Coil structure, linear motor, and method of manufacturing the coil structure

Abstract

To provide a coil structure, a linear motor, and a method for manufacturing the coil structure, which have a compact and simple structure and generate high thrust per volume.SOLUTION: A coil structure 30 having a rectangular air-core coil that is single-layered in the axial direction includes a first coil set 31 including two first coil pairs 31A in which two air-core coils with opposite winding directions are laminated in the axial direction, and both ends in the length direction of each first coil pair 31A are bent in the same direction in the axial direction. The two first coil pairs 31A are laminated in the axial direction such that the bending directions of the respective ends are opposite to each other.SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] The present invention relates to a coil structure, a linear motor, and a method for manufacturing a coil structure. [Background technology]

[0002] In recent years, linear motors using flat air-core coils have become widespread. For example, Patent Document 1 discloses a linear motor in which multiple air-core coils, each of which is a single layer, are arranged in the axial direction while partially overlapping each other. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 5508362 Summary of the Invention [Problem to be solved by the invention]

[0004] Patent Document 1 describes a linear motor in which multiple air-core coils are partially overlapped, but because the air-core coils are single-layered, high thrust cannot be expected. Patent Document 1 also discloses a linear motor in which air-core coils are overlapped four times to achieve high thrust, but in order to overlap four times, multiple types of air-core coils of different sizes are required, making the structure complicated.

[0005] The present invention has been made in consideration of the above circumstances, and an object of the present invention is to provide a coil structure, a linear motor, and a method for manufacturing a coil structure that are compact and simple in structure and can increase the thrust generated per volume. [Means for solving the problem]

[0006] The coil structure of the present invention is a coil structure having a rectangular air-core coil that is a single layer in the axial direction, and is equipped with a first coil set having two first coil pairs in which two air-core coils with opposite winding directions are stacked in the axial direction, and both longitudinal ends of each first coil pair are bent in the same direction in the axial direction, and the two first coil pairs are stacked in the axial direction so that the bending directions of each end are opposite to each other.

[0007] In the present invention, the first coil set has two first coil pairs, and the two first coil pairs are stacked in the axial direction so that the bending directions of both ends of each are opposite to each other, thereby simplifying the structure while increasing the thrust generated per volume.

[0008] In the coil structure of the present invention, each first coil pair has two long sides and two short sides connecting the ends of the two long sides, and both ends of the two long sides are bent in the axial direction within a range of 15° to 35°.

[0009] In the present invention, both ends of the two long sides of the first coil pair are bent in the range of 15° to 35° in the axial direction of the first coil pair, thereby preventing defects such as scratches on the first coil pair during press processing due to a bending angle that is too large, while preventing a reduction in the area of ​​the stacked portion when two first coil pairs are stacked due to a bending angle that is too small, and as a result, preventing a reduction in the strength of the first coil set.

[0010] The coil structure of the present invention comprises a second coil set in which two air-core coils with opposite winding directions are stacked in the axial direction, and two second coil pairs having long and short sides arranged on the same plane are stacked in the axial direction, the two second coil sets are arranged side by side with the axial direction parallel, one long side of each of the two second coil sets adjacent to each other is positioned inside the first coil set, and the short sides of the two second coil sets are interposed between the short sides of the two first coil pairs.

[0011] In the present invention, one of the adjacent long sides of the two juxtaposed second coil sets is positioned inside the first coil set, and the short sides of the two second coil sets are interposed between the short sides of the two first coil pairs, thereby making it possible to compact the structure while increasing the thrust generated per volume.

[0012] In the coil structure of the present invention, each air-core coil of the first and second coil pairs has an inner lead wire and an outer lead wire, and the connection portion between the inner lead wires of the second coil pair is provided between a long side portion of the first coil set and the other long side portion of the second coil set.

[0013] In the present invention, the connection portion between the inner lead wires of the second coil pair is provided between the long side portion of the first coil set and the other long side portion of the second coil set, thereby improving the insulation of such connection portion.

[0014] In the coil structure of the present invention, in the first and second coil pairs, the outer lead wire of one of the two air core coils and the outer lead wire of the other air core coil are each provided on different long side portions.

