Armatures and rotating electric machines

Abstract

We provide rotating electric machines with high torque characteristics. [Solution] An armature 20 having a plurality of armature cores 21 made of a magnetic material, a plurality of coils wound around each of the plurality of armature cores, and support members 25, 26 made of a non-magnetic material that arrange and fix the plurality of armature cores in an annular shape, wherein the armature core has a winding portion 211 around which the coils are wound and protrusions 213 provided at both ends of the winding portion in the axial direction, and the support members are arranged at both ends of the plurality of armature cores in the axial direction and have two annular bottom portions 252, 262 having a plurality of through holes 251, 261 through which the protrusions pass.

Description

Technical Field

[0001] The present disclosure relates to an armature and a rotating electric machine.

Background Art

[0002] As a thin rotating electric machine, an axial-gap type rotating electric machine in which a disk-shaped armature and a rotor are arranged to face each other in the axial direction is known. As an armature of a conventional axial-gap type rotating electric machine, a structure is disclosed in which a support plate that holds an armature core made of a compressed powder body from both sides in the axial direction is provided, and this support plate is fixed to the frame of the armature (see, for example, Patent Document 1). Further, as another armature, an armature core made of a compressed powder body has a plurality of teeth and an annular back yoke arranged on the outer peripheral side of the teeth, and the teeth are inserted into a groove of the back yoke provided in the circumferential direction from the axial direction and fixed to the back yoke. A structure has been disclosed (see, for example, Patent Document 2).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0004] In a conventional armature, since a support plate or a back yoke is arranged between the armature core and the rotor, there is a problem that the gap between the armature core and the rotor cannot be narrowed. Therefore, in a conventional axial-gap type rotating electric machine, there is a problem that the torque characteristics are low.

[0005] This disclosure was made to solve the above-mentioned problems and aims to provide a rotating electric machine with high torque characteristics by narrowing the gap between the armature core and the rotor. [Means for solving the problem]

[0006] The armature of the present disclosure comprises a plurality of armature cores made of a magnetic material, a plurality of coils wound around each of the plurality of armature cores, and a support member made of a non-magnetic material that arranges and fixes the plurality of armature cores in an annular shape, wherein the armature core has a winding portion around which the coils are wound and protrusions provided at both ends of the winding portion in the axial direction, and the support member has two annular bottom portions arranged at both ends of the plurality of armature cores in the axial direction and having a plurality of through holes through which the protrusions pass. [Effects of the Invention]

[0007] In the armature of this disclosure, support members are arranged at both axial ends of a plurality of armature cores, and each has two annular bottoms with a plurality of through holes through which a protrusion passes, so that the gap between the armature core and the rotor can be narrowed. Therefore, the torque characteristics of a rotating electric machine equipped with this armature can be improved. [Brief explanation of the drawing]

[0008] [Figure 1] This is a cross-sectional view of a rotating electric machine according to Embodiment 1. [Figure 2] This is a perspective view of the armature core according to Embodiment 1. [Figure 3] This is a perspective view of the armature according to Embodiment 1. [Figure 4] This is a cross-sectional view of the armature according to Embodiment 1. [Figure 5] This is a perspective view of the armature core according to Embodiment 2. [Figure 6] This is a perspective view of the first support member according to Embodiment 2. [Figure 7] This is a perspective view of the armature core according to Embodiment 3. [Figure 8] This is a perspective view of the armature core according to Embodiment 4. [Modes for carrying out the invention]

[0009] The armature and rotating electric machine relating to embodiments for implementing this disclosure will be described in detail below with reference to the drawings. In each drawing, the same reference numerals indicate the same or corresponding parts.

[0010] Embodiment 1. Figure 1 is a cross-sectional view of a rotating electric machine according to Embodiment 1. Figure 1 is a cross-sectional view of a plane parallel to the axis of rotation. As shown in Figure 1, the rotating electric machine 100 according to this embodiment has a housing 10 consisting of a cylindrical frame 11 with a bottom and an end plate 12 that closes the opening of the frame 11, an armature 20 fixed to the inner diameter side of the frame 11, and a rotor 30 arranged with an axial gap between the armature 20 and the rotor.

[0011] The armature 20 includes a plurality of armature cores 21 made of a magnetic material, a plurality of coils 22 wound around the armature cores 21, a connection plate 23 for distributing current to the plurality of coils 22, a bobbin 24 for electrically insulating the armature cores 21, the coils 22 and the connection plate 23, and a first support member 25 and a second support member 26 for supporting the armature cores 21 from the axial direction. Three connection plates 23 are provided, one for each of the three phases, and each is electrically connected to a coil 22 of a different phase. Methods such as TIG (Tungsten Inert Gas) welding, resistance brazing, laser welding, and pressure welding can be used for the electrical connection between the connection plates 23 and the coils 22. The bobbin 24 is made of an insulator such as resin. The first support member 25 and the second support member 26 are made of a non-magnetic material, and as the non-magnetic material, for example, aluminum or resin can be used.

