WO2013011627A1 - 回転電動機およびその製造方法 - Google Patents
回転電動機およびその製造方法 Download PDFInfo
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- WO2013011627A1 WO2013011627A1 PCT/JP2012/003874 JP2012003874W WO2013011627A1 WO 2013011627 A1 WO2013011627 A1 WO 2013011627A1 JP 2012003874 W JP2012003874 W JP 2012003874W WO 2013011627 A1 WO2013011627 A1 WO 2013011627A1
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- coating material
- layer coating
- armature
- upper layer
- viscosity
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/30—Windings characterised by the insulating material
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
- H01B3/002—Inhomogeneous material in general
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/12—Impregnating, heating or drying of windings, stators, rotors or machines
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/12—Impregnating, heating or drying of windings, stators, rotors or machines
- H02K15/125—Heating or drying of machines in operational state, e.g. standstill heating
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K2205/00—Specific aspects not provided for in the other groups of this subclass relating to casings, enclosures, supports
- H02K2205/12—Machines characterised by means for reducing windage losses or windage noise
Definitions
- the present invention relates to a rotary motor composed of a field having at least a field winding and an armature having an armature winding coated with a coating material having electrical insulation used for a vacuum cleaner and the like, and its manufacture Regarding the method.
- FIG. 2 is a side partial cross-sectional view illustrating the configuration of a commutator electric blower incorporating a general rotary electric motor.
- the commutator electric blower incorporating the rotary motor includes a motor unit 6 and a fan unit 7.
- the motor unit 6 includes a field 16 having at least a field winding 17, and an armature 1 including a commutator 8 and an armature winding 9.
- the armature 1 is provided with a shaft 10, and the armature 1 is supported by press-fitting the shaft 10 into bearings 11 provided on a fan side bracket 12 and a commutator side bracket 13 that constitute both ends of the motor.
- the brush holder 14 is made of metal with a built-in carbon brush 15 and is held by the commutator side bracket 13.
- the fan unit 7 is provided with a fan 18 that sucks air from the air inlet 19 (upper side in FIG. 2) and blows it out to the outer periphery of the fan 18. A part of the wind (air) blown to the outer periphery of the fan 18 is guided to the inside of the motor unit 6 to cool the armature winding 9 and the like of the armature 1.
- the electric wires constituting the field winding 17 of the field 16 of the rotary motor incorporated in the commutator electric blower having the above structure or the armature winding of the armature 1 are fixed by a so-called varnish coating material.
- a so-called varnish coating material has been.
- the vibration and the sound resulting from the movement of the electric wire at the time of rotation of a rotary motor are suppressed.
- covers an electric wire by the electric wires rubbing is prevented. Therefore, the varnish (coating material) applied in order to sufficiently fix the electric wires in the slot and the slot and the electric wire is important.
- the efficiency of a rotary motor decreases due to mechanical loss such as iron loss, copper loss, bearing loss and brush wear loss, and windage loss. Therefore, in order to drive the rotary motor with high efficiency, it is important to reduce these losses.
- rotary motors used for blower motors for vacuum cleaners are currently driven at a high speed rotation of 40,000 revolutions / minute or more. Therefore, in a rotary electric motor that rotates at a high speed, windage loss is dominant, resulting in an efficiency reduction of about 10%. That is, in a rotary electric motor that rotates at a high speed, efficiency can be greatly improved by reducing windage loss.
- the varnish is applied only to the extent that the wires are fixed to each other at the coil end of the armature 1 having the armature winding 9. Therefore, in the coil end of the armature 1, there is a problem that turbulence is generated due to the unevenness formed by the overlapping of the electric wires, and the windage loss increases.
- Patent Documents 1 to 4 disclose electric motors that disclose a method for reducing windage loss due to unevenness.
- the AC commutator motor of Patent Document 1 applies a coating material having an electrical insulating property with different viscosities two or more times to increase the thickness of the coating material, and smoothes the unevenness caused by the overlapping of the coil end wires.
- the technology is disclosed. Specifically, first, a low-viscosity coating material is applied to the coil end wires, the coating material is infiltrated between the wires, and the wires in the slot or between the slots and the wires are fixed. Thereafter, the coating material having a high viscosity is applied on the coil end to which the coating material having a low viscosity is applied. Thereby, it is said that the unevenness can be smoothed by thickly applying the coating material to the coil end.
- Patent Document 2 discloses a technique of flattening the unevenness of the coil end with an insulating mold material and integrally forming a rotation balance adjusting member.
- the commutator electric blower of Patent Document 3 discloses a technique for covering the outer periphery of the winding portion on the fan side of the armature with a windage loss reducing cover made of an insulating material.