[0015] In the present invention, the two outer lead wires of the first coil pair are provided on different long sides of the first coil pair, and the two outer lead wires of the second coil pair are provided on different long sides of the second coil pair. Therefore, in the case of wiring, the coil structure and the outer lead wires do not overlap in the axial direction, and the thickness of the coil structure can be prevented from increasing.

[0016] A linear motor according to the present invention includes any one of the coil structures described above, and magnets arranged on both sides of the coil structure so as to face each other in the axial direction of the first coil set.

[0017] In the present invention, as described above, a coil structure that is compact and has a simple structure is used, so that the linear motor can be made compact and the generated thrust force per volume can be improved.

[0018] The manufacturing method of a coil structure according to the present invention is a manufacturing method of a coil structure having a rectangular air-core coil that is a single layer in the axial direction, in which two air-core coils are stacked in the axial direction with opposing winding directions to form a coil pair, both longitudinal ends of the coil pair are bent in the same direction in the axial direction, and the two coil pairs are stacked in the axial direction so that the bending direction of the end of one coil pair is opposite to that of the other coil pair to form a coil set.

[0019] In the present invention, a coil set is formed by laminating two air-core coils with opposing winding directions, bending both ends of the coil pair in the longitudinal direction in the same direction, and laminating the two coil pairs so that the bending directions of both ends are opposite to each other, thus simplifying the manufacturing process. Effect of the Invention

[0020] According to the present invention, it is possible to provide a coil structure, a linear motor, and a method for manufacturing a coil structure that have a compact and simple structure and generate a high thrust force per volume. [Brief description of the drawings]

[0021] [Figure 1] 1 is a perspective view showing an appearance of a linear motor according to an embodiment of the present invention; [Diagram 2] FIG. 2 is a schematic cross-sectional view taken along line II-II in FIG. [Diagram 3] FIG. 2 is a perspective view showing a mover of the linear motor of the present embodiment. [Figure 4] FIG. 2 is a perspective view showing a coil structure of the linear motor of the present embodiment. [Diagram 5] 5 is a view taken along line VV in FIG. 4. [Figure 6] 4 is a perspective view showing a second coil pair of the linear motor of the present embodiment. FIG. [Figure 7] 5A to 5C are explanatory diagrams illustrating a manufacturing method for the second coil pair of the linear motor of the present embodiment. [Figure 8] 2 is a perspective view showing a first coil pair of the linear motor of the present embodiment. FIG. [Figure 9] 9 is a view taken along line IX-IX in FIG. 8. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0022] Hereinafter, a coil structure and a linear motor according to an embodiment of the present invention will be described in detail with reference to the drawings.

[0023] 1 is a perspective view showing the appearance of a linear motor 100 according to an embodiment of the present invention. The linear motor 100 is, for example, a moving coil type linear motor, and includes a stator 10 and a mover 20. The mover 20 is connected to a power supply unit (not shown).

[0024] The stator 10 has a pair of yokes 11 each having a rectangular flat plate shape, and an intermediate portion 12 that is interposed between the pair of yokes 11 and connects both ends of the yokes 11. The intermediate portion 12 is disposed on the short side of the yoke 11. The yokes 11 are disposed facing each other at a predetermined distance by the intermediate portion 12, and a mover 20 is interposed between the pair of yokes 11. The mover 20 is movable in the opposing direction of both long sides of the yoke 11 (the direction of the arrow in FIG. 1). That is, the arrow in FIG. 1 indicates the movement direction of the mover 20.

[0025] Each yoke 11 has a rectangular flat plate shape and is made of a magnetic material such as iron. The intermediate portion 12 is made of a non-magnetic material such as resin or a magnetic material such as iron. The intermediate portion 12 is fixed to the yoke 11 by, for example, a screw.

[0026] Fig. 2 is a schematic cross-sectional view taken along line II-II in Fig. 1. For convenience, the movable element 20 is omitted in Fig. 2. A magnet unit 13 is attached to the inner surface of each yoke 11. The magnet unit 13 is disposed between the yoke 11 and the mover 20. In other words, the mover 20 is interposed between a pair of magnet units 13.

