KR20150004600A - Moter Having Divisional Core Type Stator and Fabricating Method thereof - Google Patents

Abstract

The present invention relates to a motor having a divisional core type stator and to a method for producing the same. The divisional core is implemented in a combination structure of two pieces of a teeth and a yoke or three pieces of the teeth, an extension unit, and the yoke so as to reduce production costs. The present invention reduces winding time and improves productivity by winding a coil on the yoke. The present invention reduces winding weight by reducing the width of the yoke as half of the width of the teeth and increases motor efficiency by reducing a resistance value.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a motor having a divided core type stator,

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a motor, and more particularly, to a motor having a segmented core type stator and a manufacturing method thereof.

Generally, if a BLDC motor is classified according to the presence or absence of a stator core, it is divided into a core type (or a radial type) and a coreless type (or an axial type) having a cup (cylindrical) structure.

The BLDC motor of the core type has an inner magnet type comprising a cylindrical stator in which a coil is wound to have an electromagnet structure on a plurality of projections formed on an inner peripheral portion and a rotor made of a cylindrical permanent magnet, And a rotor made of a cylindrical permanent magnet having a coil wound in an up-and-down direction and being multipolar-magnetized outside thereof.

The applicant of the present invention has proposed a BLDC motor in which a stator core can be formed in a fully split type by having a single stator / double rotor structure in a radial core type in Korean Patent Publication No. 2004-2349. Korean Patent Laid-Open Publication No. 2004-2349 discloses a stator core in which a rotor is simultaneously disposed on the inner side and the outer side of the stator core, and the flow of the magnetic path is formed by the inner and outer permanent magnets and the yoke, Thereby proposing a structure capable of greatly increasing the productivity of the stator core and the output of the motor.

The present applicant has proposed a divided cored stator technique in which coils are successively wound around a plurality of split core teeth and adjacent bobbins are joined together and fixed using a support bracket in Korean Patent Publication No. 2012-0058765, However, there is a limit to increase the fill factor by winding the coil on the teeth, and it is difficult to reduce the weight of the winding and the resistance value .

Korean Patent Publication No. 2004-0002349 Korea Patent Publication No. 2012-0058765

SUMMARY OF THE INVENTION The present invention has been accomplished in view of the problems of the prior art, and an object of the present invention is to provide a three-piece piece made of two pieces of a tooth and a yoke, The amount of scrap remaining is reduced, and manufacturing costs can be reduced, and a method of manufacturing the same.

Another object of the present invention is to provide a motor having a divided core type stator capable of shortening the winding time and improving the productivity by winding the coil on the yoke and reducing the length of the teeth in the radial direction, .

It is still another object of the present invention to provide a split core type in which the width of the yoke can be reduced to half the width of the tooth width to reduce the weight of the winding and reduce the resistance value, A motor having a stator, and a method of manufacturing the same.

Still another object of the present invention is to provide a motor having a divided core type stator capable of increasing a fill factor than a case where a coil is wound on a straight portion of a yoke and a coil is wound on a tooth, have.

Still another object of the present invention is to provide a motor having a divided core type stator capable of shortening a winding time and improving productivity by winding a coil on a yoke, and a manufacturing method thereof.

In order to achieve the above object, according to an embodiment of the present invention, there is provided a stator comprising: a stator having a plurality of yokes coupled to a plurality of teeth and assembled in an annular shape; And a rotor disposed inside or outside the stator and rotating in cooperation with the coils.

The plurality of teeth are spaced apart and arranged in an annular shape, and each of the plurality of yokes may be coupled to two teeth.

A coupling groove is formed on one side and the other side of the tooth, and the yoke has a rectangular shape and a relatively short side end region is inserted into the coupling groove of the tooth.

The coil may be wound on the relatively long side of the yoke.

The extension may extend on the lower surface of the tooth so that the tooth may have a T shape.

A coupling groove is further formed in the extended portion, and a lower surface of the tooth can be coupled to a coupling groove formed in the extended portion.

