Motor

Abstract

To improve characteristics.SOLUTION: The motor includes an insulator having an inner wall, an outer wall, and a tube connecting the inner wall and the outer wall. The tube has a first portion connected to the inner wall and a second portion connected to the outer wall. In the circumferential direction, the first portion is offset relative to the second portion.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present invention relates to a motor. [Background technology]

[0002] It is known that motors that must handle large currents, such as motors for vehicles, use extra-thick windings with a diameter of about 2.0 to 3.0 mm. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Publication No. 2021-141763 [Patent Document 2] Japanese Patent Application Laid-Open No. 2008-29157 Summary of the Invention [Problem to be solved by the invention]

[0004] When using extra-thick windings, the number of turns that can be wound within the effective winding area of ​​the core cannot be increased, which can result in a deterioration in motor characteristics.

[0005] In one aspect, an object is to provide a motor that can improve characteristics. [Means for solving the problem]

[0006] In one embodiment, a motor includes an insulator having an inner wall, an outer wall, and a tube connecting the inner wall and the outer wall. The tube has a first portion connected to the inner wall and a second portion connected to the outer wall. The first portion is offset from the second portion in the circumferential direction.

[0007] According to one embodiment, the characteristics can be improved. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a cross-sectional view showing an example of a motor according to a first embodiment. [Figure 2] FIG. 2 is a perspective view showing an example of a split core to which an insulator and a coil are attached according to the first embodiment. [Figure 3] FIG. 3 is a perspective view illustrating an example of the first insulator in the first embodiment. [Figure 4] FIG. 4 is a perspective view illustrating an example of the second insulator in the first embodiment. [Figure 5] FIG. 5 is a perspective view illustrating an example of an insulator according to the first embodiment. [Figure 6] FIG. 6 is a perspective view showing an example of an assembly process for the split stator according to the first embodiment. [Figure 7] FIG. 7 is a cross-sectional perspective view showing an example of a stator segment according to the first embodiment. [Figure 8] FIG. 8 is a bottom view showing an example of a split stator according to the first embodiment. [Figure 9] FIG. 9 is a partial cross-sectional view showing an example of a stator according to the first embodiment. [Figure 10] FIG. 10 is an exploded perspective view showing an example of an assembly process for the split stator according to the second embodiment. [Figure 11] FIG. 11 is a cross-sectional view showing an example of a stator segment according to the second embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0009] Each embodiment of the motor disclosed herein will be described in detail below with reference to the drawings. Note that the dimensional relationships and ratios of elements in the drawings may differ from reality. The dimensional relationships and ratios may also differ between the drawings. To facilitate understanding, each drawing may illustrate a coordinate system in which the direction in which a shaft 99 (described later) extends (the rotational axis direction) is the Z-axis direction, and the radially inner side of a split stator 10A (described later) is the negative side of the Y-axis. In this case, the circumferential direction of split stator 10A substantially coincides with the X-axis. Note that the same components are designated by the same reference numerals throughout the description of each embodiment.

[0010] [First embodiment] First, a motor according to the first embodiment will be described with reference to Figs. 1 and 2. Fig. 1 is a cross-sectional view showing an example of a motor according to the first embodiment. Fig. 2 is a perspective view showing an example of a split core to which an insulator and a coil according to the first embodiment are attached. Fig. 1 shows a cross section of motor 1 taken at the position indicated by line AA in Fig. 2. As shown in Fig. 1, motor 1 according to the first embodiment includes a stator 2 and a rotor 9.

[0011] The rotor 9 in the first embodiment has a rotor core 91, a magnet 92, and a shaft 99. As shown in Fig. 1, the motor 1 in the first embodiment is a so-called inner rotor type motor in which the rotor 9 is disposed radially inward of the stator 2. The stator 2 and the rotor 9 may be housed in a frame or the like (not shown).

[0012] The stator 2 in the first embodiment is formed by arranging the split stators 10 shown in Fig. 2 in a circular ring shape along the circumferential direction and connecting and integrating adjacent split stators 10. Note that, below, when the multiple split stators 10 included in the stator 2 in the first embodiment are to be individually described, they may be referred to as split stators 10A to 10R. Note that the split stators 10A to 10R each have approximately the same shape and components, and the following description may be given using split stator 10A as an example.

