plan view of the inner rotor of the embodiment according to the present invention.

Figure 11 is a detailed view of the seating portion (D) of the inner rotor of the embodiment according to the present invention.

12 is a flowchart illustrating a manufacturing method of an embodiment according to the present invention.

Description of the Related Art [0002]

311: internal stator core, 316: internal coil,

321: external stator core, 322: external stator split core plate,

323: York section, 324: Tisbu,

325: home, 326: outer coil,

410: inner rotor, 411: inner rotor core,

412: internal rotor frame, 413: flux barrier,

414: inner rotor split core plate, 415: seating portion,

421: permanent magnet, 422: external rotor frame,

43: injection joint, 5: fixed frame,

51: protrusions, 6: connections,

61: serration, 7: insulator,

X: phase, Y: torque,

MT, MT ': magnetic torque, RT, RT': reluctance torque,

OT, OT ': working torque, MOP, MOP': maximum working torque point,

The present invention relates to a motor and a method of manufacturing the same that can minimize the loss of the steel sheet during stator fabrication.

In general, an electric motor is composed of a stator, a rotor, and a housing, and uses the principle that the rotor is rotated by a coupling force generated when the polarity on the stator side and the polarity on the rotor side are the same as the repulsive force generated when the polarity is different.

The brushless and commutator-less BCD motors have an outer rotor with rotors on the outside, an inner rotor with rotors on the inside, and a disk with a relatively thin axial thickness. As a motor, there is an axial gap type, which is a structure arranged in the axial direction of the rotor.

In more detail, the internal rotor type BLC motor has a cylindrical stator wound around a coil in order to have an electromagnet structure on a plurality of protrusions formed in the inner circumference thereof and is formed of a cylindrical permanent magnet therein. In the external rotor type BCD motor, a coil is wound around a plurality of protrusions formed on the outer periphery of the stator, and a multi-pole magnetized cylindrical permanent magnet is formed on the outside of the rotor.

The main path of the magnetic flux in the conventional BCD motor as described above forms a magnetic circuit that travels in the permanent magnet of the rotor, passes through the air gap, and passes through the stator again in the direction of the permanent magnet and the yoke.

In the case of the inner rotor type, a plurality of “T” core portions of the coiled stator core are protruded from the outside inward, and the inner end portions of each core portion form a circle of a constant diameter, The rotor is fitted with a cylindrical permanent magnet with a rotating shaft or a ring permanent magnet attached to a cylindrical yoke with a rotary shaft in the center. The method of rotating the motor is the same as the external rotor type.

Since the internal rotor type and the external rotor type have a structure in which the magnetic circuit is radially symmetric about the axis, there is little vibrational noise in the axial direction, suitable for low speed rotation, and extremely small portion of the void in the direction of the magnetic path. High magnetic flux density can be obtained even by using this low magnet or reducing the amount of magnet, which has the advantage of high torque and high efficiency.

On the other hand, a dual rotor type motor including an inner rotor and an outer rotor at the same time is also disclosed. The conventional dual rotor type motor has a symmetrical magnetic circuit with respect to the stator and the rotating shaft, and the stator coil is doubled and the field magnet is also doubled by the internal and external rotors and the stator. And the magnetic flux density is doubled to obtain at least twice as much torque as the single rotor structure.

A conventional double rotor type motor is disclosed in Korean Patent Laid-Open No. 2001-0097204 (2001.11.08). It is a motor that can increase output by winding coils inside and outside of the stator, and by forming a dual inside and outside rotor with a predetermined gap inside and outside of the stator.

In the conventional method of manufacturing the stator core, when the steel sheet is punched out by pressing as shown in Figs. 4a and 4b, there is a problem in that a lot of stiffness of the steel sheet is inevitably generated due to the curvature of the stator core, thereby increasing the material cost.

The present invention has been made to solve the above-described problems of the prior art, to prevent the increase in the material cost due to the occurrence of a lot of steel sheet in the stator core fabrication.

