Electric motor and manufacturing method of an armature constituting the electric motor

Abstract

An electric motor (10) includes: an armature (14) including an iron core (26) and an armature coil (24) arranged to surround the iron core (26); and a movable member (12) configured to face the armature (14), wherein the iron core (26) includes: a plurality of U-shaped members (28); and a plurality of U-shaped members (30) perpendicular to the U-shaped members (28), each of the U-shaped members (28) and the U-shaped members (30) being U-shaped and having a pair of parallel or substantially parallel sides (42) and a middle portion connecting the pair of sides, the sides forming teeth of the iron core (26) and the middle portion forming a yoke of the iron core (26).

Description

Technical Field

[0001] The present invention relates to an electric motor having a magnetic circuit in which magnetic flux flows in a three-dimensional manner, and a method for manufacturing the armature constituting the electric motor. Background Technology

[0002] An electric motor is known, comprising: an armature having an armature coil and an iron core; and a movable member facing the armature. In conventional electric motors, magnetic flux flows along a plane, for example, along the movable direction. On the other hand, an electric motor with a three-dimensional magnetic pole structure has been reported, in which magnetic flux flows not only along the movable direction but also along directions intersecting the movable direction. For example, the electric motor described in Patent Document 1 is such an electric motor. The electric motor described in Patent Document 1 is configured such that the magnetic flux output from an open side surface of the magnetic pole block branches in the movable direction and in directions intersecting the movable direction.

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Publication No. 6835692

[0006] In the electric motor described in Patent Document 1, which has a structure for the magnetic flux to flow in a three-dimensional manner (three-dimensional magnetic pole structure), it is necessary to form a magnetic circuit for realizing the structure, but Patent Document 1 does not report a suitable structure or manufacturing method. Summary of the Invention

[0007] The object of the present invention is to provide an electric motor having a structure suitable for forming a magnetic circuit that allows magnetic flux to flow in a three-dimensional manner, and a method for manufacturing the armature constituting the electric motor.

[0008] To address the aforementioned problems, one aspect of the present invention relates to an electric motor comprising: an armature including an iron core and an armature coil disposed in a manner surrounding the iron core; and a movable member configured to face the armature, wherein the iron core of the armature comprises a plurality of members formed of electrical steel sheets, each of the plurality of members being U-shaped and having a pair of parallel or substantially parallel sides and a central portion connecting the pair of sides, the plurality of members comprising: a plurality of first members; and a plurality of second members, wherein the long side direction of the central portion of the second members is perpendicular to the long side direction of the central portion of the first members, the central portion of the first members and the central portion of the second members each constitute a yoke of the iron core, and the side portions of the first members and the side portions of the second members each constitute a tooth of the iron core.

[0009] One aspect of the present invention relates to a method for manufacturing an armature constituting an electric motor, comprising: a first step of forming a plurality of first components and a plurality of second components; a second step of forming a plurality of blocks for fixing the plurality of first components and the plurality of second components in a predetermined number; and a third step of connecting the plurality of blocks to each other to form a retaining member.

[0010] Another aspect of the present invention relates to a method for manufacturing an armature constituting an electric motor, comprising: a first step of forming a plurality of first members and a plurality of second members; and a second step of inserting a side portion of each of the plurality of first members and a side portion of each of the plurality of second members into an insertion hole of a retaining member. Attached Figure Description

[0011] Figure 1 This is a perspective view illustrating an embodiment of the electric motor according to the present invention.

[0012] Figure 2 It's a magnified display. Figure 1 A diagram of a portion of the electric motor along its rotational direction.

[0013] Figure 3 It's a magnified display. Figure 2 The upper part of the diagram after removing the armature coil.

[0014] Figure 4 Viewed from the direction along the axis of rotation Figure 3 The image.

[0015] Figure 5 Viewed from the direction of rotation Figure 3 The image.

[0016] Figure 6 This diagram illustrates the bending of the side portion of a U-shaped component.

[0017] Figure 7 It indicates assembly. Figure 6 A diagram showing the state of the U-shaped component.

[0018] Figure 8 This is a diagram illustrating the manufacturing method of a U-shaped component.

[0019] Figure 9A This is another diagram illustrating the manufacturing method of the U-shaped component, and it shows the state before the U-shaped component is formed.

[0020] Figure 9B This is another diagram illustrating the manufacturing method of the U-shaped component, and it shows the state of the U-shaped component after it has been formed.

[0021] Figure 10AThis is another diagram illustrating the manufacturing method of the U-shaped component, and it shows the state before the U-shaped component is formed.

[0022] Figure 10B This is another diagram illustrating the manufacturing method of the U-shaped component, and it shows the state of the U-shaped component after it has been formed.

[0023] Figure 11 This diagram illustrates a solution for fixing a U-shaped member using a retaining structure.

[0024] Figure 12A It is a diagram showing the steps of inserting the U-shaped member into the armature coil, and also a diagram showing the state just before the U-shaped member is inserted into the armature coil.

[0025] Figure 12B This is another diagram showing the steps of inserting the U-shaped member into the armature coil, and also a diagram showing the state after the U-shaped member has been inserted into the armature coil.

[0026] Figure 13A It is a diagram showing one scheme for forming a block for retaining components, and is a top view of the block.

[0027] Figure 13B This is another diagram showing one scheme for forming a block for retaining components, and it is a side view of the block.

