Rotary electrical machine

Abstract

The present invention provides a rotary electrical machine comprising: a stator which has a rotor that has a first magnet and a second magnet disposed so as to face each other in the axial direction, a core that is disposed between the first magnet and the second magnet, and a coil body that is provided around the core; and a stator fixation member to which the stator is fixed, wherein the core includes a plurality of tooth parts which are disposed at intervals in the circumferential direction and which each form a magnetic flux path between the first magnet side and the second magnet side and a circumferential direction connection part which connects the plurality of tooth parts in the circumferential direction on at least one of the radially outward side and the radially inward side of the plurality of tooth parts, and the circumferential direction connection part is fixed to the stator fixation member.

Description

Rotating electrical machine Cross-reference to related applications

[0001] This application is based on Japanese Application No. 2024-158637 filed on September 12, 2024, claims the benefit of its priority, and all the contents of the patent application are incorporated herein by reference.

[0002] This disclosure relates to a rotating electrical machine.

[0003] Japanese Patent Application Laid-Open No. 2009-183072 discloses a coil assembly for a rotating electrical machine that realizes improvement of torque characteristics by effectively utilizing magnetic flux and reduction of eddy current loss generated in a coil. The coil assembly for a rotating electrical machine described in this document includes first and second coil plates in which wiring patterns are formed such that coil segments made of conductors are adjacent to each other via slits, and magnetic flux transmission member slots formed in the slits and wider than the slits. Further, the coil assembly for a rotating electrical machine includes a coil in which the coil plates are laminated so that the magnetic flux transmission member slots overlap, and a magnetic flux transmission member inserted into the magnetic flux transmission member slots of the coil.

[0004] As a result of the inventors' detailed examination, the following problems were found. That is, a coil such as the coil assembly for a rotating electrical machine described in the above document may be arranged around a core having a plurality of tooth portions. In this case, it is preferable to ensure the positional accuracy of the plurality of tooth portions and the positional accuracy of the core.

[0005] This disclosure provides a rotating electrical machine capable of ensuring the positional accuracy of a plurality of tooth portions and the positional accuracy of a core.

[0006] The rotating electric machine according to this disclosure comprises a rotor rotatably supported around the axis of the rotating shaft, having a first magnet and a second magnet arranged opposite to each other in the axial direction of the rotating shaft; a stator having a core disposed between the first magnet and the second magnet, and a coil body provided around the core, which generates a rotating magnetic field when current is supplied to the coil body; and a stator fixing member to which the stator is fixed. The core comprises a plurality of teeth arranged at intervals in the circumferential direction and forming a magnetic flux path between the first magnet side and the second magnet side, and a circumferential connecting portion connecting the plurality of teeth in the circumferential direction on at least one side of the radially outer and radially inner sides of the plurality of teeth, the circumferential connecting portion being fixed to the stator fixing member.

[0007] This is a perspective view showing a part of the motor of the first embodiment cut in half. This is a perspective view showing the motor of the first embodiment disassembled. This is a perspective view showing the core. This is a plan view showing the core. This is a plan view showing a part of the core enlarged. This is a plan view showing another form of the core. This is a plan view showing another form of the core. This is a schematic diagram showing the compacted magnetic core constituting the stator core of the first embodiment. This is a schematic diagram showing the manufacturing process of the stator core. This is a schematic cross-sectional view showing a cross-section of the motor according to the first embodiment cut along the axial and radial directions. This is a schematic cross-sectional view showing a cross-section of the motor according to the second embodiment cut along the axial and radial directions. This is a schematic cross-sectional view showing a cross-section of the motor according to the third embodiment cut along the axial and radial directions. This is a perspective view showing the core of the motor of the fourth embodiment. This is a perspective view showing a divided core. This is a perspective view showing the core of the motor of the fourth embodiment in the process of assembly. This is a plan view showing the core of the motor of the fourth embodiment in the process of assembly. This is a schematic cross-sectional view showing a cross-section of the motor according to the fifth embodiment cut along the axial and radial directions. This is a schematic cross-sectional view showing a cross-section of the motor according to the sixth embodiment cut along the axial and radial directions. This is a perspective view showing the stator of the motor of the seventh embodiment. This is a perspective view showing the stator of the motor according to the seventh embodiment in an exploded view. This is a perspective view showing the stator of the motor according to the eighth embodiment in an exploded view. This is a schematic cross-sectional view showing the stator of the motor according to the ninth embodiment cut along the axial and radial directions. This is a plan view of the stator of the motor according to the tenth embodiment as seen from the axial direction. This is a perspective view showing the core of the motor according to the eleventh embodiment. This is a perspective view showing the stator of the motor according to the twelfth embodiment. This is a perspective view showing the core and other components of the motor according to the twelfth embodiment.

[0008] (First Embodiment) The configuration of a motor 10 of the first embodiment to which the structure of the rotating electric machine of this disclosure is applied will be described using Figures 1 to 10. The arrows Z, R, and C shown in the figures as appropriate indicate one axial side, radially outward side, and one circumferential side of the rotation axis 22 of the rotor 12, which will be described later. Furthermore, when simply referring to the axial direction, radial direction, and circumferential direction, unless otherwise specified, these refer to the axial direction, radial direction, and circumferential direction of the rotation axis 22. The motor 10 is an example of a rotating electric machine.

[0009] As shown in Figures 1 and 2, the motor 10 of this embodiment is a double axial gap type brushless motor in which a rotor 12 as a rotor and a stator 14 as a stator and armature are arranged facing each other in the axial direction. This motor 10 comprises a rotor 12 that is rotatably supported with the axial direction as the direction of the rotation center axis, and a stator 14 that generates a rotating magnetic field. The motor 10 also comprises a first frame 21 and a second frame 23 as stator fixing members to which the stator 14 is fixed and to which the rotor 12 is rotatably supported.

