WO2014203849A1

WO2014203849A1 - Rotating electric machine and rotating electric machine manufacturing method

Info

Publication number: WO2014203849A1
Application number: PCT/JP2014/065882
Authority: WO
Inventors: 智行畠山; 治関口
Original assignee: 日本電産サーボ株式会社
Priority date: 2013-06-21
Filing date: 2014-06-16
Publication date: 2014-12-24

Abstract

An M-phase rotating electric machine (10) is formed by housing a rotor (14) and a stator (15) in a case (11), said stator being formed by winding a coil around each of a plurality of teeth (25) disposed in a radial fashion. In the rotating electric machine, the stator has a plurality of small cores (24A) each equipped with a predetermined number of teeth and a core back (26) for coupling the base portions of these teeth and disposed in a circumferential direction at constant angle intervals and is provided with gap regions (27) between adjacent small cores. The small cores are integrated by a ring-shaped insulating member (28) that couples the coil bobbin portions (29) of the teeth through a connection portion (30). Alternatively, the small cores are integrated in such a way that the insulating member is provided that couples the coil bobbin portions of the teeth through the connection portion, the coil is wound around each of the teeth, and then the core back is fixed to the case by a fixing means (33, 34, 35).

Description

Rotating electric machine and method of manufacturing rotating electric machine

The present invention relates to various types of electric motors and generators using an inner rotor type and an outer rotor type (hereinafter, the electric motor and the generator are collectively referred to as a rotating electric machine).

Conventionally, an inner rotor type brushless DC motor is formed by arranging a columnar rotor concentrically with respect to a stator inside a substantially cylindrical stator. A stator core is produced by connecting the bases of a plurality of teeth protruding on the inner peripheral side with a cylindrical core back, and a coil is wound around each tooth.

That is, FIG. 16 is a plan view showing a rotor and a stator in a conventional inner rotor type brushless DC motor. In the electric motor 1, the rotor 2 is configured by arranging, for example, an annular magnet 3 magnetized so that different magnetic poles are alternately arranged in the circumferential direction, and a rotating shaft is provided at the center. The stator core 4 is disposed so as to surround the rotor 2, and a stator 7 is configured by winding coils 6 around a plurality of teeth 5 protruding inward. FIG. 16 shows an example of 3 phases and 12 slots, and the rotor 2 has 8 poles.

Regarding such an electric motor, Patent Document 1 proposes a method in which a coil is wound around a plurality of divided cores, and then these divided cores are integrated to produce a stator.

Patent Documents

2 and 3 disclose a configuration in which the rotor is driven by a plurality of stator bodies.

JP-A-2-123933 JP 2007-110861 A JP 2010-288426 A

Incidentally, in rotating electrical machines, it is desired to reduce the materials used.

The present invention has been made in consideration of the above points, and an object of the present invention is to reduce the materials used in a rotating electrical machine as compared with the related art.

The present inventor has intensively studied to solve the above-mentioned problems, and has led to the idea of providing a plurality of gap portions as a gap portion where a core back is not provided between adjacent teeth. The invention has been completed. The idea is to incorporate the stator into the case by integrating the small cores thus created with an insulating member, or by providing each small core with an insulating member, and fixing each small core to the case. As a result, the present invention has been completed.

(1) One of the rotating electrical machines according to the present invention is:
In a rotating electrical machine in which a rotor and a stator are housed in a case, and the stator is formed by winding coils around a plurality of radially arranged teeth.
The stator includes a plurality of small cores each having a predetermined number of teeth and a core back that connects the bases of the predetermined number of teeth, and the adjacent small cores are arranged at regular angular intervals in the circumferential direction. Each is provided by providing a gap portion,
The plurality of small cores are integrated by an annular insulating member in which a coil bobbin portion related to the teeth of each of the plurality of small cores is connected by a connecting portion, and each core back is fixed to the case by a fixing means. ing.

According to the rotating electrical machine of (1), the material related to the core can be reduced by the amount of the gap portion provided for the electric motor. Further, by integrating a plurality of small cores with the insulating member and incorporating them into the case, an increase in work man-hours can be prevented. Further, by fixing the core back to the case and storing the small core in the case, it is possible to sufficiently reduce the mounting error of the plurality of small cores.

(2) One of the methods for manufacturing a rotating electrical machine according to the present invention is:
A small core creation step of creating a small core with a shape in which base portions of a predetermined number of teeth arranged radially are connected by a core back by lamination of electromagnetic steel sheets;
An integration step of creating a stator core by integrating a plurality of the small cores with an annular insulating member in which coil bobbin portions related to each tooth are connected by a connection portion;
A winding step of winding a coil on the teeth of the stator core via the coil bobbin portion to produce a stator;
An assembly step of incorporating the stator and the rotor into a case,
The incorporation step is
The core back of the small core is fixed to the case by a fixing means, and the stator is incorporated into the case.

