TW201618428A - Axial gap type rotary electric machine and insulating member - Google Patents

Abstract

An axial-gap rotary electric machine having: an iron core comprising an approximately cylindrical body having a radial direction cross section shape in which the width in the direction of rotation increases from the shaft center toward the external periphery; an insulation member having an inner cylinder shape that is approximately the same as the external peripheral shape of the iron core; a stator having a core member comprising a coil wound around an outer cylinder part of the insulation member, a plurality of the core members being annularly arranged around a rotating shaft; and at least one rotor facing at least one end surface of the stator iron core across a gap in the rotating shaft direction; wherein: the insulation member has a first insulation member that contacts the external peripheral surface where the rotation-direction width is greatest, and a second insulation member that contacts an external periphery portion of the iron core excluding the external peripheral surface that contacts the first insulating member, and both radial ends of the second insulation member contact both rotation-direction ends of the first insulation member.

Description

Axial gap type rotating electric machine and insulating member [Reference]

The present application claims priority to Japanese Patent Application No. 2014-224849, filed on Nov. 5, 2014, the content of which is hereby incorporated by reference.

The present invention relates to an axial gap type rotating electric machine and an insulating member, and relates to an axial gap type rotating electric machine and an insulating member that perform insulation of a stator core.

In the progress of electricization in various fields, such as energy saving or transportation equipment, it is imperative to reduce the size and efficiency of a rotating electric machine (for example, a motor). In general, small and high efficiency are the opposite elements, but in recent years their demand for coexistence has become higher and higher. In such a background, attention is paid to a small-sized, space-saving, and high-output axial gap type rotating electric machine.

The axial gap type rotating electric machine has a characteristic that it is easy to output a torque with a magnetic flux area having a wide radial section. Therefore, flattening in the axial direction can be expected. The axial gap type rotating electric machine has various combinations of "stator" and rotor (1", "1 stator, 2 rotor" or "2 stator, 1 rotor", and is easy to respond to rotary electric machine applications. The characteristics of the requirements of the load or construction of the end.

Patent Document 1 discloses an axial gap motor having an armature structure in which one stator is sandwiched between two rotors. The motor disclosed in Patent Document 1 has a ring-shaped arrangement centering on a rotation axis. Cutting the stator structure of the core member. In this case, the composition or material of each of the divided cores is also various combinations. Patent Document 1 discloses that each of the cores of the divided core members is a wound core, or an annular body of a thin plate for rolling a core is obtained, and each of them is cut at an equal angle from the end surface side to obtain each. The composition of the iron core. Further, Patent Document 1 also discloses that an amorphous metal is used for the core material for the core.

Further, Patent Document 2 discloses an axial gap type rotating electric machine having a core in which a rectangular steel plate piece cut into a single piece or a plurality of pieces by a specific width is laminated on a core member in a radial direction from a rotating shaft.

In order to fix the laminated or wound core, it is necessary to have its fixing fixture. Further, in consideration of electrical insulation between the coil and the core, an insulating material such as an insulating paper or a bobbin may be necessary. Patent Document 2 discloses a configuration in which an insulating paper or a resin material is provided on the outer circumference of the core, or a core material is inserted into the cylindrical resin material, and the insertion is facilitated.

Further, Patent Document 3 discloses that an insulating material is applied to the outer peripheral side of the laminated core, and an insulator is provided by insert molding the laminated core provided in the metal mold, or is divided in the direction of the rotation axis. The insulator is formed by sandwiching a laminated core on both sides in the direction of rotation.

[Previous Technical Literature] [Patent Literature]

[Patent Document 1] Japanese Patent Laid-Open Publication No. 2009-284578

[Patent Document 2] Japanese Patent Laid-Open Publication No. 2013-121226

[Patent Document 3] Japanese Laid-Open Patent Publication No. 2011-193564

In the axial gap type rotating electric machine, as described in Patent Document 1 or 2, the use of a thin plate of amorphous metal in the circumferential or radial lamination has the advantage of reducing the eddy current loss generated by the stator core and achieving high efficiency. The advantages of the motor.

In the core structure, when an insulating material is applied to the outer periphery of the core, in the resin molding of the resin disclosed in Patent Document 3, it is necessary to set the steel plate to be fixed to the metal by a predetermined method or the like. The mold or various components or steps of fixing and positioning the laminated core in the metal mold.

In order to omit such a configuration or step, there is also a method of inserting a laminated core into an insulating member formed into a cylindrical shape. In this case, it is necessary to insert and fix the laminated core in advance by a material or the like, or to insert the core while pressing the laminated core in the direction of lamination, but there is also a difference in the space factor due to unevenness of the laminated sheets, or deformation. It is difficult to insert into the insulating member, or the core is peeled off after insertion.

The difficulty in inserting or inserting the core is not limited to the laminated core, and it is also common to insert a solid core obtained by pressing or cutting into a predetermined shape of the insulating material. Further, there is also a problem that the individual difference of the solid insulating member itself having a predetermined shape becomes a problem.

It is desirable to eliminate the performance degradation caused by the individual difference of the members of the core or the insulating member or to improve the convenience of manufacture.

In order to solve the above problems, for example, the configuration described in the scope of the patent application is applied. That is, an axial gap type rotating electrical machine includes: a core member including: a core, which is a substantially cylindrical column having a radial cross-sectional shape that has a width in the rotational direction from the axial center side toward the outer peripheral side. a body member; an insulating member; having an inner cylinder shape substantially the same as a peripheral shape of the core; and a coil wound around the outer tubular portion of the insulating member; and the axial gap type rotating electrical machine includes: a stator And forming at least one of the core members in a ring shape around the rotating shaft; and at least one rotor facing at least one end surface of the stator core with a gap therebetween in a direction of a rotation axis; the insulating member includes a first insulating member that is in contact with the outer peripheral surface on the side in which the width in the rotation direction is increased; and a second insulating member that is in contact with the outer surface other than the first insulating member. The outer peripheral portion of the core is in contact with each other; and both end portions of the second insulating member are in contact with both end portions of the first insulating member in the rotational direction.