[0012] The rotor 30 has an annular yoke 31 made of a steel plate that easily conducts magnetic flux, and permanent magnets 32 arranged circumferentially on the yoke 31. A rotating shaft 40 is fastened to the center of the rotor 30. In this embodiment, the rotating electric machine 100 has two rotors 30 facing each other on both sides of the armature 20 with a gap in between in the axial direction. The rotating shaft 40 is rotatably supported by the frame 11 and end plate 12 via bearings 50. The rotor 30 rotates relative to the armature 20 around the rotating shaft 40. Here, the direction parallel to the rotating shaft 40 is called the axial direction, the direction perpendicular to the rotating shaft 40 is called the radial direction, and the direction in which the rotor 30 rotates is called the circumferential direction. The inner diameter side is the direction approaching the rotating shaft 40 in the radial direction, and the outer diameter side is the direction moving away from the rotating shaft 40 in the radial direction.

[0013] The frame 11 and the first support member 25 at the position where the armature 20 is fixed are provided with through holes 13 for flowing coolant. By flowing coolant through these through holes 13 into the space sealed by the first support member 25 and the second support member 26, the armature 20 can be cooled.

[0014] The rotating electric machine 100 of this embodiment is an axial gap type rotating electric machine, in which the armature 20 is located in the axial center, and two rotors 30 are arranged opposite each other on both sides of the armature 20 in the axial direction, forming a double rotor structure. Compared to a radial gap type rotating electric machine in which the armature and rotor are arranged opposite each other in the radial direction, this axial gap type rotating electric machine can increase the area through which magnetic flux passes, and is therefore characterized by its ability to increase the power density of the rotating electric machine.

[0015] FIG. 2 is a perspective view of the armature core according to the present embodiment. The armature core 21 of the present embodiment is composed of a compressed powder core obtained by compression molding powder such as iron. As shown in FIG. 2, the armature core 21 of the present embodiment includes a winding portion 211 where the coil is wound, a flange portion 212 having a cross-sectional area larger than the cross-sectional area of the cross-section orthogonal to the axial direction of the winding portion 211 at both axial ends of the winding portion 211, and a convex portion 213 protruding outward in the axial direction from the flange portion 212. The inner diameter side surface of the convex portion 213 is located on the outer diameter side with respect to the inner diameter side surface of the flange portion 212, and the outer diameter side surface of the convex portion 213 is located on the inner diameter side with respect to the outer diameter side surface of the flange portion 212. Further, both circumferential side surfaces of the convex portion 213 are located on the central side of the flange portion 212 with respect to both circumferential side surfaces of the flange portion 212. In the armature of the present embodiment, a plurality of armature cores shown in FIG. 2 are arranged in an annular shape.

[0016] FIG. 3 is a perspective view of the armature according to the present embodiment. In FIG. 3, the coil and the bobbin are omitted. Also, actually, the armature core 21, the first support member 25, and the second support member 26 are tightly fastened in the axial direction, but in FIG. 3, for the sake of explanation, they are shown separated.

[0017] The first support member 25 includes a bottom portion 252 provided with through holes 251 for passing through the convex portions 213 of the armature core 21 arranged in the circumferential direction, an outer peripheral wall 253 for fixing the first support member 25 to the inner peripheral surface of the frame, and an inner peripheral wall 254. The outer peripheral wall 253 is provided with a through hole 13 for flowing a coolant. The second support member 26 includes a bottom portion 262 provided with through holes 261 for passing through the convex portions 213 of the armature core 21 arranged in the circumferential direction, an outer peripheral wall 263, and an inner peripheral wall 264. As a method for fixing the outer peripheral wall 253 of the first support member 25 to the inner peripheral surface of the frame, methods such as shrink fitting and press fitting can be used.

[0018] The armature of this embodiment is configured by sandwiching an armature core 21 from the axial direction between a first support member 25 and a second support member 26. The convex portions 213 at both axial ends of the armature core 21 penetrate through the through holes 251 of the first support member 25 and the through holes 261 of the second support member 26 respectively and are exposed to the outside in the axial direction.