According to the method for manufacturing a rotating electrical machine of (2), with respect to the method for manufacturing a rotating electrical machine in which the amount of use of the core is reduced by the gap portion, by integrating a plurality of small cores with an insulating member, An increase can be prevented. Further, by fixing the core back to the case and storing the small core in the case, it is possible to sufficiently reduce the mounting error of the plurality of small cores.

(3) Another one of the rotating electrical machines of the present invention is
In a rotating electrical machine in which a rotor and a stator are housed in a case, and the stator is formed by winding coils around a plurality of radially arranged teeth.
In the stator, a plurality of small cores each including a predetermined number of teeth and a core back that connects the bases of the predetermined number of teeth are arranged in the circumferential direction at constant angular intervals, and adjacent small cores are arranged. It is configured by providing gap portions between the cores,
The plurality of small cores are provided with an insulating member constituted by a coil bobbin portion related to each tooth and a connection portion connecting these coil bobbin portions, and the coil is wound around each tooth via the coil bobbin portion,
The plurality of small cores are integrated with each other by fixing the respective core backs to the case by fixing means.

According to the rotating electrical machine of (3), the material related to the core can be reduced by the amount of the gap portion. Moreover, after providing an insulating member and a coil in each small core, and fixing to a case and integrating, the attachment error of a some small core can be made small enough by a case.

(4) Another method for manufacturing a rotating electrical machine of the present invention is as follows:
A small core creation step of creating a small core with a shape in which base portions of a predetermined number of teeth arranged radially are connected by a core back by lamination of electromagnetic steel sheets;
A winding step of arranging an insulating member for each small core and winding a coil around each tooth;
A plurality of small cores wound with the coil, and an assembling step of incorporating the rotor into the case,
The incorporation step is
The core back of the small core is fixed to the case by a fixing means, and the plurality of small cores are sequentially arranged in the circumferential direction through gap portions, respectively, and the plurality of small cores are integrated. The stator is incorporated in the case.

According to the method for manufacturing a rotating electrical machine of (4), the material related to the core can be reduced by the amount of the gap portion. Moreover, after providing an insulating member and a coil in each small core, and fixing to a case and integrating, the attachment error of a some small core can be made small enough by a case.

According to the present invention, it is possible to reduce the amount of material used for the core, and it is also possible to reduce the material used by increasing the number of cores. In addition, an increase in the number of work steps can be prevented, and furthermore, attachment errors of a plurality of small cores can be sufficiently reduced.

It is sectional drawing which shows the electric motor which concerns on 1st Embodiment of this invention. It is a figure where it uses for description of the core which concerns on the electric motor of FIG. It is a figure where it uses for description of the number of cores concerning the conventional electric motor. It is a figure where it uses for description of the number of cores concerning the electric motor of FIG. It is a figure where it uses for description of the fixing method of the core which concerns on the electric motor of FIG. It is a flowchart which shows the manufacturing process of the electric motor of FIG. It is a figure where it uses for description of the electric motor which concerns on 2nd Embodiment of this invention. It is a figure where it uses for description of the electric motor which concerns on 3rd Embodiment of this invention. It is a figure where it uses for description of the electric motor which concerns on 4th Embodiment of this invention. It is a figure where it uses for description of the electric motor which concerns on 5th Embodiment of this invention. It is a figure where it uses for description of the fixing method of the core in the electric motor which concerns on 6th Embodiment of this invention. It is a figure which shows the detailed structure of FIG. It is a flowchart which shows the manufacturing process of the electric motor of FIG. It is a figure where it uses for description of the electric motor which concerns on 7th Embodiment of this invention. It is a figure where it uses for description of the electric motor which concerns on 8th Embodiment of this invention. It is a figure where it uses for description of the conventional inner rotor type | mold electric motor.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the following description, the upper side in the central axis direction of the motor is simply referred to as “upper side”, and the lower side is simply referred to as “lower side”. This vertical direction does not indicate the positional relationship or direction when incorporated in an actual device. A direction parallel to the central axis is referred to as an “axial direction”, a radial direction centered on the central axis is simply referred to as “radial direction”, and a circumferential direction centered on the central axis is simply referred to as “circumferential direction”.

[First Embodiment]
FIG. 1 is a cross-sectional view showing an electric motor according to a first embodiment of the present invention. The electric motor 10 is an inner rotor type three-phase brushless DC electric motor. For example, the first casing 11A and the second casing 11B are formed in a cup shape by aluminum die casting, and the first casing 11A and the second casing 11B are mutually connected. The case 11 is formed in a substantially cylindrical shape by being coupled with the openings facing each other. The electric motor 10 is configured by housing a rotor 14, a stator 15, and the like in the case 11.

The rotor 14 is rotatably supported by

ball bearings

12A and 12B whose rotation shaft 13 is held by the first casing 11A and the second casing 11B, respectively. A stator 15 is provided concentrically with the rotor 14 so as to surround the rotor 14 from the outer peripheral direction, and a wiring board 16 on which a drive circuit for exciting a coil in the stator 15 is mounted is disposed on the ball bearing 12B side of the stator 15. Be placed. The wiring board 16 is provided with a rotational position detection mechanism of the rotor 14 using a hall element or the like. The excitation state of the coil is controlled, and thereby the rotor 14 is rotated.

