Linear motor armature and linear motor

Abstract

Provided are a linear motor armature and a linear motor, in which a plurality of armature cores can be fitted to one another by dovetail grooves, connecting members, and the like, and can be joined without screwing. A linear motor armature according to the present disclosure is provided with: a plurality of armature cores each having a back yoke section and a tooth section; a plurality of armature windings; and molded resin. The plurality of back yoke sections are lined up in a first direction and abut against one another. Each of the tooth sections protrudes out from the back yoke sections to one side in a second direction orthogonal to the first direction. A recess extending in the first direction is formed at the end of each of the back yoke sections on the other side of the second direction. The plurality of recesses are connected in the first direction. The plurality of back yoke sections are joined to one another by welding on the insides of the recesses of two adjacent back yoke sections. The molded resin is provided in each of the recesses. Respective weld portions are covered with the molded resin.

Description

Linear motor armature, and linear motor

[0001] The present disclosure relates to a linear motor armature and a linear motor.

[0002] In the linear motor disclosed in Patent Document 1, in order to wind the coils at a high density, the armature core is configured to be separated individually. Then, a coil is wound around each armature core, and the individual armature cores with the coils wound thereon are connected by the mutual fitting of the concave portions and the protruding portions provided on each armature core, as well as the mutual fitting of the slit groove and the coupling member. Further, the coupling member is fixed to a fixing member (armature mounting plate) by screws and assembled.

[0003] Japanese Patent Application Laid-Open No. 2000-217334

[0004] In the technique of Patent Document 1, there are many fitting portions, the shape of the armature core becomes complicated, and the manufacturing cost increases. Also, when assembling the armature, after fitting the concave portion and the protruding portion to each other and connecting the slit groove and the coupling member by sliding fitting, it is necessary to screw them to maintain the fitting state, which requires an assembling operation that requires complicated operations and has poor assembling workability. Further, since the coil wound around the armature core contacts and rubs against each other by sliding, there is a risk of insulation failure and disconnection, so there is a problem that the difficulty of the assembling operation is high.

[0005] An object of the present disclosure is to provide a linear motor armature and a linear motor that can connect a plurality of armature cores to each other by means of a slit groove and a coupling member or the like without screwing.

[0006] The linear motor armature according to this disclosure comprises: a plurality of armature cores, each having a back yoke portion and a tooth portion protruding from the back yoke portion; a plurality of armature windings wound around each of the tooth portions; and a molded resin for fixing the plurality of armature cores and the plurality of armature windings, wherein the plurality of back yoke portions are arranged in a first direction and abut each other, each tooth portion protrudes from the back yoke portion to one side in a second direction perpendicular to the first direction, a recess extending in the first direction is formed at the other end of each back yoke portion in the second direction, the plurality of recesses are connected in the first direction, the plurality of back yoke portions are connected to each other by welding inside the recesses of two adjacent back yoke portions, the molded resin is provided in each recess, and each welded portion is covered by the molded resin.

[0007] The linear motor according to this disclosure comprises the linear motor armature described above, and a magnetic field disposed on one side of the linear motor armature in the second direction, wherein the linear motor armature and the magnetic field are moved relative to each other, with either the linear motor armature or the magnetic field being the stator and the other being the movable element.

[0008] According to the linear motor armature and linear motor of this disclosure, a recess extending in the first direction is formed at the other end of the second direction, which is the back side of each back yoke portion. Multiple recesses are connected in the first direction, and multiple back yoke portions are connected to each other by welding inside the recesses of two adjacent back yoke portions. Therefore, as in Patent Document 1, there is no need to provide a fitting portion, and the manufacturing cost of the armature core can be reduced. Furthermore, as in Patent Document 1, there is no need for assembly work that requires complex movements such as fitting a dovetail groove and a connecting member by sliding and screwing them together. Multiple recesses connected in the first direction can be connected by a simple welding operation in which they are sequentially welded to each other in the first direction. In addition, since the welded portion is formed in the recess, it is possible to suppress the welded portion from protruding to the other side of the back yoke portion in the second direction. Furthermore, since molded resin is provided in each recess, and each welded portion is covered with molded resin, it is possible to suppress the welded portion from being exposed to the outside. Therefore, the welded portion can be protected with molded resin, the reliability of the connection can be improved, and the appearance of the linear motor armature can be improved.