[0010] The rotor 12 includes a rotating shaft 22, a first magnet 18 fixed to the rotating shaft 22 via a first magnet support member 24 which serves as a magnet support member, and a second magnet 19 fixed to the rotating shaft 22 via a second magnet support member 25 which serves as a magnet support member.

[0011] The first magnet support member 24 and the second magnet support member 25 are formed using a non-magnetic material and are shaped like discs with the axial direction as the thickness direction. Alternatively, the first magnet support member 24 and the second magnet support member 25 may be formed using a magnetic material, or the first magnet support member 24 and the second magnet support member 25 may be formed using a combination of magnetic and non-magnetic materials. The first magnet support member 24 and the second magnet support member 25 are fixed to the rotation shaft 22 with an axial gap between them.

[0012] The first magnet 18 and the second magnet 19 are, for example, ring magnets formed in an annular shape along the circumferential direction. The first magnet 18 and the second magnet 19 may also be configured with multiple segment magnets arranged in an annular shape along the circumferential direction. The first magnet 18 is fixed to the other axial side of the first magnet support member 24. The second magnet 19 is fixed to the one axial side of the second magnet support member 25. As a result, the first magnet 18 and the second magnet 19 are positioned opposite each other in the axial direction. Furthermore, the magnetic pole centers of the north pole of the first magnet 18 and the south pole of the second magnet 19 are positioned opposite each other in the axial direction and at the same position in the circumferential direction. Similarly, the magnetic pole centers of the north pole of the second magnet 19 and the south pole of the first magnet 18 are positioned opposite each other in the axial direction and at the same position in the circumferential direction. Furthermore, the magnetic pole center of the north pole of the first magnet 18 and the magnetic pole center of the south pole of the second magnet 19 may be offset in the circumferential direction. Also, the magnetic pole center of the north pole of the second magnet 19 and the magnetic pole center of the south pole of the first magnet 18 may be offset in the circumferential direction.

[0013] The stator 14 is composed of a core 26 positioned between a first magnet 18 and a second magnet 19, and a coil body 32 provided around the core 26.

[0014] As shown in Figures 2 to 5 and Figure 10, the core 26 is provided with a plurality of teeth portions 26A that are spaced apart in the circumferential direction and serve as magnetic flux paths between the first magnet 18 and the second magnet 19. Arrow B in Figure 10 indicates the magnetic flux flowing from the first magnet 18 to the second magnet 19 via the teeth portions 26A. The core 26 also includes an inner flange portion 26B that serves as a circumferential connection portion connecting the plurality of teeth portions 26A in the circumferential direction on the radially inward side. Furthermore, the core 26 includes an outer flange portion 26C that serves as a circumferential connection portion connecting the plurality of teeth portions 26A in the circumferential direction on the radially outward side.

[0015] Multiple (72 in this embodiment) tooth portions 26A are set to have the same shape and dimensions as each other and are arranged at equal intervals along the circumferential direction. In this embodiment, each of the multiple tooth portions 26A is formed as a plate-like (rectangular block-like) shape that extends axially with the circumferential direction as the thickness direction. The thickness dimension of the tooth portion 26A gradually increases towards the radially outward direction. Furthermore, the axial dimension of the tooth portion 26A is set to a constant dimension along both the radial and circumferential directions. Here, one axial side surface of the tooth portion 26A is a first opposing surface 26D that is positioned axially opposite to the first magnet 18. The other axial side surface of the tooth portion 26A is a second opposing surface 26E that is positioned axially opposite to the second magnet 19. The first opposing surface 26D and the second opposing surface 26E extend along the radial and circumferential directions, respectively.

[0016] The inner flange portion 26B is formed in an annular shape, extending circumferentially with the axial direction as the thickness direction. The thickness dimension of the inner flange portion 26B is set to be smaller than the axial dimension of the multiple teeth portions 26A. The inner flange portion 26B connects the axial centers of the radially inner ends of the multiple teeth portions 26A along the circumferential direction.

[0017] The outer flange portion 26C is formed in an annular shape, extending circumferentially with the axial direction as the thickness direction. The thickness dimension of the outer flange portion 26C is set to be smaller than the axial dimension of the multiple teeth portions 26A, and is set to be the same as the thickness dimension of the inner flange portion 26B. In addition, multiple notches 26F are formed on the outer circumference of the outer flange portion 26C, serving as anti-rotation portions, with the radially outer side open. In this embodiment, 16 notches 26F are formed. The 16 notches 26F are arranged at equal intervals along the circumferential direction. The 16 notches 26F have the function of preventing rotation of the first frame 21 and the second frame 23, which will be described later, and the function of allowing bolts 50 to pass through. Note that, as shown in Figure 6, the core 26 can also be configured such that the function of preventing rotation of the first frame 21 and the second frame 23, which will be described later, is provided by the notches 26F, and the function of allowing bolts 50 to pass through is provided by a circular opening 26G. Alternatively, as shown in Figure 7, the outer periphery of the outer flange portion 26C may be formed into a polygonal shape (hexagonal in the example shown in Figure 7), and the outer flange portion 26C may be fitted into the first frame 21 and the second frame 23, which will be described later, thereby preventing the core 26 from rotating relative to the first frame 21 and the second frame 23.