- the electric motor of Patent Document 4 smoothly applies the electric insulating resin to the coil end by providing a resin movement suppressing member that suppresses the flow of the electric insulating resin to be applied on the outer peripheral portion of the rotating shaft of the coil end.
- the technology is disclosed.
- Patent Document 1 discloses that two or more types of coating materials having different viscosities are applied, but does not disclose the specific configuration or viscosity of the coating material.
- the viscosity of the coating material varies greatly depending on the temperature. Therefore, in the disclosed contents of Patent Document 1, it is unclear which temperature the viscosity is suitable for the coating material and how much viscosity difference is effective. For example, even if a coating material with a high viscosity at room temperature is used, the effect of smoothing the unevenness due to a decrease in the viscosity of the coating material while it is heated to the curing temperature of the coating material after application is not obtained There is.
- an insulative mold material that also serves as a rotation balance adjusting member is integrally formed, so that a mold having a complicated structure is required.
- the commutator electric blower of Patent Document 3 has a problem that the temperature of the fan-side winding portion rises due to the air layer between the wind loss reducing cover and the coil end and the copper loss increases. Further, in order to use the commutator electric blower as a motor for a vacuum cleaner, a thick and large windage loss reduction cover that can withstand the centrifugal force of the armature rotating at high speed is required. Therefore, it becomes a motor that is difficult to actually use.
- the electric motor of Patent Document 4 is provided with a resin movement suppressing member, so that even when a low-viscosity varnish is used, it is possible to apply the coating material to a certain extent.
- a large resin movement suppressing member is required to apply a sufficient varnish in the gaps or slots between the electric wires and to apply a varnish capable of smoothing the unevenness caused by the electric wires at the coil end.
- the resin suppressing member cannot be installed at the coil end on the commutator side of the armature, there is a problem that the windage loss due to the unevenness of the electric wire on the commutator side of the armature cannot be suppressed.
- a rotary electric motor includes a field having at least a field winding and an armature having an armature winding coated with a coating material having electrical insulation. Is composed of at least two layers of a lower layer coating material comprising a first low-viscosity resin liquid and a second low-viscosity resin liquid to which at least hollow glass beads and a thermoplastic resin are added.
- the method for manufacturing a rotary electric motor of the present invention includes a preheating step of heating the armature before applying the coating material, and a coating step of applying or extruding the coating material while rotating the armature around the shaft. And a curing step of further heating the coated armature to cure the coating material.
- the application material can be applied in a symmetrical conical shape with the shaft as the center, and the occurrence of unbalance of the axial load can be suppressed. As a result, a reduction in efficiency due to windage can be prevented, and a highly reliable rotary electric motor can be easily manufactured by suppressing cracking and peeling of the coating material.
- FIG. 1 is a partial cross-sectional view of an armature of a rotary motor according to Embodiment 1 of the present invention.
- FIG. 2 is a side partial cross-sectional view illustrating the configuration of a commutator electric blower incorporating a general rotary electric motor.
- Embodiment 1 the rotary electric motor according to Embodiment 1 of the present invention will be described with reference to FIG.
- the rotary electric motor of the present embodiment is basically the same as the configuration of the rotary electric motor described in the background art with reference to FIG. This will be described in detail below.
- FIG. 1 is a partial cross-sectional view of an armature of a rotary motor according to Embodiment 1 of the present invention.
- the armature 1 of the rotary electric motor includes an insulating paper made of, for example, polyamide paper in a slot formed in a laminated core 2 made of, for example, an electromagnetic steel plate, and coils the electric wires. It is configured to be wound in a shape.
- the coil-shaped electric wire is covered with a coating material composed of at least two layers of an upper layer coating material 5 and a lower layer coating material. Specifically, the lower layer coating material is first applied to the electric wire wound in a coil shape. Thereby, the electric wires of the fan side coil end 3 and the commutator side coil end 4, the slots, the insulating paper and the electric wires are fixed by the lower layer coating material.
- the upper layer coating material 5 is further applied so as to cover the irregularities formed on the surfaces of the fan side coil end 3 and the commutator side coil end 4.
- the viscosity of the upper layer coating material 5 is at least larger than the viscosity of the lower layer coating material.
- a lower layer coating material which is a first low-viscosity resin liquid made of a thermosetting resin such as unsaturated polyester, is infiltrated into the gaps between the electric wires, and the electric wires in the slots and the slots and the electric wires Adhering via a lower underlayer coating.
- At least the hollow glass beads and a thermoplastic resin such as saturated polyester are added to the upper layer of the electric wires of the fan side coil end 3 and the commutator side coil end 4 fixed with the lower layer coating material.
- a high-viscosity upper layer coating material 5 composed of the second low-viscosity resin liquid is applied.
- the upper layer coating material 5 can be thickly applied so as to cover the unevenness caused by the overlapping of the electric wires of the fan side coil end 3 and the commutator side coil end 4.