In order to solve the above technical problem, a configuration of the present invention includes a housing forming an appearance, a rotor rotatably supported inside the housing, and a stator positioned inside the housing and having a stator core plate laminated thereon. The stator core plate is provided with a plurality of split core plates connected to each other to form an annular shape, and a groove is provided in the yoke portion of the stator core plate so as to be easily bent in an annular shape, and one end of the divided core plate has a protrusion. The other end is composed of a motor provided with each engaging portion.

The stator may include a motor including an external stator core having a tooth portion at an outer circumference portion and an inner stator core having a tooth portion at an inner circumference portion while being positioned inside the outer stator core.

The stator may include a motor including an external stator core having a tooth portion at an inner circumference and an inner stator core having a tooth portion at an outer circumference thereof while being positioned inside the outer stator core.

In addition, the inner and outer stator core may be composed of a motor provided as a separate member.

In addition, the fixing frame provided with protrusions at regular intervals, the fixing frame is coupled to the upper or lower portion of the inner and outer stator core, the projection may be composed of a motor inserted between the inner and outer stator core. have.

The rotor may include a motor including an external rotor provided outside the external stator core and an internal rotor provided inside the internal stator core.

On the other hand, as a manufacturing method, the first step of punching the steel sheet in the form in which the divided core plate is disposed so that the teeth portion cross each other and cross each other, the laminated and bent and connected between the punched divided core plate to the internal and external stator And a third step of forming a core and a third step of coupling the inner stator core to the inside of the outer stator core.

In addition, the third step is a method comprising the step of engaging the fixing frame provided with protrusions at a predetermined interval to the upper or lower portion of the inner and outer stator core, the projection is inserted between the inner and outer stator core Can be prepared.

The method may further include coupling an insulator to the outside of the internal and external stator cores, winding a coil to a tooth portion of the stator core to which the insulator is coupled, and integrally the internal and external stator cores to which the coil is wound. It may be prepared by a method further comprising the step of resin injection molding.

Hereinafter, the embodiment according to the present invention will be described in detail. 1 is a plan view of an embodiment according to the invention, Figure 2 is a cross-sectional view. The housing forming the exterior is not shown for convenience.

First, referring to the external rotor, as shown in FIGS. 1 and 2, the external rotor includes a plurality of permanent magnets 421 installed at predetermined intervals on the surface of the external rotor frame 422, and the permanent magnets 421 are disposed. And an outer rotor frame 422 to be fixed.

The outer rotor frame 422 is a disk-shaped frame coupled to the rotation axis in a direction orthogonal to its outer peripheral portion is extended in parallel with the rotation axis and a permanent magnet 421 is disposed on the inner peripheral surface.

In addition, the outer rotor frame 422 is composed of a steel plate as a conductor in order to minimize the loss of the magnetic flux generated in the permanent magnet 421 and to form a movement path of the magnetic flux. However, it is also possible to produce a resin material in this case, by installing a separate steel plate on the surface of the outer rotor frame 422 serves as a movement path of the magnetic flux.

In order to connect the outer rotor frame 422 and the rotating shaft to transmit the rotational force, a central portion of the outer rotor frame 422 includes a connection part 6 formed of an insulator resin material. The connecting portion 6 is also coupled to the inner rotor frame 412, and the serrated serration portion 61 is provided at the center thereof to increase the coupling force with the rotating shaft.

Next we look at the stator. 5 and 6, in the present embodiment, in the external stator, the plurality of yoke portions 323 and the plurality of teeth portions 324 provided in the yoke portion form one external stator split core plate 322. The outer stator split core plates are stacked to form an outer stator split core, and the outer stator split cores are coupled in a ring to form inner and outer stator cores 311 and 321.

5 and 6, grooves 325 are provided in the yoke portions of the inner and outer stator cores 311 and 321. As described below, the inner and outer stator dividing core plate 322 to the band-shaped steel sheet to face each other while the punching in the state arranged so as to intersect to reduce the occurrence of stuttering of the steel sheet.