[0013] As shown in Fig. 2, the split stator 10 in the first embodiment includes a split core 300, an insulator 20 attached to the split core 300, and a coil 400 wound around the split core 300 via the insulator 20. The split core 300 is a member formed by stacking multiple magnetic bodies, such as stainless steel, electromagnetic steel, or magnetic steel, in the Z-axis direction. The stator 2 is formed, for example, by connecting split stators 10A to 10R in the circumferential direction. The split stators 10A to 10R are joined together, for example, by welding the outer circumferential surfaces of the split cores 300 included in each split stator 10.

[0014] The insulator 20 includes a first insulator 100 and a second insulator 200, each made of an insulating material such as resin. The first insulator 100 covers the split core 300 from the positive side along the Z axis, and the second insulator 200 covers the split core 300 from the negative side along the Z axis.

[0015] The coil 400 is formed, for example, from an insulating-coated conductor wire (e.g., copper wire) and is wound around the split core 300 via the insulator 20. The conductor wire forming the coil 400 in the first embodiment is, for example, a round wire with a substantially circular cross section and a diameter of 2 to 3 mm. As shown in FIG. 2, the coil 400 has two terminals 419 and 429 that protrude in the positive direction along the Z axis. These two terminals 419 and 429 are formed at one end and the other end of the conductor wire, respectively. The two terminals 419 and 429 are electrically connected to external members such as a bus bar or a circuit board, either directly or via another member.

[0016] As shown in Fig. 3, the first insulator 100 has an inner wall 110, an outer wall 120, and a tube 140 connecting the inner wall 110 and the outer wall 120. Fig. 3 is a perspective view showing an example of the first insulator in the first embodiment. The inner wall 110 has an end face 111 on the other side in the circumferential direction (the negative side on the X-axis) and an end face 112 on one side in the circumferential direction (the positive side on the X-axis). Similarly, the outer wall 120 has an end face 121 on the other side in the circumferential direction and an end face 122 on one side in the circumferential direction.

[0017] The tube 140 has a first portion 150 connected to the inner wall 110 and a second portion 160 connected to the outer wall 120. If necessary, a third portion (intermediate portion) may be provided between the first and second portions. As shown in FIG. 3, the first portion 150 is formed radially inward of the second portion 160. The tube 140 also has an axially extending opening 130, within which a split core 300 is disposed. The outer wall 120 has end faces 121 and 122 on both sides in the circumferential direction. The end faces 121 and 122 of the outer wall 120 are located circumferentially inward of a portion of the coil 400 wound around the second portion 160.

[0018] In the first embodiment, the second portion 160 is offset in the circumferential direction with respect to the first portion 150. Specifically, as shown in Fig. 3, the first portion 150 has a first protruding portion 152 that protrudes further in the circumferential direction than the second portion 160. The second portion 160 also has a second protruding portion 161 that protrudes further in the circumferential direction than the first portion 150. Steps 156 and 165 are formed between the first portion 150 and the second portion 160 of the tube 140.

[0019] Similarly to the first insulator 100, the second insulator 200 also includes an inner wall 210, an outer wall 220, and a tube 240 connecting the inner wall 210 and the outer wall 220. Fig. 4 is a perspective view showing an example of the second insulator according to the first embodiment. In the second insulator 200, the first portion 250 of the tube 240 also includes a first protruding portion 254 that protrudes toward one side in the circumferential direction relative to the second portion 260. The second portion 260 also includes a second protruding portion 263 that protrudes toward the other side in the circumferential direction relative to the first portion 250.

[0020] In the first embodiment, the first insulator 100 and the second insulator 200 are disposed opposite to each other in the Z-axis direction so that the first protrusion 152 of the first insulator 100 and the first protrusion 254 of the second insulator 200 are substantially flush with each other. In this case, the second protrusions 161 and 263 are also substantially flush with each other as shown in FIG. 5 . FIG. 5 is a perspective view showing an example of an insulator according to the first embodiment. In the first embodiment, as shown in FIG. 5 , the surfaces 151 and 253 located on the opposite side in the circumferential direction to the first protrusions 152 and 254, which are not visible from the viewpoint shown in FIG. 5 , are also substantially flush with each other. In this case, the surfaces 162 and 264 located on the opposite side in the circumferential direction to the second protrusions 161 and 263, which are not visible from the viewpoint shown in FIG. 5 , are also substantially flush with each other.