Here, the rotor 14 is formed by press-fitting the rotary shaft 13 into a rotor magnet 14A made of, for example, a ferrite plastic magnet. The rotor magnet 14 A has an outer peripheral portion facing the stator 15, and is provided with a magnet portion 23 in which a plurality of magnetic poles are formed circumferentially on the outer peripheral portion by magnetization, and the magnet portion 23 is provided on the stator 15. opposite.

FIG. 2 is a diagram showing a configuration of the magnet portion 23 of the rotor 14 and the stator core 24 of the stator 15. In this embodiment, the magnet portion 23 of the rotor 14 is configured by eight magnetic poles. The stator 15 has a plurality (12) of teeth 25 formed so that the tip faces the rotor 14, and these teeth 25 are arranged radially and at regular angular intervals in the circumferential direction. Each coil is wound to form a magnetic pole.

In this embodiment, the stator core 24 is configured using a plurality of small cores 24A having a shape in which the outer peripheral sides of a predetermined number of teeth 25 are connected by a core back 26. The plurality of small cores 24A are arranged at regular intervals in the circumferential direction, and a portion (hereinafter referred to as a gap portion) 27 where the core back 26 does not exist between adjacent teeth 25 of the adjacent small cores 24A is provided. . In other words, the stator core 24 of the annular stator 15 surrounding the rotor 14 is divided into small cores 24 A having a substantially arc shape (substantially fan shape) by the gap portion 27.

Here, the interval between the gap portions 27 is set so that the number of teeth 25 between adjacent gap portions 27 is M × n (n is an integer of 1 or more), where M is the number of phases of the electric motor 10. Is done. In this embodiment, n is set to a value of 1, and the number of teeth 25 between adjacent gap portions 27 is set to three. As a result, the small core 24A is formed in a substantially arc shape (substantially fan shape) in which base portions of M × n teeth arranged radially at a constant angular interval are connected by a core back, and the four small cores 24A A stator core 24 is formed. Each small core 24A is manufactured by laminating electromagnetic steel sheets.

As described above, when the gap portion 27 is provided and the number of the teeth 25 between the adjacent gap portions 27 is set to be M × n, the core back 26 between the teeth 25 in the small core 24A A magnetic closed circuit can be formed for each tooth of the small core 24A, thereby driving the rotor 14 in the same manner as in the case where the stator is formed by the annular core according to the conventional configuration described above with reference to FIG. be able to.

Thus, by providing the gap portion 27, the amount of the core material used can be reduced by the amount of the gap portion 27 as compared with the conventional case. In addition, since the stator core 24 is manufactured by the four small cores 24A in this way, the number of the small cores 24A can be increased and the material used can be reduced. That is, for example, when a core is formed by stacking electromagnetic steel plates, as shown in FIG. 3, in the conventional annular shaped stator core 4, a rectangular region having a length H whose one side is longer than the diameter of the stator core 4. It is necessary to punch and laminate the electromagnetic steel sheet. On the other hand, as shown in FIG. 4 in comparison with FIG. 3, in this embodiment, eight small cores 24A can be produced from a rectangular region having a length H on one side. Can be increased to reduce the material associated with the core.

In the stator core 24 manufactured in this way, the performance of the electric motor can be improved by effectively using the gap of the gap portion 27. For example, the air gap of the gap portion 27 is set as a cooling gas flow path to improve the heat dissipation efficiency, thereby improving the performance. Further, by providing a metal piece, a heat pipe, or the like that is thermally coupled to the radiating fins in the gap, the radiating efficiency can be improved, thereby improving the performance. Furthermore, this gap can be used for the wiring space of the device in which the electric motor 10 is disposed and the space for arranging various members, thereby simplifying the configuration of the device.

2 and 4, both end portions on the circumferential side of the small core 24A are formed so that the end portion of the core back 26 becomes the end portion of the tooth 25, and the core back 26 is formed with an arc shape on the outer peripheral side. Although simplified in the drawing, the shape of the end portion and the shape of the outer peripheral side are appropriately modified according to the arrangement method and fixing method of the small core 24A described later.

[Stator arrangement]
By the way, in the case of producing the stator core with the annular shape in FIG. 16 described above, the relative misalignment of the plurality of teeth can be sufficiently reduced by punching, and the stator core can be produced with high accuracy. However, when the stator core 24 is produced by arranging the plurality of small cores 24A apart from each other by the gap portion 27 as in this embodiment, the production accuracy of the stator core 24 decreases, and as a result, the rotor 14 There is a risk that the magnetic poles of the stator 15 cannot be arranged close to each other.