- thermoplastic resin particularly a saturated polyester resin
- the molding shrinkage during curing of the coating material is reduced, and the heat generated during rotation of the rotary electric motor and the cooling during stoppage are reduced.
- the influence of the heat shock caused by can be reduced.
- the second low-viscosity resin liquid, the thermoplastic resin, and the hollow glass beads constituting the upper layer coating material 5 are, for example, a blade-type stirring mixer, a Banbury mixer, a roll, depending on the required viscosity of the upper layer coating material 5
- the mixing is performed using an optimal mixer such as a planetary mixer.
- the upper layer coating material 5 can be applied on the electric wires at the coil end portions of the fan side coil end 3 and the commutator side coil end 4 sufficiently thickly so as to cover the unevenness and make it smooth. As a result, windage loss can be reduced and efficiency can be improved.
- the weight per occupied volume (hereinafter may be referred to as “specific gravity”) can be reduced compared to general glass powder and inorganic fillers. It is possible to make the weight per occupied volume equal to or less than that of the resin. That is, the weight per occupied volume of the upper layer coating material can be significantly reduced as compared with the upper layer coating material to which other inorganic fillers having a solid configuration are added. Thereby, the centrifugal force proportional to the weight (mass) applied to the upper layer coating material when the armature is rotated at a high speed can be further reduced. As a result, it is possible to further suppress peeling of the upper layer coating material 5 due to centrifugal force applied when the armature rotates.
- the lower layer coating material constituting the coating material can fix the wires in the slots and the slots and the wires with sufficient strength.
- the upper layer coating material 5 constituting the coating material covers and smoothes the unevenness caused by the overlapping of the electric wires at the coil end portions of the fan side coil end 3 and the commutator side coil end 4, thereby reducing windage loss. High efficiency can be achieved. As a result, it is possible to realize a highly efficient rotary motor with high reliability without cracking or peeling of the coating material.
- the unsaturated polyester resin is described as an example of the first low-viscosity resin liquid and the second low-viscosity resin liquid.
- a liquid varnish that is usually used for fixing an armature coil may be used. You may comprise the 2 low-viscosity resin liquid.
- the viscosity of the first low-viscosity resin liquid and the second low-viscosity resin liquid is small.
- the upper coating material 5 is adjusted so as to increase the viscosity by adding hollow glass beads to the second low viscosity resin liquid, it is preferable that the viscosity of the second low viscosity resin liquid itself is small.
- the viscosity of the first low-viscosity resin liquid and the second low-viscosity resin liquid is preferably greater than 0 (zero) Pa ⁇ s and 1 Pa ⁇ s or less at 25 ° C. (Zero) Pa ⁇ s is more preferably 0.7 Pa ⁇ s or less.
- the reason is that if the first low-viscosity resin liquid and the second low-viscosity resin liquid having a viscosity exceeding 1 Pa ⁇ s are used, the permeability of the armature into the slot is lowered, so that the wire is not sufficiently fixed. And the application time is prolonged. Therefore, the said malfunction can be avoided by making small the viscosity of a 1st low viscosity resin liquid and a 2nd low viscosity resin liquid.
- the particle size of the hollow glass beads is in the range of 1 to 30 ⁇ m, and the ratio of the hollow glass beads in the upper layer coating material 5 is 28 to 44% by weight is preferred.
- the particle size of the hollow glass beads is preferably 1 to 25 ⁇ m, and the proportion of the hollow glass beads in the upper coating material 5 is more preferably 30 to 40% by weight.
- the particle size of the hollow glass beads is small and less than 1 ⁇ m, or the proportion of the hollow glass beads in the upper layer coating material 5 is large and exceeds 44% by weight, the viscosity of the upper layer coating material 5 becomes too large. , Handling and application itself become difficult.
- the particle size of the hollow glass beads is large and exceeds 30 ⁇ m, or the proportion of the hollow glass beads in the upper layer coating material 5 is small and less than 28% by weight, the viscosity of the upper layer coating material 5 becomes too small. , Thixotropy cannot be imparted. Therefore, the upper layer coating material 5 cannot be applied more thickly as the unevenness of the electric wires at the coil end portions of the fan side coil end 3 and the commutator side coil end 4 is smoothly covered. Furthermore, the upper layer coating material 5 flows between the armature shaft, the laminated core, the commutator copper pieces, and the like, and problems such as the electrical connection of the armature and the unbalance of the axial load applied to the shaft occur.