[0027] The magnet unit 13 has a plurality of permanent magnets 131. Each permanent magnet 131 has a square bar shape extending in the longitudinal direction of the yoke 11, and the plurality of permanent magnets 131 are arranged in parallel at equal intervals in the moving direction of the mover 20.

[0028] The pair of magnet units 13 form an alternating magnetic field. More specifically, the magnetic poles of each permanent magnet 131 face in the opposing direction of the pair of magnet units 13, and in the opposing direction, the magnetic poles of the permanent magnets 131 are reversed, and the magnetic poles of adjacent permanent magnets 131 are also reversed.

[0029] FIG. 3 is a perspective view showing the mover 20 of the linear motor 100 of this embodiment. The mover 20 includes a coil structure 30 consisting of a plurality of stacked air-core coils, and a clamping member 40 that clamps the coil structure 30. The clamping member 40 clamps the coil structure 30 from both sides in the axial direction of the air-core coils of the coil structure 30.

[0030] The clamping member 40 has a rectangular flat plate shape and includes a pair of contact portions 41 arranged opposite to each other and a gusset portion 42 connecting the pair of contact portions 41. That is, adjacent short sides of the pair of contact portions 41 are connected by the gusset portion 42. The gusset portion 42 has a length substantially equal to the width dimension of the contact portion 41 and has a long and narrow rectangular plate shape. The pair of contact portions 41 and the gusset portion 42 are integrally formed and are made of, for example, carbon fiber reinforced plastic (CFRP).

[0031] Further, a spacing portion 43 is provided between the pair of contact portions 41, extending from approximately the middle of the contact portions 41 in the longitudinal direction to the other short side portion. The spacing portion 43 has a rectangular plate shape having approximately the same thickness as the width dimension of the gusset portion 42, and is attached to the contact portions 41 by screws or adhesive to maintain the spacing between the contact portions 41. The spacing portion 43 is made of, for example, glass fiber reinforced plastic (GFRP).

[0032] With the above-described configuration, in the clamping member 40, gaps are formed between the contact portions 41, and between the gusset portions 42 and the spacing retaining portions 43, and the coil structure 30 is interposed in the gaps. The gusset portions 42 prevent the coil structure 30 from coming loose, and an insulating sheet (not shown) made of, for example, GFRP may be interposed between the contact portions 41 and the coil structure 30.

[0033] Fig. 4 is a perspective view showing the coil structure 30 of the linear motor 100 of this embodiment, and Fig. 5 is a view taken along line VV in Fig. 4. For convenience, the inner lead wires and the outer lead wires of the first coil set 31 and the second coil set 32 ​​are not shown in Fig. 5.

[0034] The coil structure 30 includes one first coil set 31 and two second coil sets 32. The first coil set 31 and the second coil set 32 ​​are both substantially rectangular and have the same dimensions in the length direction and width direction.

[0035] Each of the second coil sets 32 is a hollow rectangle, and includes two long sides 321, 322 and two short sides 323, 324. In the second coil set 32, the two long sides 321, 322 have the same dimension in the width direction, and are formed apart from each other by a distance equivalent to the sum of the dimensions of the long sides 321, 322 in the width direction.

[0036] Like the second coil set 32, the first coil set 31 is a hollow rectangle having two long sides 311, 312 and two short sides 313, 314. In the first coil set 31, the two long sides 311, 312 have the same dimension in the width direction and are formed apart by a distance equivalent to the sum of the dimensions of the long sides 311, 312 in the width direction.

[0037] The first coil set 31 and the two second coil sets 32 are arranged so that their longitudinal directions are parallel to each other, and the first coil set 31 partially overlaps with the two second coil sets 32.

[0038] The second coil set 32 ​​has two stacked second coil pairs 32B. Fig. 6 is a perspective view showing the second coil pair 32B of the linear motor 100 of this embodiment, and Fig. 7 is an explanatory diagram explaining a manufacturing method of the second coil pair 32B of the linear motor 100 of this embodiment. In Fig. 7, the solid arrow indicates the winding direction.