Therefore, in this embodiment, by holding the plurality of small cores 24A constituting the stator core 24 in the casing 11A constituting the case 11, the positioning error between the small cores 24A is sufficiently reduced, and the accuracy of the stator core 24 is improved. I try to prevent the decline. Further, by effectively using the insulating member used for winding the coil, and holding the plurality of small cores 24A constituting the stator core 24 by the insulating member in the casing 11A, the stator core 24 is A reduction in the efficiency of the mounting work when the small core 24A is used is prevented. Moreover, in the state which integrated each small core 24A using the insulation member, the coil 15 is wound around each tooth | gear 25, the stator 15 is created, and the stator 15 is arrange | positioned to casing 11A after that, The conventional circle | round | yen is arrange | positioned. The coil can be wound by effectively utilizing the winding equipment applied to the stator core having the ring shape.

FIG. 5 is a plan view (FIG. 5 (B)) showing a state where the stator 15 is arranged in the casing 11A, and a cross-sectional view (FIG. 5 (A)) taken along line AA. In this embodiment, the insulator 28 is used as an insulating member for integrating the small cores 24A. Here, the insulator 28 extends along the inner peripheral side of the core back 26 with the coil bobbin portion 29 provided for each tooth 25 of each small core 24A constituting the stator core 24 and the coil bobbin portion 29 of the tooth 25 in each small core 24A. It is formed in an annular shape by the connecting portion 30 that is connected in all shapes. In addition, the coil bobbin part 29 is comprised by the site | part which covers the teeth 25, and the collar part.

Here, the insulator 28 is a protective material for insulating the core and the magnet wire and preventing the magnet wire from being damaged during winding. For example, a flame-retardant resin such as 66 nylon is injection-molded. Is produced. The insulator 28 includes an upper insulator 28A that covers each of the teeth 25 from above and a lower insulator 28B that covers each of the teeth 25 from below, and a small core is formed from both sides in the axial direction by the pair of

insulators

28A and 28B. The four small cores 24A are integrated by sandwiching 24A.

After integrating the four small cores 24A with the insulator 28, the coils 32 are wound around the teeth 25 to form the stator 15, and then incorporated into the casing 11A. Here, in each small core 24A, both end portions of the core back 26 extend to the gap portion 27 side, and a through hole 33 is formed in the extended portion. The casing 11A is provided with a step 31 inside, and the stator 15 is positioned in the direction along the rotation axis by contacting the outer peripheral side portion of the core back 26 of each small core 24A with the step 31. . The casing 11 A is provided with a positioning hole 34 corresponding to the through-hole 33 at the level difference 31. The stator 15 can fix both ends of each small core 24 A in the circumferential direction to the case 11 by inserting the pin portion of the fixing pin 35 into the through hole 33 of the core back 26 and press-fitting into the positioning hole 34. Thus, the stator core 24 including the four small cores 24 A is supported by the case 11.

In this embodiment, the fixing pin 35 is formed in a U-shape, and the two pin portions of the fixing pin 35 are respectively inserted into the through holes 33 of the adjacent small cores 24A and press-fitted into the positioning holes. Adjacent ends of the core 24A are collectively fixed to the casing 11A to simplify the attaching operation of the stator 15.

FIG. 6 is a diagram showing a manufacturing process of the stator 15 according to this embodiment. In this manufacturing process, first, a small core 24A is produced by punching and laminating electromagnetic steel sheets (steps ST1-ST2). Subsequently, after the four small cores 24A are integrated using the insulator 28 (step ST3), coils are wound around the teeth 25 of the small cores 24A to produce the stator 15 (steps ST4-ST5). In this case, when the winding operation is performed after the small cores 24A are integrated, the teeth 25 are arranged in an annular shape, so that the winding in the conventional annularly shaped stator core 4 (FIG. 16) is performed. It can be performed in the same manner as the process. In addition, since the winding process of the stator ring by the conventional annular shape can be used in this way, the stator core 4 is divided into a plurality of small cores 24A as shown in FIG. The stator 15 can be configured by the windings.

According to the first embodiment described above, by providing the gap portion 27 where the core back is not provided between the adjacent teeth 25, the amount of material used can be reduced with respect to the core. The material used can be reduced due to the increase in the number of parts. Further, by integrating the plurality of small cores 24A with the insulating member, it is possible to prevent an increase in man-hours for winding work and the like. Further, by fixing the core back 26 of the plurality of small cores 24A to the case 11 and storing the stator core 24 in the case 11, the mounting error of the plurality of small cores 24A can be sufficiently reduced.

Further, the insulating members are a pair of

insulators

28A and 28B, and a plurality of small cores 24A are sandwiched and integrated from both sides in the axial direction by the pair of

insulators

28A and 28B, thereby configuring the pair of

insulators

28A and 28B. The small cores 24A can be integrated by effectively utilizing the above.

Furthermore, by fixing each small core 24A to the case 11 using the through-hole 33 provided in the core back 26 of each small core 24A, each small core 24A can be accurately used by effectively utilizing the configuration of the case 11. Can be held.