[0009] This is a side cross-sectional view of a gap-facing linear motor according to Embodiment 1. This is a perspective view showing the configuration of the linear motor armature according to Embodiment 1. This is a perspective view of the linear motor armature cut at the I-I cross-sectional position in Figure 2 according to Embodiment 1. This is a perspective view of the linear motor armature cut at the II-II cross-sectional position in Figure 2 according to Embodiment 1. This is a perspective view showing the configuration of the linear motor armature according to a modified example of Embodiment 1. This is a perspective view of Embodiment 1 before the recesses of each armature core are fixed by welding. This is a top view of Embodiment 1 before each armature core is fixed by welding. This is a top view of Embodiment 1 after each armature core has been fixed by welding. This is a top view of Embodiment 1 after each armature core has been fixed by welding. This is a perspective view of Embodiment 1 after the I-I cross-sectional position in Figure 2 according to a modified example of Embodiment 1. This is a side view of Embodiment 1 when each armature core is connected by welding. This is a perspective view showing the configuration of the linear motor armature according to a modified example of Embodiment 1. This is a perspective view of a linear motor armature cut at the II-II cross-sectional position in Figure 13, relating to a modified example of Embodiment 1. This is a perspective view showing the configuration of a linear motor armature relating to a modified example of Embodiment 1.

[0010] 1. Embodiment 1 The linear motor armature 3 according to Embodiment 1 will be described with reference to the drawings. Figure 1 is a side cross-sectional view of a gap-facing type linear motor 1 according to Embodiment 1. Figure 2 is a perspective view showing the configuration of the linear motor armature 3 according to Embodiment 1. Figure 3 is a perspective view of the linear motor armature 3 cut at the I-I cross-sectional position in Figure 2. Figure 4 is a perspective view of the linear motor armature 3 cut at the II-II cross-sectional position in Figure 2. Figure 5 is a perspective view showing the configuration of the linear motor armature 3 according to a modified example of Embodiment 1. Figure 6 is a perspective view according to Embodiment 1 before the recesses 11 of each armature core 6 are connected by welding. Figure 7 is a top view according to Embodiment 1 before the recesses 11 of each armature core 6 are connected by welding. Figure 8 is a top view according to Embodiment 1 after the recesses 11 of each armature core 6 are connected by welding. Figure 9 is a top view according to a modified example of Embodiment 1 after the recesses 11 of each armature core 6 are connected by welding. Figure 10 is a perspective view of the linear motor armature 3 cut at the I-I cross-sectional position in Figure 2, according to a modified example of Embodiment 1. Figure 11 is a side view of the armature cores 6 connected by welding, according to Embodiment 1. Figure 12 is a perspective view showing the configuration of the linear motor armature, according to a modified example of Embodiment 1. Figure 13 is a perspective view of the linear motor armature cut at the II-II cross-sectional position in Figure 13, according to a modified example of Embodiment 1.

[0011] 1-1. Configuration of the Linear Motor Armature The linear motor armature 3 comprises a plurality of armature cores 6, each having a back yoke portion 15 and a tooth portion 16 protruding from the back yoke portion 15; a plurality of armature windings 8 wound around each of the tooth portions 16; and a molded resin 9 that fixes the plurality of armature cores 6 and the plurality of armature windings 8. In this embodiment, the linear motor armature 3 comprises a plurality of insulators 7 attached to the tooth portions 16 around which the armature windings 8 are wound. The plurality of back yoke portions 15 are arranged in a first direction X and are in contact with each other. Each tooth portion 16 protrudes from the back yoke portion 15 to one side Z1 in a second direction perpendicular to the first direction X.

[0012] In this disclosure, the direction in which the multiple back yoke portions 15 are arranged is defined as the first direction X. The direction in which each tooth portion 16 protrudes from the back yoke portion 15 is defined as one side Z1 of the second direction, and the opposite side as the other side Z2. The second direction Z is perpendicular to the first direction X. The direction perpendicular to both the first direction X and the second direction Z is defined as the third direction Y.

[0013] As shown in Figure 1, the linear motor 1 comprises a linear motor armature 3 and a field magnet 2 positioned on one side Z1 of the linear motor armature 3 in the second direction. In the linear motor 1, the field magnet 2 and the linear motor armature 3 face each other with a gap between them. The field magnet 2 is composed of a rectangular plate-shaped stator yoke 4 extending in the first direction X and the third direction Y, and a plurality of permanent magnets 5 arranged at predetermined intervals along the first direction X on the stator yoke 4, with alternating polarities. Either the linear motor armature 3 or the field magnet 2 is used as the stator, and the other as the movable element, thereby moving the linear motor armature 3 and the field magnet 2 relative to each other.