[0028] Figure 14A This diagram illustrates the use of retaining members to achieve a fixing structure for the U-shaped member, and it shows the state before the U-shaped member is inserted into the retaining member.

[0029] Figure 14B This is another diagram illustrating the use of retaining members to achieve the fixing structure of the U-shaped member, and it shows the state after the U-shaped member is inserted into the retaining member.

[0030] Figure 14C This is another diagram illustrating the fixing structure of the U-shaped member using retaining members, and it shows the state in which the U-shaped member is inserted into all the insertion holes of the retaining members.

[0031] Figure 15 This is a flowchart illustrating the manufacturing process of the armature, which includes a U-shaped component.

[0032] Figure 16 This is a flowchart illustrating another scenario of the manufacturing process of an armature including a U-shaped component. Detailed Implementation

[0033] [Overall structure of the electric motor]

[0034] Preferred embodiments of the present invention will now be described with reference to the accompanying drawings. Figure 1 This is a perspective view illustrating an embodiment of the electric motor 10 according to the present invention. Figure 2 It's a magnified display. Figure 1 A diagram of a portion of the electric motor 10 along the direction of rotation.

[0035] The electric motor 10 includes a movable element 12 (sometimes referred to as a rotor or rotating element) and an armature 14 (sometimes referred to as a stator or stationary element) disposed on the outer periphery of the movable element 12. The electric motor 10 of this embodiment is a radially gap-type electric motor, wherein the movable element 12 is rotatably disposed inside the armature 14. The movable element 12 and the armature 14 are arranged radially toward each other, and a radial gap is formed between the movable element 12 and the armature 14.

[0036] The movable member 12 is formed in the shape of a ring and is configured to rotate around the axis of rotation CL of a rotation shaft (output shaft) not shown in the figure that rotates together with the movable member 12.

[0037] The movable member 12 has a plurality of magnetic pole blocks 16 and a back yoke 18. Each of the plurality of magnetic pole blocks 16 has an iron core 20 (rotor core) arranged opposite to the armature 14, and a plurality of permanent magnets 22A to 22C with an open surface facing the armature 14 and surrounding the iron core 20.

[0038] The multiple permanent magnets 22A to 22C constituting the magnetic pole blocks 16 are arranged such that the same magnetic pole faces the iron core 20. Furthermore, adjacent magnetic pole blocks 16 are connected such that one side of each of the permanent magnets 22A to 22C is in contact with the other side. The back yoke 18 is an annular component, for example, formed of a soft magnetic material. The multiple magnetic pole blocks 16 are arranged adjacent to each other along the rotational direction (circumferential direction) on the outer periphery of the back yoke 18.

[0039] The armature 14 is formed in a circular shape and is fixed in a non-rotatable manner, such as by being connected to a housing not shown in the figure. The armature 14 has multiple armature coils 24 and an iron core 26 (stator core).

[0040] Each armature coil 24 has a frame shape with frame holes 25 formed inside (see Figure 12). Furthermore, the armature coil 24 is formed in a cuboid shape, with its long side arranged along the direction of the rotation axis CL (hereinafter referred to as the axial direction). Additionally, the multiple armature coils 24 are arranged in the rotation direction and connected in series along the axial direction.

[0041] The core 26 includes a plurality of U-shaped members 28 formed in a U-shape, and a plurality of U-shaped members 30A to 30C (hereinafter, without distinction, referred to as: U-shaped members 30). Specifically, each of the plurality of U-shaped members 28 includes a pair of parallel (or substantially parallel) sides 42 and a middle portion 44 connecting the pair of sides 42 (see reference). Figure 4 Furthermore, the plurality of U-shaped members 30A to 30C each include a pair of parallel (or substantially parallel) sides 46A to 46C (referred to as side 46 when not distinguished), and a middle portion 48A to 48C (referred to as middle portion 48 when not distinguished) connecting the pair of sides 46A to 46C (refer to). Figure 5 U-shaped components 28 and 30 are respectively made of wire rod 32 (see reference). Figure 8 The wire 32 is formed from electrical steel sheet. It should be noted that the U-shaped member 28 corresponds to the "first member" in this invention, and the U-shaped members 30A to 30C correspond to the "second member" in this invention.

[0042] The U-shaped member 30 is arranged in a position perpendicular to the U-shaped member 28. That is, the long side direction of the middle portion 44 of the U-shaped member 28 is perpendicular to the long side direction of the middle portions 48A to 48C of the U-shaped members 30A to 30C.

[0043] A pair of sides 42 of each U-shaped member 28 are inserted into the frame holes 25 formed on each armature coil 24 in such a way that they cross over the armature coils 24 adjacent to each other in the direction of rotation. In addition, a pair of sides 46A to 46C of each U-shaped member 30 are inserted into the frame holes 25 formed on each armature coil 24 in such a way that they cross over the armature coils 24 arranged in series (two rows) in the axial direction.

[0044] Figure 3 It's a magnified display. Figure 2 The upper part is shown in the diagram after removing the armature coil 24. Furthermore, Figure 4 Viewed from the direction along the axis of rotation Figure 3 The picture, Figure 5 Viewed from the direction of rotation Figure 3 The image. It should be noted that... Figures 3 to 5 The arrow shown indicates armature coil 24 ( Figures 3 to 5 (Not shown) The flow of magnetic flux when energized.

