Motor coils, stators, and motors

Abstract

To easily form a terminal on a coil with a large cross-sectional area.SOLUTION: A motor coil includes a first conductor wound in the direction of a winding axis, and a second conductor connected to the first conductor. The first conductor has a side surface extending in the circumferential direction around which the first conductor is wound, and a hole formed in the side surface. A portion of the second conductor is disposed in the hole.SELECTED DRAWING: Figure 5

Description

Technical Field

[0001] The present invention relates to a motor coil, a stator, and a motor.

Background Art

[0002] A technique for manufacturing a motor coil by cutting a cylindrical conductor such as copper is known. At that time, the terminals of the coil are formed, for example, by bending the cut ends. For example, in a technique for manufacturing a coil by cutting a conductive cylindrical body in a spiral shape, techniques for forming terminals by cutting out projections or rods at both ends of the cylindrical body or further bending the terminals to form bent terminals are known. Also, in a technique for cutting a cylindrical conductor in a spiral shape to form a flat wire, it is known that the circuit terminal portion is formed by bending the end portion of the flat wire formed by the cut of the cylindrical conductor.

Prior Art Documents

[0007] According to one embodiment, terminals can be easily formed on a coil having a large cross-sectional area. [Brief explanation of the drawing]

[0008] [Figure 1] Figure 1 shows an example of a motor in an embodiment. [Figure 2] Figure 2 is an exploded perspective view showing an example of mounting a motor coil to the stator in an embodiment. [Figure 3] Figure 3 is a perspective view showing an example of a motor coil attached to a stator in an embodiment. [Figure 4] Figure 4 is a perspective view showing an example of a motor coil in an embodiment. [Figure 5] Figure 5 is an exploded perspective view showing an example of a motor coil in an embodiment. [Figure 6] Figure 6 is a perspective view showing an example of a second conductor in the embodiment. [Modes for carrying out the invention]

[0009] The embodiments of the motor coil, stator, and motor disclosed in this application will be described in detail below with reference to the drawings. Note that the dimensional relationships and ratios of the elements in the drawings may differ from those in reality. There may also be differences in dimensional relationships and ratios between drawings. In some drawings, coordinate systems based on the circumferential, radial, and axial directions of the rotor, which will be explained later, may be shown to facilitate understanding of the explanation.

[0010] [Embodiment] First, the motor in the embodiment will be described using Figure 1. Figure 1 is a diagram showing an example of a motor in the embodiment. As shown in Figure 1, the motor 1 in the embodiment is a so-called inner rotor type motor in which the stator 80 is arranged radially outward from the rotor 91.

[0011] As shown in Figure 1, the motor 1 comprises a stator 80, a rotor 91, and a shaft 99. The stator 80 comprises a coil 2, an insulator 83, and a stator core 81. The stator core 81 is an annular member formed by stacking multiple magnetic materials, such as stainless steel or magnetic steel sheets, in the axial direction.

[0012] As shown in Figure 2, the stator core 81 is provided with teeth 82 that extend radially inward. Figure 2 is an exploded perspective view showing an example of mounting a motor coil to the stator in an embodiment. As shown in Figure 2, the coil 2 is mounted on the teeth 82 via an insulator 83. Note that the coil 2 is an example of a motor coil.

[0013] The insulator 83 is formed of an insulating material such as resin. As shown in Figure 3, the insulator 83 is inserted through the teeth 82, for example, surrounded by the coil 2. Figure 3 is a perspective view showing an example of a motor coil attached to a stator. In this case, the stator core 81 is surrounded by the coil 2 via the insulator 83.

[0014] The rotor 91 is rotatably mounted in the motor 1 around the shaft 99, which is the axis of rotation. The rotor 91 comprises the shaft 99, a rotor yoke (yoke), and a magnet (not shown).

[0015] The shaft 99 is a rotation axis and is formed in a columnar shape at the innermost in the radial direction in the rotor 91. The rotor yoke is formed in a cylindrical shape from a magnetic material such as iron, for example. And the inner peripheral surface of the rotor 91 is arranged to contact the outer peripheral surface of the shaft 99.