[0039] The second coil pair 32B is a hollow rectangle having two long sides 321B, 322B and two short sides 323B, 324B. The two long sides 321B, 322B and the two short sides 323B, 324B are provided on the same plane.

[0040] The second coil pair 32B is formed by stacking two rectangular air core coils 300B, each having a single layer in the axial direction, in such a way that the winding directions are opposite to each other. That is, as shown in Fig. 7, one of the two air core coils 300B having the same winding direction is inverted and stacked coaxially with the other.

[0041] Each air core coil 300B is formed by winding, for example, a strip-shaped 0.835×0.6 mm conductor flat wire (including a doubled 0.835×0.3 mm conductor flat wire) 15 times in a direction perpendicular to the axial direction. The flat wires are wound so as to overlap each other in the thickness direction. That is, the air core coil 300B is a single layer in the axial direction, a multi-layer in the direction perpendicular to the axial direction, and both end faces in the axial direction are approximately flat. Such flat wire is wound with a thermosetting resin adhesive such as epoxy resin applied to the outer circumferential surface. The adhesive is hardened at room temperature or by heating. This maintains the shape of the air core coil 300B, and in the second coil pair 32B and the second coil set 32, the air core coils 300B stacked in the axial direction are fixed to each other. 4 to 7, for convenience, the end surface in the axial direction of the air core coil 300B (multi-layer coil) is simply shown.

[0042] The air core coil 300B has an inner lead wire 325B and an outer lead wire 326B, and the inner lead wire 325B is drawn out from the inside of the short side of the air core coil 300B and is positioned shifted toward the long side rather than the center in the width direction of the air core coil 300B. The outer lead wire 326B is drawn out from one of the long sides of the outermost layer of the air core coil 300B.

[0043] As described above, the second coil pair 32B is formed by stacking the two air core coils 300B on the same axis with one of them inverted, so that in the second coil pair 32B, the outer lead wires 326B of each air core coil 300B are drawn out from the outer surfaces of the different long sides 321B and 322B. In this case, the inner lead wires 325B are connected to each other by a connection part 327B formed by soldering, for example, and are positioned closer to the long side 322B than the center in the width direction of the second coil pair 32B.

[0044] Each second coil set 32 ​​is formed by stacking two second coil pairs 32B coaxially. In other words, the second coil set 32 ​​has four air-core coils 300B stacked in the axial direction. In this case, the second coil set 32 ​​has two connection parts 327B, one connection part 327B is provided closer to the short side part 324, and the other connection part 327B is provided closer to the short side part 323.

[0045] The first coil set 31 has two stacked first coil pairs 31A. Fig. 8 is a perspective view showing the first coil pair 31A of the linear motor 100 of this embodiment, and Fig. 9 is a view taken along line IX-IX in Fig. 8. For convenience, the drawing wires are omitted from Fig. 9.

[0046] The first coil pair 31A is a hollow rectangle having two long sides 311A, 312A and two short sides 313A, 314A. The first coil pair 31A is formed by stacking two rectangular air-core coils 300A, each having a single layer in the axial direction, in the axial direction with their winding directions opposite to each other, similar to the second coil pair 32B. That is, one of the two air-core coils 300A, which have the same winding direction, is inverted and stacked coaxially with the other. The first coil pair 31A has the same shape as the second coil pair 32B, except for a bent portion 318A, which will be described later.

[0047] Each air core coil 300A has substantially the same shape as the air core coil 300B. It has an inner lead wire 315A and an outer lead wire 316A, and the inner lead wire 315A is drawn out from the inside of the short side of the air core coil 300A and is positioned shifted toward the long side from the center in the width direction of the air core coil 300A. The outer lead wire 316A is drawn out from one of the long sides of the outermost layer of the air core coil 300A. For convenience, FIG. 8 shows only the end surface (multi-layered coil) in the axial direction of the air core coil 300A.

[0048] As described above, the first coil pair 31A is formed by inverting one of the two air core coils 300A and stacking it coaxially with the other, so that in the first coil pair 31A, the outer lead wires 316A of each air core coil 300A are each drawn out from the outer surfaces of different long side portions 311A, 312A. At this time, the inner lead wires 315A are connected to each other by, for example, soldering to form a connection portion 317A, and are disposed offset toward the long side portion 312A from the center in the width direction of the first coil pair 31A.