[0018] Figure 8 schematically shows the compacted magnetic core 40 that constitutes the core 26. This compacted magnetic core 40 is formed from magnetic powder 42 that has been molded to a predetermined shape and dimensions. This magnetic powder 42 is composed of iron powder 44 as a base material and a coating portion 46 that covers the iron powder 44. The iron powder 44 is iron powder that has been crushed to a particle size within a predetermined range. The coating portion 46 is a coating film formed using an inorganic material that has insulating properties and is more insulating than the iron powder 44 that is the base material. The coating portion 46 that covers the magnetic powder 42 is formed by applying paint to the magnetic powder 42 to form this coating film. Here, an example of a material for forming the coating portion 46 is a phosphate-based material or SiO ２ (Silicon dioxide system), Al ２ O ３Materials such as alumina-based, magnesium oxide-based (MgO-based), and ferrite-based materials can be used. Furthermore, these materials can be used in combination. In a stator core 26 (powder core 40) formed using magnetic powder 42 having iron powder 44 and a covering portion 46 that covers the iron powder 44, the insulating properties of the covering portion 46 reduce the eddy currents I when magnetic flux B from various directions links with the stator core 26 (powder core 40). As a result, heat generation in the stator core 26 (powder core 40) is suppressed, and the losses of a motor comprising the stator core 26 (powder core 40) can be reduced.

[0019] Figure 9 schematically shows the manufacturing process of the core 26. To manufacture the core 26, first, a coating 46 is applied to the iron powder 44. This covers the iron powder 44 with the coating 46, forming the magnetic powder 42. Next, a predetermined amount of magnetic powder 42 is placed into a mold and pressurized (compressed) to shape the magnetic powder 42 into a predetermined shape and dimensions. That is, the magnetic powder 42 placed into the mold is shaped to a shape and dimensions corresponding to the shape and dimensions of the core 26. Next, the magnetic powder 42 that has been shaped to the predetermined shape and dimensions is heated. Here, annealing is performed as a heat treatment. The core 26 is manufactured through these processes.

[0020] As shown in Figures 1, 2, and 3, the coil body 32 is composed of multiple coil layers 54, each having a conductor portion 52 that is arranged to reciprocate between the radially inward and radially outward directions as it moves toward one side in the circumferential direction and is stacked in the axial direction. In this embodiment, two of the four coil layers 54 are mounted on one side of the axial direction of the core 26 in an axially overlapping state. The remaining two of the four coil layers 54 are mounted on the other side of the axial direction of the core 26 in an axially overlapping state. When the four coil layers 54 are mounted on the core 26, that is, when the coil body 32 is mounted on the core 26, the conductor portion 52 of each coil layer 54 is positioned between a pair of adjacent teeth portions 26A in the circumferential direction. The four coil layers 54 are connected in a predetermined state. Furthermore, the configuration of the stator 14 in this embodiment corresponds to a distributed winding in which the winding is wound across multiple teeth portions 26A.

[0021] As shown in Figures 1, 2, and 10, the first frame 21 comprises a disc portion 21A formed in a disc shape with the axial direction as the thickness direction, and a peripheral wall portion 21B that bends and extends from the outer circumference of the disc portion 21A toward the other axial direction. The second frame 23 comprises a disc portion 23A formed in a disc shape with the axial direction as the thickness direction, and a peripheral wall portion 23B that bends and extends from the outer circumference of the disc portion 23A toward the one axial direction. Through holes are formed in the center of the disc portions 21A and 23A of the first frame 21 and the second frame 23, respectively, penetrating the disc portion in the axial direction, and bearings 20 are fixed to the inner circumference of these through holes. The rotation axis 22 of the rotor 12 is rotatably supported by a pair of bearings 20 fixed to the disc portions 21A and 23A of the first frame 21 and the second frame 23. Furthermore, the peripheral walls 21B and 23B of the first frame 21 and the second frame 23 have multiple (eight in this embodiment) insertion holes 21C and 23C into which bolts are inserted. These insertion holes 21C and 23C are arranged at equal intervals along the circumferential direction. Additionally, at the axial end of the peripheral wall 21B of the first frame 21, multiple (four in this embodiment) anti-rotation projections 21D are formed, projecting toward the other axial direction. These multiple anti-rotation projections 21D are also arranged at equal intervals along the circumferential direction. Moreover, these multiple anti-rotation projections 21D are positioned in the center of a pair of adjacent insertion holes 21C in the circumferential direction. Furthermore, at the axial end of the peripheral wall 23B of the second frame 23, multiple (four in this embodiment) anti-rotation projections 23D are formed, projecting toward the other axial direction. These multiple anti-rotation projections 23D are also arranged at equal intervals along the circumferential direction. Furthermore, the multiple anti-rotation protrusions 23D are positioned in the center of a pair of circumferentially adjacent insertion holes 23C. In addition, the multiple anti-rotation protrusions 23D are positioned at a 90° offset in the circumferential direction from the multiple anti-rotation protrusions 21D.Then, by fitting the anti-rotation projection 21D of the first frame 21 and the anti-rotation projection 23D of the second frame 23 into the notch 26F formed in the outer flange portion 26C of the core 26, the core 26 is prevented from rotating relative to the first frame 21 and the second frame 23. In addition, bolts 50 and nuts 56 are screwed into insertion holes 21C and 23C formed in the peripheral wall portions 21B and 23B of the first frame 21 and the second frame 23. As a result, the core 26 is fixed to the first frame 21 and the second frame 23 with the outer flange portion 26C of the core 26 sandwiched between the peripheral wall portion 21B of the first frame 21 and the peripheral wall portion 23B of the second frame 23. In other words, the stator 14 is fixed to the first frame 21 and the second frame 23.

[0022] (Operation and Effects of this Embodiment) Next, the operation and effects of this embodiment will be described.

[0023] As shown in Figures 1 and 2, in the motor 10 of this embodiment described above, when current is supplied to the coil body 32 of the stator 14, a rotating magnetic field is generated around the stator 14. As a result, the rotor 12 rotates.