[0016] As shown in FIG. 4, the coil 2 includes a first conductor 10 wound in the winding axis direction and a second conductor 30 connected to the first conductor. FIG. 4 is a perspective view showing an example of a motor coil in an embodiment. As shown in FIG. 4, the first conductor 10 of the coil 2 is wound with the radial direction of the rotor 91 as the winding axis direction. Further, the coil 2 in the embodiment further includes a second conductor 40 connected to the first conductor 10.

[0017] The first conductor 10 of the coil 2 is formed by cutting out a conductor such as copper, for example. For example, by making a spiral cut in a cylindrical copper, the first conductor 10 shown in FIG. 4 is formed. Note that after the cut is made in the first conductor 10, an insulating film is applied by electrodeposition coating or the like. Thereby, adjacent portions in the winding axis direction of the first conductor 10 are insulated from each other.

[0018] As shown in FIG. 5, the first conductor 10 includes side surfaces 15, 16, 17, 18 that extend in the circumferential direction around which the first conductor 10 is wound. FIG. 5 is an exploded perspective view showing an example of a motor coil in an embodiment. As shown in FIG. 5, the side surface 15 is located on the positive side in the axial direction, and the side surface 17 is located on the negative side in the axial direction. Also, the side surface 16 is located on one side in the circumferential direction, and the side surface 18 is located on the other side in the circumferential direction.

[0019] The first conductor 10 in the embodiment has a cross-sectional area of, for example, 4 square mm or more. As shown in FIG. 5, for example, when the thickness W1 in the winding axis direction of the first conductor 10 is 1 mm, the thickness W2 in the axial direction is 4 mm to 6 mm.

[0020] In this embodiment, the first conductor 10 comprises one end 11 and the other end 12 in the winding axis direction. As shown in Figure 5, both the one end 11 and the other end 12 are located on the positive side surface 15 in the axial direction.

[0021] Furthermore, the first conductor 10 is provided with holes 13 and 14 formed on its side surface 15. As shown in Figure 5, hole 13 is formed near one end 11, and hole 14 is formed near the other end 12. In this embodiment, holes 13 and 14 have a substantially circular cross-section, for example, with a diameter of about 0.8 mm.

[0022] In this embodiment, the second conductor 30 is placed in the hole 13 of the first conductor 10, and the second conductor 40 is placed in the hole 14 of the first conductor 10. In this case, as shown in Figure 5, the second conductor 30 is placed near one end of the coil 2 in the winding axis direction, and the second conductor 40 is placed near the other end of the coil 2 in the winding axis direction.

[0023] Figure 6 is a perspective view showing an example of the second conductor in the embodiment. Although Figure 6 shows the second conductor 40, the second conductor 30 has a similar configuration, so a detailed explanation of the second conductor 30 may be omitted below.

[0024] As shown in Figure 6, the second conductor 40 has one end 41 on the side of the first conductor 10 and the other end 42. Note that the one end 31 and 41 are examples of parts of the second conductor.

[0025] One end 31 of the second conductor 30 is inserted through the hole 13 of the first conductor 10 from the positive axial direction, and one end 41 of the second conductor 40 is inserted through the hole 14 of the first conductor 10 from the positive axial direction. In this case, one end 31 is in the hole 13, and the other end 41 is in the hole 14. That is, parts of the second conductors 30 and 40 are located within the holes 13 and 14. In this case, the cross-sections of the ends 31 and 41 are approximately the same as, or slightly smaller than, the diameter W3 of the cross-sections of the holes 13 and 14. For example, the diameter W3 of the cross-sections of the ends 31 and 41 is about 0.7 mm.

[0026] One end 31 and 41 of the second conductor 30 are electrically connected to the first conductor 10. That is, at least a portion of the one end 31 and 41 is not insulated and is fixed to the holes 13 and 14 of the first conductor 10 by soldering. In this case, as shown in Figure 1, the second conductors 30 and 40 extend in the direction of the rotation axis of the rotor 91.