According to the present invention, the insulating member can be easily disposed on the outer circumference of the core. Other problems, configurations, and effects of the present invention will be apparent from the following description.

1‧‧‧Motor

2‧‧‧stator

3a‧‧‧Rotor

3b‧‧‧Rotor

4‧‧‧Rotary axis

5‧‧‧Laminated iron core

6‧‧‧Insulator

6a‧‧‧锷

7‧‧‧ coil

8a‧‧‧Rotor magnet

8b‧‧‧Rotor magnet

9a‧‧‧Rotor core

9b‧‧‧Rotor core

10a‧‧‧Rotor flange

10b‧‧‧Rotor flange

11a‧‧‧ inner peripheral side protrusion

12a‧‧‧Outer protrusion

20‧‧‧ Shell

21‧‧‧Flange

22‧‧‧ Bearing

23‧‧‧ bearing bracket

30‧‧‧ Body Department

31‧‧‧ 盖部

31a‧‧‧ Cover end

32‧‧‧Slots

32a‧‧‧The inner wall of the trough

32b‧‧‧The inner wall of the trough

32c‧‧‧Surface

35‧‧‧ Grounding groove

206‧‧‧Insulator

230‧‧‧ Body Department

231‧‧‧ 盖部

231a‧‧‧ Cover end

231b‧‧‧Steps Department

232‧‧‧Slots

232a‧‧‧ slot inner wall

232b‧‧‧ slot inner wall

330‧‧‧ Body Department

331‧‧‧ 盖部

333a‧‧‧Deduction

333b‧‧‧Deduction

334a‧‧‧Hooks

334b‧‧‧ hook

430‧‧‧ Body Department

431‧‧‧ 盖部

431a‧‧‧Cap

431b‧‧‧ Cover

432‧‧‧ slot department

433‧‧‧ protruding parts

530‧‧‧ Body Department

531‧‧‧ 盖部

531a‧‧‧ Cover

531b‧‧‧ Cover

533a‧‧‧Deduction

533b‧‧‧Deduction Department

534a‧‧‧Hooks

534b‧‧‧ hook

600‧‧‧Mezzanine

630‧‧‧ Body Department

631‧‧‧ 盖部

631a‧‧‧ convex

R‧‧‧distance

R‧‧‧vertical distance

R'‧‧‧ vertical distance

Fig. 1 is a developed perspective view showing a schematic configuration of an axial gap type motor to which an embodiment of the present invention is applied.

2(a) and 2(b) are partial cross-sectional views showing an axial gap type motor to which an embodiment of the present invention is applied.

3(a) and 3(b) are schematic views showing the configuration of the insulator of the first embodiment.

4(a) and 4(b) are schematic views showing the assembled state of the insulator of the first embodiment.

Fig. 5 is a schematic view showing the configuration of an insulator according to a modification of the first embodiment.

Fig. 6 (a) and (b) are schematic views showing the configuration of the insulator of the second embodiment.

Fig. 7 (a) and (b) are schematic views showing the configuration of the insulator of the third embodiment.

Fig. 8 (a) and (b) are schematic views showing the configuration of the insulator of the fourth embodiment.

Fig. 9 (a) and (b) are schematic views showing the configuration of an insulator of a fifth embodiment.

Fig. 10 (a) and (b) are schematic views showing the configuration of an insulator of a sixth embodiment.

Hereinafter, the form for carrying out the invention will be described in detail using the drawings.

[First Embodiment]

In Fig. 1, an armature structure to which an axial gap type motor (hereinafter referred to as "motor 1") according to the first embodiment of the present invention is applied is schematically shown.

The motor 1 includes a "1 stator and 2 rotor" structure of the stator 2 and the rotors 3a and 3b. The rotors 3a and 3b have a specific gap and are formed to be sandwiched by a rotating shaft (not shown). Further, the present invention is not limited to this configuration, and the number of the stator and the rotor is arbitrary.

The stator 2 has a configuration in which a plurality of (9 in the figure) divided core members are arranged in a ring shape around the rotation axis. Each of the divided core members includes a laminated core 5, an insulator 6, and a coil 7. The laminated core 5 is composed of an amorphous metal material which is formed into a tape shape and is thin (for example, about 25 μm), and sequentially laminates a strip having a smaller width toward the axis, and has a substantially trapezoidal cylinder. shape. Further, the laminated core 5 may be laminated in the direction of rotation, and the shape is not limited to a substantially trapezoidal shape, and is not limited to an amorphous magnetic material, and may be an electromagnetic steel sheet, a powder magnetic core, or an iron-cobalt alloy (Permendur). Soft magnetic material. Further, in the case of applying an amorphous metal, an electromagnetic steel sheet, an iron-cobalt alloy or the like, in order to suppress eddy current, the laminated core 5 is preferably laminated in the circumferential direction or the radial direction.

The insulator 6 is a non-magnetic and non-conductive insulating material, and a resin is used in the present embodiment. The insulator 6 has a cylindrical shape having an inner circumferential shape substantially matching the outer circumferential shape of the laminated core 5, and is obtained by injection molding, light shaping, or three-dimensional molding. The laminated core 5 is inserted by the insulator 6, and the coil 7 including copper or aluminum is wound around the tubular portion of the insulator 6, thereby constituting one divided core member.

