Motor

Abstract

To improve characteristics.SOLUTION: A motor includes a coil formed of a first conductive wire formed of a round wire and a second conductive wire electrically connected to the first conductive wire and formed of a rectangular wire.SELECTED DRAWING: Figure 1

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 Application Laid-Open No. 2008-278654 [Patent Document 2] Japanese Patent Application Laid-Open No. 2008-148480 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, the motor includes a coil formed of a first conductor formed of a round wire and a second conductor formed of a rectangular wire that is electrically connected to the first conductor.

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

[0008] [Figure 1] FIG. 1 is a perspective view showing an example of a split stator according to an embodiment. [Figure 2] FIG. 2 is a cross-sectional view showing an example of a motor according to an embodiment. [Figure 3] FIG. 3 is an exploded perspective view showing an example of a split stator according to the embodiment. [Figure 4] FIG. 4 is a top view showing an example of a split stator according to the embodiment. [Figure 5] FIG. 5 is a perspective view showing an example of an assembly process for the split stator in the embodiment. [Figure 6] FIG. 6 is an enlarged perspective view showing an example of a split stator in the embodiment. [Figure 7] FIG. 7 is a side cross-sectional view showing an example of a split stator in the embodiment. [Figure 8] FIG. 8 is an exploded perspective view showing an example of a process for attaching the split stator to the substrate in the embodiment. [Figure 9] FIG. 9 is an exploded perspective view showing an example of a process for attaching the split stator to the bus bar in the first modified example. DETAILED DESCRIPTION OF THE INVENTION

[0009] An embodiment of a 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 first terminal 411 and second terminal 531 (described later) extend is the positive side of the Z axis, and the radially inner side of split stator 10A 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 the embodiments.

[0010] [Embodiment] A motor 1 according to an embodiment includes a plurality of stator segments 10 as shown in FIG. 1. FIG. 1 is a perspective view showing an example of a stator segment according to an embodiment. FIG. 2 is a cross-sectional view showing an example of a motor according to an embodiment. FIG. 3 is an exploded perspective view showing an example of a stator segment according to an embodiment. FIG. 4 is a top view showing an example of a stator segment according to an embodiment. FIG. 2 shows a cross-section of motor 1 taken at the position indicated by line AA in FIG. 1.

[0011] Motor 1 in this embodiment includes stator 2 as shown in FIG. 2, in which split stators 10 shown in FIG. 1 are arranged in a circular ring shape along the circumferential direction and adjacent split stators 10 are joined together to form an integrated unit. Motor 1 in this embodiment is a so-called inner rotor type motor in which rotor 92 shown in FIG. 2 is arranged radially inside stator 2. Shaft 99 shown in FIG. 2 is fixed to the center of rotor 92 in the radial direction, and rotor 92 and shaft 99 rotate in conjunction with each other. Note that, hereinafter, when the multiple split stators 10 included in stator 2 are to be individually referred to, they may be referred to as split stators 10A to 10L, respectively.

[0012] As shown in FIG. 1 , the split stator 10 includes an insulator 20, a split core 300, and a coil 40. The split core 300 is a component formed by stacking multiple magnetic bodies, such as stainless steel or magnetic steel plates, in the axial direction. As shown in FIG. 3 , the split core 300 includes a curved portion (hereinafter referred to as a first arc-shaped portion) 310 extending in the circumferential direction, a curved portion (hereinafter referred to as a second arc-shaped portion) 320, and a portion (hereinafter referred to as a protruding portion) 330 extending in the radial direction. The split core 300 in this embodiment is a so-called T-core, which includes the first arc-shaped portion 310 and the second arc-shaped portion 320 protruding in the circumferential direction on both the inner and outer radial sides. In this embodiment, the split stators 10 are joined to each other, for example, by welding the circumferential ends of the second arc-shaped portions 320 of the split cores 300.

[0013] Also, as shown in Figures 1 and 3, the insulator 20 includes a first insulator 100 and a second insulator 200, and the coil 40 is formed of a first conductor 400 formed of a round wire and a second conductor 500 formed of a rectangular wire.