[0019] FIG. 4 is a cross-sectional view of the armature according to this embodiment. The bottom portion 252 of the first support member 25 and the bottom portion 262 of the second support member 26 are airtightly fastened to the flange portion 212 of the armature core 21. Also, the outer peripheral wall 253 of the first support member 25 and the outer peripheral wall 263 of the second support member 26 are airtightly fastened, and the inner peripheral wall 254 of the first support member 25 and the inner peripheral wall 264 of the second support member 26 are airtightly fastened. These members can be airtightly fastened using, for example, an adhesive, resin, or the like. Therefore, the inside of the armature 20 can be cooled by flowing a coolant through the through hole 13.

[0020] In the armature configured as described above, the convex portions of the armature core are exposed at both axial ends of the armature. As a result, in a rotating electric machine using this armature, the gap between the armature core and the rotor can be narrowed. Therefore, the torque characteristics of the rotating electric machine provided with this armature can be improved.

[0021] In this embodiment of the armature, the first and second support members, which fix multiple armature cores, each wound with multiple coils, in a circumferential arrangement, are fastened together at a position close to the axial end. In this embodiment of the armature, the support members, each positioned at both axial ends of the multiple armature cores, have two annular bottoms with multiple through holes through which protrusions pass, a cylindrical outer circumferential wall positioned on the outer diameter side of the armature cores and fastening the outer diameters of the two bottoms in the axial direction, and a cylindrical inner circumferential wall positioned on the inner diameter side of the armature cores and fastening the inner diameters of the two bottoms in the axial direction, and the support members are divided into two at any axial position. If the support members are divided into two at any axial position, the multiple armature cores can be fixed in an annular arrangement by sandwiching them between the two divided support members.

[0022] Embodiment 2. Figure 5 is a perspective view of the armature core according to Embodiment 2. The armature configuration of this embodiment is the same as that of the armature in Embodiment 1, but the structure of the armature core is different. As shown in Figure 5, the armature core 21 of this embodiment has a winding portion 211 in which the coil is wound, flange portions 212 at both axial ends of the winding portion 211 having a cross-sectional area larger than the area of ​​the cross-section perpendicular to the axial direction of the winding portion 211, and a convex portion 213 that protrudes outward in the axial direction from the flange portion 212. The inner diameter side surface of the convex portion 213 is located on the outer diameter side than the inner diameter side surface of the flange portion 212, and the outer diameter side surface of the convex portion 213 is located on the inner diameter side than the outer diameter side surface of the flange portion 212. Unlike the armature core of Embodiment 1, the armature core 21 of this embodiment has both circumferential sides of the convex portion 213 that are on the same plane as both circumferential sides of the flange portion 212. In this embodiment, the armature, as shown in Figure 5, has multiple armature cores that are sandwiched and fastened between the first support member and the second support member described in Embodiment 1.

[0023] Figure 6 is a perspective view of the first support member according to this embodiment. Figure 6 is a perspective view of the first support member 25 as seen from the armature core side. The first support member 25 of this embodiment is provided with a beam portion 255 that connects the fastening surface 252a on the outer diameter side of the bottom portion 252 and the fastening surface 252b on the inner diameter side of the bottom portion 252. The fastening surface 252a on the outer diameter side and the fastening surface 252b on the inner diameter side of the bottom portion 252 of the first support member 25 are fastened to the flange portion 212 of the armature core. In other words, the through holes 251 arranged in a circumferential direction are partitioned by the beam portion 255. In the armature core 21 of this embodiment shown in Figure 5, the protrusions 213 pass through the through holes 251 and are arranged in a circumferential direction. At this time, since both circumferential sides of the protrusion 213 of the armature core 21 and both circumferential sides of the flange 212 are on the same plane, the beam 255 is fastened to both the protrusion 213 and the circumferential sides of the flange 212 of the armature core 21.

[0024] In the armature configured in this way, since both circumferential sides of the protrusion 213 of the armature core 21 and both circumferential sides of the flange 212 are on the same plane, the axial thickness of the beam 255 of the first support member 25 can be made thicker than the thickness of the protrusion 213. Therefore, the strength of the armature can be improved compared to the armature of Embodiment 1. Furthermore, in the armature of this embodiment, the thickness of the beam portion of the second support member can also be increased, similar to the first support member, thereby further improving the strength of the armature.