Further, in the vicinity of both edge portions in the axial direction of the insulator 6, a flange portion 6a extending in a specific width in the axial direction or the rotation direction along the outer circumferential shape of the cylinder is formed, that is, an eddy current generated in consideration of the axial direction is considered. The insulation or the adjacent split cores are positioned relative to each other. In the case of a radial gap type motor, the magnetic flux for generating torque is mainly radial, and in order to reduce the eddy current of the core, the stator is generally formed by laminating a thin plate in the axial direction. On the other hand, in the case of the motor 1, the magnetic flux axis direction is dominant, and in order to reduce the eddy current in the in-plane direction, the flow of the magnetic flux in the radial direction or the circumferential direction must be electrically insulated in the vertical direction. It is preferable to further provide a shielding member for insulation on the surface side of the crotch portion 6a facing the rotors 3a and 3b. Further, the present invention is not limited to the aspect in which the crotch portion 6a is provided to the insulator 6. Further, it is also possible to provide a part 6a so as not to be provided over the entire circumference of the outer circumference of the tubular portion.

Further, in the present embodiment, the stator 2 is integrally molded in a resin ring shape. The columns are separated from each other and the housing. This is to ensure the strength and insulation of the divided cores and to be fixed to the outer casing. By abutting the side faces in the rotational direction of the adjacent crotch portions 6a, the positioning in the mold frame at the time of resin molding is facilitated. Therefore, the width of the pair of radially outer peripheral sides of the crotch portion 6a is larger than the thickness of the coil 7 wound around the outer tubular portion of the insulator 6. Further, the present invention is not limited to the resin molding, and may be a splicing of a resin or a metal connecting piece to the dam portion 6a of the adjacent insulator 6 or rivet, or radially outward of the dam portion 6a and/or The annular member is disposed on the axial side and is then fixed by rivets.

The rotor 3a includes a rotor magnet 8a, a rotor core 9a, and a rotor flange 10a. In addition, since the rotor 3b has the same structure, description is abbreviate|omitted.

The rotor magnet 8a includes a permanent magnet such as neodymium or ferrite. A ring shape having a substantially fan-shaped magnet in which magnetic poles having different radial divisions are alternately arranged. Further, the rotor magnet 8a may be configured as a single body shape in addition to the configuration in which the poles are divided in the circumferential direction.

In the present embodiment, since the end surface of the rotor magnet 8a and the stator core 2 face each other in the axial direction, the magnetic flux is directly changed as in the case of the stator core 2, and magnetic flux is generated in a direction to prevent the change. The phenomenon of eddy current flow.

Although the neodimium magnet has a large energy product and can expect a large torque, on the other hand, since the electric resistance is low, the eddy current easily flows, resulting in a decrease in efficiency. Therefore, when a neodymium magnet is used, it is possible to divide the magnet in the vertical direction with respect to the axis, apply electrical insulation, or embed the rotor core 5 described below, and reduce the influence of the magnetic flux change or the like.

On the other hand, the ferrite magnet has a smaller energy product than the neodymium magnet, but the electric resistance is high and the eddy current hardly flows. Therefore, it is not necessary to adopt a configuration in which the magnet is divided or buried in the rotor core 5 or the like. Moreover, since the material is iron oxide, it has the characteristics of rust resistance.

The rotor core 9a is the same as the laminated core 5, and is made of a soft magnetic material such as an electromagnetic steel sheet, a powder magnetic core, an amorphous metal or an iron-cobalt alloy, or iron, and has a rotating shaft through. The doughnut shape of the central hole. The rotor core 9a also generates a magnetic flux change when the motor 1 is driven. However, since the influence of the eddy current is relatively small as compared with the laminated core 5, it can also be configured as an iron member. When it is desired to suppress eddy current loss as much as possible, it is preferable to use a powder magnetic core or a laminate material such as an electromagnetic steel sheet, an amorphous metal, or an iron-cobalt alloy. In this case, the material of the above-mentioned material can also be used as the structure of the wound core.

The rotor flange 10a is a member for fixing the rotor magnet 8a and the rotor core 9a, and has a donut shape in which a hole through which the rotating shaft passes through the center is provided. On the inner circumferential side and the outer circumferential side of the rotor flange 10a, an inner circumferential side protrusion 11a and an outer circumferential side protrusion 12a extending toward the stator core 2 side along the rotation axis are provided. The rotor magnet 8a and the rotor core 9a are disposed so as to be sandwiched by the radial end faces by an adhesive or the like, and are sandwiched between the inner circumferential side protrusions 11a and the outer circumferential side protrusions 12a.

This configuration is to obtain a stress corresponding to the centrifugal force generated in the rotor magnet 8a and the rotor core 9a. In this case, the outer peripheral side projections 12a may be provided. However, when the rotor core 9a is divided into the configuration, the inner peripheral side projections 11a are also provided, so that the inner peripheral side can be prevented from being rolled or assembled. Advantages of positioning and other advantages.

Further, in the present embodiment, the width of the projections in the direction of the rotation axis is near the center of the circumferential side surface of the rotor magnet 8a. It takes into account the stress corresponding to the centrifugal force and the influence on the eddy current. In the present embodiment, the inner circumferential side protrusion 11a and the outer circumferential side protrusion 12a are formed as continuous wall portions along one circumference, but may be formed discontinuously at regular intervals, or both or one of them may be provided. For the claws and so on.

In Fig. 2, a configuration example of the outer casing and the armature of the motor 1 is shown. Fig. 2(a) shows the configuration of the first embodiment, and Fig. 2(b) shows the configuration of the modification. In Fig. 2(a), as described above, the stator 2 is integrally fixed to the inner periphery of the outer casing 20 by resin. The centers of the rotors 3a and 3b are fixed to the rotating shaft 4. Both end portions of the rotary shaft 4 are rotatably connected to the flange 21 via a bearing 22, and the outer peripheral side of the flange 21 is connected to the vicinity of the opening portions on both sides of the substantially cylindrical outer casing 20.