[0045] like Figures 3 to 5 As shown, a plurality of U-shaped members 28 are arranged with the middle portion 44 along the rotation direction of the armature 14. Furthermore, each U-shaped member 28 is arranged at equal angular intervals along the rotation direction, and the plurality of U-shaped members 28 are stacked along the axial direction.

[0046] The intermediate portions 48A to 48C of a plurality of U-shaped members 30A to 30C are arranged along the rotation axis CL. Furthermore, the plurality of U-shaped members 30A to 30C are arranged such that their pairs of side portions 46A to 46C overlap with the pairs of side portions 46A to 46C of adjacent U-shaped members 30A to 30C in the axial direction, and that their intermediate portions 48A to 48C overlap with the intermediate portions 48A to 48C of adjacent U-shaped members 30A to 30C in the radial direction centered on the rotation axis CL.

[0047] Specifically, the pair of side portions 46A of the U-shaped member 30A are arranged at the innermost position in the axial direction, and the middle portion 48A is arranged at the innermost position in the radial direction. The pair of side portions 46B of the U-shaped member 30B are arranged to overlap with the pair of side portions 46A of the U-shaped member 30A at the outermost position in the axial direction, and the middle portion 48B is arranged to overlap with the middle portion 48A of the U-shaped member 30A at the outermost position in the radial direction. The pair of side portions 46C of the U-shaped member 30C are arranged to overlap with the pair of side portions 46B of the U-shaped member 30B at the outermost position in the axial direction, and the middle portion 48C is arranged to overlap with the middle portion 48B of the U-shaped member 30B at the outermost position in the radial direction. That is, among the plurality of U-shaped members 30A to 30C, the pair of side portions 46C of the U-shaped member 30C are arranged at the outermost position in the axial direction, and the middle portion 48C is arranged at the outermost position in the radial direction.

[0048] In the assembled state, the sides 42, 46A to 46 of each U-shaped member 28, 30 are positioned with their ends facing the movable member 12 and surrounded by the armature coil 24. In the iron core 26 (stator core), these sides 42, 46 form teeth surrounded by the armature coil 24. Furthermore, in the iron core 26 (stator core), the middle portions 44, 48A to 48C of each U-shaped member 28, 30 form a yoke connecting a pair of sides 42, 46A to 46C.

[0049] If the armature coil 24 in the armature 14 constructed as described above is energized, a magnetic circuit in which magnetic flux flows in a three-dimensional manner is formed. That is, as... Figures 3 to 5 As indicated by the arrows, magnetic flux flows radially into the teeth (sides 42, 46A to 46C) of each U-shaped member 28 and 30. Furthermore, the radially moving magnetic flux not only branches to one side and the other side along the rotational direction of the middle portion 44 (yoke) of the U-shaped member 28, but also branches to the axial direction along the middle portion 48 (yoke) of the U-shaped member 30. Accordingly, a magnetic circuit in which magnetic flux flows in a three-dimensional manner is formed.

[0050] Here, the shorter the magnetic flux path, the less the total amount of wire 32. Furthermore, the loss of magnetic flux as it changes over time depends on the volume of the core 26 through which the flux passes; therefore, a shorter path reduces losses. Accordingly, it is preferable to connect the magnetic flux path with the shortest possible route. Therefore, in the core 26 of the armature 14, a stacked U-shaped member 30 is arranged at the center in the axial direction, the stacking direction being the direction in which magnetic flux flows along the axial direction. In the armature 14, stacked U-shaped members 28 are arranged on both sides of the U-shaped member 30 in the axial direction, the stacking direction being the direction in which magnetic flux flows along the rotational direction. Furthermore, regarding the U-shaped member 30, the magnetic flux path is shortened by employing a nested structure in which three U-shaped members 30A to 30C of different sizes are stacked without gaps.

[0051] Furthermore, the cross-sections of the U-shaped members 28 and 30 are formed into quadrilaterals (squares). By forming the cross-sections of the U-shaped members 28 and 30 into quadrilaterals, the teeth and yokes can be densely formed when the U-shaped members 28 and 30 are stacked. In other words, the cross-sectional area of ​​the teeth and yokes in the U-shaped members 28 and 30 used for magnetic flux passage can be maximized.

[0052] Furthermore, the surfaces of the U-shaped members 28 and 30 are each covered with insulation. By covering the surfaces of the U-shaped members 28 and 30 with insulation, it is possible to prevent conductivity between adjacent U-shaped members 28 and 30. It should be noted that if conductivity occurs between adjacent U-shaped members 28 and 30, losses will increase due to the generation of eddy currents. Compared to the case where the entire iron core is composed of a single iron block, even if conductivity occurs between adjacent U-shaped members 28 and 30, the generation of eddy currents can be reduced through contact resistance. Moreover, in order to sufficiently reduce losses caused by the generation of eddy currents, it is preferable that the surfaces of the U-shaped members 28 and 30 are each covered with insulation. By sufficiently reducing losses caused by the generation of eddy currents, the motor 10 can be made suitable for high-speed drive.

[0053] In addition, such as Figure 5 As shown, because the intermediate portions 48A to 48C (yokes) of the U-shaped members 30A to 30C are stacked radially, the intermediate portions 48A to 48C protrude radially, which may cause the armature 14 to increase in the radial direction. In contrast, as Figure 6 and Figure 7 As shown, in the U-shaped member 30, by bending the middle portion 48C of the U-shaped member 30C relative to a pair of side portions 46C in the direction of rotation, it is also possible to prevent the middle portion 48C from protruding radially, wherein the pair of side portions 46C (teeth) are located at both ends of the U-shaped member 30C in the axial direction.