[0049] In addition, the first coil pair 31A is curved by pressing both ends in the length direction. The length of the first coil pair 31A after the pressing is approximately the same as that of the second coil pair 32B. Although the first coil pair 31A becomes slightly shorter than the second coil pair 32B depending on the bending angle described later, this does not affect the generated thrust per volume. As a result, in the first coil pair 31A, bending portions 318A are formed on both ends of the two long sides 311A ​​and 312A. As described above, the first coil pair 31A has approximately the same shape as the second coil pair 32B except for the bending portion 318A. In other words, the first coil pair 31A before the pressing has approximately the same shape as the second coil pair 32B.

[0050] The bent portion 318A is bent in the axial direction, for example, at an angle between 15° and 35°. That is, each bent portion 318A is formed at an angle between 15° and 35° with respect to a direction perpendicular to the axial direction of the first coil pair 31A. If the bending angle of the bent portion 318A exceeds 35°, defects such as scratches may occur in the first coil pair 31A during press processing. If the bending angle of the bent portion 318A is less than 15°, the obliquely formed portion (inclined portion) in the long side portions 311A ​​and 312A becomes wider, and when the two first coil pairs 31A are stacked and fixed with an adhesive, the area of ​​the contact portion of the two first coil pairs 31A becomes narrower, so that the strength of the first coil set 31 decreases.

[0051] The first coil set 31 is formed by stacking two first coil pairs 31A on the same axis. In other words, the first coil set 31 has four air-core coils 300A stacked in the axial direction. In this case, the bending direction of the bent portion 318A of one of the two first coil pairs 31A is opposite to the bending direction of the bent portion 318A of the other first coil pair 31A. Therefore, in the first coil set 31, gaps are formed between the short side portions 313 and between the short side portions 314 of the two first coil pairs 31A.

[0052] In the coil structure 30, two second coil sets 32 are arranged side by side with their axial directions parallel and their long sides 321 adjacent to each other. The long sides 321 of the two second coil sets 32 are disposed inside the first coil set 31. In this case, the long sides 321 of the two second coil sets 32 and the long side 311 of the first coil set 31 are flush with each other except for the bent portion 318A of the first coil pair 31A.

[0053] Furthermore, parts of short sides 323 of the two second coil sets 32 are interposed in the gap between the short sides 313 of the two first coil pairs 31A. Further, parts of short sides 324 of the two second coil sets 32 are interposed in the gap between the short sides 314 of the two first coil pairs 31A.

[0054] In this case, the connection portions 327B of the two second coil sets 32 are arranged in the space between the long side portion 311 of the first coil set 31 and the long side portion 322 of the second coil set 32, and between the long side portion 312 of the first coil set 31 and the long side portion 322 of the second coil set 32.

[0055] When a current is applied to the coil structure 30 of the linear motor 100 having such a configuration, a thrust force is generated in a direction (hereinafter, the moving direction) that crosses the alternating magnetic field formed between the pair of magnet units 13 based on Fleming's left-hand rule, and the coil structure 30 is pushed in the moving direction, causing the mover 20 to move (see the arrow in FIG. 1).

[0056] In the linear motor 100 of this embodiment, as described above, the first coil set 31 and the two second coil sets 32 of the coil structure 30 each consist of four layers of air-core coils 300A, 300B. Furthermore, the long side portions 321 of the two second coil sets 32 are arranged on the same plane inside the first coil set 31. Also, parts of the short side portions 323, 324 of the two second coil sets 32 are interposed in the gap between the short side portions 313, 314 of the two first coil pairs 31A. Therefore, it is possible to increase the generated thrust per volume with a compact and simple structure.

[0057] In addition, in the linear motor 100 of this embodiment, during the manufacture of the first coil set 31, before the bent portion 318A is formed in the first coil pair 31A by press working, the shape of the first coil pair 31A is substantially the same as that of the second coil pair 32B. Therefore, the first coil pair 31A and the second coil pair 32B can be manufactured using the same bobbin, which improves workability and reduces manufacturing costs.