In the configuration of FIG. 2(b), the bearing holder 23 which is integrally formed is provided on the inner peripheral side of the stator 2, and the bearing 22 is disposed in the vicinity of both end portions in the rotation axis direction of the bearing holder 23, and is fixed. The rotating shafts 4 of the rotors 3a, 3b are connected. The bearing holder 23 is the same as the brackets 21 and 20 of (a) since the bearing bracket 23 of Fig. 2(b) functions, so in the case (b), the housing 20 and the bracket 21 are not required. . In the case of (b), the configuration of the flatness of the motor 1 can be ensured by additionally ensuring the configuration of the stator 2.

Further, in the case where the split core member and the outer casing are integrally molded by resin molding, each of the divided core members may be first resin-molded, and then placed annularly in the mold frame and integrated with the outer casing 20 resin. Molding. Alternatively, each of the divided core members may be made of a metal annular ring, and the inner peripheral side and/or the outer peripheral side of the crotch portion 6a may be fixed, and the adjacent divided cores may be coupled to each other by the plate-like piece, or one of the crotch portions 6a may be buckled with each other. In a combined manner, the joint is formed. Further, the fixing of the stator 2 and the outer casing is not limited to the integrally molded molding by resin, and a continuous or discontinuous annular projection may be provided on the inner circumference of the outer casing 20, and the configuration or bolt of the stator 2 may be disposed. Other components such as fixing.

Next, the configuration of the insulator 6 which is one of the features of the embodiment will be described.

In Fig. 3, the structure of the insulator 6 is shown. The same figure (a) shows a cross section in the direction of the rotation axis, and (b) shows a partial enlarged view. In addition, either of the display crotch portions 6a is omitted.

The insulator 6 includes a main body portion 30 (second insulating member) and a lid portion 31 (first insulating member).

The main body portion 30 has an inner bottom surface of the laminated core 5 including a substantially trapezoidal cylindrical shape and an inner side surface substantially conforming to the shape of the side surface of the oblique side, and is integrally formed with the crotch portion 6a. The inner side surface is in substantial contact with each of the faces of the laminated core. Further, groove portions 32 are formed at both end portions in the rotational direction of the inner side surface of the main body portion 30. After the laminated core 5 is inserted into the main body portion 30, the groove portion 32 is fitted into the cover end portion 31a which is the side surface in the rotation direction of the lid portion 31.

Here, the groove inner wall 32a on the axial side of the groove portion 32 is a slope which is gentle from the bottom of the groove portion 32 toward the inner wall of the insulator 6. On the contrary, the groove inner wall 32b on the radially outer peripheral side of the groove portion 32 is The buckled state is confirmed to be parallel to the outer peripheral side of the lid portion 31.

The lid portion 31 has a square shape and has a size in which the length W in the rotational direction substantially coincides with the length between the bottom portions of the groove portions 32 of the main body portion 30. The radial thickness of the lid end portion 31a has a size slightly smaller than the distance between the inner walls 32a and 32b of the groove portion 32 of the body portion 30. This is to ensure the friction between the inner circumferential surface of the insulator 6 and the laminated core 5 as will be described later.

The main body portion 30 has a vertical distance from the groove edge portion 32c on the axial center side of the groove portion 32 to the inner surface of the upper bottom side as R', and when the vertical distance between the upper bottom and the lower bottom of the laminated core 5 is R, R is slightly larger than The size of R'. In order to press the laminated core 5 toward the inner cylinder side of the insulator 6, the frictional force between the insulator 6 and the laminated core 5 is ensured, and the fixed state of both is confirmed. In addition, even if the thickness R of the laminated core 5 is uneven, the length R is slightly smaller than a predetermined value, and the pressurization of a certain degree is required to ensure the fixed state of the insulator 6 and the laminated core 5. The gap functions.

In FIG. 4, the main body portion 30 and the lid portion 31 are schematically shown in a buckled state. (a) is a perspective view from the outer peripheral side of the motor 1, and (b) is a perspective view from the direction of the rotation axis ((b) the dam portion 6a is omitted).

In the main body portion 30, the laminated core 5 is inserted in the direction of the rotation axis via one of the flange portions 6a, and the lid portion 31 is press-fitted in the axial direction so as to be in contact with the groove portion 32. Since the thickness of the laminated core 5 in the direction of the rotation axis passes only through the thin crotch portion 6a, it contributes significantly to prevention of rolling of the laminated sheet at the time of insertion or improvement in workability. In particular, in the present embodiment, since the laminated sheet is made of a strip-shaped amorphous metal material which is thinner than the steel sheet used in the conventional laminated core, the rigidity with respect to the direction of the rotation axis is low. In particular, an effect can be expected when using such a core of a laminated sheet having a low rigidity in the direction of the rotation axis.

Further, since the axial center side of the side surface in the rotation direction of the lid end portion 31a is the same as the groove inner wall 32a, a gentle inclination is formed toward the inner circumferential side of the insulator 6, so that the inclination expands the outer circumferential side of the groove inner wall 32b in the rotation direction. The cover portion 31 is easily fitted into the body portion 30. Furthermore, since the outer peripheral side surface of the cover end portion 31a and the inner wall portion 32b of the groove are extended with respect to the radial direction from the axial center Since the lid portion 31 and the groove portion 32 are fastened, it is difficult to fall off.

Further, by making the cross-sectional shape of the lid end portion 31a slightly smaller than the cross-sectional shape of the groove portion 32, the accumulated thickness of the laminated core 5 is absorbed and the pressing force on the inner peripheral side of the insulator 6 is generated, so that the main body portion 30 can be The fixed state with the lid portion 31 is true.