- the ranges such as the viscosity of the first low-viscosity resin liquid and the second low-viscosity resin liquid described above, the particle size of the hollow glass beads, and the ratio in the upper layer coating material are examples, and are limited to this range. It goes without saying that it is not done. The reason is various such as coating temperature, armature rotation speed, coating speed such as coating speed and coating time, preheating and curing conditions, shape and dimensions of armature to be applied, wire dimensions and number of turns, etc. There is an optimum coating material due to various factors. Therefore, the viscosity of the first low-viscosity resin liquid and the second low-viscosity resin liquid, the particle size of the hollow glass beads, and the ratio in the upper layer coating material cannot be uniquely set.
- the saturated polyester has been described as an example of the thermoplastic resin.
- the shrinkage during curing of the second low-viscosity resin liquid of the upper layer coating material 5 can be reduced, and the occurrence of cracks in the coating material is suppressed.
- Any thermoplastic resin that can be used is not limited to this.
- an elastomeric thermoplastic resin such as polyvinyl acetate, polystyrene, saturated polyester resin, or SBS (styrene / butadiene) can be used.
- a saturated polyester resin is particularly preferable in consideration of compatibility with the second low-viscosity resin liquid made of a thermosetting resin such as an unsaturated polyester resin and a melting point.
- the ratio of the thermoplastic resin in the upper layer coating material 5 is preferably 6 to 15% by weight.
- the reason is that when the ratio of the thermoplastic resin in the upper layer coating material 5 is less than 6% by weight, a sufficient low shrinkage effect on the upper layer coating material 5 and a suppression effect on the occurrence of cracks cannot be obtained.
- the ratio of the thermoplastic resin in the upper layer coating material 5 exceeds 15% by weight, the strength of the upper layer coating material 5 (for example, mechanical strength such as bending strength and tensile strength) and the fixing force (for example, electric wire) (Adhesive force) of the armature is reduced, and there may be a problem such as peeling of the upper layer coating material when the armature rotates.
- the specific gravity of the upper layer coating material 5 is preferably greater than 0 (zero) and 1.5 or less. If the specific gravity of the upper layer coating material 5 exceeds 1.5, cracks and peeling of the upper layer coating material due to centrifugal force are likely to occur during high-speed rotation of the armature.
- thermosetting property such as unsaturated polyester resin
- the 1st low-viscosity resin liquid of the lower layer coating material which comprises a coating material is used as the 1st low-viscosity resin liquid of the lower layer coating material which comprises a coating material
- the 2nd low-viscosity resin liquid of an upper layer coating material is used as the 1st low-viscosity resin liquid of the lower layer coating material which comprises a coating material
- the 2nd low-viscosity resin liquid of an upper layer coating material is used as the 1st low-viscosity resin liquid of the lower layer coating material which comprises a coating material
- the 2nd low-viscosity resin liquid of an upper layer coating material is not limited to this.
- different thermosetting resins may be used for the first low-viscosity resin liquid and the second low-viscosity resin liquid.
- thermosetting resin in consideration of adhesion between the upper layer coating material 5 and the lower layer coating material, work efficiency, and the like.
- the upper layer coating material is applied to both the fan side coil end and the commutator side coil end.
- the present invention is not limited to this.
- the upper layer coating material can be easily applied to either the fan side coil end or the commutator side coil end of the armature, for example, at least one of the fan side coil end and the commutator side coil end,
- coats an upper layer coating material may be sufficient. Thereby, according to the characteristic, productivity, and cost which are requested
- Example 1 As Example 1, the following coating material was applied to produce an armature, and the coating material was evaluated from the state of application and the characteristics of the rotary motor.
- first low-viscosity resin liquid and a second low-viscosity resin liquid Hitachi Chemical WP2851 which is an unsaturated polyester having a viscosity at 25 ° C. of 0.5 Pa ⁇ s was used. Moreover, Hitachi Chemical Industries CT48 was used as a hardening
- DH Material's Sandoma PB987 in which saturated polyester is dissolved in styrene, is used as a thermoplastic resin. Using. At this time, the content of saturated polyester in Sandoma PB987 was 65%.
- an upper layer coating material 75 parts by weight of WP2851 and 2 parts by weight of CT48 and 25 parts by weight of Sandoma PB987 were stirred / mixed with a blade-type stirring mixer to prepare a resin liquid. Then, the hollow glass beads A were added to the prepared resin solution in a change amount of 0, 20, 30, 40, 50, 70, 80, and 90 parts by weight, and mixed using a planetary mixer that rotates and revolves. . Thereby, in the following (Table 1) No. 1 to No. Eight types of upper layer coating materials shown in Sample No. 8 were produced.
- an armature in which an electric wire having a diameter of 0.5 mm is wound around a laminated iron core having a thickness of 20 mm and an outer diameter of 40 mm and 22 slots, and a commutator having a diameter of 20 mm and a height of 18 mm is arranged on one side.
- the height of the coil end portion of the fan side coil end was about 7 mm
- the height of the coil end portion of the commutator side coil end was about 10 mm.