[0025] Embodiment 3. Figure 7 is a perspective view of the armature core according to Embodiment 3. The armature configuration of this embodiment is the same as that of the armature in Embodiment 1, but the structure of the armature core is different. As shown in Figure 7, the armature core 21 of this embodiment has a winding portion 211 around which the coil is wound, and protrusions 213 that project outward from the winding portion 211 in the axial direction at both ends of the winding portion 211. The area of ​​the cross-section of the protrusions 213 perpendicular to the axial direction is smaller than the area of ​​the cross-section of the winding portion 211 perpendicular to the axial direction. The inner diameter side surface of the protrusions 213 is located on the outer diameter side than the inner diameter side surface of the winding portion 211, and the outer diameter side surface of the protrusions 213 is located on the inner diameter side than the outer diameter side surface of the winding portion 211. In addition, both circumferential sides of the protrusions 213 are located closer to the center of the winding portion 211 than both circumferential sides of the winding portion 211. In this embodiment, the armature, as shown in Figure 7, has multiple armature cores that are sandwiched and fastened between the first support member and the second support member described in Embodiment 1.

[0026] The armature core configured in this way allows pre-processed coils to be placed around the winding section 211 when assembling the armature. Methods for pre-processing into a coil shape include edgewise bending of flat wire and nozzle winding of round wire. More specifically, pre-winding the coils onto bobbins can be prepared, and the bobbins with the wound coils can be placed around the winding section 211. Alternatively, pre-winding the coils onto winding frames of the same shape as the bobbins can be prepared, and the coils removed from the winding frames can be placed around the winding section 211 together with the bobbins.

[0027] In an armature configured in this way, pre-processed coils can be arranged around the winding portion of the armature core, thus improving productivity.

[0028] Embodiment 4. Figure 8 is a perspective view of the armature core according to Embodiment 4. The armature configuration of this embodiment is the same as that of the armature in Embodiment 1, but the structure of the armature core is different. As shown in Figure 8, the armature core 21 of this embodiment has a winding portion 211 in which the coil is wound, and protrusions 213 that project outward from the winding portion 211 in the axial direction at both ends of the winding portion 211. The area of ​​the cross-section of the protrusions 213 perpendicular to the axial direction is smaller than the area of ​​the cross-section of the winding portion 211 perpendicular to the axial direction. The inner diameter side surface of the protrusions 213 is located on the outer diameter side than the inner diameter side surface of the winding portion 211, and the outer diameter side surface of the protrusions 213 is located on the inner diameter side than the outer diameter side surface of the winding portion 211. Unlike the armature core of Embodiment 3, the armature core 21 of this embodiment has both circumferential sides of the protrusions 213 that are on the same plane as both circumferential sides of the winding portion 211. In this embodiment, the armature, as shown in Figure 8, has multiple armature cores that are sandwiched and fastened between the first support member and the second support member described in Embodiment 1.

[0029] In the armature configured in this way, similar to the armature of Embodiment 3, pre-processed coils can be arranged around the winding portion of the armature core, thereby improving productivity. Furthermore, in the armature of this embodiment, the area of ​​the cross-section of the protrusion 213 perpendicular to the axial direction is larger than that of the armature of Embodiment 3, thus improving torque performance.

[0030] The various aspects of this disclosure are summarized below as an appendix. (Note 1) An armature comprising a plurality of armature cores made of a magnetic material, a plurality of coils wound around each of the plurality of armature cores, and a support member made of a non-magnetic material that arranges and fixes the plurality of armature cores in a ring shape, The armature core has a winding portion around which the coil is wound, and protrusions provided at both ends of the winding portion in the axial direction, The armature is characterized in that the support member has two annular bottom portions, each having multiple through holes through which the protrusions pass, and is positioned at both axial ends of the plurality of armature cores. (Note 2) The armature according to Appendix 1, characterized in that the protrusions of the armature core are exposed at both ends in the axial direction. (Note 3) The armature according to Appendix 1 or 2, characterized in that the inner diameter side of the protrusion is located on the outer diameter side of the inner diameter side of the winding portion, and the outer diameter side of the protrusion is located on the inner diameter side of the winding portion. (Note 4) The armature according to Appendix 3, characterized in that both circumferential sides of the convex portion are located closer to the center of the winding portion than both circumferential sides of the winding portion. (Note 5) The armature according to Appendix 1 or 2, characterized in that it is provided with flange portions between the protrusions at both ends and the winding portion, each having a cross-sectional area larger than the cross-sectional area perpendicular to the axial direction of the winding portion. (Note 6) The armature according to Appendix 5, characterized in that the inner diameter side of the protrusion is located on the outer diameter side of the flange, and the outer diameter side of the protrusion is located on the inner diameter side of the flange. (Note 7) The armature according to Appendix 6, characterized in that both circumferential sides of the convex portion are located closer to the center of the flange portion than both circumferential sides of the flange portion. (Note 8) The armature according to any one of the appendices 1 to 7, characterized in that the support member has a cylindrical outer peripheral wall that is positioned on the outer diameter side of the armature core and fastens the two outer diameter portions of the bottom in the axial direction, and a cylindrical inner peripheral wall that is positioned on the inner diameter side of the armature core and fastens the two inner diameter portions of the bottom in the axial direction. (Note 9) The armature according to Appendix 8, characterized in that the support member is composed of a first support member and a second support member which are divided into two in the axial direction, and the multiple armature cores, each around which the multiple coils are wound, are sandwiched between the first support member and the second support member and fixed in an annular arrangement. (Note 10) The armature according to Appendix 5, characterized in that the plurality of through holes provided in the bottom of the support member are partitioned by beam portions, and the axial thickness of the beam portions is greater than the axial thickness of the flange portions. (Note 11) The armature described in Appendix 8, The armature and the rotor are arranged with a gap in the axial direction, A rotating electric machine having a cylindrical housing for fixing the armature inside, A rotating electric machine characterized in that the outer peripheral wall of the support member is fastened to the inner surface of the housing and the armature is fixed inside the housing.