The rotor may be implemented by attaching an N pole and an S pole magnet alternately annularly to the back yoke.

In order to minimize the noise caused by cogging, the outer circumferential surface of the tooth and the corner portion of the magnet may be rounded.

The magnetic circuit of the motor may pass through the N-pole magnet, the right half region of the tooth, the yoke, the left half region of the tooth, the S-pole magnet, and the back yoke.

The stator may be formed by molding an annular integral type outer side surface of the stator by thermosetting resin by an insert molding method.

The width of the yoke may be half the size of the tooth width.

The rotor may be connected to a rotating shaft of a dewatering tank for performing washing and dewatering of the washing machine, or a rotating shaft of a pulsator rotatably disposed inside the dewatering tank to form washing water.

The stator may be fixed to the underside of the washing tub.

The rotor is integrally formed with the rotor support by insert molding. The rotor support is in the form of a disk, and is formed at the center and is coupled to the outer circumferential surface of the rotation shaft. The rotor support is bent at the outermost right angle, And a rotor support portion to which the rotor support portion is installed.

A bobbin which is an insulative nonmagnetic material is formed on the yoke, and the coil may be wound on the bobbin.

According to an embodiment of the present invention, there is provided a method of assembling an annular stator, the method comprising: assembling an annular stator by coupling a plurality of yokes, each coil being wound, to a plurality of teeth; And arranging a rotor that cooperates with the coil to form a magnetic circuit on the inside or outside of the annular stator.

Wherein the plurality of teeth are formed on the first electromagnetic steel plate by engaging a plurality of yokes each wound with the coils on a plurality of teeth to assemble the annular stator, And winding the coil on the plurality of yokes.

According to an embodiment of the present invention, there is provided a method of manufacturing a stator, comprising: assembling an annular stator by coupling a plurality of yokes to a plurality of teeth; Winding a coil on the plurality of yokes; And arranging a rotor that cooperates with the coil to form a magnetic circuit on the inside or outside of the annular stator.

As described above, in the present invention, the tooth portion and the yoke portion are formed by being formed on separate electromagnetic steel sheets, and the two tooth pieces made of the tooth and the yoke are formed by alternately forming the tooth portions so as to be alternately positioned, The remaining amount of scrap can be reduced, thereby reducing manufacturing costs.

In the present invention, it is possible to separate the tooth portion by the tooth and the extension portion, and to form the three pieces of the tooth, the extension portion, and the yoke by using a separate electromagnetic steel sheet to reduce unnecessary portions of the electromagnetic steel sheet.

In the present invention, it is possible to optimize the positions of the teeth and the yokes to be punched out of the electromagnetic steel sheet, thereby forming more cores than the same electromagnetic steel sheet area.

In the present invention, the outer circumferential surface of the teeth may be rounded, or the edges of the magnet may be rounded to minimize noise caused by cogging.

In the present invention, by winding the coil on the yoke, the winding time can be shortened, productivity can be improved, and the length of the teeth can be reduced in the radial direction.

In the present invention, the coil windings can be successively conducted successively to the yokes, and even if the gap between the divided cores spreads when the three-phase divided cores are alternately arranged by the jump line of the coil for assembly, it can sufficiently cope.

According to the present invention, the yoke acts to connect the teeth, the width of the yoke can be reduced to half the width of the teeth, the coil can be wound on the yoke having a relatively small width to reduce the weight of the winding, , It is possible to increase the motor efficiency and reduce the manufacturing cost.

In the present invention, a fill factor can be utilized to the maximum as compared with a case where a coil is wound on a straight portion of a yoke to wind a coil on a tooth.