That is, the inner and outer stator dividing core plate 322 is punched out in a straight shape by laminating the groove, and then laminated and bent in a round shape to produce more core plates with a steel sheet in a constant area.

Although the internal and external stator cores 311 and 321 may be integrally formed, the external stator cores 311 and 321 are separated into the external stator core 321 and the internal stator core 311.

As shown in Figure 5 and 6, when separating into the inner and outer stator core, each stator core can be manufactured separately and combined, which is advantageous to reduce the stiffness (S) of the steel sheet.

That is, since the 'T'-shaped yoke portion and the tooth portion are combined by punching the split core plate formed with a plurality of coupling forms, it is advantageous to reduce the stiffness (S) of the steel sheet than when the split core plate is formed at the same time the inner and outer tooth portions are formed at the same time. will be.

In the present embodiment, the divided core plate has a four-split configuration. However, it is obvious that 6 or 8 divisions may be possible in some cases.

In this embodiment, the configuration is provided with a tooth portion on the outer peripheral portion of the outer stator core 321 and the inner peripheral portion of the inner stator core 311, on the contrary, a configuration in which the tooth portion is provided on the inner peripheral portion of the outer stator core and the outer peripheral portion of the inner stator core. Of course it is possible.

Next, the internal rotor will be described in detail. The inner rotor core 411 of the inner rotor provided inside the inner stator has a configuration in which a plurality of steel sheets are stacked. A plurality of flux barriers 413 are formed in the inner rotor core 411 to be formed at positions corresponding to the respective poles to maximize the difference in magnetoresistance. In addition, the inner rotor frame 412 is provided inside the inner rotor core 411 and is coupled to the inner rotor core 411 in order to transfer the rotational force of the inner rotor core 411 to the rotating shaft.

The flux barrier 413 is for inducing reluctance torque between the inner rotor and the inner stator.

Hereinafter, the flux barrier 413 and the reluctance torque will be described in detail. In general, the synchronous reluctance motor (SYNCHRONOUS RELUCTANCE MOTOR) uses a phenomenon that the rotational force is generated by the change of the magnetoresistance according to the rotation of the rotor and the operating principle of the internal rotor in the present invention is similar.

The inner rotor is formed by stacking several sheets of steel, and the flux barrier 413 positioned therein is formed to penetrate upward and downward to fill air. When a current is applied to the coil wound on the stator, a flux is formed by the applied current, and a reluctance torque is generated by the difference in inductance according to the position of the rotor, thereby rotating the rotor. As the position of the flux barrier 413 formed in the rotor changes as the rotor rotates, the magnetoresistance is changed. The energy accumulated in the gap between the stator and the rotor is changed by the change of the magnetoresistance. Therefore, the change in energy of the rotor rotational position becomes a torque to generate a rotational force, the rotational force generated in the rotor is transmitted to the outside through the power transmission shaft.

Hereinafter, a line connecting the rotational axis between the two side ends of the adjacent flux barrier 413 will be referred to as the d-axis, and a line connecting the central axis and the rotational axis of the flux barrier 413 will be referred to as the q-axis. The magnetoresistance is greatly different between the d-axis and the q-axis, thereby generating reluctance torque.

Accordingly, in the case of the d-axis, the flux barrier 413 does not exist to facilitate the flux flow, and in the case of the q-axis, the flux barrier 413 is positioned so that the flux flow is disturbed as much as possible. As shown in Fig. 9 to Fig. 11, in this embodiment, a configuration in which a plurality of strips of an equilateral trapezoidal shape and a semicircular arc shape are provided is applied.

The inner rotor core 411 is formed by stacking the respective inner rotor split core plates 414 having the flux barrier 413 to form an inner rotor split core, and the inner rotor split cores are connected to form an annular inner rotor core. 411 is formed. In the present Example, the center part of a core board is provided in empty ring shape.