[0054] Figure 6The U-shaped component 30C-1 on the left represents the shape before bending, and the U-shaped component 30C-2 on the right represents the shape after bending. For example... Figure 6 As shown, the middle portion 48C of the U-shaped member 30C-2 on the right is bent at approximately a right angle (90 degrees) relative to the pair of side portions 46C forming the teeth.

[0055] Figure 7 This indicates the state when the U-shaped member 30C-2, after being bent relative to the pair of side portions 46C (teeth), is assembled onto the armature 14. Additionally, in Figure 7 The image also shows a U-shaped member 30C-1 in the middle portion 48C that is not bent relative to a pair of side portions 46C. Figure 7 The middle portion 48C of the U-shaped member 30C-2 shown is bent in the direction of rotation relative to a pair of side portions 46C (teeth), so that the middle portion 48C (yoke) is located radially inward than the middle portion 48C of the U-shaped member 30C-1. As a result, the middle portion 48C no longer protrudes radially, preventing the armature 14 from increasing radially.

[0056] It should be noted that, Figure 7 The middle portion 48C of the U-shaped member 30C-2 is bent at approximately a right angle (90 degrees) relative to the side portion 46C (tooth portion). However, the bending angle can be freely adjusted within the range of 0 to 90 degrees, within a range that avoids interference with adjacent U-shaped members 28 and 30 after assembly. Alternatively, it can be configured such that not only U-shaped member 30C is bent, but also U-shaped members 30A and 30B are appropriately bent, thereby further preventing the armature 14 from increasing radially.

[0057] [Manufacturing method of U-shaped component]

[0058] Generally, the size of the electric motor is changed according to its application, but from the point of view of mass production, it is not easy to manufacture dedicated parts for each different size of electric motor. In addition, the size of the electric motor that can be manufactured also depends on the size of the manufacturing equipment. Therefore, for large electric motors that exceed the size of the manufacturing equipment, it is preferable to manufacture the iron core separately and then assemble them. That is, when manufacturing the iron core 26 of this embodiment, after manufacturing multiple U-shaped members 28 and 30, these U-shaped members 28 and 30 are assembled, thereby enabling the manufacture of iron cores 26 of any size.

[0059] The manufacturing methods of U-shaped components 28 and 30 will be explained below. Figure 8 This diagram illustrates the manufacturing method of U-shaped components 28 and 30. Both U-shaped components 28 and 30 are formed using a common wire 32. (The diagram is constructed using...) Figure 8 At bend point A on the left side, bend the wire 32 and cut off the excess portion indicated by the dotted line to form... Figure 8 The L-shaped member 35A is shown in the upper right corner. Additionally, through... Figure 8 At the bend point B on the left side, bend the wire 32 and cut off the excess part indicated by the dotted line to form... Figure 8 The L-shaped member 35B is shown in the lower right corner. Next, by joining the two L-shaped members 35A with their ends abutting each other, a U-shaped member of a specified size can be formed. Similarly, by joining the two L-shaped members 35B with their ends abutting each other, a U-shaped member with the same dimensions can be formed. Figure 8 The upper right corner contains U-shaped components of different sizes. Thus, by forming a U-shaped component from a pair of L-shaped components, large U-shaped components can be manufactured.

[0060] As described above, by adjusting the bending position of the wire 32, U-shaped components of any size can be formed using the common wire 32. For example, the U-shaped components 28, 30A, 30B, and 30C of this embodiment have different dimensions. Therefore, by adjusting the bending position of the wire 32 and forming L-shaped components of different sizes, these U-shaped components 28 and 30 can be formed using the common wire 32.

[0061] Furthermore, if a gap is formed at the joint of a pair of L-shaped members, it may lead to an increase in magnetic reluctance. Therefore, it is preferable to employ a structure that achieves gapless contact at the joint and still ensures strength after joining, for example, a structure that can prevent offset in the shear direction. In contrast, a structure that ensures the strength of the joint can also be obtained by forming a stepped or concave-convex shape at the ends of adjacent L-shaped members along the stacking direction, and also forming a stepped or concave-convex shape at the ends of the L-shaped members that join them. Then, when these L-shaped members are joined together to form a U-shaped member, the stepped or concave-convex shapes formed therein will fit together.

[0062] Figure 9A This indicates the case where a stepped shape 34 is formed by two adjacent L-shaped members 35X and 35Y along the stacking direction. Figure 9B Indicates will Figure 9A The state after the L-shaped components 35X and 35Y are joined.

[0063] like Figure 9A As shown on the left, a stepped shape 34 is formed by overlapping two L-shaped members 35X and 35Y of different lengths. Similarly, in Figure 9AOn the right side, a stepped shape 34 is formed by overlapping two L-shaped members 35X and 35Y of different lengths. It should be noted that they are arranged in a manner where L-shaped members 35X and 35Y of different sizes are joined together. Figure 9A Starting from the state shown, after joining the L-shaped components 35X and 35Y that are opposite each other in the left and right directions, it becomes Figure 9B The state shown is such that, since the stepped shapes 34 formed on the left and right sides fit together, and each joint is adjacent to the L-shaped members 35X and 35Y, the joints are not easily offset along the shear direction.