[Second Embodiment]
FIG. 7 shows an electric motor according to a second embodiment of the present invention. FIG. 7B is a plan view showing a state where the stator 45 is arranged on the casing 41A, and FIG. 7A is this plan view. FIG. 6 is a cross-sectional view taken along the line BB, and is used for explaining the stator 45 by comparison with FIG. This embodiment is configured in the same way as the first embodiment except that the configuration of the fixing means of each small core 44A applied to the stator 45 is different.

The four small cores 44A constituting the stator core are provided with fan-shaped convex portions 46 on the back side of the core back 26. Correspondingly, in the first casing 41A, a recess 42 for press-fitting the protrusion 46 is formed corresponding to each small core 44A. The stator 45 is held by the first casing 41A by press-fitting the convex portions 46 of the small cores 44A into the concave portions 42 of the first casing 41A from the axial direction. At this time, since each convex part 46 fits in each concave part 42 in a wedge shape, each small core 44A does not shift in the radial direction with respect to the first casing 41A.

In this embodiment, each small core 44A can be fixed by press-fitting to the first casing 41A, and each small core 24A can be accurately held using a case, which is the same as in the first embodiment. An effect can be obtained.

[Third Embodiment]
FIG. 8 shows an electric motor according to a third embodiment of the present invention. FIG. 8B is a plan view showing a state in which the stator 55 is arranged in the casing 51A, and FIG. 8A is this plan view. FIG. 6 is a cross-sectional view taken along line CC, and is used for explaining the stator 55 in comparison with FIG. This embodiment is configured in the same way as the first embodiment except that the configuration of the fixing means of the small core 54A applied to the stator 55 is different.

Through holes 53 are formed at both ends of the core back 26 in the four small cores 54A constituting the stator core. In the casing 51 A, a screw hole 54 corresponding to the through hole 53 is provided at the position of the step 31. When attaching the stator 55, by inserting a screw 56 into the through hole 53 of the small core 54A and screwing it into the screw hole 54 of the casing 51A, both circumferential ends of each small core 54A are fixed to the case, respectively. The stator core is supported by the case.

In this embodiment, each small core 54A can be fixed to the first casing 51A with a screw 56, and each small core 54A can be accurately held using a case, as in the first embodiment. The effect of can be obtained.

[Fourth Embodiment]
FIG. 9 shows an electric motor according to a fourth embodiment of the present invention. FIG. 9B is a plan view showing a state in which the stator 65 is arranged in the casing 61A, and FIG. 9A is this plan view. FIG. 6 is a cross-sectional view taken along line DD, and is used for explaining the stator 65 in comparison with FIG. This embodiment is configured in the same way as the first embodiment except that the configuration of the fixing means of the small core 64A applied to the stator 65 is different.

In this embodiment,

narrow grooves

67 and 66 are formed at positions corresponding to both ends of the small core 64A and both ends of the small core 64A in the casing 61A so as to obliquely cross the boundary between the small core 64A and the casing 61A. Is done. When the stator 65 is attached, the metal plate material 68 is press-fitted across the

narrow grooves

67 and 66, the small core 64A is held in the case, and the stator core is held in the case.

Even if the small core 64A is held in the case by the small core 64A and the metal plate material 68 press-fitted into the case across the boundary between the small core 64A and the case as in this embodiment, the same as in the above embodiment An effect can be obtained.

[Fifth Embodiment]
FIG. 10 shows an electric motor according to a fifth embodiment of the present invention in comparison with FIG. The electric motor 70 according to this embodiment is configured in the same manner as the electric motor 10 of the first embodiment except that the configuration according to FIG. 10 and related configurations are different.

The electric motor 70 is an outer rotor type three-phase brushless DC electric motor. A stator 75 is formed in a substantially cylindrical shape, and a rotor 74 is provided so as to surround the stator 75. The rotor 74 is provided with a magnet portion 73 having a large number of magnetic poles formed in the circumferential direction.

In the stator 75, a plurality of teeth 85 formed so that the tips thereof are opposed to the rotor 74 are arranged radially and at a constant angular interval in the circumferential direction, and a magnetic wire is wound around each of the teeth 85 to generate magnetic poles. It is formed. A predetermined number of adjacent teeth 85 are connected at their inner peripheral sides by a core back 86, and a magnetic closed circuit of the predetermined number of teeth 85 is formed. A predetermined number of teeth 85 are connected by a core back 86 to form a small core 84A. A plurality of such small cores 84A are arranged at regular intervals in the circumferential direction, and adjacent small cores 84A are mutually connected. A gap portion 87 where the core back 86 does not exist is provided between the adjacent teeth 85. That is, the stator 75 has a shape divided into small cores 84 A having a substantially arc shape (substantially fan shape) by the gap portion 87.

The interval between the gap portions 87 is set so that the number of teeth 85 between the adjacent gap portions 87 is the number of phases M × n of the electric motor 70 (n is an integer of 1 or more). In this embodiment, n is set to a value of 1, and the number of teeth 85 between adjacent gap portions 87 is set to three.