[Modification of the first embodiment]

A modification of the insulator 6 of the first embodiment will be described. The stator 1 of the motor 1 is electrically floating, so grounding must be provided. The radial gap type motor is electrically coupled to the stator core, for example, by hot pressing or pressing the stator core into the outer casing, and the earth can be easily obtained from the outer casing.

The motor 1 is integrally formed with the outer casing 20 by resin molding, but the coil 7 wound around the insulator 6 and the outer casing 20 must be insulated from each other, so that the coil 7 is introduced between the coil 7 and the outer casing 20. Resin. Therefore, the laminated core 5 is a structure in which the outer casing is electrically non-contact. Therefore, in the motor 1, the laminated core 5 and the outer casing 20 are electrically connected by a conductive member.

As the grounding, a conductive interlayer (band) or wire is interposed between the outer peripheral surface of the laminated core 5 and the inner peripheral surface of the insulator 6, and is connected to the inner peripheral surface of the casing. After the cover portion 31 is placed on the main body portion 30, the laminated core 5 and the inner peripheral surface of the insulator 6 have a constant pressing force and are in a sealed state, so that the conductive member is interposed therebetween, and the laminated sheet is wrinkled or damaged. After that, or the workability is reduced.

Therefore, as shown in FIG. 5, the insulator 6 of the modification is configured such that the grounding groove portion 35 extending in the direction of the rotation axis is provided in the vicinity of the center of the lid portion 31. According to the insulator 6 of the modification, the grounding or grounding of the laminated core 5 can be easily and surely performed.

In the present modification, the groove depth of the grounding groove portion 35 is substantially the same as the thickness of the conductive member. However, when the conductive member is inserted after the main body portion 30 and the lid portion 31 are joined, the conductive portion can be made conductive. One of the members (preferably near the center in the direction of the rotation axis) is bent in the axial direction, and the grounding groove portion 35 is formed to be slightly larger than the thickness of the conductive member in such a manner that the spring effect is sufficiently in contact with the laminated core 5, and it is easy. Insert a conductive member.

[Second Embodiment]

One of the features of the motor 1 of the second embodiment is that the groove portion 32 provided in the main body portion 30 of the insulator 6 of the first embodiment is provided in plural to the core side inner wall in the axial direction. In the following description, the same components as those in the first embodiment are denoted by the same reference numerals, and the detailed description thereof will be omitted.

Fig. 6 shows a cross-sectional structure of the insulator 206 of the second embodiment (the dam portion 6a is omitted). As shown in the figure (a), the inner circumferential surface of the main body portion 230 in the rotational direction has a plurality of groove portions 232 which are formed at equal intervals from the outer circumferential direction toward the axial center side. Each of the groove portions 232 is disposed apart from the extension line perpendicular to the radial extension line passing through the axial center, and is disposed apart by the distance r. The configuration of the groove inner walls 232a and 232b of each groove portion 232 is the same as that of the first embodiment.

Similarly to the first embodiment, the lid portion 231 is formed of a plate shape having substantially the same width as the width between the groove portions 232 on the outermost circumferential side in the radial direction, and has a lid end portion 231a and a step portion 231b. In the second embodiment, the lid portion 231 can be fitted in a group corresponding to the groove portion 232 of any one of the rotation directions. In other words, when the thickness unevenness of each of the laminated cores 5 is larger than r, the pressing force of the lid portion 231 against the inner peripheral side of the insulator 6 can be maintained by changing the group of the groove portions 232 that are fitted in the radial direction. Further, as the distance from the radially outer peripheral side toward the axial center side, the distance between the groups of the groove portions 232 becomes short. Therefore, by preparing the cover portion 231 for adjusting the width of the rotation direction to the respective groove portions 232, it is possible to maintain the state in which the laminated core 5 and the insulator 6 are held without applying an excessive load to the rotation direction of the main body portion 231. It is advantageous in terms of cost and operation.

The step portion 231b is formed on the outer peripheral side of the lid portion 31a of the first embodiment, and has a thickness of r. For example, when the thickness of the laminated cores 5 is uneven, when the group of the fitting groove portions 232 is changed to the one of the outermost peripheral sides on one axial side, the lid portion 231 is displaced by the amount of r toward the axial center side. When the coil is wound around the outer tube portion of the insulator 6, a gap is formed between the outer circumferential side surface of the lid portion 231 and the coil, and the groove inner wall 232b of the groove portion 232 is deformed without the coil tension. By causing the step portion 231b to protrude toward the radially outer peripheral side by only the amount of r, the coil 7 can be lowered. The effect of winding.

Further, the groove width in the axial direction of each groove portion 232 is not limited to an equal interval, and may be different.

Further, when the groove portion 232 that is fitted into the cover portion 231 is cut and formed on the portion of the groove portion 232 on the outer peripheral side, and the stator core 2 has a different diameter and the same number of slots, it is not necessary to separately prepare each of the slots. The body portion 230 of the diameter is expected to improve mass productivity.

[Third embodiment]

In the first and second embodiments, the configuration in which the flange portion 6a is provided in the main body portion 30 of the insulator 6 is assumed. In the case of this configuration, the stress in the rotational direction of the main body portion can be obtained by the portion of the crotch portion 6a on the radially outer peripheral side of the main body portion 30 or the like. Therefore, even if the cover portion 31 or the like is fitted to the groove portion 32 of the core side surface of the main body portion 30 or the like, the main body portion 30 is less damaged. In other words, in the first and second embodiments, the lid portion 31 and the like are held from the outer side in the rotational direction.

Here, in the case of the innocent portion 6a, the stress in the direction of rotation of the main body portion 30 or the like is also weakened. In the motor 1 of the third embodiment, one of the features is a configuration in which the cover portion holds the main body portion from the outer side in the rotational direction. Further, one of the features is that the radial end portion of the main body portion is engaged with the end portion in the rotational direction of the lid portion.