The inner rotor core plate 414 is preferably composed of a divided core plate divided into a plurality of pieces in order to reduce the occurrence of a stiff steel sheet due to the curved portion. In this example, a four-split configuration is disclosed. However, it is obvious that 6 or 8 divisions may be possible in some cases.

1, 2 and 11 (D), the inner rotor frame 412 is provided with a seating portion 415 protruding at a predetermined interval in order to seat the inner rotor to the inner rotor frame 412.

The inner and outer rotor frames 412 and 422 are made of steel plates, and the connecting part 6 is made of resin, and the inner and outer rotor frames 412 and 422 can be integrally ejected and combined when the connecting part 6 is injected.

On the other hand, in the above description, but the embodiment was formed through the formation of the flux barrier through the inner rotor, the permanent magnet in the outer rotor, but of course the embodiment using the flux barrier through the outer rotor and the permanent magnet in the inner rotor Possible will be apparent to those skilled in the art. However, forming a flux barrier on the inner rotor is more advantageous in preventing the permanent magnet from being separated by centrifugal force.

Hereinafter, the configuration and manufacturing method of the stator core will be described in detail. 5 to 7, 12, the inner and outer stator cores (311, 321) are manufactured separately. That is, the stator part wound around the coil is formed into an inner stator core 311 provided on the inner circumferential surface, and the plurality of tooth parts wound around the coil are formed on an outer circumferential surface.

The stator core is produced by stacking a plurality of core plates. The core plate is configured by combining a plurality of divided core plates. Each divided core plate is produced by punching a steel plate with a press. At this time, in order to minimize the occurrence of stalks, the two divided core plates provided with the teeth on only one side thereof are arranged to cross each other so that the teeth are crossed (A1).

5, the grooves 325 are provided at equal intervals in the yoke portion of the split core plate so that the split core plate is substantially straight. The punched divided core plate can be easily round-bended by the groove (A2).

Accordingly, since the two split core plates cross each other so as to cross each other on the strip-shaped steel sheet, the cutout S of the steel sheet is significantly reduced.

The divided core plates thus manufactured are laminated, and after bending in a round form, a circular stator core is formed by mutually engaging the projections and the engaging portions provided in the respective yoke portions (A2).

The split core plate may be bent first, and then the split core plate may be laminated to form a stator split core (A2). The internal and external stator cores differ only in the direction in which they are bent, but the other processes are similar.

In addition, the inner and outer stator cores 311 and 321 manufactured as described above are combined with each other to form a double ring stator core having a complete ring shape (A2).

As shown in Fig. 8, a ring-shaped fixing frame 5 is used to temporarily fix each other while maintaining a constant gap between the inner and outer stator cores. The fixed frame is coupled to the upper and lower portions of the inner and outer stator cores (A3).

In order to space the gap, the fixing frame is provided with a protrusion 51 at a predetermined interval. The protruding portion 51 is formed by placing the cutouts at fixed intervals on the fixed frame 5 and vertically bending the cutouts to form the protruding portions.

However, the present invention is not limited thereto, but a configuration in which the center portion protrudes from the cross section without forming an incision and a mountain shape is naturally possible, and this also belongs to the protection scope of the present invention.

Meanwhile, as shown in FIGS. 1, 2, and 7, after the upper and lower insulators 7 of the resin material are coupled to the stator core for insulation (A4), a coil is wound around the teeth of the insulators 7 ( A5). In order to integrate the internal and external stator cores, an injection molding part 43 is formed by insert injection (A6).

Hereinafter, the operation of the embodiment according to the present invention will be described. When current is supplied to the coils of the internal and external stators, magnetic flux is formed in the coils. When three-phase current is sequentially applied to the coils of the internal and external stators, the magnetic field is sequentially formed at the teeth of the stator, which has a form of magnetic fields that rotate sequentially.

Subsequently, the motor rotates in the direction of the rotating magnetic field by the interaction between the magnetic flux generated in the permanent magnet 421 attached to the external rotor facing the teeth of the external stator core and the magnetic field generated in the teeth of the external stator core 321. Done.