[0021] In this configuration, the split core 300 is attached to the openings 130 and 230 from the radially inner side (the negative side on the Y-axis), as shown in Fig. 6. Fig. 6 is a perspective view showing an example of the assembly process of the split stator in the first embodiment. As shown in Fig. 6, the split core 300 in the first embodiment has arc-shaped portions 310 as magnetic pole portions that extend on both sides in the circumferential direction on the radially inner side, and protrusions 330 that extend radially outward.

[0022] In the first embodiment, the side surface of the end (diametrically opposite to the arc-shaped portion 310) of the protruding portion 330 extends in the radial direction. That is, the split core 300 in the first embodiment is a so-called I-shaped core. With this configuration, as shown in Fig. 6, with the coil 400 wound around the first insulator 100 and the second insulator 200 in advance, the split core 300 can be attached from the negative side in the Y-axis, i.e., from the inner side in the radial direction.

[0023] In this case, the coil 400 is wound around the first portion 150 and the second portion 160 of the tube 140 and the first portion 250 and the second portion 260 of the tube 240. Specifically, as shown in FIGS. 7 and 8 , the coil 400 includes a portion 411 that faces the first protrusions 152 and 254 in the circumferential direction and a portion 422 that faces the second protrusions 161 and 263 in the circumferential direction. FIG. 7 is a cross-sectional perspective view showing an example of a split stator according to the first embodiment. FIG. 8 is a bottom view showing an example of a split stator according to the first embodiment. FIG. 7 shows a cross section taken along line BB in FIG. 2. Note that in FIGS. 7 and 8 , portions of the first insulator 100 and the second insulator 200 that are hidden by the coil 400 and cannot be seen are indicated by dashed lines. Furthermore, although the coil portions 411 and 412 are in contact with the insulator 20 in the circumferential direction as shown in FIG. 7, they may also have portions that are spaced apart from the insulator 20 in the circumferential direction and face each other as shown in FIG. 8.

[0024] In this configuration, a part of the conductive wire forming coil 400, which faces first protrusions 152 and 254 in the circumferential direction, 411 protrudes to one side in the circumferential direction beyond effective winding area 19 shown in FIG. 9. FIG. 9 is a partial cross-sectional view showing an example of a stator according to the first embodiment. FIG. 9 shows a cross-section taken along line AA in FIG. 2 of portions corresponding to split stators 10A and 10B of stator 2 to which split stators 10 are connected according to the first embodiment. As shown in FIG. 9, thickness D1 of the conductive wire is the same as or greater than thickness D2 of insulator 20.

[0025] 7 and 8, the portions facing second protrusions 161 and 263 in the circumferential direction protrude to the other side in the circumferential direction beyond effective winding area 19. Note that effective winding area 19 in the first embodiment is, for example, the range surrounded by a line segment connecting shaft 99 with the portion where split stator 10A and split stator 10B meet in the circumferential direction, as shown by the dashed dotted line in FIG.

[0026] Of the portion 422 of the coil 400 in the first embodiment, a part (the solid portion in FIG. 9 ) wound around the second portions 160 and 260 of the first insulator 100 and the second insulator 200 protrudes toward the other circumferential side of the effective winding area 19, for example, toward the outside in the circumferential direction of the end face 121 of the outer wall 120 of the first insulator 100. Similarly, the solid portion of the portion 411 of the coil 400 protrudes toward one circumferential side of the effective winding area 19.

[0027] On the other hand, the portion 412 of the coil 400 that faces the surface 151 in the circumferential direction is disposed on one side of the portion 422 in the circumferential direction, i.e., closer to the protruding portion 330 of the split core 300, as shown in FIGS. 7 and 8 . Similarly, the portion 421 that faces the surfaces 162 and 264 in the circumferential direction is disposed on one side of the portion 411 in the circumferential direction, i.e., closer to the protruding portion 330 of the split core 300. Note that the protruding portion 330 of the split core 300 is covered by the first insulator 100 in FIG. 7 and is covered by the second insulator 200 in FIG. 8 and is therefore not visible. Also, as shown in FIG. 7 , the portion 412 and the portion 421 of the coil 400 are connected by a connecting portion 423. This connecting portion 423 of the coil 400 is the portion of the coil 400 that spans the first portion 150 and the second portion 160 of the first insulator 100 and the second insulator 200.