The stator 75 is fixed to the case by winding a coil after the small core 84A is integrated in the same manner as in the first to fourth embodiments. Even if this embodiment is applied to an outer rotor type electric motor, the same effects as those of the above-described embodiment can be obtained.

[Sixth Embodiment]
FIG. 11 shows an electric motor according to a sixth embodiment of the present invention. FIG. 11 (B) is a plan view showing a state in which a stator 115 is arranged on a casing 111A, and FIG. 11 (A) is a plan view thereof. FIG. 6 is a cross-sectional view taken along line EE. 12A is an enlarged plan view showing the small core 124A in a state where the coil 132 is wound, and FIG. 12B is a cutaway view of FIG. 12A taken along line FF. It is sectional drawing. FIG. 12C is a plan view of the small core 124A.

In this embodiment, the insulator 128 is applied to an insulating member used for winding the coil 132. Here, the insulator 128 is provided for each of the four small cores 124 A constituting the stator core 124, and the coil bobbin portion 129 that covers the three teeth 125 in the small core 124 A and the adjacent coil bobbin portion 129 are at least the inner periphery of the core back 126. It is formed by the connection part 130 connected by the shape along the side. Moreover, the coil bobbin part 129 is comprised by the site | part which covers the teeth 125, and the collar part.

The insulator 128 is a protective material for insulating the core and the magnet wire and further preventing the magnet wire from being damaged during winding. The insulator 128 is manufactured by injection molding a flame retardant resin such as 66 nylon. . 11 and 12, the insulator 128 includes an upper insulator 128A that covers each tooth 125 from above and a lower insulator 128B that covers each tooth 125 from below, and the pair of

insulators

128A and 128B causes both sides in the axial direction. The small core 124A is sandwiched between and attached to the small core 124A.

Each of the small cores 124A is disposed in the casing 111A after the coils 132 are wound around the teeth 125 via the coil bobbin portion 129, and the four small cores 124A are provided with gap portions 127 between the adjacent small cores 124A. The stator 115 is completed by being disposed in the casing 111A. Here, in each small core 124A, both end portions of the core back 126 extend in a substantially rectangular shape in the outer peripheral direction, and a through hole 133 is formed in the extended portion. The casing 111A is provided with a step 131 on the inner side, and the step 131 abuts on the outer peripheral side portion of the core back 126 of the small core 124A, thereby positioning each small core 124A in the direction along the rotation axis. The casing 111 A is further provided with a screw hole at a position corresponding to the through hole 133. The small core 124A is supported by the case 111 by inserting screws 134 into the through holes 133 at both ends thereof and screwing them into the screw holes of the casing 111A.

FIG. 13 is a diagram showing a manufacturing process of the stator 115 according to this embodiment. In this manufacturing process, the small core 124A is manufactured by punching and laminating electromagnetic steel as described above (steps ST11 to ST12). Subsequently, the insulator 128 is disposed on the small core 124A (step ST13). Thereafter, a magnet wire is wound around each of the teeth 125 insulated by the insulator 128 (step ST14), whereby the coil 132 is wound around the small core 124A. Subsequently, each small core 124A is fixed to the case, and each small core 124A constituting the stator 115 is arranged in an annular shape and integrated. Further, a coil is connected for each phase, thereby producing a stator 115 (step ST15).

According to the sixth embodiment, by providing the gap portion 127 where the core back is not provided between the adjacent teeth 125, it is possible to reduce the amount of material used for the core, and further, As a result of the increase, the material used can be reduced. Further, by providing an insulating member on each of the small cores 124A and winding the coils 132 so that the small cores 124A are integrally held by the case, an increase in work man-hours can be prevented, and moreover, The mounting error of the small core 124A can be sufficiently reduced depending on the case.

Further, by fixing the core back 126 of each small core 124A to the case using the screws 134, the stator 115 can be reliably held in the case with a simple configuration.

[Seventh Embodiment]
FIG. 14 shows an electric motor according to a seventh embodiment of the present invention. FIG. 14 (B) is a plan view showing a state where the stator 145 is arranged on the casing 141A, and FIG. 14 (A) is this plan view. FIG. 6 is a cross-sectional view taken along line GG, and is used for explaining the stator 145 by comparison with FIG. This embodiment is configured in the same manner as the sixth embodiment except that the configuration of the fixing means of the small core 144A applied to the stator 145 is different.

Here, the small core 144A is provided with a fan-shaped convex portion 146 on the back side of the core back 126. Correspondingly, the first casing 141A is formed with a concave portion 142 into which the convex portion 146 fits. The small core 144A is held by the first casing 141A by press-fitting the convex portion 146 into the concave portion 142 of the first casing 141A from the axial direction. By holding the four small cores 144A in the first casing 141A in this way, a gap portion 127 is formed between the small cores 144A to form the stator 145, which is attached to the case.