[0014] <Armature Core> As described above, each armature core 6 is composed of a back yoke portion 15 and a teeth portion 16. Each armature core 6 is made of electromagnetic steel sheets laminated in the third direction Y. Multiple back yoke portions 15 are arranged in the first direction X and are in contact with each other. The back yoke portions 15 are formed in a rectangular parallelepiped shape, with a width in the third direction Y being longer than the width in the first direction X.

[0015] The armature winding 8 is wound around the teeth portion 16 that protrudes from the back yoke portion 15. Each teeth portion 16 protrudes from each back yoke portion 15 to one side Z1 in the second direction. The width of each teeth portion 16 in the third direction Y is equal to the width of each back yoke portion 15 in the first direction X. The width of each teeth portion 16 in the first direction X is shorter than the width of each back yoke portion 15 in the first direction X, and each teeth portion 16 is positioned at the center of each back yoke portion 15 in the first direction X. A gap is formed between two teeth portions 16 adjacent to each other in the first direction X, and the armature winding 8 is positioned in this gap.

[0016] <Insulator> The insulators 7 are attached to both ends of each armature core 6 in the third direction Y, and the armature windings 8 are wound around them. The insulators 7 are made of an insulating resin material.

[0017] <Molding Resin> As described above, the molding resin 9 fixes the multiple armature cores 6 and the multiple armature windings 8. The molding resin 9 covers the end face of one side Z1 in the second direction of each tooth portion 16. As shown in the modified example in Figure 10, the molding resin 9 does not cover the end face of one side Z1 in the second direction of each tooth portion 16, and the end face of one side Z1 in the second direction of each tooth portion 16 may be exposed to the outside.

[0018] In this embodiment, the molded resin 9 covers both sides in the third direction Y and both sides in the first direction X of the multiple armature cores 6 and the multiple armature windings 8. On the other side Z2 in the second direction of the multiple armature cores 6, the molded resin 9 is filled into the recess 11, and the parts other than the recess 11 are not covered by the molded resin 9 and are exposed. The welded portion 13 located in the recess 11 is covered by the molded resin 9.

[0019] As will be described later, the recesses 11 of multiple back yoke portions 15 are welded to each other, but the welded portions 13 are covered and protected by the molded resin 9. The screw holes 12 provided at the other end Z2 of the back yoke portion 15 in the second direction are not covered by the molded resin 9.

[0020] <Recess 11, Welded portion 13, and Protruding portion 18> A recess 11 extending in the first direction X is formed at the end of the other side Z2 in the second direction of each back yoke portion 15. Multiple recesses 11 are connected in the first direction X. Multiple back yoke portions 15 are connected to each other by welding inside the recesses 11 of two adjacent back yoke portions 15. Molded resin 9 is provided in each recess 11, and each welded portion 13 is covered with molded resin 9.

[0021] In this configuration, a recess 11 extending in the first direction X is formed at the end of the other side Z2 in the second direction, which is the back side of each back yoke portion 15. Multiple recesses 11 are connected in the first direction X, and multiple back yoke portions 15 are connected to each other by welding inside the recesses 11 of two adjacent back yoke portions 15. Therefore, as in Patent Document 1, there is no need to provide a fitting part, and the manufacturing cost of the armature core 6 can be reduced. Furthermore, as in Patent Document 1, there is no need for assembly work that requires complex movements such as fitting the dovetail groove and the connecting member by sliding and screwing them together. Multiple recesses 11 connected in the first direction X can be connected by a simple welding operation in which they are sequentially welded to each other in the first direction X. In addition, a bead is formed and rises in the welded portion 13, but since the welded portion 13 is formed in the recess 11, it is possible to suppress the welded portion 13 from protruding outwards on the other side Z2 in the second direction of the back yoke portion 15. Furthermore, since molded resin 9 is provided in each recess 11 and each welded portion 13 is covered by the molded resin 9, exposure of the welded portion 13 to the outside can be suppressed. Therefore, the welded portion 13 can be protected by the molded resin 9, improving the reliability of the connection and improving the appearance of the linear motor armature 3.

[0022] Figure 11 shows a diagram of welding the recess 11 with a welding torch 19. In this embodiment, the armature core 6 is formed by laminating electrical steel sheets in a third direction Y. The welded portion 13 extends from the recess 11 to one side Z1 in the second direction between two adjacent electrical steel sheets in the third direction Y, and the welded portion 13 that welds two adjacent back yoke portions 15 in the first direction X extends from the recess 11 to one side Z1 in the second direction. In this way, the penetration of the weld between the two electrical steel sheets can be improved, so the welded portion 13 can be extended to one side Z1 in the second direction, improving the reliability of the connection.