[0014] The first insulator 100 and the second insulator 200 are formed of an insulating material such as resin. As shown in Fig. 3, 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 first insulator 100 includes a first arc-shaped portion 110 formed on the radially inner side and protruding further in the positive direction of the Z axis than the end of the split core 300, a second arc-shaped portion 120 formed on the radially outer side and protruding further in the positive direction of the Z axis than the end of the split core 300, and a connecting portion 130 connecting the first arc-shaped portion 110 and the second arc-shaped portion 120 in the radial direction. Similarly, as will be illustrated later, the second insulator 200 includes a first arc-shaped portion 210, a second arc-shaped portion 220, and a connecting portion 230. The first arc-shaped portions 110 and 210 contact the first arc-shaped portion 310 of the split core 300 from the radially outer side, and the second arc-shaped portions 120 and 220 contact the second arc-shaped portion 320 of the split core 300 from the radially inner side. The connecting portions 130 and 230 cover the protruding portion 330 of the split core 300 in the circumferential and axial directions.

[0016] The first conducting wire 400 and the second conducting wire 500 are both made of a metal wire (e.g., copper wire) with an insulating coating. The first conducting wire 400 is a round wire wound around the split core 300 via the insulator 20. In the embodiment, the round wire forming the first conducting wire 400 is a conducting wire having an outer circumferential surface that is closed by a curved, continuous surface. The round wire has, for example, a substantially circular cross section, and is made of a metal (e.g., copper, aluminum, etc.) that is the same as or larger than the thickness (size in the circumferential direction) D5 of the member forming the insulator 20 as shown in FIG. 2.

[0017] As shown in FIG. 2, the stator segment 10 is formed with a plurality of rows 410, 420, and 430 of first conducting wires 400 wound around the insulator 20 in the radial direction. The rows 410, 420, and 430 are arranged radially from the inside to the outside, covering the insulator 20 from both sides in the circumferential direction and from the negative side in the Z-axis direction. The rows 410 and 420 are connected by a connection portion 421 shown in FIG. 4, and the rows 420 and 430 are connected by a connection portion 432 shown in FIG. 4. The row 430 is connected to a portion (hereinafter referred to as an end portion) 490 extending in the circumferential direction. A tip end (hereinafter referred to as a first terminal) 411 shown in FIG. 4 is formed on the positive side in the Z-axis direction of the row 410, and a third terminal 495 is formed on the other end (hereinafter referred to as an end) of the end portion 490. In this configuration, the first terminal 411 to the third terminal 495 are wound with a single round wire.

[0018] As shown in FIG. 3, the second conductor 500 is a rectangular wire having a substantially U-shape and multiple bends. The rectangular wire forming the second conductor 500 is, for example, a conductor having a substantially rectangular cross section (e.g., a copper wire). The second conductor 500 is formed by bending a rectangular wire. The second conductor 500 includes a second portion 520 located on the negative side of the Z axis and extending circumferentially, i.e., in the X-axis direction in FIG. 3, and a first portion 510 and a third portion 530 extending from both ends of the second portion 520 in the X-axis direction toward the positive side of the Z axis. A substantially U-shaped recess 514 is formed at the end (one end) of the first portion 510 on the positive side of the Z axis, and a second terminal 531 is formed at the end (the other end) of the third portion 530 on the positive side of the Z axis.

[0019] The second conducting wire 500 is electrically connected to the first conducting wire 400. Specifically, as shown in FIGS. 5 and 6, a third terminal 495 located at the end of the first conducting wire 400 is connected to a recess 514 of a first portion 510 of the second conducting wire 500. FIG. 5 is a perspective view showing an example of an assembly process for a split stator according to an embodiment. FIG. 6 is an enlarged perspective view showing an example of a split stator according to an embodiment. When the insulating coating is made of, for example, AIW (heat-resistant resin), the first conducting wire 400 and the second conducting wire 500 are electrically connected by removing the insulating coating from the recess 514 and the third terminal 495 by a process such as thermal caulking or resistance welding. The first conducting wire 400 and the second conducting wire 500 may also be connected by soldering, laser welding, or the like.