1 is a plan view of a motor having a divided core stator according to an embodiment of the present invention,
FIGS. 2A to 2C are views for explaining a manufacturing process of a split core stator according to an embodiment of the present invention;
FIGS. 3A through 3D are views for explaining a manufacturing process of a divided core stator according to another embodiment of the present invention; FIGS.
4 is a diagram schematically showing a part of the configuration of a motor according to an embodiment of the present invention, in which a coil is wound around a yoke of a stator,
5 is a diagram schematically showing a part of a structure for explaining a magnetic circuit of a motor according to an embodiment of the present invention.

Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings.

The sizes and shapes of the components shown in the drawings may be exaggerated for clarity and convenience. In addition, terms defined in consideration of the configuration and operation of the present invention may be changed according to the intention or custom of the user, the operator. The definitions of these terms should be interpreted based on the contents of the present specification and meanings and concepts in accordance with the technical idea of the present invention.

1 is a plan view of a motor having a divided core stator according to an embodiment of the present invention.

A motor having a divided cored stator according to an embodiment of the present invention includes a stator 100 having a plurality of teeth 130 connected to a plurality of yokes 120 wound with coils 110, ; And a rotor 200 disposed inside or outside the stator 100 and interacting with the coil 110 to form a magnetic circuit.

1, the stator 100 includes a plurality of teeth 130 arranged in an annular shape, a yoke 120 is disposed between the teeth 130 and the teeth 130, 130 to form a core. One yoke 120 is disposed between the pair of teeth 130 and one yoke 120 repeats connecting the pair of teeth 130 so that the plurality of teeth 130 are connected to the yokes 120 ). 135b are formed on one side and the other side of the teeth 130. The process of joining the yokes 120 to the coupling grooves 135a and 135b causes the teeth 130 to be connected to the yoke 120 To connect. At this time, the yoke 120 is rectangular, and a relatively short side end region is inserted into the coupling grooves 135a and 135b of the teeth 130, and the coil 110 is wound on the relatively long side. It is preferable that the extension portion 150 is extended to the lower surface of the tooth 130 so that the tooth 130 has a T shape.

The rotor 200 is realized by attaching N poles and S pole magnets 221 and 222 having a plurality of different polarities (N poles and S poles) alternately annularly to the back yoke. That is, the N-pole magnet 221 and the S-pole magnet 222 are alternately arranged, and an annular back yoke 210 is formed on the outer periphery of the N-pole magnet 221 and the S- Respectively.

1 shows an inner rotor type motor in which the rotor 200 is disposed inside the stator 100. In the present invention, the rotor 200 can also be applied to an out-rotor type motor disposed outside the stator 100 have. 1, the yoke 120 and the coil 110 connecting the teeth 130 are positioned on the inner side of the annular shape, and the rotor 200 Is disposed on the outside of the extension portion 150. [ The extension 150 has inward and outward curved surfaces at predetermined curvatures corresponding to the magnets 221 and 222 of the rotor 200, respectively.

FIGS. 2A to 2C are views for explaining a manufacturing process of a divided core type stator according to an embodiment of the present invention, and FIGS. 3A to 3D are views showing a manufacturing process of a divided core type stator according to another embodiment of the present invention Fig.

The split core type stator has an annular structure in which a tooth and a yoke are connected. In order to realize a split core type stator, a plurality of teeth and yokes are required, and each of the teeth and the yokes must maintain the same size. In the present invention, the teeth and the yokes are formed by tapping an electromagnetic steel sheet (electromagnetic steel sheet) so as to have a shape of a tooth and a yoke. At this time, by dividing the yoke portion and the tooth portion, the generation of scrap is reduced, thereby reducing manufacturing costs.

Referring to FIGS. 2A to 2C, the tooth portion is formed by the first electric steel plate 300 and the yoke portion is formed by the second electric steel plate 310 being formed. In the present invention, the first group of teeth 130a, 130c, and 130e are arranged in a line on one side edge of the first electromagnetic steel plate 300, and the extended portions 150a and 150c of the first group of teeth 130a, 130c, and 130e And 150e are adjacent to one side edge of the first electromagnetic steel plate 300 and the second group of teeth 130b and 130d are arranged in a line on the other edge of the first electromagnetic steel plate 300, 130d and 130d are adjacent to the other side edge of the first electromagnetic steel plate 300 and the second group of teeth 130b and 130d between the first group of teeth 130a, , The scrap generation is remarkably reduced.