[0064] Figure 10A This refers to the case where three or more adjacent L-shaped members 35X and 35Y along the stacking direction form a concave-convex shape 36. Figure 10B Indicates will Figure 10A The state after the L-shaped components 35X and 35Y are joined.

[0065] like Figure 10A As shown on the left, a concave-convex shape 36 is formed by alternately overlapping three or more L-shaped members 35X and 35Y of different lengths along the stacking direction. Similarly, in Figure 10A On the right side, a concave-convex shape 36 is also formed by alternately overlapping three or more L-shaped components 35X and 35Y of different lengths along the stacking direction. Figure 10A The opposing concave and convex shapes 36 are formed such that the concave portions and convex portions are opposite to each other. That is, they are arranged such that L-shaped members 35X and 35Y are joined together. Figure 10A Starting from the state shown, after joining the L-shaped members 35X and 35Y that are opposite each other, it becomes Figure 10B The state shown is such that, since the concave and convex shapes 36 formed on the left and right sides fit together, and each joint is adjacent to the L-shaped members 35X and 35Y, the joint is not easily offset along the shear direction.

[0066] [Methods for fixing the iron core]

[0067] The method for fixing the U-shaped members 28 and 30 will now be described. Since the core 26 of the armature 14 is formed by combining multiple U-shaped members 28 and 30, a structure is required to hold them in place. Furthermore, in the electric motor 10 of this embodiment, magnetic flux flows in two directions, namely the rotational direction and the axial direction, resulting in small cross-sectional areas in each direction, which causes the middle portions 44 and 48 (yokes) of the U-shaped members 28 and 30 to become thinner. Therefore, a structure capable of suppressing deformation of the core 26 of the armature 14 caused by the electromagnetic force generated when the electric motor 10 is driven is preferred. To address these issues, the entire core 26 of the armature 14 is fixed by holding the entire middle portion (entire yoke) of each U-shaped member 28 and 30 from the radially outer side by the holding member 40, which will be described later.

[0068] Figure 11 This diagram illustrates a configuration where retaining member 40 is used as a fixing structure for securing U-shaped members 28 and 30, and also shows a portion of the rotation direction of the motor 10 as viewed from the axis of rotation. Figure 11 As shown, the middle portions 44, 48 (yokes) of each U-shaped member 28, 30 are covered by a retaining member 40 formed in an annular shape, which holds the yoke as a whole. Accordingly, each U-shaped member 28, 30 is held by the retaining member 40, and the retaining member 40 also suppresses the deformation of the iron core 26.

[0069] The retaining member 40 is preferably formed of resin. Resin is characterized by its insulating properties and light weight. The retaining member 40 is located close to the armature coil 24 through which current flows when the motor 10 is driven, therefore, the retaining member 40 may come into contact with the armature coil 24. To address this, by forming the retaining member 40 with an insulating resin, it is not affected even if the retaining member 40 comes into contact with the armature coil 24. Furthermore, by forming the retaining member 40 with a lightweight resin, it is also possible to suppress any increase in the weight of the motor 10.

[0070] On the other hand, by having insulating paper 45 between the armature coil 24 and the sides 42, 46 (teeth) of the U-shaped members 28, 30, energization between the armature coil 24 and the U-shaped members 28, 30 is prevented. Figure 12A This indicates the state just before the sides 42 and 46 of a pair of adjacent U-shaped members 28 and 30 are inserted into the frame hole 25 of the armature coil 24. Figure 12B This indicates the state after the sides 42 and 46 of a pair of U-shaped members 28 and 30 are inserted into the frame hole 25 of the armature coil 24. For example... Figure 12A As shown, insulating paper 45 is pre-inserted into the frame hole 25 of the armature coil 24. From this state, the sides 42 and 46 of the U-shaped members 28 and 30 are inserted into the frame hole 25.

[0071] Here, when the retaining member 40 fixes each U-shaped member 28, 30, as shown in FIG12, the retaining member 40 is located on the middle portion 44, 48 (yoke) of the U-shaped members 28, 30 and close to the armature coil 24. If the retaining member 40 interferes with the insulating paper 45, there is a risk that proper insulation cannot be achieved between the armature coil 24 and the sides 42, 46 of the U-shaped members 28, 30 through the insulating paper 45. If the insulation is insufficient, when leakage occurs in the armature coil 24, the current cannot pass along the predetermined path, the current participating in the magnetic interaction will decrease, resulting in a decrease in electromagnetic force and adverse effects on other equipment.

[0072] To prevent this from happening, a space 49 (notch) for inserting insulating paper 45 is formed in the retaining member 40 used to cover the U-shaped members 28, 30 at the portion facing the sides 42, 46 of the U-shaped members 28, 30. The space 49 is formed at the connection between the sides (teeth) and the middle (yoke) of the U-shaped members 28, 30. By forming this space 49, when the sides 42, 46 are inserted into the frame hole 25 of the armature coil 24, as... Figure 12B As shown, the end of the insulating paper 45 is inserted into the space 49. Thus, proper insulation can be achieved between the U-shaped members 28 and 30 and the armature coil 24 through the insulating paper 45.