[0028] According to this configuration, of portions 411 and 422 of coil 400, the portions that protrude outward from effective winding area 19, as shown by dashed lines in FIG. 9, are accommodated in effective winding area 19 of the adjacent split stator 10. For example, part of portion 411 of coil 400 of split stator 10A is accommodated in effective winding area 19 of the adjacent split stator 10B, as shown in FIG. 9. In this case, the accommodated part of coil 400 of split stator 10A is adjacent to portion 412 of coil 400 of split stator 10B, as shown in FIG. 9, and effective winding area 19 of split stator 10A does not interfere with effective winding area 19 of split stator 10B. Similarly, part of portion 422 of coil 400 of split stator 10B is adjacent to portion 421 of coil 400 of the adjacent split stator 10A. In this case, effective winding area 19 of split stator 10B and effective winding area 19 of split stator 10A do not interfere with each other, and part of portion 411 of coil 400 of split stator 10A is accommodated in effective winding area 19 of split stator 10B.

[0029] As described above, the motor 1 according to the first embodiment includes an insulator 20 having inner walls 110, 210, outer walls 120, 220, and tubes 140, 240 connecting the inner walls 110, 210 and the outer walls 120, 220. The tubes 140, 240 have first portions 150, 250 connected to the inner walls 110, 210 and second portions 160, 260 connected to the outer walls 120, 220. The second portions 160, 260 are offset from the first portions 150, 250 in the circumferential direction. This configuration allows the coil 400 to be wound without being restricted by the effective winding area 19. This increases the space factor of the coil 400 in the stator 2, thereby improving the characteristics of the motor 1.

[0030] [Second embodiment] In the embodiment, the split core 300 is a so-called I-shaped core, but as shown in Figures 10 and 11, for example, the split core may have a shape that includes a portion that protrudes in the circumferential direction on the radially outer side. Figure 10 is an exploded perspective view showing an example of an assembly process for a split stator in the second embodiment. Figure 11 is a cross-sectional view showing an example of a split stator in the second embodiment. Figure 11 shows a cross-section taken along line CC in Figure 10. Note that in the following embodiment and each modified example, parts that are the same as parts shown in the drawings described above are assigned the same reference numerals, and duplicated explanations will be omitted.

[0031] As shown in Fig. 10, the split stator A10 of the second embodiment differs from those of the embodiment in the shapes of the first insulator 500, the second insulator 600, and the split core 700. In the opening 530 of the first insulator 500, a second portion 560 formed on the radially outer side is formed with a recessed portion 569 that is recessed toward the other side in the circumferential direction (the negative side on the X axis shown in Fig. 10). Similarly, in the opening 630 of the second insulator 600, a second portion 660 formed on the radially outer side is formed with a recessed portion 669 that is recessed toward the other side in the circumferential direction (the negative side on the X axis). In the second embodiment, the first insulator 500 and the second insulator 600 are arranged opposite each other in the Z axis direction so that the recessed portions 569 and 669 are substantially flush with each other.

[0032] In the second embodiment, the protruding portion 730 of the split core 700 is formed with a convex portion 769 that protrudes toward the other side in the circumferential direction on the radially outer side (the positive side of the Y axis shown in FIG. 10). The convex portion 769 is housed in the recessed portion 569 of the first insulator 500, as shown in FIG. 11. The convex portion 769 is an example of a portion that protrudes toward the other side in the circumferential direction.

[0033] As described above, in the motor according to the second embodiment, at the opening 530 of the first insulator 500, the second portion 560 is formed with a recessed portion 569 that is recessed toward the other side in the circumferential direction, and the split core 700 is provided with a portion 769 that protrudes toward the other side in the circumferential direction. Similarly, at the opening 630 of the second insulator 600, the second portion 660 is formed with a recessed portion 669 that is recessed toward the other side in the circumferential direction. With this configuration, the protruding portion 730 becomes thicker in the circumferential direction, thereby further improving the characteristics of the motor.