In this embodiment, each small core 144A can be fixed to the first casing 141A by press-fitting, and the same effect as the above-described embodiment can be obtained.

[Eighth Embodiment]
FIG. 15 is a diagram showing a small core 154A applied to the electric motor according to the eighth embodiment of the present invention. The small core 154A is formed by laminating a plurality of core sheets 151 produced by punching out electromagnetic steel sheets by pressing. During the lamination, the core sheets 151 are laminated so as to be displaced in the circumferential direction sequentially by a certain angle. As a result, in this embodiment, the small core 154A is formed so that the core sheet 151 gradually displaces in the circumferential direction including the portion of the tooth 125 that faces the rotor 114, thereby applying a skew. This embodiment is configured in the same manner as the sixth or seventh embodiment except that the skew is applied.

In this case, cogging torque and torque ripple can be sufficiently suppressed. When a stator is configured using such a small core 154A, skew can be applied with high accuracy by a simple operation in which the core sheets related to the small core 154A are sequentially displaced and stacked. Accordingly, in this embodiment, the material used is reduced as compared with the conventional case, and the cogging torque and the torque ripple are sufficiently reduced.

In addition, in the case of a configuration in which the small core 154A is skewed, as shown in FIG. 15C, the small core 154A is inclined so that the slots between the teeth 125 are oriented in the vertical direction. As shown by, each can be wound through a magnet wire in a rectangular shape. Thereby, it becomes possible to wind using the winding apparatus conventionally used. Note that in FIG. 15C, the insulator is omitted for the sake of explanation, but actually, the coil is wound after the insulator is mounted on the skewed small core 154A.

[Other Embodiments]
The specific configuration suitable for the implementation of the present invention has been described in detail above, but the present invention can be variously modified without departing from the spirit of the present invention, and various configurations of the above-described embodiments are combined. You can also.

For example, in each of the above-described embodiments, a molding resin can be applied to the small core insulating member, and a plurality of small cores can be integrated by an insert mold using the molding resin. Thus, the same effect as the above-mentioned embodiment can be acquired by integrating a small core with the insert mold which uses mold resin.

Further, in the above-described embodiment, in the three-phase electric motor, the case where n is set to the value 1 and the number of teeth between the gap portions is set to three is described, but the present invention is not limited to this. , N may be set to a value of 2 to set the number of teeth between the gap portions to six. Moreover, you may make it provide the location where the number of the teeth between three gap parts is three, and the location where the number of the teeth between gap parts is six. Furthermore, the number of teeth between the gap portions may be four or five larger than three, or may be a number other than the number of phases × n.

In the above-described embodiment, the case where the present invention is applied to a three-phase, 12-slot motor has been described. However, the present invention is not limited to this, and motors having various numbers of phases such as two-phase, and various slots. It can be widely applied to electric motors. In addition, the present invention is not limited to the application to a brushless DC motor, but can be widely applied to various motors such as an inner rotor brush DC motor, an inner rotor AC motor, and an outer rotor AC motor.

In the above-described embodiment, the case where the present invention is applied to an electric motor has been described. However, the present invention is not limited to this and can be widely applied to an inner rotor type and an outer rotor type generator.

The rotating electrical machine according to the present invention can reduce the material used and reduce the cost as compared with the conventional one, and can be applied to various motors and generators of the inner rotor type and the outer rotor type.