Fig. 7 shows the configuration of the insulator 6 of the third embodiment. The same members as those in the other embodiments are denoted by the same reference numerals and will not be described. (a) is an enlarged view of a portion of the end portion of the main body portion 330 and the lid portion 331 of the third embodiment. Further, in the present embodiment, the configuration in which the crotch portion 6a is not provided is adopted.

The end portions of the main body portion 330 and the end portions of the lid portion 331 are respectively provided in the radially engaging buckle portions 333a and 333b. The latching portion 333a has a configuration in which the latching portion 333b is engaged with the latching portion 333b located on the inner side in the rotation direction, and the end portion is hangover in the axial direction. Further, the locking portion 333a has a hook portion 334a that protrudes in the rotational direction at the distal end thereof. The locking portion 333b has a hook portion 334b protruding outward in the rotational direction at the front end thereof, and is The shapes of the internal spaces surrounded by the lid portion 331, the locking portion 333a, and the hook portion 334a are the same.

As shown in FIG. 7(b), the locking portion 333a is supported by the locking portion 333b toward the inner side in the rotational direction from the outer side in the rotational direction by the fitting body portion 330 and the lid portion 331. Therefore, stress is generated for the body portion 331 to be expanded in the rotational direction. Moreover, the hook portions 334a and 334b can prevent the main body portion 330 and the lid portion 331 from falling off in the radial direction and secure both of them to the laminated core 5.

In the present embodiment, in order to ensure the fixation of the insulator 6 and the laminated core 5, the fastening portions 333a and 333b are formed integrally with the entire end portions of the main body portion 330 and the lid portion 331 in the rotation axis direction. However, the locking portions 333a, 333b and the like may be discontinuously provided in one of the rotational directions.

Further, instead of the cover portion 331 being provided with the locking portion 333a or the like, the end portion of the lid portion 331 may be provided with a hole through which the locking portion 333b of the main body portion 330 passes. In addition, the fastening portion 333b may be discontinuously protruded from the radially outer end portion of the main body portion 330, and may be formed to penetrate the hole of the cover portion 331 so as to correspond to each of the fastening portions 333b. .

[Fourth embodiment]

In the first to third embodiments, the cover portion 31 or the like is applied to the main shaft portion 31 or the like by applying a force from the radially outer circumferential side toward the axial center side. In the fourth embodiment, a configuration example of the main body portion and the lid portion is provided by sliding in the direction of the rotation axis.

Fig. 8 is an enlarged view showing a main portion 430 of the fourth embodiment and a part of a side surface in the radial direction of the lid portion 431. In the figure (a), the main body portion 430 is provided in the vicinity of the radially outer end portion and has a groove portion 432 extending in the direction of the rotation axis. The radial width of the groove portion 432 is substantially the same as or slightly larger than the radial thickness of the lid portion 431. Further, a protruding portion 433 constituting a radially inner wall of the groove portion 432 is formed at a front end portion on the radially outer peripheral side of the main body portion 430. The protruding portion 433 has a shape that protrudes outward from the rotating direction toward the laminated core side.

The lid portion 431 has a flat plate shape in which the surface having the axial center side is in contact with the radially outer peripheral side surface of the laminated core 5, and the length in the direction of the rotation axis is about the body portion 430. The 1/2 way is divided in the center.

As shown in FIG. 2(b), each of the lid portions 431a and 431b is inserted into the groove portion 433 from the side opposite to the direction of the rotation axis.

For example, when the cover portion 431 is an undivided flat plate, since the cover portion 431 and the contact surface with the laminated core 5 are also proportionally increased as being inserted into the groove portion 432, there is also a cause and a laminated core 5 The frictional force increases to make it difficult or impossible to insert the cover portion 431. In the case where the lamination direction of the laminated core 5 is radial, the steel sheet having the outermost peripheral side surface is rolled, and when the lamination direction is the rotating direction, the steel sheet is partially wrinkled in the radial direction ( Kink).

In this embodiment, by dividing the lid portion 431 and shortening the length of each of the members in the direction of the rotation axis, the friction area with the laminated core 5 is compared with that of the laminated core portion 431 when the cover portion 431 is inserted. The case of splitting is up to 1/2. Further, since one of the lid portion 431a and the other lid portion 431b are inserted from the opposite side to the rotation axis direction, the entire laminated core 5 can be prevented from being deformed in the direction of the rotation axis of either one.

[Fifth Embodiment]

In the fifth embodiment, the cover portion and the main body portion are provided by sliding, similarly to the fourth embodiment. However, one of the feature points is such that the cover portion is supported from the outer side in the rotational direction toward the laminated core 5 side.

Fig. 9 is an enlarged view showing a main portion 530 of the fifth embodiment and a part of a side surface in the radial direction of the lid portion 531. As shown in the figure (a), the radially distal end portion of the main body portion 530 and the end portion in the rotational direction of the lid portion 531 are provided in the radially engaging buckle portions 533a and 533b. The buckle portion 533a has a shape in which the end portion is locked in the axial direction so as to be engaged with the buckle portion 533b located on the inner side in the rotation direction. Further, the locking portion 533a has a hook portion 534a that protrudes toward the rotation direction of the laminated core 5 at the tip end thereof. On the other hand, the locking portion 533b has a hook portion 534b that protrudes outward in the rotational direction at the distal end of the radial direction. The locking portion 533b is substantially in the shape of an internal space surrounded by the lid portion 531, the locking portion 533a, and the hook portion 534a. The shape.

In addition, as shown in the figure (b), the lid portion 531 has a lid portion 531a divided into a length of one-half of the length of the main body portion 530 in the direction of the rotation axis direction, and the lid portion 531b. Composition. The lid portions 531a and 531b are respectively slid to the body portion 530 from the opposite side to the rotation axis direction. Specifically, the lid portion 531 is slid in the rotation axis direction at a position where the fastening portion 533b of the main body portion 530 and the fastening portion 534a of the lid portion 531 are engaged with each other.