[0034] In the second embodiment, it is difficult to attach the split core 700 after the coil 400 is wound around the first insulator 500 and the second insulator 600. In this case, the first insulator 500 and the second insulator 600 are attached to the split core 700 from both directions along the Z axis, and then the coil 400 is wound around the split core 700.

[0035] [Variations] Although the configurations of the respective embodiments and modifications have been described above, the embodiments and modifications are not limited to these, and the respective embodiments may be combined as appropriate. For example, the coil 400 is not limited to the two turns shown in the respective embodiments, but may be wound with three or more turns.

[0036] Furthermore, the second insulator 200 may not have the steps 258, 267, for example, and the first portion 250 and the second portion 260 may be continuously connected by an inclination or a curve.

[0037] Furthermore, the motor 1 is not limited to an inner rotor type, but may be a so-called outer rotor type in which the rotor is positioned radially outward from the stator.

[0038] The effective winding area 19 may also be another range, such as the range surrounded by lines connecting the end faces 223, 224 of the outer wall 220 of the second insulator 200 and the end faces 213, 214 of the inner wall 210 shown in FIG.

[0039] Although the present invention has been described above based on the embodiments and modifications thereof, it goes without saying that the present invention is not limited to the embodiments and modifications thereof, and various modifications are possible without departing from the spirit of the present invention. Such modifications without departing from the spirit of the present invention are also included in the technical scope of the present invention, and this will be clear to those skilled in the art from the description of the claims. [Explanation of symbols]

[0040] 1 motor, 2 stator, 9 rotor, 10, 10A to 10R, A10 split stator, 19 winding effective area, 20 insulator, 91 rotor core, 92 magnet, 99 shaft, 100, 500 first insulator, 200, 600 second insulator, 110, 210 inner wall, 120, 220 outer wall, 111, 112, 121, 122, 213, 214, 223, 224 end face, 130, 230, 530, 630 opening, 140, 240 cylinder, 150, 250 first portion, 152, 254 first protrusion, 160, 260, 560, 660 second portion, 161, 263 second protrusion, 151, 162, 253, 264 Surface, 156, 165, 258, 267 Step, 569, 669 Concave portion, 300, 700 Split core, 310 Arc-shaped portion, 330, 730 Protruding portion, 769 Convex portion, 400 Coil, 411, 412, 421, 422 Opposing portion, 419, 429 Terminal

Claims

1. an insulator having an inner wall, an outer wall, and a tube connecting the inner wall and the outer wall; the tube has a first portion connected to the inner wall and a second portion connected to the outer wall; The first portion is offset relative to the second portion in the circumferential direction. Motor.

2. the first portion includes a first protruding portion that protrudes toward one side in the circumferential direction relative to the second portion, the second portion includes a second protruding portion that protrudes toward the other side in the circumferential direction than the first portion, The motor according to claim 1 .

3. 3. The motor of claim 2, further comprising a coil wound around the first and second portions of the barrel.

4. Among the conductors forming the coil, a portion facing the first protruding portion in the circumferential direction protrudes to one side in the circumferential direction beyond an effective winding area; a portion of the winding core facing the second protruding portion in the circumferential direction protruding toward the other side in the circumferential direction beyond the winding effective area; The motor according to claim 3.

5. The outer wall has end surfaces on both sides in the circumferential direction, an end surface of the outer wall is located circumferentially inside a part of the coil that is wound around the second portion; 5. The motor according to claim 4.

6. The motor according to claim 1 , wherein a step is formed between the first portion and the second portion of the cylinder.

7. Equipped with a split core, The barrel has an axially extending opening; The split core is disposed in the opening. The motor according to claim 1 .

8. In the opening, a recessed portion is formed in the second portion toward the other side in the circumferential direction, The split core has a portion protruding to the other side in the circumferential direction. The motor according to claim 7.

9. a plurality of insulators including the insulator; The plurality of insulators are arranged in a circumferential direction.

9. A motor according to any one of claims 1 to 8.

Images