[0024] As shown in Figures 1 to 5 and Figure 10, the core 26 of the motor 10 in this embodiment is provided with an inner flange portion 26B that connects a plurality of teeth portions 26A radially inward to the plurality of teeth portions 26A in the circumferential direction, and an outer flange portion 26C that connects a plurality of teeth portions 26A radially outward to the plurality of teeth portions 26A in the circumferential direction. In this configuration, the inner flange portion 26B and the outer flange portion 26C maintain the state in which the plurality of teeth portions 26A are arranged at equal intervals along the circumferential direction. This ensures the positional accuracy of the plurality of teeth portions 26A. Furthermore, in this embodiment, the core 26 is fixed to the first frame 21 and the second frame 23 with the outer flange portion 26C of the core 26 sandwiched between the circumferential wall portion 21B of the first frame 21 and the circumferential wall portion 23B of the second frame 23. This ensures the positional accuracy of the core 26 with respect to the first frame 21 and the second frame 23. The outer flange portion 26C of the core 26 is sandwiched between the peripheral wall portion 21B of the first frame 21 and the peripheral wall portion 23B of the second frame 23, thereby allowing heat from the core 26 and coil body 32 to be dissipated through the first frame 21 and the second frame 23.

[0025] Furthermore, as shown in Figures 3 to 9, the core 26 of this embodiment is constructed by compressing magnetic powder 42 having a powdery base material (iron powder 44) made from an iron-based material. In other words, the core 26 is formed from a compacted magnetic core 40. With this configuration, the generation of carbon dioxide associated with the manufacture of the core 26 can be suppressed compared to, for example, the case where the core is formed by stacking steel plates cut to a predetermined shape in the axial direction. In addition, with this configuration, the core 26 can be returned to the magnetic powder 42 by crushing the core 26. This allows the core 26 and the like to be manufactured again using the magnetic powder 42 returned from the core 26. Thus, the core 26 of this embodiment has excellent recyclability. Moreover, the configuration in which the core 26 is formed from a compacted magnetic core 40 can accommodate more complex core 26 shapes compared to, for example, the case where the core is formed by stacking steel plates cut to a predetermined shape in the axial direction. It is also possible to adopt a configuration in which a part of the core 26, for example, any of the multiple teeth portions 26A, the inner flange portion 26B, and the outer flange portion 26C, is formed from magnetic powder 42.

[0026] Furthermore, in this embodiment, the first magnet support member 24 to which the first magnet 18 is fixed, the stator 14, and the second magnet support member 25 to which the second magnet 19 is fixed are arranged axially between the first frame 21 and the second frame 23. In this configuration, for example, the motor 10 can be manufactured by assembling the second magnet support member 25 to which the second magnet 19 is fixed, the stator 14, the first magnet support member 24 to which the first magnet 18 is fixed, and the first frame 21 in order on the second frame 23. The motor 10 can also be disassembled by removing the first magnet support member 24 to which the first magnet 18 is fixed, the stator 14, and the second magnet support member 25 to which the second magnet 19 is fixed in order from the first frame 21 side. In this way, the motor 10 of this embodiment can achieve one-way assembly and one-way disassembly.

[0027] In this embodiment, an example has been described in which the entire core 26 is formed by a compacted magnetic core 40, but the present invention is not limited thereto. For example, a configuration can be adopted in which any of the multiple tooth portions 26A, inner flange portion 26B, and outer flange portion 26C are formed by a compacted magnetic core 40.

[0028] Furthermore, as shown in Figures 1 and 2, in this embodiment, by fitting the anti-rotation projection 21D of the first frame 21 and the anti-rotation projection 23D of the second frame 23 into the notch 26F formed in the outer flange portion 26C of the core 26, the circumferential displacement of the core 26 relative to the first frame 21 and the second frame 23 can be restricted.

[0029] (Second and Third Embodiments) Next, the motor 58 according to the second embodiment and the motor 60 according to the third embodiment will be described with reference to Figures 11 and 12. In the motor 58 according to the second embodiment and the motor 60 according to the third embodiment, the members and parts corresponding to the aforementioned motor 10 are denoted by the same reference numerals as the members and parts corresponding to the aforementioned motor 10, and their descriptions may be omitted.

[0030] As shown in Figures 11 and 12, in the motor 58 according to the second embodiment and the motor 60 according to the third embodiment, most of the first opposing surface 26D is a teeth-side inclined surface 26D1 that slopes radially outward towards the other axial side, and most of the second opposing surface 26E is a teeth-side inclined surface 26E1 that slopes radially outward towards one axial side. Furthermore, the radially inner end of the first opposing surface 26D is a teeth-side vertical surface 26D2 that is perpendicular to the axial direction, and the radially inner end of the second opposing surface 26E is a teeth-side vertical surface 26E2 that is perpendicular to the axial direction.

[0031] In addition, the majority of the surface on the other axial side of the first magnet 18 is a magnet-side inclined surface 18A1 that is inclined in the same direction as the teeth-side inclined surface 26D1, and the majority of the surface on one axial side of the second magnet 19 is a magnet-side inclined surface 19A1 that is inclined in the same direction as the teeth-side inclined surface 26E1. Furthermore, the radially inner end of the surface on the other axial side of the first magnet 18 is a magnet-side vertical surface 18A2 that is perpendicular to the axial direction, and the radially inner end of the surface on one axial side of the second magnet 19 is a magnet-side vertical surface 19A2 that is perpendicular to the axial direction. The teeth-side inclined surface 26D1 and the magnet-side inclined surface 18A1 are arranged facing each other in the axial direction, and the teeth-side inclined surface 26E1 and the magnet-side inclined surface 19A1 are arranged facing each other in the axial direction. Furthermore, the vertical surface 26D2 on the teeth side and the vertical surface 18A2 on the magnet side are arranged facing each other in the axial direction, and the vertical surface 26E2 on the teeth side and the vertical surface 19A2 on the magnet side are arranged facing each other in the axial direction.