[0031] While this disclosure describes various exemplary embodiments and examples, the various features, aspects, and functions described in one or more embodiments are not limited to the application of a particular embodiment, but are applicable to the embodiments individually or in various combinations. Accordingly, countless variations not illustrated are conceivable within the scope of the art disclosed in this specification. These include, for example, modifying, adding or omitting at least one component, or even extracting at least one component and combining it with components of other embodiments. [Explanation of Symbols]

[0032] 10 Housing, 11 Frame, 12 End plate, 13 Through hole, 20 Armature, 21 Armature core, 22 Coil, 23 Connection plate, 24 Bobbin, 25 First support member, 26 Second support member, 30 Rotor, 31 Yoke, 32 Permanent magnet, 40 Rotating shaft, 50 Bearing, 211 Winding section, 212 Flange section, 213 Protrusion section, 251, 261 Through hole, 252, 262 Bottom section, 253, 263 Outer peripheral wall, 254, 264 Inner peripheral wall, 252a, 252b Fastening surface, 255 Beam section, 100 Rotating electric machine.

Claims

1. An armature comprising a plurality of armature cores made of a magnetic material, a plurality of coils wound around each of the plurality of armature cores, and a support member made of a non-magnetic material that arranges and fixes the plurality of armature cores in a ring shape, The armature core has a winding portion around which the coil is wound, and protrusions provided at both ends of the winding portion in the axial direction, The armature is characterized in that the support member has two annular bottom portions, each having multiple through holes through which the protrusions pass, and is positioned at both axial ends of the plurality of armature cores.

2. The armature according to claim 1, characterized in that the protrusions of the armature core are exposed at both ends in the axial direction.

3. The armature according to claim 1 or 2, characterized in that the inner diameter side of the protrusion is located on the outer diameter side of the inner diameter side of the winding portion, and the outer diameter side of the protrusion is located on the inner diameter side of the winding portion.

4. The armature according to claim 3, characterized in that both circumferential sides of the convex portion are located closer to the center of the winding portion than both circumferential sides of the winding portion.

5. The armature according to claim 1 or 2, characterized in that it is provided with flange portions between the protrusions at both ends and the winding portion, each having a cross-sectional area larger than the area of ​​the cross-section perpendicular to the axial direction of the winding portion.

6. The armature according to claim 5, characterized in that the inner diameter side of the protrusion is located on the outer diameter side of the flange, and the outer diameter side of the protrusion is located on the inner diameter side of the flange.

7. The armature according to claim 6, characterized in that both circumferential sides of the convex portion are located closer to the center of the flange portion than both circumferential sides of the flange portion.

8. The armature according to claim 1 or 2, characterized in that the support member has a cylindrical outer peripheral wall that is positioned on the outer diameter side of the armature core and fastens the two outer diameter portions of the bottom in the axial direction, and a cylindrical inner peripheral wall that is positioned on the inner diameter side of the armature core and fastens the two inner diameter portions of the bottom in the axial direction.

9. The armature according to claim 8, characterized in that the support member is composed of a first support member and a second support member which are divided into two in the axial direction, and the multiple armature cores, each around which the multiple coils are wound, are sandwiched between the first support member and the second support member and fixed in an annular arrangement.

10. The armature according to claim 5, characterized in that the plurality of through holes provided in the bottom of the support member are partitioned by beam portions, and the axial thickness of the beam portions is greater than the axial thickness of the flange portions.

11. The armature according to claim 8, The armature and the rotor are arranged with a gap in the axial direction, A rotating electric machine having a cylindrical housing for fixing the armature inside, A rotating electric machine characterized in that the outer peripheral wall of the support member is fastened to the inner surface of the housing and the armature is fixed inside the housing.

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