[0023] In this embodiment, the cross-section of the recess 11 is formed in a rectangular shape. Each of the rectangular recesses 11 is connected in a row in the first direction X. The cross-section of the recess 11 may be formed in any shape, such as a semicircle.

[0024] In this embodiment, protrusions 18 are formed at both ends in the third direction Y of the other end Z2 in the second direction of each back yoke portion 15, projecting outward from the recess 11. The other end Z2 in the second direction of the protrusion 18 is exposed to the outside from the molded resin 9.

[0025] With this configuration, when the other end Z2 of the back yoke portion 15 in the second direction is attached to the outside, the protrusions 18 on both sides in the third direction Y can be brought into contact with the external member, thereby improving the stability of the attachment in the third direction Y.

[0026] Two recesses 11 are formed on both sides of the center of the third direction Y at the end of the other side Z2 in the second direction of each back yoke portion 15, and welded portions 13 are provided in the two recesses 11. Each of the two protrusions 18 protrudes from each of the two recesses 11. That is, the portion of the recess 11 on one side in the third direction Y that is on one side in the third direction Y is the protrusion 18 on one side in the third direction Y, and the portion of the recess 11 on the other side in the third direction Y that is on the other side in the third direction Y is the protrusion 18 on the other side in the third direction Y.

[0027] With this configuration, two recesses 11 are formed on both sides of the third direction Y, and welded portions 13 are provided in the two recesses 11, thereby increasing the connection strength against twisting. In addition, the portions on both sides of the two recesses 11 in the third direction Y are made up of two protrusions 18, which simultaneously achieves improved connection strength and stability of attachment in the third direction Y when mounted externally.

[0028] In this embodiment, a projection 18 is formed at the center of the third direction Y at the end of the other side Z2 in the second direction of each back yoke portion 15, projecting outward from the recess 11. That is, the center of the third direction Y, sandwiched between the two recesses 11 on both sides of the third direction Y, is the projection 18 at the center of the third direction Y. The end of the projection 18 on the other side Z2 in the second direction is exposed to the outside from the molded resin 9.

[0029] When the other end Z2 of the back yoke portion 15 in the second direction is attached to the outside, the protruding portion 18 at the center in the third direction Y can be brought into contact with the external member to improve the stability of the attachment.

[0030] In this embodiment, the end faces of the three protrusions 18 on both sides in the third direction Y and in the center, and the other side Z2 in the second direction, are formed on the same plane. With this configuration, the end faces of the three protrusions 18 can be brought into contact with a planar external member for attachment, thereby improving the stability of attachment. Note that the end faces of the three protrusions 18 do not necessarily have to be formed on the same plane; they may be formed in a shape that matches the shape of the external member.

[0031] In this embodiment, the projection 18 at the center of the third direction Y has a screw hole 12 at the other end Z2 in the second direction for fixing the linear motor armature 3 to the outside. Screw holes 12 are provided in the two back yoke portions 15 at both ends in the X direction and in the one or two back yoke portions 15 closest to the center in the X direction. Screw holes 12 may also be provided in other back yoke portions 15.

[0032] As shown in Figure 5, a modified example is shown, where each of the two protrusions 18 on both sides of the third direction Y may have a screw hole 12 for fixing the linear motor armature 3 to the outside. With this configuration, the two screw holes 12 on both sides of the third direction Y allow it to be fixed to an external member, thus improving the stability of the mounting in the third direction Y. Screw holes 12 are provided in two back yoke portions 15 that are close to both sides in the X direction of the multiple back yoke portions 15. Screw holes 12 may also be provided in other back yoke portions 15.

[0033] As shown in Figure 14, a modified example is provided. One end of the back yoke portion 15 in the third direction Y has a single end projection 21 that protrudes further in the third direction Y than the teeth portion 16, and the other end of the back yoke portion 15 in the third direction Y has a single end projection 21 that protrudes further in the third direction Y than the teeth portion 16. The single end projection 21 constitutes the single end of the single projection 18 in the third direction Y, and the single end projection 21 constitutes the other end of the other projection 18 in the third direction Y. With this configuration, by providing two double end projections 21, the width of each projection 18 in the third direction Y can be increased without changing the shape of the wound teeth portion 16. When cutting screw holes 12 in each projection 18, the width between the screw hole 12 and both ends of each projection 18 in the third direction Y can be increased, preventing deformation of the screw hole 12 and improving the reliability of the screw hole 12.

[0034] As shown in Figure 8, the welded portion 13 is provided at the end of the third direction Y at the bottom of each recess 11 (in this example, the end on the side of the center in the third direction Y at the bottom of each recess 11).