[0032] In this configuration, where the inclined surface 26D1 on the teeth side and the inclined surface 18A1 on the magnet side are arranged facing each other in the axial direction, and the inclined surface 26E1 on the teeth side and the inclined surface 19A1 on the magnet side are arranged facing each other in the axial direction, the area in which the first magnet 18 and the teeth 26A face each other can be increased, and the area in which the second magnet 19 and the teeth 26A face each other can be increased, compared to the motor 10 described above. This makes it possible to increase the output power and miniaturize the motors 58 and 60.

[0033] Furthermore, in a configuration where the teeth-side vertical surface 26D2 and the magnet-side vertical surface 18A2 are arranged facing each other in the axial direction, and the teeth-side vertical surface 26E2 and the magnet-side vertical surface 19A2 are arranged facing each other in the axial direction, for example, by inserting a thickness gauge between the teeth-side vertical surface 26D2 and the magnet-side vertical surface 18A2, the axial clearance between the first magnet 18 and the teeth-side 26A can be easily measured. Similarly, by inserting a thickness gauge between the teeth-side vertical surface 26E2 and the magnet-side vertical surface 19A2, the axial clearance between the second magnet 19 and the teeth-side 26A can be easily measured.

[0034] In the motor 58 according to the second embodiment, the axial thickness dimension of the inner flange portion 26B is set to be larger than the axial thickness dimension of the outer flange portion 26C. In the motor 60 according to the third embodiment, the axial thickness dimension of the radially inner end of the inner flange portion 26B is set to be larger than the axial thickness dimension of the outer flange portion 26C.

[0035] Incidentally, while the motors 58 and 60 (rotors 12) are rotating, the rotating magnetic field generated by the stator 14 and the positions of the magnetic pole centers of the first magnet 18 and the second magnet 19 change, and as a result, forces are repeatedly applied to each part of the core 26 that attempt to displace each part of the core 26 in one axial direction and the other. Therefore, by setting the thickness dimension of the inner flange portion 26B, which is not fixed to the first frame 21 and the second frame 23, as described above, deformation of the inner flange portion 26B in response to the above forces can be suppressed. In a configuration in which the inner flange portion 26B is fixed to the first frame 21 and the second frame 23, deformation of the outer flange portion 26C in response to the above forces can be suppressed by setting the axial thickness dimension of the outer flange portion 26C to be larger than the axial thickness dimension of the inner flange portion 26B.

[0036] (Fourth Embodiment) Next, the motor core 26 according to the fourth embodiment will be described with reference to Figures 13 to 16. In the motor core 26 according to the fourth embodiment, parts corresponding to the motor 10 etc. core 26 described above are given the same reference numerals as the motor 10 etc. core 26 described above, and their description may be omitted.

[0037] As shown in Figures 13 to 16, the core 26 of this embodiment is composed of a plurality of divided cores 62 that are divided in the circumferential direction.

[0038] As shown in Figures 13 and 14, the divided core 62 has one tooth portion 26A. The divided core 62 also has an inner extension portion 62A that extends radially inward from the axial center of the radially inward end of the tooth portion 26A. Furthermore, the divided core 62 has an outer extension portion 62B as a connecting piece that extends radially outward from the axial center of the radially outward end of the tooth portion 26A. The inner extension portion 62A and the outer extension portion 62B constitute a part of the inner flange portion 26B and a part of the outer flange portion 26C, respectively.

[0039] As shown in Figures 14, 15, and 16, a fitting projection 62C, which serves as a connecting and holding portion, is formed at one end of the outer extension 62B in the circumferential direction and protrudes toward the one end. Similarly, a fitting projection 62C, which serves as a connecting and holding portion, is formed at the other end of the outer extension 62B in the circumferential direction and protrudes toward the other end. The fitting projection 62C on the other end of the outer extension 62B in the circumferential direction is located radially outward from the fitting projection 62C on the one end of the outer extension 62B in the circumferential direction.

[0040] A fitting recess 62D, which serves as a connecting and holding portion, is formed on one axial side of the circumferential end of the outer extension portion 62B, and is recessed toward the other axial side. Similarly, a fitting recess 62D, which serves as a connecting and holding portion, is formed on one axial side of the other circumferential end of the outer extension portion 62B, and is recessed toward the other axial side. The fitting recess 62D on the other circumferential side of the outer extension portion 62B is located radially inward from the fitting recess 62D on the circumferential side of the outer extension portion 62B.

[0041] Then, by fitting the fitting convex portion 62C and the fitting concave portion 62D of the divided cores 62 adjacent to each other in the circumferential direction, the circumferential connection state of the plurality of divided cores 62 is maintained, and the plurality of divided cores 62 are integrated in a state of being arranged annularly along the circumferential direction. Here, the inner flange portion 26B is formed by the inner extending portions 62A of the plurality of divided cores 62. Further, the outer flange portion 26C is formed by the outer extending portions 62B of the plurality of divided cores 62. Here, as shown in FIG. 16, a gap 64 is formed between the radially inner end portion of the outer extending portion 62B of one divided core 62 adjacent to each other in the circumferential direction and the radially inner end portion of the outer extending portion 62B of the other divided core 62. Also, a gap 64 is formed between the radially outer end portion of the outer extending portion 62B of one divided core 62 adjacent to each other in the circumferential direction and the radially outer end portion of the outer extending portion 62B of the other divided core 62.

[0042] As described above, the core 26 of the present embodiment is composed of a plurality of divided cores 62 divided in the circumferential direction. In this configuration, manufacturing equipment of a size corresponding to the manufacture of the divided cores 62 can be used. Thereby, compared with the case of manufacturing the core 26 as one part, an increase in the size of the manufacturing equipment can be suppressed. Thereby, the amount of carbon dioxide emissions associated with the manufacture of the core 26 can be reduced and an increase in the cost of the manufacturing equipment can be suppressed.