[0020] 2, the second conducting wire 500 overlaps in the circumferential direction with a portion of the plurality of rows 430 and 420. In this case, the second conducting wire 500 surrounds a portion of the first conducting wire 400 wound around the insulator 20.

[0021] 2, in this embodiment, the thickness (size in the circumferential direction) T5 of the rectangular wire forming the second conductor 500 is smaller than the thickness (diameter) D4 of the first conductor 400. Also, as shown in FIG. 4, the second conductor 500 may have inclined surfaces (notches) 519, 539. This configuration allows the second conductor 500 to be accommodated without protruding from the effective winding area 19 shown in FIG. 2. Note that the effective winding area 19 in this embodiment is the area enclosed by a line segment connecting the second arc-shaped portion 320 of the split core 300 and the shaft 99, as shown in FIG. 2, for example.

[0022] If the thickness D4 of the round wire forming the first conducting wire 400 is large, winding the round wire in the second layer will result in the wire going outside the effective winding area 19, as shown by the dashed line 440 in Figure 2. On the other hand, according to the embodiment, the number of turns of the coil 40 can be increased within the effective winding area 19, thereby improving the characteristics of the motor 1.

[0023] 5, the second conducting wire 500 may be provided with a connecting portion 600 that connects to the insulator 20. The connecting portion 600 is formed, for example, from resin, and is attached to the second portion 520 of the second conducting wire 500 as shown in FIG. 7. FIG. 7 is a side cross-sectional view showing an example of a divided stator in an embodiment. FIG. 7 shows a cross section taken along line BB in FIG. 1.

[0024] The coupling part 600 includes, for example, a through-hole. The second conducting wire 500 is inserted into the through-hole, thereby attaching the coupling part 600 to the second conducting wire 500. Note that, for example, the coupling part 600 may be attached to the second conducting wire 500 by placing the second conducting wire 500 in a mold and filling it with a resin member. Alternatively, the coupling part 600 may include one end, the other end, and an intermediate part located between the one end and the other end in the direction in which the second conducting wire 500 extends (for example, the X-axis direction in FIG. 7). In this case, a portion of the second conducting wire 500 may fit into a recess in the intermediate part, thereby coupling the coupling part 600 to the second conducting wire 500.

[0025] The protruding portion 620 of the connecting portion 600 protrudes radially outward (toward the positive side of the Y-axis shown in FIG. 5). The protruding portion 620 fits into a notch 260 shown in FIG. 5 that is formed in the second arc-shaped portion 220 of the second insulator 200 from the negative side of the Z-axis. In this case, the protruding portion 620 of the connecting portion 600 may further be formed with a boss portion (convex portion) 629 that protrudes toward the positive side of the Z-axis, and the notch (concave portion) 260 of the second insulator 200 may further be formed with a concave portion 269 into which the boss portion 629 of the connecting portion 600 fits.

[0026] In the embodiment, the first terminal 411 of the first conducting wire 400 and the second terminal 531 of the second conducting wire 500 are portions that are electrically connected to an external member. The external member is, for example, a substrate 700 shown in FIG. 8. FIG. 8 is an exploded perspective view showing an example of a process for attaching a split stator to a substrate in the embodiment. The substrate 700 is, for example, a printed circuit board or a thick copper substrate. The substrate 700 includes, for example, a wire W shown in FIG. 8 and a land L electrically connected to the wire W. The first terminal 411 and the second terminal 531 of the split stator 10A are electrically connected to the land L of the substrate 700 by solder or the like.

[0027] 8, first terminal 411 and second terminal 531 of split stator 10A are inserted into through holes 701 and 702 formed in substrate 700. Furthermore, first terminal 411 and second terminal 531 protruding from through holes 701 and 702 are connected to lands L surrounding through holes 701 and 702 with a joining member such as solder. Substrate 700 may also have further through holes formed therein to which first terminals 411 and second terminals 531 of other split stators 10B to 10L are respectively connected. With this configuration, split stator 10 is electrically connected to substrate 700.