- the lower layer coating material, the upper layer coating material, and the armature were prepared as described above.
- the lower layer coating material and the upper layer coating material were applied to the armature by the method described below.
- the armature was preheated to 110 ° C., the armature shaft was tilted 5 ° from the horizontal, the commutator side was directed upward, and the armature was attached to the rotating jig.
- the lower layer coating material was dropped and applied between the wires in the slot and between the slots and the wires using a tubing pump. .
- the armature was rotated and placed in a constant temperature bath at 140 ° C. for 20 minutes to harden the wires in the slot and the slots and the wires.
- the armature coated with the lower layer coating material is preheated to 110 ° C. again, and the upper layer coating material is simultaneously applied to the fan side coil end and the commutator side coil end under the same conditions as the coating of the lower layer coating material.
- the upper layer coating material was rotated and placed in a 140 ° C. constant temperature bath and cured for 20 minutes.
- the coating amount of the upper layer coating material applied to each sample was applied so as to be almost the same volume regardless of the addition amount of the hollow glass beads A.
- No. In the sample No. 8 since 90 parts by weight of the upper layer coating material of the hollow glass beads A could not be dropped by a tubing pump, it was coated by extrusion coating using a cylinder.
- a coating material composed of a lower layer coating material and an upper layer coating material was applied and produced.
- 1 to No. Eight sample armatures were evaluated by applying the upper layer coating material, the efficiency measured by assembling the armature to the rotary motor, and the reliability test (ON-OFF test) incorporating the rotary motor into the vacuum cleaner body. did.
- No. 1 coated with an upper layer coating material added with 40 parts by weight (about 28% by weight) or more of hollow glass beads A was applied. 4 to No.
- the sample of No. 7 had almost no unevenness due to the electric wires at the fan side coil end and the armature side coil end, and could be applied smoothly (smoothly). It was also found that the efficiency can be improved by about 0.4%.
- No. 1 coated with an upper layer coating material added with 0, 20, or 30 parts by weight of hollow glass beads A was used. 1 to No. Of the three samples, no. 2 and No. In the sample No. 3, the unevenness due to the electric wires at the fan side coil end and the armature side coil end could be applied almost smoothly, but no significant improvement in efficiency was realized. The reason for this is considered to be that most of the upper layer coating material drips during coating because the viscosity of the upper layer coating material is small. Furthermore, 0 part by weight of No. In the sample 1, the viscosity of the upper layer coating material was too small, and the upper layer coating material could not be thickly applied to the fan side coil end and the armature side coil end, and irregularities due to electric wires were observed.
- Example 2 As Example 2, an armature was produced by changing the filler added to the upper coating material of the coating material shown below, and the coating material was evaluated from the application state and the characteristics of the rotary motor in the same manner as in Example 1. At this time, the constituents and manufacturing method of the lower layer coating material and the upper layer coating material other than the filler, the manufacturing method of the armature, and the like were performed under the same conditions as in Example 1.
- No. An armature was prepared using hollow glass beads B having a particle size range of 10 to 50 ⁇ m and an average particle size of 35 ⁇ m as the filling of the sample 2.
- No. An armature was produced using glass powder obtained by pulverizing glass fibers having a diameter of 10 ⁇ m to a length of several ⁇ m to 100 ⁇ m as a filling of the sample 3.
- No. An armature was prepared using calcium carbonate having a particle size range of 1 to 60 ⁇ m and an average particle size of 10 ⁇ m as a filling of the sample No. 4.
- Table 2 The increase in efficiency in (Table 2) is the same as that in Example 1. No. 1 on the basis of the efficiency of 0% by weight (parts by weight) of the hollow glass bead A added as a sample. The rate of increase / decrease (%) for one sample is shown.
- the filler added to the upper layer coating material is preferably hollow glass beads having a small specific gravity and a predetermined particle size range. Thereby, it turned out that adjustment of the viscosity of an upper layer coating material and provision of thixotropy can be performed.
- Example 3 As Example 3, armatures were prepared by changing the amount of the thermoplastic resin made of saturated polyester added to the upper layer coating material of the coating material shown below. The coating material was evaluated from the characteristics. At this time, components other than the additive amount of the thermoplastic resin, the constituents and manufacturing method of the upper coating material, the manufacturing method of the armature, and the like were performed under the same conditions as in Example 1.
- the amount of the thermoplastic resin added to the upper layer coating material is 0, 10, 15, 25, 35, 40 parts by weight. 1 to No. Six samples were prepared. At this time, according to the addition amount of the thermoplastic resin, the ratio of WP2851, which is the second low-viscosity resin made of the unsaturated polyester of Example 1, is set to 100, 90, 85, 75, 65, 60 parts by weight, and the upper layer A coating material was prepared. Each sample was prepared with the addition amount of the curing agent CT48 being constant at 2 parts by weight and the addition amount of the hollow glass beads A being constant at 50 parts by weight.