In the present embodiment, the cover portion 531 is configured to hold the main body portion 530 on the side of the laminated core 5 from the outer side in the rotational direction. Therefore, even in the main body portion 530, for example, there is no member that causes stress in the rotational direction of the crotch portion 6a. In this case, there is no possibility that the main body portion 530 is unfolded outward in the rotational direction.

Further, by hooking the hook portions 534a and 534b to each other in the opposite direction to the rotation direction, the fixed state of the insulator 6 and the laminated core 5 can be sufficiently maintained.

The effect of the configuration of the division or the sliding arrangement of the lid portion 531 is the same as that of the fourth embodiment.

[Sixth embodiment]

In the same manner as the first to fifth embodiments, the sixth embodiment is characterized in that the radially outer end portions of the main body portion are in contact with both end portions in the rotational direction of the lid portion to form the tubular insulator 6. One of the points is not a structure in which the two are fitted or fastened, and the tension of the wound coil 7 is used to maintain the state in which the insulator 6 and the laminated core 5 are fixed.

Fig. 10 shows the configuration of the main body portion 630 and the lid portion 631 of the sixth embodiment. In the figure (a), the left side indicates the front surface of the main body portion 630 and the lid portion 631 in the direction of the rotation axis, and the right side of the figure (b) indicates the radial front surface.

The flange portion 6a of the insulator 6 is divided into a body portion 630 and a lid portion 631, and each of them is integrally formed. Unlike the other embodiments, the surface of the main body portion 630 that is in contact with the lid portion 631 is substantially flat. Further, in the contact surface between the main body portion 630 and the lid portion 631, a concave-convex portion or the like may be provided as a combination for positioning.

Further, a convex portion 631a is provided on the radial axial side surface of the lid portion 631. The convex portion 631a is configured to extend in the direction of the rotation axis of the side surface, and has a width in the rotation direction that is slightly smaller than a length between both end portions of the radially outer side of the body portion 631. When the lid portion 631 and the body portion 630 are combined, the convex portion 631a presses the laminated core 5 in the axial direction. That is, it functions to ensure that the insulator 6 and the laminated core 5 are fixed. In addition, it is also expected that the convex portion 631a functions as a spacer in the case where the thickness of the laminated core 5 is uneven.

After the laminated core 5 is placed in the inner tubular portion of the main body portion 630, the convex portion 631a is placed toward the laminated core 5 side to provide the lid portion 631. Next, as shown in the figure (b), the coil 7 is continuously wound around the outer cylinder with a specific tension. Alternatively, after the lid portion 631 is disposed, the coil 7 may be wound by being temporarily fixed by a band 600, an adhesive or an adhesive tape.

As described above, in the sixth embodiment, the configuration of the main body portion 630 and the lid portion 631 and the vicinity of the contact surface can be easily realized. Further, since the crotch portion 6a is also divided, there is no possibility that an excessive load is applied when the two are combined. Further, with respect to the force applied to the side of the laminated core 5 by the tension of the coil 7, the pressing force generated by the convex portion 631 further contributes to the stress of the laminated core 5, and the body portion 630 and the cover portion 631 can be made. Fixed indeed.

Further, in the sixth embodiment, the configuration in which the insulator 6 has the crotch portion 6a is taken as an example, and the effect of the present embodiment can be expected even if it is constituted by the flawless portion 6a.

〔Production method〕

Finally, a method of manufacturing the insulator 6 of the first to sixth embodiments will be described. The insulator 6 composed of an insulating resin is generally produced by injection molding in which a resin is enclosed in a mold frame, but may be produced by three-dimensional molding or the like. In the case of using a three-dimensional shape, not only the insulator 6 itself but also a mold frame for injection molding can be used. As the three-dimensional shape, for example, a laminate forming machine, a cutting RP device, or the like is used.

As a laminate formation, a photo-forming method, a powder sintering laminate forming method, an ink jet method, a resin melting lamination method, a gypsum powder method, a sheet forming method, and a film transfer pattern can be applied. Image layering and metal light shaping Composite processing methods, etc.

The above-mentioned data for the formation or cutting process is produced by the CAM processing the 3D data generated in the CAD or CG software or the 3D scanner into NC data. The three-dimensional shape is formed by inputting the data to a three-dimensional forming machine or a cutting RP apparatus. In addition, NC data can be directly generated from 3D data by CAD/CAM software.

Further, as a method of obtaining the insulator 6, the following manufacturing method may be employed: a data provider or a service provider who creates the 3D material or the NC data of the insulator 6 may be distributed in a specific file form via a communication line such as the Internet. The user downloads the data from a 3D forming machine or a computer controlling the same, or accesses it as a cloud type service, and forms the output in a 3D shape forming machine. . In addition, the data provider can also record the 3D data or the NC data on the non-volatile recording medium and provide the method to the user.

When one aspect of the insulator 6 formed by such a manufacturing method is shown, a method of manufacturing an insulating member including: an inner cylindrical portion which is changed from a shaft center side toward an outer peripheral side having a width in a rotating direction The outer core of the substantially radial cross-sectional shape has substantially the same outer shape; the outer tubular portion is wound around the outer circumferential side of the core; and the three-dimensional data based on the insulating member is as follows: In the method of manufacturing a molding machine, the insulating member includes: a first insulating member that is in contact with an outer peripheral surface of a core on a side where the width in the rotation direction is increased; and a second insulating member that is in contact with the first insulating member The outer peripheral portion of the core other than the outer peripheral surface of the core is in contact with each other; and both end portions of the second insulating member are in contact with both end portions of the first insulating member in the rotational direction.