Since the yoke portion has a rectangular shape, the yokes 120a, 120b, 120c, 120d, 120e, 120f, 120g, and 120h are disposed on the second electromagnetic steel plate 310 so as to be positioned in rows and columns.

Therefore, in the divided core type stator of this embodiment, the tooth portion and the yoke portion are formed by being formed on separate electromagnetic steel sheets, and a pair of teeth and a yoke are formed by tapping the tooth portions alternately, The amount of scrap remaining after punching can be reduced, thereby reducing manufacturing costs. That is, it is possible to optimize the positions of the teeth and the yokes to be punched out of the electromagnetic steel sheet, and to form more divided cores than the same electromagnetic steel sheet area.

As shown in FIG. 2C, after the tooth and the yoke are formed by knitting, the yoke 120a 'is coupled to the coupling groove' 135a 'of one tooth' 130a 'and the coupling groove' 135b 'of another tooth' 130b ' Thereby assembling the annular stator. Then, the coil is wound on each yoke.

On the other hand, when the rotor rotates, an effective area difference of magnetic force (magnetic flux) between the magnet and the stator core occurs depending on the rotation angle, resulting in severe cogging and leakage of magnetic flux.

Accordingly, in order to minimize noise caused by cogging, it is possible to round the outer circumferential surface of the teeth or edge-process the rounded corners of the magnets.

3A to 3D, a divided core type stator according to this embodiment is formed by separating a tooth portion into a tooth and an extended portion and tapping the three pieces made of the tooth, the extended portion, and the yoke into a separate electromagnetic steel sheet .

131a, 131f, 131g, and 131h (FIG. 3A), and the electromagnetic steel plate 510 is pressed to form the extended portions 151a and 151b 121b, 121c, 121d, 121e, 121f, 121g and 121h are formed by pressing the electromagnetic steel plates 520a, 511b, 511c, 511d, 151e, 151f, 151g and 151h (Figure 3c). 131b, 131c, 131d, 131e, 131f, 131g, 131h, extension portions 151a, 151b, 151c, 151d, 151e, 151f, 151g, 151h, yokes 121a, 121b, 121c, 121d, 121e 121f, 121g, and 121f are placed in rows and columns in the electromagnetic steel plates 500, 510, and 520, respectively, so that the amount of scrap can be significantly reduced. 131b, 131c, 131d, 131e, 131f, 131g, and 131h are provided with coupling grooves 155 for coupling with the teeth 131a, 131b, 131c, 131d, 131e, 131f, 131g, and 131h, Respectively.

The teeth '131a' is coupled to the coupling groove '155' of the extended portion '151a', and the teeth '131a' and the teeth ' The operation of coupling the yoke '120a' to the coupling groove '135b' of the coupling groove '135a' and the tooth '131b' is repeated to assemble the annular stator, and then the coil is wound on each yoke.

In the coil winding process, after the bobbin is integrally formed on the outer periphery of the yoke before being assembled into the divided cores of the stator as described above, the yokes are aligned horizontally between the yokes using an alignment jig (not shown) And then the coil windings are successively conducted successively using the universal winder on the bobbles arranged next to each other. In this case, it is also possible to connect the yoke to the hollow portion of the bobbin after the coil is wound on the bobbin to which the yoke is not coupled.

At this time, since the yoke and the yoke have a certain margin when assembling, they are connected by a jump line. The winding process is repeated to continuously wind the coils on the plurality of yokes. In the case of the three phases, the three sets of divided cores corresponding to the respective phases of U, V, and W are alternately arranged around each phase. Since the divided cores for each phase are connected by a long jump line, even if the interval between the divided cores spreads when the divided cores of three phases are alternately arranged, it can sufficiently cope.