[0058] Furthermore, in the linear motor 100 of this embodiment, as described above, the connection parts 327B between the inner lead wires 325B of the two air-core coils 300B are disposed between the long side part 311 of the first coil set 31 and the long side part 322 of the second coil set 32, and between the long side part 312 of the first coil set 31 and the long side part 322 of the second coil set 32 ​​(see FIG. 4). This makes it possible to make the linear motor 100 more compact and improve the insulation of the connection parts 327B.

[0059] Furthermore, in the linear motor 100 of this embodiment, as described above, in the first coil pair 31A, the outer lead wires 316A of each air core coil 300A are drawn out from the outermost layer, respectively different long sides 311A, 312A. Also, in the second coil pair 32B, the outer lead wires 326B of each air core coil 300B are drawn out from the outermost layer, respectively different long sides 321B, 322B. Therefore, when wiring the outer leads 316A, 326B, the coil structure 30 and the outer leads 316A, 326B do not overlap in the axial direction, and the thickness of the coil structure 30 can be prevented from increasing.

[0060] In the above, the linear motor 100 has been described with an example in which the first coil pair 31A is made up of two air core coils 300A and the second coil pair 32B is made up of two air core coils 300B, but the present invention is not limited to this. The first coil pair 31A may be made up of three or more air core coils 300A, and the second coil pair 32B may be made up of three or more air core coils 300B.

[0061] The disclosed embodiments should be considered to be illustrative and not restrictive in all respects. The scope of the present invention is defined by the claims, not the above description, and is intended to include all modifications within the meaning and scope of the claims. [Explanation of symbols]

[0062] 13 Magnet unit 30 Coil structure 31 First coil set 31A 1st coil pair 32 Second coil set 32B Second coil pair 100 Linear motor 300A air core coil 300B Air Core Coil 311, 312, 311A, 312A, 321, 322, 321B, 322B Long side 313A, 314A, 323B, 324B Short side 325B, 315A Inner lead wireInner lead wire 326B, 316A Outer lead wire Outer lead wire 327B Connection

Claims

1. In a coil structure having a rectangular air-core coil that is a single layer in the axial direction, a first coil set including two first coil pairs each including two air-core coils with opposing winding directions stacked in an axial direction; Each of the first coil pairs has two long sides and two short sides connecting ends of the two long sides, Both ends of the two long sides are bent in the same direction within a range of 15° to 35° toward the axial center, The two first coil pairs are stacked in the axial direction so that the bending directions of both ends of each pair are opposite to each other.

2. a second coil set in which two air-core coils having opposing winding directions are stacked in the axial direction, and a second coil pair having long and short sides on the same plane is stacked in the axial direction; The two second coil sets are arranged side by side with their axial directions parallel to each other, adjacent long side portions of the two second coil sets are disposed inside the first coil set, The coil structure according to claim 1 , wherein the short sides of the two second coil sets are interposed between the short sides of the two first coil pairs.

3. Each of the air-core coils of the first and second coil pairs has an inner lead and an outer lead, The coil structure according to claim 2 , wherein a connection portion between the inner lead wires of the second coil pair is provided between a long side portion of the first coil set and the other long side portion of the second coil set.

4. 4. The coil structure according to claim 3, wherein in the first and second coil pairs, the outer lead wire of one of the two air core coils and the outer lead wire of the other air core coil are provided on different long side portions.

5. The coil structure according to any one of claims 1 to 4, magnets arranged on both sides of the coil structure so as to face each other in the axial direction of the first coil set; A linear motor comprising:

6. A method for manufacturing a coil structure having a rectangular air-core coil, the coil having a single layer in an axial direction, and two long side portions and two short side portions connecting ends of the two long side portions, comprising: The two air-core coils are stacked in an axial direction so that the winding directions are opposite to each other to form a coil pair; Both ends of the two long sides of the coil pair are bent in the same direction in the axial direction by an angle of 15° to 35°; A manufacturing method for a coil structure, in which the two coil pairs are stacked in the axial direction so that the bending direction of the end of one coil pair is opposite to that of the other coil pair to form a coil set.

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