- Example 3 The increase in efficiency in (Table 3) is the same as that in Example 1. No. 1 of Example 1 on the basis of the efficiency of the addition amount of 0% by weight (parts by weight) of the hollow glass beads A of the sample 1. The rate of increase / decrease (%) for one sample is shown. Further, the weight% of the thermoplastic resin in (Table 3) represents the weight% of the saturated polyester excluding styrene.
- thermoplastic resin added As shown in (Table 3), no. 1 to No. In all 6 samples, the efficiency increased by about 0.4%. However, the amount of thermoplastic resin added is small. 1 and No. In sample 2, microcracks were generated in the coating material after coating. This is presumably because the amount of the thermoplastic resin added was as small as 10 parts by weight or less, so that a sufficient low shrinkage effect could not be obtained in the upper layer coating material.
- thermoplastic resin added was 40 parts by weight of No.
- the amount of thermoplastic resin added was 40 parts by weight of No.
- microcracks were generated in the coating material, and peeling of microscopic pieces of the coating material was observed. This is considered to be due to the fact that the adhesive force of the coating material was reduced and the centrifugal force by the reliability test could not be endured.
- thermoplastic resin in the upper layer coating material.
- Example 4 As Example 4, the thermoplastic resin of Sandoma PB987 made by DH Material added in Example 1 was changed to a 50% styrene solution of SBS elastomer 315P made by Asahi Kasei Chemicals, and other conditions were No. . An armature was produced under the same conditions as the sample No. 5, and the coating material was evaluated from the coating state and the characteristics of the rotary motor in the same manner as in Example 1. That is, the amount of the filler consisting of the hollow glass beads A was 50 parts by weight (32.9% by weight).
- thermoplastic resin made of a 50% styrene solution of SBS elastomer 315P manufactured by Asahi Kasei Chemicals is effective as an additive for the upper layer coating material in addition to the thermoplastic resin of Sandoma PB987.
- Example 5 As Example 5, the first low-viscosity resin liquid and the second low-viscosity resin liquid of WP2851 manufactured by Hitachi Chemical Co., Ltd., which are unsaturated polyesters added in Example 1, were changed to NV270 manufactured by Nitto Shinko.
- Example 2 the coating material of 8 samples was evaluated from the state of application and the characteristics of the rotary motor.
- Example 4 As shown in (Table 4), it was found that the same effect as in Example 1 was obtained even when the resin liquids of the first low viscosity resin liquid and the second low viscosity resin liquid were changed. That is, the viscosities of the first low-viscosity resin liquid and the second low-viscosity resin liquid are different from those of Example 1, but by adding hollow glass beads, the viscosity of the upper coating material is greatly increased. It was found that thixotropy can also be imparted. As a result, the same result as that of Example 1 was obtained when the addition amount of the hollow glass beads of Example 5 was within the same range as the addition amount of the hollow glass beads of Example 1.
- Embodiment 2 Below, the manufacturing method of the rotary electric motor in Embodiment 2 of this invention is demonstrated.
- the preheated armature is rotated around the shaft of the armature, and the two layers of the lower layer coating material and the upper layer coating material constituting the coating material are used. Is applied by drop coating or extrusion coating. Thereafter, the armature is further heated to cure the two-layer coating material.
- the composition of the lower layer coating material and the upper layer coating material constituting the coating material and the configuration of the armature are the same as those in the first embodiment, and thus description thereof is omitted.
- an armature having an armature winding by winding an electric wire is preheated (preheated) by heating it in, for example, a 110 ° C. constant temperature bath.
- an armature is attached to the rotating jig and heated while rotating at a rotation speed of, for example, 25 rotations / minute.
- the rotational speed may not be the above rotational speed as long as the lower layer coating material does not drip.
- the lower layer coating material constituting the coating material is used in a predetermined amount, for example, a tubing pump, and the fan side coil end and the commutator side coil end of the armature. For example, it is applied dropwise to the coil end.
- an armature is further hardened, for example for 20 minutes, for example with a 140 degreeC thermostat. Thereafter, the armature is cooled to room temperature, for example.
- the lower layer coating material applied to the coil end portion of the preheated armature rapidly decreases in viscosity due to the heat and penetrates into the gaps between the armature slots and the electric wires. Thereafter, the infiltrated lower layer coating material starts to gel and finally hardens, and the wires in the slot and the slots and the wires are fixed with sufficient strength.
- the lower layer coating material is composed of a low-viscosity resin liquid (first low-viscosity resin liquid), it has high fluidity and is not thickly applied to the coil end portion of the armature. Therefore, it is insufficient to cover and smooth the unevenness caused by the overlapping of the electric wires in the coil end portion of the armature.