On the other hand, when three-phase power is applied to the coil of the internal stator, the magnetic flux is emitted from the tooth part and flows into the d-axis of the internal rotor core 411 because the d-axis has a low magnetic resistance, and the q-axis is a flux barrier. This is because the magnetoresistance is large as the magnetic flux is disturbed by 413. Therefore, in the inner rotor, a force to move to a position where the magnetoresistance is smaller according to the difference in the magnetoresistance of the d-axis and the q-axis appears, and this force is the reluctance torque.

As shown in FIG. 3, the flux flow between the outer rotor and the outer stator and the flux flow between the inner rotor and the inner stator may overlap linearly.

Therefore, when the generating point of the maximum magnetic torque coincides with the generating point of the maximum reluctance torque, both forces are used most efficiently.

The method of matching the maximum point of the magnetic torque MT and the reluctance torque RT is to adjust the magnetic torque MT 'when the phases of the external rotor and the internal rotor are changed by a predetermined angle as shown in the second graph of FIG. And the phase of the reluctance torque RT 'is changed by a to form the maximum working torque point MOP'.

That is, the coupling angles at which the maximum voltage is generated among the measured values by measuring the output voltage while coupling the inner and outer rotor frames 412 and 422 to each other at a predetermined coupling angle between the inner rotor and the outer rotor, respectively, and driving at a predetermined rotation speed. By way of finding out (B1).

The inner and outer rotor frames are integrally operated in the process of injection molding the inner and outer rotor frames arranged as described above (B2). Since the outer and inner rotor frames 412 and 422 are connected to each other by the connecting part 6, the magnetic torque MT and the reluctance torque RT may be simultaneously used to exhibit high torque.

The following effects can be obtained by the constitution of the present invention described above.

Since the steel plate is punched by arranging the split core plates in a straight line to cross each other, the occurrence of stuttering of the steel sheet is reduced. Especially in the case of a motor employing the inner and outer stator methods, the stinging occurs because the inner and outer stator cores are configured separately. Even more significantly.

In addition, it is easy to combine and manufacture the internal and external stator core using a fixed frame has the effect of improving the work efficiency.

Claims (9)

A housing forming an appearance, A rotor rotatably supported within the housing; Located in the housing includes a stator laminated stator core plate, The stator core plate is provided with a plurality of split core plates to be connected to each other to form an annular shape, The yoke portion of the stator core plate is provided with a groove to be easily bent in an annular shape, Protruding portion is provided at one end in the longitudinal direction of the split core plate, and engaging portions are provided at the other end, The stator includes an external stator core having a tooth portion provided at an outer circumference thereof; Located inside the outer stator core includes an inner stator core provided with a tooth portion on the inner circumference, The inner and outer stator cores are coupled to the upper or lower fixed frame motor. delete delete The method of claim 1, The inner and outer stator cores are provided as separate members. 5. The method of claim 4, The fixed frame includes a protrusion provided at a predetermined interval, The protrusion is inserted between the inner and outer stator core. The method according to any one of claims 1, 4 or 5, The rotor and the outer rotor provided on the outside of the outer stator core, A motor comprising an inner rotor provided inside the inner stator core. In the method of manufacturing a motor according to claim 1, A first step of punching a steel sheet in a form in which the split core plate is disposed such that the teeth are crossed while facing each other; A second step of forming the inner and outer stator cores by laminating, bending and connecting the punched divided core plates; And a third step of coupling the inner stator core to the inside of the outer stator core. 8. The method of claim 7, The third step is a method of manufacturing a motor comprising the step of coupling the fixing frame provided with protrusions at a predetermined interval to the upper or lower portion of the inner and outer stator core, the projection is inserted between the inner and outer stator core. . 9. The method of claim 8, Coupling an insulator to the inner and outer stator cores; Winding a coil on a tooth portion of the stator core to which the insulator is coupled; And resin injection molding the inner and outer stator cores of which the coil is wound.

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