[0043] Also, in the present embodiment, the above-described gap 64 is formed between the outer extending portion 62B of one divided core 62 adjacent to each other in the circumferential direction and the outer extending portion62B of the other divided core 62. This gap 62 serves as a flux barrier, and the leakage magnetic flux from the tooth portion 26A of one divided core 62 adjacent to each other in the circumferential direction to the tooth portion 26A of the other divided core 62 can be reduced.

[0044] (Fifth Embodiment, Sixth Embodiment) Next, the motor 66 according to the fifth embodiment and the motor 68 according to the sixth embodiment will be described with reference to FIGS. 17 and 18. In the motor 66 according to the fifth embodiment and the motor 68 according to the sixth embodiment, members and parts corresponding to the above-described motor 10 and the like may be denoted by the same reference numerals as those of the members and parts corresponding to the above-described motor 10, and the description thereof may be omitted.

[0045] As shown in FIGS. 17 and 18, in the motor 66 according to the fifth embodiment and the motor 68 according to the sixth embodiment, the tooth portion 26A, the first magnet 18, and the second magnet 19 face each other in a state where they have a defined clearance and the convex portion enters the concave portion.

[0046] More specifically, as shown in FIG. 17, in a cross-sectional view taken along the axial direction and the radial direction, a single convex portion 18B protruding toward the tooth portion 26A is formed at the central portion in the radial direction of the first magnet 18. Further, a single concave portion 26H into which the convex portion 18B enters with a clearance is formed at one end portion of the tooth portion 26A in the axial direction. Note that a magnet-side inclined surface 18A1 is provided on the convex portion 18B, and a tooth-side inclined surface 26D1 is provided on the concave portion 26H.

[0047] Also, in a cross-sectional view taken along the axial direction and the radial direction, a single convex portion 19B protruding toward the tooth portion 26A is formed at the central portion in the radial direction of the second magnet 19. Further, a single concave portion 26J into which the convex portion 19B enters with a clearance is formed at the other end portion of the tooth portion 26A in the axial direction. Note that a magnet-side inclined surface 19A1 is provided on the convex portion 19B, and a tooth-side inclined surface 26E1 is provided on the concave portion 26J.

[0048] As shown in Figure 18, in a cross-sectional view taken along the axial and radial directions, the first magnet 18 has a plurality of (three in this embodiment) convex portions 18B that protrude toward the teeth portion 26A and are spaced apart in the radial direction. In addition, a plurality of (three in this embodiment) concave portions 26H are formed at one end of the teeth portion 26A on the axial side, into which the plurality of convex portions 18B fit with clearance.

[0049] Furthermore, in a cross-sectional view taken along the axial and radial directions, the second magnet 19 has multiple (three in this embodiment) convex portions 19B that protrude toward the teeth portion 26A and are spaced apart in the radial direction. Additionally, at the other axial end of the teeth portion 26A, there are multiple (three in this embodiment) concave portions 26J into which the multiple convex portions 19B fit with clearance.

[0050] In the motor 66 according to the fifth embodiment and the motor 68 according to the sixth embodiment described above, compared to a configuration in which the teeth portion 26A and the first magnet 18 and the second magnet 19 do not face each other while maintaining a predetermined clearance and with the convex portion recessed, the area in which the first magnet 18 and the teeth portion 26A face each other can be increased, and the area in which the second magnet 19 and the teeth portion 26A face each other can be increased. As a result, the motors 66 and 68 can be made more powerful and smaller.

[0051] (Seventh Embodiment, Eighth Embodiment) Next, the stator 14 of the motor according to the seventh embodiment and the stator 14 of the motor according to the eighth embodiment will be described with reference to Figures 19 to 22. In the stator 14 of the motor according to the seventh embodiment and the stator 14 of the motor according to the eighth embodiment, the same reference numerals as those used for the stator 14 of the motor 10 described above will be used for the members and parts corresponding to the stator 14 of the motor 10 described above, and their descriptions may be omitted.

[0052] As shown in Figures 19 and 20, in the stator 14 of the motor according to the seventh embodiment, the conductor portion 52 constituting the coil body 32 is formed on an insulating sheet-like member 70. More specifically, the sheet-like member 70 is formed in an annular shape extending along the circumferential direction with the axial direction as the thickness direction. Conductor portions 52 are formed on one axial side surface and the other axial side surface of this sheet-like member 70. In this embodiment, the conductor portion 52 is formed on each of a plurality of sheet-like members 70 that are stacked in the axial direction. The stator 14 is constructed by attaching the plurality of sheet-like members 70 to the core 26. The sheet-like member 70 has a plurality of tooth portion insertion holes 70A into which a plurality of tooth portions 26A are inserted. In the stator 14 of the motor according to the seventh embodiment described above, the handling of the coil body 32 during assembly and disassembly of the motor can be made easier compared to a configuration in which the conductor portion 52 constituting the coil body 32 is not formed on a sheet-like member 70.

[0053] As shown in Figures 21 and 22, the stator 14 of the motor according to the eighth embodiment has the same configuration as the stator 14 of the motor according to the seventh embodiment, except for the following points. In the stator 14 of the motor according to the eighth embodiment, a plurality of conductor locking protrusions 72 are formed on the outer circumference of the outer flange portion 26C of the core 26, projecting toward one side in the axial direction. These plurality of conductor locking protrusions 72 are arranged at equal intervals along the circumferential direction. When a plurality of sheet-like members 70 are attached to the core 26, the conductor portions 52 formed on the sheet-like members 70 are arranged between adjacent conductor locking protrusions 72 in the circumferential direction. This allows the coil body 32 to be positioned circumferentially with respect to the core 26.

[0054] (Ninth and Tenth Embodiments) Next, the configurations of the motor stator 14 according to the ninth embodiment and the motor stator 14 according to the tenth embodiment will be described with reference to Figures 23 and 24. In the motor stator 14 according to the ninth embodiment and the motor stator 14 according to the tenth embodiment, members and parts corresponding to the stator 14 of the motor 10 etc. described above are denoted by the same reference numerals as the members and parts corresponding to the stator 14 of the motor 10 etc. described above, and their descriptions may be omitted.