Therefore, in the present invention, by winding the coil on the yoke, the winding time can be shortened, productivity can be improved, and the length of the teeth can be reduced in the radial direction.

Meanwhile, in the present invention, after the coil is wound on the yoke, the assembling process can be performed. As described above, the annular integrated type stator can be obtained by assembling the annular shape by performing the assembling process and the coil winding process, and then molding the outer side surface of the annular type stator with the thermosetting resin by the insert molding method.

After the above-described stator assembly process is completed, a process of arranging a rotor that cooperates with the coil to form a magnetic circuit on the inside or outside of the annular stator can be performed. Here, the arrangement includes aligning, locating, assembling, and may mean a motor-driven coupling between the annular stator and the rotor. Conversely, the annular stator can be assembled inside or outside the fixed rotor.

4 is a diagram schematically showing a part of the configuration of a motor according to an embodiment of the present invention, in which a coil is wound around a yoke of a stator, and FIG. 5 is a cross- Fig. 8 is a diagram showing a part of the configuration schematically for explaining a circuit.

4, a bobbin 125, which is an insulative non-magnetic body, is formed on the yoke 120 of the stator, and the coil 110 is wound around the bobbin 125. [ The bobbin 125 is formed to be wrapped around the outer circumferential surface of the yoke 120 by insert molding.

In the present invention, the coil 110 is wound on the yoke 120, instead of winding the coil 110 on the tooth 130, so that the coil 130 is wound in the radial direction The torque can be increased by increasing the outer diameter (diameter) of the magnets 221 and 222 as the tooth length is reduced. (For reference, the torque is proportional to the square of the diameters of the magnets 221 and 222).

Generally, the amount of magnetic flux flowing in the yoke portion is set to about 1/2 of the tooth portion because the magnetic flux passing through the tooth portion is divided and flows along one side and the other side of the tooth located on both sides of the tooth.

In the present invention, when the yoke 120 connects the teeth 130 to form a magnetic circuit, the width W1 of the yoke 120 can be reduced to almost half the width W2 of the teeth 130 have. Thus, when the coil 110 is wound with the same number of turns as the yoke 120 having a relatively small width, the weight of the winding can be reduced, the resistance value can be reduced, the motor efficiency can be increased, .

In the present invention, a series of coils 110 wound on a yoke 120 is assembled by arranging a series of coils 110 to form a stator. Thus, among the coils 110, An end turn of the coil 110 which is a phenomenon that a magnetic field effect is reduced in a region can be reduced and the coil 110 can be easily processed and the coil 110 is wound on a straight portion of the yoke 120, The fill factor can be utilized to the maximum as compared with the case where the coil 110 is wound on the coil 130.

Generally, in the prior art in which coils are wound on teeth, since the interval between the teeth is limited, there is a problem that the coil winding can not be performed with a high fill factor, The present invention does not cause such a problem.

5, the magnetic circuit of the motor according to the present invention includes an N-pole magnet 221, a right half region of the tooth '130a', a yoke 120, a left half region of the tooth '130b' The width of the yoke 120 can be reduced to a half of the size of the teeth 130 by passing through the back yoke 210. [

The motor according to the present embodiment can be mainly used in a washing machine, and can be used in other devices requiring a driving force in addition to a washing machine.

In particular, the motor is installed at a lower portion of the automatic washing machine and has a structure suitable for rotationally driving the washing machine of the washing machine in the forward and reverse directions. However, the motor is not limited to the structure, but may be installed in the tub of the drum washing machine, / ≪ / RTI >

On the other hand, when the motor is applied to a washing machine, a motor having a divided cored stator has a structure in which a rotor is rotatably disposed on a rotating shaft of a dewatering tank for washing and dewatering the washing machine, or a pulsator And is connected to the rotating shaft and rotated. The stator is fixed to the lower side of the washing machine, and the rotor is disposed with a constant gap on the outer circumferential surface of the stator.