Alternatively, the first insulating member and the second insulating member may be manufactured by a three-dimensional forming machine.

In addition, when another aspect is displayed, the three-dimensional forming machine data of the insulating member is transmitted and distributed via a communication line, and the insulating member includes an inner cylindrical portion which is self-centered by having a width in the rotational direction. a substantially cylindrical shape with a radial cross-sectional shape that becomes larger toward the outer peripheral side The core of the body composition has substantially the same outer shape; the outer tubular portion is wound around the outer circumferential side of the core; and the first insulating member includes a core having a side in which the width in the rotational direction is increased. The outer peripheral surface contact; and the second insulating member is in contact with the outer peripheral portion of the core other than the outer peripheral surface of the core in contact with the first insulating member; and the radial both end portions of the second insulating member and the first portion The two ends of the insulating member are in contact with each other in the direction of rotation.

Further, it may be a method of independently transmitting and distributing the first insulating member and the three-dimensional forming device of the second insulating member.

The embodiments of the present invention have been described above, but the present invention is not limited to the above-described embodiments, and various modifications can be made without departing from the scope of the invention.

For example, the insulator 6 having the laminated core 5 and the inner cylinder corresponding to the outer peripheral shape thereof is exemplified as a substantially trapezoidal cross section, but some or all of them may be curved surfaces. In other words, in the case where the plurality of divided core members are arranged annularly in the stator 2, it is also conceivable that the surface on the radial axis side and/or the outer peripheral side of the core is substantially concentric with the other cores. In this case, the cross-section on the radially outer peripheral side and/or the inner peripheral side of each of the cores or the like is a curved curved surface.

Further, in the present embodiment, the motor is exemplified as the rotating electrical machine, but it may be a generator.

5‧‧‧Laminated iron core

6‧‧‧Insulator

30‧‧‧ Body Department

31‧‧‧ 盖部

31a‧‧‧ Cover end

32‧‧‧Slots

32a‧‧‧The inner wall of the trough

32b‧‧‧The inner wall of the trough

32c‧‧‧Surface

R‧‧‧vertical distance

R'‧‧‧ vertical distance

Claims (16)

An axial gap type rotating electric machine comprising a core member, the core member comprising: a core body consisting of a substantially cylindrical body having a radial cross-sectional shape in which a width in a rotation direction increases from an axial center side toward an outer circumference side; an insulating member; An inner cylinder shape substantially the same as a peripheral shape of the iron core; and a coil wound around the outer tubular portion of the insulating member; and the axial gap type rotating electrical machine includes: a stator centered on a rotating shaft Forming a plurality of the core members in a shape; and at least one rotor facing at least one end surface of the stator core with a gap therebetween in a direction of a rotation axis; and the insulating member includes: a first insulating member And the second insulating member is in contact with the outer peripheral portion of the core other than the peripheral surface in contact with the first insulating member; and the second insulating layer is in contact with the outer peripheral surface on the side in which the width in the rotation direction is increased; and the second insulating member is in contact with the outer peripheral portion of the core other than the first insulating member; The radially end portions of the member are in contact with both end portions of the first insulating member in the rotational direction. The axial gap rotary electric machine according to claim 1, wherein the second insulating member includes a groove portion on a surface of the core side in the vicinity of both end portions in the radial direction, and the groove portion and the rotation of the first insulating member Both ends of the direction are fitted. The axial gap rotary electric machine according to claim 2, wherein a radial width of the groove portion is larger or substantially the same as a radial thickness of both end portions of the first insulating member in a rotational direction. The axial gap rotary electric machine according to claim 2, wherein the second insulating member has a plurality of the groove portions in the axial direction. The axial gap rotary electric machine according to claim 4, wherein the first insulating member has a convex portion extending in a direction of a rotation axis on a surface on a radially outer peripheral side. The axial gap type rotary electric machine according to claim 2, wherein the groove portion extends in the direction of the rotation axis. The axial gap rotary electric machine according to claim 2, wherein the first insulating member is fitted to the first insulating member by pressing the first insulating member from the radially outer peripheral side toward the axial center side. The axial gap type rotating electrical machine according to claim 2, wherein the first insulating member includes a plurality of members that are divided in the radial direction. The axial gap rotary electric machine according to claim 2 or 8, wherein the first and second insulating members are fitted by inserting the first insulating member from the direction of the rotation axis. The axial gap rotary electric machine according to claim 1, wherein the radially opposite end portions of the first insulating member and the radially opposite end portions of the second insulating member have engaging portions that are engaged with each other. The axial gap rotary electric machine according to claim 1, wherein the first insulating member has a groove extending in a direction of a rotation axis in a surface in contact with a peripheral surface of the side having a larger width in the rotation direction. The axial gap type rotating electrical machine according to any one of claims 1 to 2, wherein said radial section of said core is substantially rectangular. The axial gap type rotating electrical machine according to any one of claims 1 to 2, wherein the radial cross section of the core is substantially trapezoidal. The axial gap type rotating electrical machine according to any one of claims 1 to 2, wherein the iron core is a laminated core. An axial gap type rotating electrical machine according to any one of claims 1, 2 or 10, wherein The iron core is a laminated core in which steel sheets are laminated in the radial direction. An insulating member comprising: an inner cylindrical portion having substantially the same shape as a peripheral shape of a core composed of a substantially cylindrical shape having a radial cross-sectional shape which has a width in a rotation direction from an axial center side toward an outer peripheral side; and an outer cylinder a coil that is disposed around the outer circumference side of the core, and includes: a first insulating member that is in contact with a peripheral surface that is larger in width in the rotation direction; and a second insulating member that is different from the first insulating member (1) The insulating member contacts the outer peripheral portion of the core other than the outer peripheral surface; and the both end portions of the second insulating member are in contact with both end portions of the first insulating member in the rotational direction.