[0055] As shown in Figure 23, in the stator 14 of the motor according to the ninth embodiment, locking portions 26K are provided that protrude radially inward from both axial ends of the radially inward end of the tooth portion 26A. In addition, locking portions 26K are provided that protrude radially outward from both axial ends of the radially outward end of the tooth portion 26A. In this configuration, the coil body 32 attached to the core 26 is locked by the locking portions 26K, thereby preventing the coil body 32 from coming off the core 26.

[0056] As shown in Figure 24, in the stator 14 of the motor according to the tenth embodiment, locking portions 26L are provided that protrude from both axial ends of the radially inward portion of the teeth portion 26A toward the other circumferential side. In addition, locking portions 26M are provided that protrude radially inward from both axial ends of the radially inward end of the teeth portion 26A. In this configuration, the coil body 32 (conductor portion 52) attached to the core 26 is locked by the locking portion 26L, thereby preventing the coil body 32 and the sheet-like member 70 from coming off the core 26. Furthermore, the sheet-like member 70 attached to the core 26 is locked by the locking portion 26M, thereby preventing the coil body 32 and the sheet-like member 70 from coming off the core 26.

[0057] (Eleventh Embodiment) Next, the motor core 26 according to the eleventh embodiment will be described with reference to Figure 25. In the motor core 26 according to the eleventh embodiment, parts corresponding to the core 26 of the motor 10 etc. described above are given the same reference numerals as the parts corresponding to the core 26 of the motor 10 etc. described above, and their description may be omitted.

[0058] As shown in Figure 25, the outer flange portion 26C of the motor core 26 of this embodiment has wiring passage holes 26N formed therein, through which wiring (not shown) connected to the coil body 32 (see Figure 1, etc.) passes in the axial direction. In this embodiment, three wiring passage holes 26N are formed in the outer flange portion 26C. The three wiring passage holes 26N are arranged at intervals in the circumferential direction in a part of the outer flange portion 26C. The wiring passing through the wiring passage holes 26N is for supplying power to the coil body 32, or for making connections inside the coil body 32, etc. As described above, in the motor core 26 of this embodiment, wiring can be routed through the wiring passage holes 26N formed in the outer flange portion 26C. It is also possible to route wiring through wiring passage holes 26N formed in the inner flange portion 26B.

[0059] In the embodiments described above, examples were described in which the stator 14 is configured to have a distributed winding configuration in which the winding is wound across multiple tooth sections 26A. However, the present invention is not limited to these configurations. For example, a stator 14 can also be adopted that has a configuration corresponding to a concentrated winding configuration in which the winding is wound around a single tooth section 26A, as shown in the 12th embodiment of the motor in Figures 26 and 27.

[0060] Although the embodiments of this disclosure have been described above, this disclosure is not limited to those described above, and it is of course possible to implement it in various other ways without departing from the spirit of the disclosure. Furthermore, all or part of the configurations of the embodiments described above can be combined with each other. Also, the configuration of the motor 10, etc., may be applied to a generator.

[0061] Although one embodiment of the present disclosure has been described above, the present disclosure is not limited to the above, and it is of course possible to implement it in various other forms without departing from its spirit.

[0062] <Note> (Note 1) A rotor (12) having a first magnet (18) and a second magnet (19) arranged opposite to each other in the axial direction of the rotating shaft (22), and supported to be rotatable around the axis of the rotating shaft; a stator (14) having a core (26) disposed between the first magnet and the second magnet, and a coil body (32) provided around the core, which generates a rotating magnetic field when the coil body is energized; and stator fixing members (21, 23) to which the stator is fixed, wherein the core has a plurality of teeth (26A) arranged at intervals in the circumferential direction and forming a magnetic flux path between the first magnet side and the second magnet side, and circumferential connecting parts (26B, 26C) that connect the plurality of teeth in the circumferential direction on at least one side of the radially outer and radially inner sides, Rotating electric machine (10, 58, 60, 66, 68) in which the circumferential connection portion is fixed to the stator fixing member. (Note 2) The rotating electric machine according to Note 1, wherein the plurality of teeth portions are constructed by compressing magnetic powder (42) having a powdery base material (44) made of an iron-based material. (Note 3) The rotating electric machine according to Note 1 or Note 2, wherein the circumferential connection portion is constructed by compressing magnetic powder (42) having a powdery base material (44) made of an iron-based material. (Note 4) The circumferential connection portion comprises an outer flange portion (26C) formed in an annular shape along the circumferential direction on the radially outer side with respect to a plurality of teeth portions, and an inner flange portion (26B) formed in an annular shape along the circumferential direction on the radially inner side with respect to a plurality of teeth portions, and one of the outer flange portion and the inner flange portion is fixed to the stator fixing member, and the axial thickness dimension of the other of the outer flange portion and the inner flange portion that is not fixed to the stator fixing member is set to be larger than the axial thickness dimension of one of the outer flange portion and the inner flange portion, as described in any one of Notes 1 to 3.(Note 5) The rotating electric machine according to any one of Notes 1 to 4, wherein the circumferential connection portion and the stator fixing member are provided with anti-rotation portions (26F, 21D, 23D) that limit the circumferential displacement of the core relative to the stator fixing member. (Note 6) The rotating electric machine according to any one of Notes 1 to 5, wherein the circumferential connection portion has a wiring pass-through hole (26N) through which wiring connected to the coil body passes in the axial direction. (Note 7) The rotating electric machine according to any one of Notes 1 to 6, wherein the core has a configuration having a plurality of divided cores (62) divided in the circumferential direction, and the divided core comprises the teeth portion and a connecting piece portion (62B) which is formed integrally with the teeth portion and constitutes a part of the circumferential connection portion, and the connecting piece portion is provided with a connecting holding portion (62C, 62D) which maintains the circumferential connection state of a pair of adjacent divided cores in the circumferential direction. (Note 8) The rotating electric machine according to any one of Notes 1 to 7, wherein in a cross-sectional view taken along the axial and radial directions, the teeth portion and the first magnet and the second magnet face each other with a predetermined clearance and the convex portion is recessed. (Note 9) The rotating electric machine according to any one of Notes 1 to 8, wherein in a cross-sectional view taken along the axial and radial directions, the teeth portion is provided with a teeth portion side inclined surface (26D1, 26E1) that is inclined in the axial direction with respect to the radial direction, the first magnet and the second magnet are provided with a magnet side inclined surface (18A1, 19A1) that is inclined in the same direction as the teeth portion side inclined surface, and the teeth portion side inclined surface and the magnet side inclined surface are arranged to face each other in the axial direction. (Note 10) In a cross-sectional view taken along the axial and radial directions, the teeth portion is provided with teeth-side vertical surfaces (26D2, 26E2) perpendicular to the axial direction, the first magnet and the second magnet are provided with magnet-side vertical surfaces (18A2, 19A2) perpendicular to the axial direction, and the teeth-side vertical surface and the magnet-side vertical surface are arranged opposite each other in the axial direction, as described in Note 9.(Note 11) The stator is provided on an insulating sheet-like member (70) that extends circumferentially with the axial direction as the thickness direction, and the sheet-like member is attached to the core, as described in any one of Notes 1 to 10. (Note 12) The core is provided with locking portions (26K, 26L, 26M) that maintain the state in which the coil body is attached to the core, as described in any one of Notes 1 to 11.