The rotor support body has a disc shape as a whole, includes a rotation shaft coupling portion formed at the center and coupled to the outer circumferential surface of the rotation shaft, and a rotor support portion formed to be bent at the outermost right angle and provided with a rotor. Here, the rotor support is integrally formed with the rotor by insert molding.

The rotor includes an annular back yoke fixed to an inner surface of a rotor support portion of a rotor support member, a plurality of rotor yokes mounted on an outer circumferential surface of the back yoke and arranged opposite to each other with a predetermined gap therebetween, Includes magnets.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is clearly understood that the same is by way of illustration and example only and is not to be construed as limited to the embodiments set forth herein. Various changes and modifications may be made by those skilled in the art.

100: stator 110: coil
120: York 125: Bobbin
130: Teeth 150: Extension part
200: rotor 210: back yoke
220,221,222: magnet 300,310,500,510,520: electromagnetic steel plate

Claims (18)

A stator in which a plurality of yokes are coupled to a plurality of teeth and assembled into an annular shape, and coils are wound on each of the plurality of yokes; And
And a rotor disposed inside or outside the stator and rotating in cooperation with the coil. The method according to claim 1,
Wherein the plurality of teeth are spaced apart and arranged in an annular shape, and each of the plurality of yokes is coupled to two teeth. The method according to claim 1,
Wherein a coupling groove is formed on one side and the other side of the tooth, and the yoke has a rectangular shape and a relatively short side end region is inserted into the coupling groove of the teeth. The method of claim 3,
And the coil is wound on the relatively long side of the yoke. The method of claim 3,
And an extension extends on a lower surface of the tooth so that the tooth has a T shape. 6. The method of claim 5,
Wherein a coupling groove is further formed in the extended portion, and a lower surface of the tooth is coupled to a coupling groove formed in the extended portion. The method according to claim 1,
Wherein the rotor is realized by attaching the N pole and the S pole magnet to the back yoke alternately in an annular shape. 8. The method of claim 7,
Wherein the outer periphery of the teeth and the corner portions of the magnet are rounded to minimize noise caused by cogging. 8. The method of claim 7,
Wherein the magnetic circuit of the motor passes through the N pole magnet, the right half region of the tooth, the yoke, the left half region of the tooth, the S pole magnet and the back yoke, . The method according to claim 1,
Wherein the stator is molded in an annular integral shape by thermosetting resin on an outer surface thereof by an insert molding method. The method according to claim 1,
And the width of the yoke is half the width of the tooth. The method according to claim 1,
Wherein the rotor is connected to a rotary shaft of a dewatering tank for performing washing and dewatering of the washing machine or a rotary shaft of a pulsator for rotatably disposed in the dewatering tank to form washing water, . 13. The method of claim 12,
Wherein the stator is fixed on a lower side of the washing machine. The method according to claim 1,
The rotor is integrally formed with the rotor support by insert molding. The rotor support is in the form of a disk, and is formed at the center and is coupled to the outer circumferential surface of the rotation shaft. The rotor support is bent at the outermost right angle, And a rotor supporting portion on which the rotor is mounted. The method according to claim 1,
Wherein a yoke which is an insulative nonmagnetic material is formed on the yoke, and the coil is wound on the bobbin. Assembling an annular stator by coupling a plurality of yokes each of which is wound with a coil to a plurality of teeth; And
And arranging a rotor that cooperates with the coil to form a magnetic circuit on the inside or outside of the annular stator. 17. The method of claim 16,
Wherein the plurality of teeth are formed on the first electromagnetic steel plate by engaging a plurality of yokes each wound with the coils on a plurality of teeth to assemble the annular stator, And the step of winding the coils on the plurality of yokes is carried out. Assembling an annular stator by coupling a plurality of yokes to a plurality of teeth;
Winding a coil on the plurality of yokes; And
And arranging a rotor that cooperates with the coil to form a magnetic circuit on the inside or outside of the annular stator.

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