10, 70 Electric motor 11

Case

11A, 11B, 41A, 51A, 61A, 111A, 141A Casing 13

Rotating shaft

14, 74, 114

Rotor

15, 45, 55, 65, 75, 115, 145

Stator

25, 85, 125

Teeth 24A

44A, 54A, 64A, 84A, 124A, 144A,

154A Small core

26, 86, 126 Core back 27, 87, 127

Gap part

28, 28A, 28B, 128, 128,

128B Insulator

29, 129

Coil bobbin part

30, 130

Connection part

32, 132 Coil 35

Fixing pin

42, 142

Concave part

46, 146

Convex part

56, 134 Screw

Claims

In a rotating electrical machine in which a rotor and a stator are housed in a case, and the stator is formed by winding coils around a plurality of radially arranged teeth.
In the stator, a plurality of small cores each including a predetermined number of teeth and a core back that connects the bases of the predetermined number of teeth are arranged in the circumferential direction at constant angular intervals, and adjacent small cores are arranged. It is configured by providing gap portions between the cores,
The plurality of small cores are integrated by an annular insulating member in which coil bobbin portions related to the teeth of the plurality of small cores are connected by a connection portion, and the core backs are fixed to the case by fixing means. , Rotating electrical machinery.
The insulating member includes a pair of insulators formed by injection molding an insulating resin, and the pair of insulators integrates the plurality of small cores by sandwiching the plurality of small cores from both sides in the axial direction. The rotating electrical machine according to claim 1.
The insulating member is a mold resin,
The rotating electrical machine according to claim 1, wherein the plurality of small cores are integrated by an insert mold using a mold resin for the insulating member.
The rotating electrical machine according to claim 1, wherein the fixing means is a pin or a screw that is fixed to the case through a through hole provided in a core back of the small core.
The rotating electrical machine according to claim 1, wherein the small core has a core back fixed to the case by press-fitting into the case.
The rotating electrical machine according to claim 1, wherein the fixing means is a plate member press-fitted into the small core and the case across a boundary between the small core and the case.
A small core creation step of creating a small core with a shape in which base portions of a predetermined number of teeth arranged radially are connected by a core back by lamination of electromagnetic steel sheets;
An integration step of creating a stator core by integrating a plurality of the small cores with an annular insulating member in which coil bobbin portions related to each tooth are connected by a connection portion;
A winding step of winding a coil on the teeth of the stator core via the coil bobbin portion to produce a stator;
An assembly step of incorporating the stator and the rotor into a case,
The incorporation step is
A method of manufacturing a rotating electrical machine, wherein a core back of the small core is fixed to the case by a fixing means, and the stator is incorporated into the case.
The insulating member comprises a pair of insulators formed by injection molding an insulating resin,
The method of manufacturing a rotating electrical machine according to claim 7, wherein the integrating step integrates the plurality of small cores by sandwiching the plurality of small cores from both sides in the axial direction by the pair of insulators.
The insulating member is a mold resin,
The method of manufacturing a rotating electrical machine according to claim 7, wherein in the integration step, the plurality of small cores are integrated by an insert mold using a mold resin for the insulating member.
The fixing means is a pin or a screw fixed to the case through a through hole provided in a core back of the small core,
8. The assembly step according to claim 7, wherein the pin or screw is inserted into the through hole and fixed to the case, thereby fixing the core back of the small core to the case and incorporating the stator into the case. The manufacturing method of the rotary electric machine of description.
The method of manufacturing a rotating electrical machine according to claim 7, wherein the assembling step includes pressing the small core into the case to fix the core back of the small core to the case and assembling the stator into the case.
In the assembling process, a plate material is press-fitted into the small core and the case across the boundary between the small core and the case, thereby fixing the core back of the small core to the case and fixing the stator to the case. The manufacturing method of the rotary electric machine of Claim 7 integrated in a case.
In a rotating electrical machine in which a rotor and a stator are housed in a case, and the stator is formed by winding coils around a plurality of radially arranged teeth.
The stator includes a plurality of small cores each having a predetermined number of teeth and a core back that connects the bases of the predetermined number of teeth, and is arranged at constant angular intervals in the circumferential direction, and adjacent small cores. Each is provided by providing a gap portion,
Each of the plurality of small cores is provided with an insulating member formed by a coil bobbin portion relating to each of the teeth and a connection portion connecting the coil bobbin portions for each of the small cores. Is wound,
The plurality of small cores is a rotating electric machine in which each core back is fixed to the case by a fixing means and integrated by the case.
The insulating member comprises a pair of insulators formed by injection molding an insulating resin,
The rotating electric machine according to claim 13, wherein the pair of insulators are provided on the small core by sandwiching the small core from both sides in the axial direction.
The insulating member is a mold resin,
The rotating electrical machine according to claim 13, wherein the insulating member is provided on the plurality of small cores by an insert mold using the mold resin.
14. The rotating electrical machine according to claim 13, wherein the fixing means is a pin or a screw that is fixed to the case through a through hole provided in a core back of the small core.
The rotating electrical machine according to claim 13, wherein the small core has a core back fixed to the case by press-fitting into the case.
A small core creation step of creating a small core with a shape in which base portions of a predetermined number of teeth arranged radially are connected by a core back by lamination of electromagnetic steel sheets;
A winding step of arranging an insulating member for each small core and winding a coil around each tooth;
A plurality of small cores wound with the coil, and an assembling step of incorporating the rotor into the case,
In the assembling step, a core back of the small core is fixed to the case by a fixing means, and the plurality of small cores are sequentially arranged in the circumferential direction via gap portions, respectively. A method of manufacturing a rotating electrical machine in which a stator is incorporated into the case by integrating.
The insulating member comprises a pair of insulators formed by injection molding an insulating resin,
The method of manufacturing a rotating electrical machine according to claim 18, wherein in the winding step, the insulating member is disposed on the small core by sandwiching the small core from both sides in the axial direction by the pair of insulators.
The method for manufacturing a rotating electrical machine according to claim 18, wherein the insulating member is configured by an insert mold using a mold resin.
The fixing means is a pin or a screw fixed to the case through a through hole provided in a core back of the small core,
19. The assembly step according to claim 18, wherein the pin or screw is inserted into the through hole and fixed to the case, thereby fixing the core back of the small core to the case and incorporating the stator into the case. The manufacturing method of the rotary electric machine of description.
19. The method of manufacturing a rotating electrical machine according to claim 18, wherein the assembling step includes pressing the small core into the case to fix the core back of the small core to the case and assembling the stator into the case.