Claims

1. A rotor (12) rotatably supported around the axis of the rotating shaft (22), having a first magnet (18) and a second magnet (19) arranged opposite to each other in the axial direction of the rotating shaft (22); a stator (14) having a core (26) disposed between the first magnet and the second magnet, and a coil body (32) provided around the core, which generates a rotating magnetic field when the coil body is energized; and stator fixing members (21, 23) to which the stator is fixed, wherein the core has a plurality of teeth (26A) arranged at intervals in the circumferential direction and forming a magnetic flux path between the first magnet side and the second magnet side, and circumferential connecting parts (26B, 26C) that connect the plurality of teeth in the circumferential direction on at least one side of the radially outer and radially inner sides, The circumferential connection portion is fixed to the stator fixing member of the rotating electric machine (10, 58, 60, 66, 68).

2. The rotating electric machine according to claim 1, wherein the plurality of teeth portions are constructed by compressing magnetic powder (42) having a powdery base material (44) formed from an iron-based material.

3. The rotating electric machine according to claim 1 or claim 2, wherein the circumferential connection portion is constructed by compressing magnetic powder (42) having a powdery base material (44) formed from an iron-based material.

4. The circumferential connection portion comprises an outer flange portion (26C) formed in an annular shape along the circumferential direction on the radially outer side with respect to a plurality of teeth portions, and an inner flange portion (26B) formed in an annular shape along the circumferential direction on the radially inner side with respect to a plurality of teeth portions, wherein one of the outer flange portion and the inner flange portion is fixed to the stator fixing member, and the axial thickness dimension of the other of the outer flange portion and the inner flange portion that is not fixed to the stator fixing member is set to be larger than the axial thickness dimension of one of the outer flange portion and the inner flange portion.

5. The rotating electric machine according to any one of claims 1 to 4, wherein the circumferential connection portion and the stator fixing member are provided with anti-rotation portions (26F, 21D, 23D) that restrict the circumferential displacement of the core relative to the stator fixing member.

6. The rotating electric machine according to any one of claims 1 to 5, wherein the circumferential connection portion has a wiring pass-through hole (26N) through which the wiring connected to the coil body passes in the axial direction.

7. The rotating electric machine according to any one of claims 1 to 6, wherein the core has a configuration having a plurality of divided cores (62) divided in the circumferential direction, and each divided core comprises a tooth portion and a connecting piece portion (62B) which is formed integrally with the tooth portion and constitutes a part of the circumferential connection portion, and the connecting piece portion is provided with a connecting holding portion (62C, 62D) which maintains the circumferential connection state of a pair of adjacent divided cores in the circumferential direction.

8. The rotating electric machine according to any one of claims 1 to 7, wherein, in a cross-sectional view taken along the axial and radial directions, the teeth portion and the first magnet and the second magnet face each other with a predetermined clearance and the convex portion recessed into the concave portion.

9. In a cross-sectional view taken along the axial and radial directions, the teeth portion is provided with teeth-side inclined surfaces (26D1, 26E1) that are inclined in the axial direction with respect to the radial direction, the first magnet and the second magnet are provided with magnet-side inclined surfaces (18A1, 19A1) that are inclined in the same direction as the teeth-side inclined surfaces, and the teeth-side inclined surfaces and the magnet-side inclined surfaces are arranged facing each other in the axial direction, according to any one of claims 1 to 8.

10. In a cross-sectional view taken along the axial and radial directions, the teeth portion is provided with teeth-side vertical surfaces (26D2, 26E2) perpendicular to the axial direction, the first magnet and the second magnet are provided with magnet-side vertical surfaces (18A2, 19A2) perpendicular to the axial direction, and the teeth-side vertical surfaces and the magnet-side vertical surfaces are arranged facing each other in the axial direction, as described in claim 9.

11. The rotating electric machine according to any one of claims 1 to 10, wherein the stator comprises an insulating sheet-like member (70) that extends circumferentially with the axial direction as the thickness direction, and the sheet-like member is attached to the core.

12. The rotating electric machine according to any one of claims 1 to 10, wherein the core is provided with locking portions (26K, 26L, 26M) for maintaining the state in which the coil body is attached to the core.

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