[0073] [Armature manufacturing method]

[0074] Next, the manufacturing method of the armature 14 will be described. The retaining member 40 comprises a plurality of blocks, which are formed by assembling these blocks. Each block has the function of fixing a predetermined number of U-shaped members 28, 30 in a bundled state. For example, Figure 3 Multiple U-shaped components 28, enclosed by dashed lines, are modularized into a single block and fixed. Furthermore, Figure 3 The U-shaped components 30A to 30C, surrounded by double-dotted lines, are modularized into a single block and fixed.

[0075] Figure 13 shows one scheme for forming the block 50 of the retaining member 40, in which a fixing structure of multiple U-shaped members 28 is shown. Figure 13A This is a top view of block 50. Figure 13B This is a side view of block 50. In Figure 13, the portion of the U-shaped member 28 housed within block 50 is shown in dashed lines. As shown in Figure 13, when multiple U-shaped members 28 are bundled together, the middle portion 44 of the U-shaped members 28 is covered and fixed by block 50. Furthermore, multiple adjacent U-shaped members 28 along the rotational direction after assembly are also fixed by block 50 in the same way.

[0076] Each block 50 has engaging protrusions 52 and engaging holes 54 for engaging with adjacent blocks 50 after assembly. The engaging protrusions 52 are formed on one side of the rotation direction, while the engaging holes 54 are formed on the other side of the rotation direction. During assembly, the adjacent blocks 50 are connected by engaging the engaging protrusions 52 and engaging holes 54 of the adjacent blocks 50. The engaging protrusions 52 and engaging holes 54 are not limited to the shapes shown in FIG13; their shapes can be appropriately modified as long as they are capable of engaging with each other.

[0077] Furthermore, the U-shaped members 30A to 30C are also fixed in a bundled manner by blocks. Each block has engaging protrusions or engaging holes for connection with adjacent blocks 50 along the axial direction. During assembly, the blocks used to fix the U-shaped members 30A to 30C are connected to the blocks 50 by engaging the engaging protrusions or engaging holes (not shown in the figure) formed in the axial direction of the adjacent blocks 50. Thus, the blocks adjacent in both the rotational and axial directions are interconnected, thereby forming a retaining member 40 that holds multiple U-shaped members 28, 30 radially outward after the blocks are assembled. That is, a core 26 is formed by the retaining member 40 holding multiple U-shaped members 28, 30.

[0078] Alternatively, retaining members 60 formed by a 3D printer can be used to fix the U-shaped members 28 and 30, instead of retaining members 40 which includes the plurality of blocks.

[0079] Figure 14 is a diagram illustrating the fixing structure of the U-shaped members 28 and 30 using retaining member 60. Figure 14A This indicates the assembly step of inserting the U-shaped component 28 into the retaining component 60. Figure 14B This indicates the state after the U-shaped component 28 is inserted into the retaining component 60. Figure 14C This indicates a state where U-shaped component 28 has been assembled, and U-shaped component 30 has also been assembled.

[0080] The retaining member 60 is formed of resin, for example, and has a ring shape. Multiple insertion holes 62 are formed in the retaining member 60 for inserting the sides 42, 46 of a plurality of U-shaped members 28, 30. During assembly, after inserting the sides 42, 46 of each U-shaped member 28, 30 into their respective designated insertion holes 62, the U-shaped members 28, 30 are bonded to the retaining member 60 using an adhesive or the like. Thus, it becomes... Figure 14B and Figure 14C The state shown indicates that the retaining member 60 secures each U-shaped member 28, 30. Furthermore, the retaining member 60 can be a single member or a combination of multiple blocks.

[0081] Figure 15 This is a flowchart illustrating the manufacturing process of the armature 14, which includes U-shaped components 28 and 30. Figure 15 The flowchart corresponds to the scheme using the aforementioned retaining member 40.

[0082] exist Figure 15 In the first basic step, the wire 32 is bent at a specified position and the excess portion is cut off, thereby forming a plurality of L-shaped components of the desired size. In the second basic step, the L-shaped components formed in the first basic step are joined together to form a plurality of U-shaped components 28, 30 of the desired size. In the modularization step, a plurality of blocks 50 are formed to fix only a predetermined number of U-shaped components 28 in a bundled state, and a plurality of blocks are formed to fix only a predetermined number of U-shaped components 30A to 30C in a bundled state. In the assembly step, the formed plurality of blocks are connected to each other to form a retaining member 40. At this time, the adjacent blocks are connected into a whole by engaging the engaging portions (engaging protrusions 52, engaging holes 54) formed on the adjacent blocks. It should be noted that the second basic step is equivalent to the "first step" in this invention, the modularization step is equivalent to the "second step" in this invention, and the assembly step is equivalent to the "third step" in this invention.

[0083] Figure 16 This is a flowchart illustrating the manufacturing process of the armature 14 when retaining member 60 is used instead of retaining member 40. Figure 16 In the first basic step, the wire 32 is bent at a specified position and the excess portion is cut off, thereby forming a plurality of L-shaped components of the desired size. In the second basic step, the L-shaped components formed in the first basic step are joined together to form a plurality of U-shaped components 28, 30 of the desired size. In the assembly step, the sides 42, 46 of the U-shaped components 28, 30 formed in the second basic step are inserted radially outward into the insertion holes 62 formed on the retaining member 60 made by the 3D printer, and the U-shaped components 28, 30 are fixed to the retaining member 60 with adhesive or the like. It should be noted that the second basic step is equivalent to the "first step" in this invention, and the assembly step is equivalent to the "second step" in this invention.