[0028] As described above, the motor 1 in this embodiment includes a coil 40 formed from a first conductor 400 made of a round wire and a second conductor 500 made of a rectangular wire and electrically connected to the first conductor 400. This configuration increases the space factor of the coil 40 within the effective winding area 19, thereby improving the motor characteristics. Furthermore, because the second conductor 500 surrounds the first conductor 400, it is possible to prevent the first conductor 400 from becoming unwound.

[0029] In the embodiment, the first conducting wire 400 and the second conducting wire 500 are preferably formed to have substantially the same cross-sectional area. With this configuration, the amount of current passing through the first conducting wire 400 and the second conducting wire 500 can be made substantially the same.

[0030] [First Modification] Although the configuration of the embodiment has been described above, the embodiment is not limited to this. For example, the external member connected to first terminal 411 and second terminal 531 may be bus bar 800 as shown in FIG. 9 instead of substrate 700. FIG. 9 is an exploded perspective view showing an example of a process for attaching the split stator to the bus bar in the first modified example. Bus bar 800 shown in FIG. 9 is formed of a conductive metal such as copper. Note that in the following embodiments and modified examples, parts that are the same as those shown in the drawings described above are designated by the same reference numerals, and duplicated explanations will be omitted.

[0031] Busbar 800 in the first modified example has first busbar 810 and second busbar 820. As shown in Fig. 9 , first terminal 411 of split stator 10 is connected to through-hole 821 of second busbar 820, and second terminal 531 of split stator 10 is connected to through-hole 811 of first busbar 810. Further, first busbar 810 or second busbar 820 may have further through-holes to which first terminal 411 and second terminal 531 of other split stators 10B to 10L are respectively connected. Further, first busbar 810 and second busbar 820 are examples of busbars, and busbar 800 may have three or more members or may be composed of a single member.

[0032] The cross-sectional area of ​​bus bar 800 is relatively large, and it can stably pass a large current because it is only slightly deformed by heat even when motor 1 is running. Note that board 700 in the embodiment may also be a thick copper board in which bus bars are laminated with an internal circuit, for example.

[0033] 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 relative to the stator. Furthermore, the split cores 300 may be so-called I-shaped cores that do not have any circumferentially protruding portions on the radially outer or inner sides.

[0034] Alternatively, for example, the second conductor 500 may cover all of the rows 410, 420, and 430 of the first conductor 400. In this case, it is preferable that the second conductor 500 be accommodated within the effective winding area 19 by adjusting the thickness T5 of the second conductor 500 shown in Fig. 2 and the sizes of the notches 519 and 539 shown in Fig. 4. Note that a configuration in which curved surfaces are formed instead of the notches 519 and 539 may also be used.

[0035] While the present invention has been described above based on the embodiments and modifications, it goes without saying that the present invention is not limited to the embodiments and modifications, 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]

[0036] 1 motor, 2 stator, 10, 10A split stator, 19 winding effective area, 20 insulator, 40 coil, 92 rotor, 99 shaft, 100 first insulator, 200 second insulator, 300 split core, 400 first conductor, 410, 420, 430 row, 411 first terminal, 495 third terminal, 500 second conductor, 510 first portion, 514 recess, 520 second portion, 530 third portion, 531 second terminal, 600 connecting portion, 700 substrate, 800 bus bar

Claims

1. A motor having a coil formed of a first conductor made of a round wire and a second conductor made of a rectangular wire that is electrically connected to the first conductor.

2. Equipped with insulators, a plurality of rows of the first conducting wire wound around the insulator are formed in the radial direction; the second conducting wire overlaps a part of the plurality of rows in the circumferential direction; The motor according to claim 1 .

3. The motor according to claim 2 , wherein the second conductor surrounds a part or all of the first conductor wound around the insulator.

4. The motor according to claim 2 or 3, wherein the second conductor is provided with a connecting portion that connects to the insulator.

5. 5. The motor according to claim 1, wherein the thickness of the second conductor is smaller than the thickness of the first conductor.

6. The motor according to claim 1 , wherein the second conductor comprises a portion electrically connected to the first conductor and a portion electrically connected to an external member.

7. The motor according to claim 6 , wherein the external member is a bus bar or a substrate.

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