[0027] The thickness W4 of the other end 42 of the second conductor 40 is, for example, larger than the diameter W3 of the first end 41. Also, at least a portion of the other end 42 of the second conductor 40 is not insulated. In this case, the other end 42 serves as a terminal for connecting to an external device. This eliminates the need to process the end of the first conductor 10 to form a connection terminal, thus improving the workability when forming the connection terminal.

[0028] Furthermore, in order to allow a large current to flow through coil 2, it is preferable to make the second conductors 30 and 40, which serve as connection terminals, thicker. According to this embodiment, the other ends 32 and 42 of the second conductors 30 and 40 can be made thicker than the thickness W1 of the first conductor 10. For example, if the thickness W1 of the first conductor 10 in the winding axis direction is 1 mm, the thickness W4 of the other ends 32 and 42 of the second conductors 30 and 40 can be 2 mm or more.

[0029] As described above, the motor coil 2 in the embodiment comprises a first conductor 10 wound in the winding axis direction and second conductors 30 and 40 connected to the first conductor 10. The first conductor 10 has side surfaces 15, 16, 17, and 18 extending in the circumferential direction around which the first conductor 10 is wound, and holes 13 and 14 formed in the side surface 15. A portion 31 of the second conductor 30 is arranged in the hole 13. The stator 80 in the embodiment comprises the motor coil 2, an insulator 83, and a stator core 81 surrounded by the motor coil 2 via the insulator 83. The motor 1 in the embodiment comprises a rotor 91, and the second conductors 30 and 40 extend in the direction of the rotation axis of the rotor 91. With this configuration, terminals can be easily formed on a coil having a large cross-sectional area.

[0030] [Differentiation] The configuration of the embodiment has been described above, but the embodiment is not limited thereto. For example, a coil having two second conductors 30 and 40 has been described, but it is not limited to this, and a motor coil may have only one second conductor, or it may have three or more second conductors.

[0031] The second conductors 30 and 40 may be oriented in directions other than the axial direction of the rotor 91, such as the radial or circumferential direction of the rotor 91. Furthermore, the second conductors 30 and 40 may have bent portions or curved shapes. Also, the second conductors 30 and 40 may have different shapes from each other.

[0032] Furthermore, the second conductors 30 and 40 may be arranged on the first conductor 10 by other methods such as welding. The shape of the holes 13 and 14 in which the second conductors 30 and 40 are arranged is not limited to having a substantially circular cross-section as shown in Figure 5.

[0033] In addition, the coil 2 in this embodiment may be used in an outer rotor type motor.

[0034] Although the present invention has been described above based on embodiments and various modifications, it goes without saying that the present invention is not limited to embodiments and various modifications, and that various modifications are possible without departing from the spirit of the invention. Various modifications that do not depart from the spirit 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]

[0035] 1 Motor, 2 Coils, 10 First wire, 11 One end, 12 Other end, 13,14 Holes, 15,16,17,18 Sides, 30,40 Second wire, 31,41 One end, 32,42 Other end, 80 Stator, 81 Stator core, 82 Teeth, 83 Insulator, 91 Rotor, 99 Shaft

Claims

1. A first conductor wound spirally in the direction of the winding axis, A second conductor connected to the first conductor, Equipped with, The first conductor has one end on the side of the second conductor, the other end, and a side surface that extends in the circumferential direction around which the first conductor is wound. It comprises a hole formed in a portion of the side surface that extends toward one end, The second conductor comprises one end on the side of the first conductor and the other end, One end of the second conductor is located inside the hole. The other end of the second conductor is a terminal for connecting to an external device. Motor coil.

2. A motor coil according to claim 1, Insulators and The stator core, surrounded by the motor coils, is connected via the insulator. A stator equipped with the following features.

3. The stator according to claim 2, Rotor and, Equipped with, The second conductor extends in the direction of the rotor's axis of rotation. Motor.

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