[0084] [Functions, etc.]

[0085] As explained above, by constructing the core 26 from multiple U-shaped members 28 and 30, and by arranging the middle portion 44 of the U-shaped members 28 along the rotation direction and the middle portion 48 of the U-shaped members 30 along the rotation axis CL, a magnetic circuit in which magnetic flux flows in a three-dimensional manner can be easily formed. Furthermore, by fixing the U-shaped members 28 and 30 with the retaining member 40, an armature 14 (core 26) including multiple U-shaped members 28 and 30 can be easily manufactured. Alternatively, an armature 14 (core 26) including multiple U-shaped members 28 and 30 can also be easily manufactured by utilizing a retaining member 60 having insertion holes 62 for inserting the sides 42 and 46 of the U-shaped members 28 and 30.

[0086] [Variation Example]

[0087] The embodiments of the present invention have been described above. However, the present invention is not limited to the above embodiments, and appropriate modifications can be made without departing from the essential points of the present invention. For example, in the above embodiments, a U-shaped member 28, 30 is formed by connecting a pair of L-shaped members 35. However, for example, if the motor 10 is small, a U-shape can also be formed by bending one wire 32 at two locations.

[0088] In the above embodiment, among the U-shaped members 30A to 30C whose middle portions overlap radially, only the outermost U-shaped member 30C located radially is bent. However, the U-shaped members 30A and 30B can also be bent.

[0089] In the above embodiment, two armature coils 24 are connected in series along the axial direction, but it is not limited to two. That is, three or more armature coils 24 can also be connected in series along the axial direction.

[0090] In the above embodiments, the surfaces of the U-shaped members 28 and 30 are covered with insulation; however, insulation may not be implemented. For example, the cross-sections of the U-shaped members 28 and 30 may be set to be circular to minimize the contact area between adjacent U-shaped members 28 and 30, thereby reducing losses.

[0091] In the above embodiments, the blocks used to fix the plurality of U-shaped members 28, 30 are provided with engaging protrusions 52 and engaging holes 54. Adjacent blocks are connected by engaging the engaging protrusions 52 and engaging holes 54 of adjacent blocks. However, the method of connecting the blocks is not limited to this. For example, threaded holes may be formed in each block, and adjacent blocks may be connected by fixing with screws. Alternatively, engaging portions for engaging clamping members may be provided in each block, and clamping members arranged to span across adjacent blocks may be used to connect the blocks. Alternatively, adjacent blocks may be connected by adhesive or welding.

[0092] In the above embodiment, after inserting the plurality of U-shaped members 28 and 30 into the insertion hole 62 of the retaining member 60, they are bonded and fixed with an adhesive or the like. However, it is not limited to using an adhesive. For example, the U-shaped members 28 and 30 may also be pressed into the insertion hole 62 for fixing.

[0093] The first aspect of the present invention relates to an electric motor comprising: an armature including an iron core and an armature coil disposed in a manner surrounding the iron core; and a movable member configured to face the armature, wherein the iron core of the armature comprises a plurality of members formed of electrical steel sheets, each of the plurality of members being U-shaped and having a pair of parallel or substantially parallel sides and a middle portion connecting the pair of sides, the plurality of members comprising: a plurality of first members; and a plurality of second members, wherein the long side direction of the middle portion of the second members is perpendicular to the long side direction of the middle portion of the first members, the middle portion of the first members and the middle portion of the second members each constitute a yoke of the iron core, and the side portions of the first members and the side portions of the second members each constitute a tooth of the iron core.

[0094] According to the first scheme, by arranging the middle portions of the first component and the middle portions of the second component in the iron core, which is formed into a U-shape and constitutes the armature, in a manner oriented in mutually orthogonal directions, a magnetic circuit in which magnetic flux flows in a three-dimensional manner can be easily realized.

[0095] The second embodiment involves a motor as follows: In the motor of the first embodiment, the movable member is configured to rotate about a rotation axis, the middle portions of the plurality of first members are arranged along the rotation direction of the movable member, and the middle portions of the plurality of second members are arranged along the rotation axis. According to this second embodiment, a magnetic circuit in which magnetic flux flows along both the rotation direction and the rotation axis direction can be easily realized.

[0096] The third embodiment involves a motor as follows: In the motor of the second embodiment, the plurality of second components are disposed at the center in the direction of the rotation axis of the armature; the plurality of first components are disposed on both sides of the second components in the direction of the rotation axis of the armature. According to this third embodiment, a magnetic circuit with the shortest magnetic flux path can be formed.

[0097] The fourth embodiment involves an electric motor in which the surfaces of the plurality of components formed from the electrical steel sheets are respectively covered with insulation. According to this third embodiment, losses caused by eddy current generation can be effectively reduced.

[0098] The fifth embodiment involves an electric motor in which the electrical steel sheet is made of wire, as described in any of the first to fourth embodiments. According to this fifth embodiment, a U-shaped component can be easily formed by bending the wire.