- the armature coated with the lower layer coating material is preheated (preheated) again, for example, by heating in a constant temperature bath at 110 ° C.
- an armature is attached to the rotating jig and heated while rotating at a rotation speed of, for example, 25 rotations / minute.
- the rotation speed is not limited to the above rotation speed as long as the upper layer coating material does not drip.
- the second low viscosity to which at least hollow glass beads and a thermoplastic resin are added using, for example, a tubing pump or a cylinder while rotating the armature attached to the rotary jig at a rotation speed of 25 rotations / minute.
- the upper layer coating material composed of the resin liquid is dropped or extruded onto the fan side coil end of the armature and the lower layer coating material of the commutator side coil end.
- the upper layer coating material applied on the lower layer coating material at the coil end portion of the preheated armature has its viscosity lowered by the heat and spreads so as to smoothly cover the uneven surface of the coil end portion.
- the viscosity starts to increase rapidly and deposits thickly on the wire of the coil end portion coated with the lower layer coating material.
- the upper layer coating material is formed in a smooth state covering the unevenness caused by the overlapping of the electric wires.
- the armature is further cured, for example, in a constant temperature bath at 140 ° C., for example, for 20 minutes. Thereafter, the armature is cooled to room temperature, for example. Thereby, the upper layer coating material is heated to the curing temperature, and finally the upper layer coating material is cured.
- the armature of the rotary motor is manufactured, and the rotary motor is manufactured by incorporating the manufactured armature.
- the applied lower layer coating material and the coating material constituting the upper layer coating material can be prevented from dripping before the start of gelation.
- the surface of the upper layer coating material apply
- the coating material can be applied in a symmetrical conical shape around the shaft. Therefore, since imbalance of the shaft load is unlikely to occur, the bearing loss can be reduced and the efficiency can be increased.
- the coating material is applied while rotating the armature.
- the present invention is not limited to this, and the armature may be rotated when the coating material is heat-cured.
- the coating material is applied while rotating the armature shaft horizontally
- the present invention is not limited to this.
- the coating material may be applied while rotating the shaft of the armature from the horizontal, for example, by 5 ° and turning the commutator side upward.
- an application material can be penetrate
- a highly reliable armature and rotary motor can be realized.
- the upper layer coating material when the upper layer coating material is applied, the example is described in which the upper layer coating material is cured while being heated uniformly in a thermostatic bath, but is not limited thereto.
- the upper layer coating material may be heated and cured by blowing hot air having a temperature higher than that of the thermostatic chamber to the coil end portion to which the upper layer coating material is applied.
- the coating material is composed of two layers of the lower layer coating material and the upper layer coating material has been described, but the present invention is not limited to this.
- it may be applied three times (three layers) or more depending on the size of the armature and the coating amount of the coating material required to eliminate the unevenness of the coil end portion.
- the next coating material may be applied at least in a gelled state, and after the previously applied coating material is completely cured, An application material may be applied.
- the present invention is not limited to this, and drop coating or extrusion coating can be selected according to the viscosity of the coating material. That is, when the viscosity of the coating material is large and it is difficult to apply dropwise, it is preferable to apply extrusion. Furthermore, when the viscosity of the coating material is large, the coating material may be preliminarily heated to a gelation start temperature or lower and applied in a state where the viscosity of the coating material is reduced. Thereby, even in the case of a coating material having a high viscosity, it can be applied dropwise and workability is improved.
- the present invention is not limited to this, and the application may be performed using a conventional dropping application device such as a varnish.
- coating apparatus can be used as it is or with some changes, such as a pump change. Therefore, the apparatus cost can be suppressed, and the manufacturing conditions and the like do not need to be greatly changed / adjusted, and can be easily introduced. As a result, productivity is high and an armature or the like can be manufactured at low cost.