[0099] The sixth embodiment involves a motor as follows: In the motors involved in any of the first to fifth embodiments, each of the plurality of second members is configured such that its pair of sides overlaps with the pair of sides of an adjacent second member in the direction of the rotation axis, and its middle portion overlaps with the middle portion of an adjacent second member in the radial direction centered on the rotation axis; in the second members at both ends of the pair of sides located in the direction of the rotation axis, at least the middle portion is bent relative to the pair of sides in the direction of rotation. Since the middle portions of the second members are overlapped in the radial direction, the core tends to increase in the radial direction. In contrast, according to this sixth embodiment, in the second members at both ends of the direction of the rotation axis where at least a pair of sides are located, by bending the middle portion relative to the pair of sides in the direction of rotation, the radial increase of the core can be mitigated.

[0100] The seventh embodiment involves an electric motor as follows: In any of the electric motors described in embodiments 1 to 6, the electric motor includes a retaining member formed of resin, which retains the entire yoke formed by the intermediate portion of the plurality of members from the radially outer side. According to this seventh embodiment, when the electric motor is driven, deformation of the iron core can be suppressed by the retaining member. Furthermore, since the retaining member is formed of resin, the weight increase caused by the installation of the retaining member can also be reduced.

[0101] The eighth embodiment relates to a motor as follows: In the motor of the seventh embodiment, the retaining member has an insertion hole for the side portions of the plurality of members to be inserted radially outward. According to this eighth embodiment, during assembly, the core can be easily formed by inserting the side portions of the plurality of members into the insertion holes formed in the retaining member.

[0102] The ninth aspect of the present invention relates to a method for manufacturing an armature as follows: the armature is the armature for manufacturing the motor of the seventh aspect, and the manufacturing method includes: a first step of forming each of the plurality of first components and the plurality of second components; a second step of forming a plurality of blocks for fixing each of the plurality of first components and the plurality of second components in a predetermined number; and a third step of connecting the plurality of blocks to each other to form the retaining member. According to this ninth aspect, by forming a plurality of blocks for fixing a predetermined number of first components and second components, and connecting the plurality of blocks to each other to form the retaining member, an armature including a plurality of first components and a plurality of second components can be easily manufactured.

[0103] The tenth aspect of the present invention relates to a method for manufacturing an armature as follows: the armature is the armature for manufacturing the motor of the eighth aspect, and the manufacturing method includes: a first step of forming each of the plurality of first components and the plurality of second components; and a second step of inserting the side portions of each of the plurality of first components and the side portions of each of the plurality of second components into the insertion holes of the retaining member. According to this tenth aspect, by inserting the side portions of each of the plurality of first components and the side portions of each of the plurality of second components into the insertion holes formed in the retaining member, an armature including a plurality of first components and a plurality of second components can be easily manufactured.

Claims

1. An electric motor characterized by include: An armature includes an iron core and an armature coil arranged to surround the iron core; as well as, The movable element is configured to face the armature, wherein, The armature's core comprises multiple components formed of electrical steel sheets. Each of the plurality of components is U-shaped and has a pair of parallel or substantially parallel sides and a middle portion connecting the pair of sides. The plurality of components includes: a plurality of first components; and a plurality of second components, wherein the long side direction of the middle portion of the second component is perpendicular to the long side direction of the middle portion of the first component. The middle portion of the first component and the middle portion of the second component each constitute the yoke of the iron core. The side portion of the first component and the side portion of the second component each constitute the teeth of the iron core.

2. The electric motor according to claim 1, characterized in that, The movable element is configured to rotate about a rotation axis. The middle portions of the plurality of first components are arranged along the rotational direction of the movable member. The middle portions of the plurality of second components are configured along the axis of rotation.

3. The electric motor according to claim 2, characterized in that, The plurality of second components are disposed at the center in the direction of the rotation axis in the armature. The plurality of first components are arranged on both sides of the second component in the direction of the rotation axis in the armature.

4. The electric motor according to any one of claims 1 to 3, characterized in that, The surfaces of the plurality of components formed from the electrical steel sheets are each covered with insulation.

5. The electric motor according to any one of claims 1 to 3, characterized in that, The electrical steel sheet is made of wire.

6. The electric motor according to claim 2 or 3, characterized in that, Each of the plurality of second members is configured such that its pair of sides overlaps with the pair of sides of an adjacent second member in the direction of the rotation axis, and that its middle portion overlaps with the middle portion of an adjacent second member in the radial direction centered on the rotation axis. In the second member at both ends of the pair of sides located in the direction of the rotation axis, at least the middle portion is bent in the direction of rotation relative to the pair of sides.

7. The electric motor of any one of claims 1 to 3, wherein include: The retaining member is formed of resin and retains the yoke integrally formed by the middle portion of the plurality of members from the radially outer side.

8. The electric motor according to claim 7, characterized in that, The retaining member has an insertion hole for the side portions of the plurality of members to be inserted radially outward.

9. A method of manufacturing an armature, characterized by, The armature is the armature constituting the electric motor of claim 7, and the manufacturing method includes: Step 1: Form each of the plurality of first components and the plurality of second components; Step 2: Forming a plurality of blocks, the plurality of blocks being used to fix each of the plurality of first components and the plurality of second components in a predetermined number; and, Step 3: Connect the plurality of blocks together to form the retaining member.

10. A method for manufacturing an armature, characterized in that, The armature is the armature constituting the electric motor of claim 8, and the manufacturing method includes: Step 1: Forming each of the plurality of first components and the plurality of second components; and, In the second step, the side portions of each of the plurality of first components and the side portions of each of the plurality of second components are respectively inserted into the insertion holes of the retaining member.

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