Abstract
Description
以下、本発明の実施の形態1における回転電動機について、図1を用いて説明する。なお、本実施の形態の回転電動機は、基本的には、背景技術で図2を用いて説明した回転電動機の構成と同様であるので説明を省略し、本発明の特徴である電機子について、以下で詳細に説明する。
実施例1として、以下に示す塗布材を塗布して電機子を作製し、塗布の状態および回転電動機の特性から塗布材を評価した。
実施例2として、以下に示す塗布材の上層塗布材に添加する充填物を変えて電機子を作製し、実施例1と同様に、塗布の状態および回転電動機の特性から塗布材を評価した。このとき、充填物以外の下層塗布材や上層塗布材の構成要素や作製方法、および電機子の作製方法などは実施例1と同様の条件で行った。
実施例3として、以下に示す塗布材の上層塗布材に添加する飽和ポリエステルからなる熱可塑性樹脂の添加量を変えて電機子を作製し、実施例1と同様に、塗布の状態および回転電動機の特性から塗布材を評価した。このとき、熱可塑性樹脂の添加量以外の下層塗布材や上層塗布材の構成要素や作製方法、および電機子の作製方法などは実施例1と同様の条件で行った。
実施例4として、実施例1で添加したディーエイチマテリアル製サンドーマPB987の熱可塑性樹脂を、旭化成ケミカルズ製のSBS系エラストマー315Pの50%スチレン溶液に変更して、他の条件は実施例1のNo.5のサンプルと同様の条件で電機子を作製し、実施例1と同様に塗布の状態および回転電動機の特性から塗布材を評価した。つまり、中空ガラスビーズAからなる充填物の添加量を、50重量部(32.9重量%)として作製した。
実施例5として、実施例1で添加した不飽和ポリエステルである日立化成工業製WP2851の第1の低粘度樹脂液および第2の低粘度樹脂液を、日東シンコー製NV270に変更し、実施例1で添加した日立化成工業製CT48の硬化剤を、日東シンコー製No.5(t-ブチルパーオキシベンゾエート)の硬化剤に変更して、No.1からNo.8のサンプルの電機子を作製した。このとき、NV270の25℃での粘度は0.25Pa・sであった。
以下に、本発明の実施の形態2における回転電動機の製造方法について説明する。
2 積層コア
3 ファン側コイルエンド
4 整流子側コイルエンド
5 上層塗布材
6 モータ部
7 ファン部
8 整流子
9 電機子巻線
10 シャフト
11 軸受
12 ファン側ブラケット
13 整流子側ブラケット
14 ブラシホルダー
15 カーボンブラシ
16 界磁
17 界磁巻線
18 ファン
19 吸気口
Claims (8)
- 少なくとも界磁巻線を有する界磁と、電気絶縁性を有する塗布材を塗布した電機子巻線を有する電機子から構成される回転電動機であって、
前記塗布材は、第1の低粘度樹脂液からなる下層塗布材と、少なくとも中空ガラスビーズおよび熱可塑性樹脂を添加した第2の低粘度樹脂液からなる上層塗布材の、少なくとも2層から構成される回転電動機。 - 前記第1の低粘度樹脂液および前記第2の低粘度樹脂液は、不飽和ポリエステル樹脂、エポキシ変性不飽和ポリエステル樹脂、エポキシ樹脂の少なくとも1種の熱硬化性樹脂である請求項1に記載の回転電動機。
- 前記第1の低粘度樹脂液および前記第2の低粘度樹脂液の25℃における粘度が、ゼロを超えて1Pa・s以下である請求項1に記載の回転電動機。
- 前記中空ガラスビーズの粒径が、1~30μmの範囲である請求項1に記載の回転電動機。
- 前記熱可塑性樹脂が、飽和ポリエステル樹脂である請求項1に記載の回転電動機。
- 前記中空ガラスビーズの割合が28重量%~44重量%、前記熱可塑性樹脂の割合が6重量%~15重量%である請求項1に記載の回転電動機。
- 前記上層塗布材の比重が、ゼロを超えて1.5以下である請求項1に記載の回転電動機。
- 請求項1から請求項7のいずれか1項に記載の回転電動機の製造方法であって、
塗布材を塗布する前に電機子を加熱する予熱ステップと、
シャフトを中心に前記電機子を回転させながら、前記塗布材を滴下塗布あるいは押出塗布する塗布ステップと、
塗布後の前記電機子をさらに加熱して前記塗布材を硬化させる硬化ステップと、
を含む回転電動機の製造方法。
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US14/117,264 US9647503B2 (en) | 2011-07-15 | 2012-06-14 | Rotary motor and manufacturing method therefor |
JP2013524583A JP5919468B2 (ja) | 2011-07-15 | 2012-06-14 | 回転電動機およびその製造方法 |
EP12815139.6A EP2733825B1 (en) | 2011-07-15 | 2012-06-14 | Rotary motor and manufacturing method therefor |
CN201280034984.4A CN103650298B (zh) | 2011-07-15 | 2012-06-14 | 旋转电动机及其制造方法 |
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US (1) | US9647503B2 (ja) |
EP (1) | EP2733825B1 (ja) |
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- 2012-06-14 WO PCT/JP2012/003874 patent/WO2013011627A1/ja active Application Filing
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JPWO2013011627A1 (ja) | 2015-02-23 |
EP2733825A4 (en) | 2017-03-22 |
US9647503B2 (en) | 2017-05-09 |
US20150130300A1 (en) | 2015-05-14 |
EP2733825A1 (en) | 2014-05-21 |
CN103650298B (zh) | 2016-03-30 |
EP2733825B1 (en) | 2018-12-05 |
CN103650298A (zh) | 2014-03-19 |
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