[0035] Figure 11 shows the welding of the end of the recess 11 in the third direction Y using the torch 19 of the welding machine. By welding the end of the recess 11 in the third direction Y, the gap 20 between the welding machine torch 19 and the armature core 6 becomes larger. Furthermore, even when the height of the armature core 6 in the second direction Z varies, interference between the welding machine torch 19 and the armature core 6 can be prevented, thereby improving the accuracy of the welding position.

[0036] As shown in the modified example in Figure 9, the welded portion 13 may be provided at the center of the third direction Y at the bottom of each recess 11. With this configuration, when welding, the protrusions 18 on both sides in the third direction Y prevent spatter from scattering during welding. As a result, the risk of insulation failure is reduced, and reliability can be improved.

[0037] As shown in Figures 12 and 13, two recesses 11 are formed at both ends in the third direction Y at the other end Z2 in the second direction of each back yoke portion 15, and a welded portion 13 may be provided in the two recesses 11. A protrusion 18 is provided between the two recesses 11, and the protrusion 18 protrudes from the two recesses 11. Similar to the above configuration, the welded portion 13 may be provided at the end on the side closer to the center in the third direction Y at the bottom of each recess 11, or at the center in the third direction Y at the bottom of each recess 11.

[0038] 1 Linear motor, 2 Field magnet, 3 Linear motor armature, 4 Stator yoke, 5 Permanent magnet, 6 Armature core, 7 Insulator, 8 Armature winding, 9 Molded resin, 11 Recess, 12 Screw hole, 13 Welded part, 15 Back yoke part, 16 Teeth part, 18 Protrusion, 19 Welding machine torch, 20 Gap, 21 Protrusions at both ends

Claims

1. A linear motor armature comprising: a plurality of armature cores, each having a back yoke portion and a tooth portion protruding from the back yoke portion; a plurality of armature windings wound around each of the tooth portions; and a molded resin for fixing the plurality of armature cores and the plurality of armature windings, wherein the plurality of back yoke portions are arranged in a first direction and abut each other; each tooth portion protrudes from the back yoke portion to one side in a second direction perpendicular to the first direction; a recess extending in the first direction is formed at the other end of each back yoke portion in the second direction; the plurality of recesses are connected in the first direction; the plurality of back yoke portions are connected to each other by welding inside the recesses of two adjacent back yoke portions; the molded resin is provided in each recess; and each welded portion is covered by the molded resin.

2. A linear motor armature according to claim 1, wherein a direction perpendicular to the first direction and the second direction is defined as a third direction, and protrusions protruding from the recess are formed at both ends of the third direction at the other end of the back yoke portion in the second direction, and the other end of the protrusion in the second direction is exposed to the outside from the molded resin.

3. The linear motor armature according to claim 2, wherein two recesses are formed on both sides of the center in the third direction at the other end of each back yoke portion in the second direction, the welded portion is provided in the two recesses, and each of the two protrusions protrudes from each of the two recesses.

4. The linear motor armature according to claim 2 or 3, wherein each of the two protrusions has a screw hole for fixing a linear motor armature to the outside.

5. A linear motor armature according to claim 4, wherein the direction perpendicular to the first direction and the second direction is defined as the third direction, one end of each back yoke portion in the third direction has a single end projection that protrudes further to the side of the third direction than each tooth portion, the other end of each back yoke portion in the third direction has a single end projection that protrudes further to the side of the third direction than each tooth portion, the single end projection constitutes the end of the recess on the side of the third direction in the third direction, and the single end projection constitutes the end of the recess on the other side of the third direction in the third direction.

6. A linear motor armature according to any one of claims 1 to 5, wherein the direction perpendicular to the first direction and the second direction is defined as the third direction, the armature core is formed by laminating electromagnetic steel sheets in the third direction, the welded portion extends from the recess to one side in the second direction between two adjacent electromagnetic steel sheets in the third direction, and the welded portion that welds two adjacent back yoke portions in the first direction extends from the recess to one side in the second direction.

7. A linear motor armature according to any one of claims 1 to 6, wherein the direction perpendicular to the first direction and the second direction is defined as the third direction, and the welded portion is provided at the end of the third direction at the bottom of each recess.

8. A linear motor armature according to any one of claims 1 to 6, wherein the direction perpendicular to the first direction and the second direction is defined as the third direction, and the welded portion is provided at the center of the third direction at the bottom of each recess.

9. A linear motor comprising a linear motor armature according to any one of claims 1 to 8, and a magnetic field disposed on one side of the linear motor armature in the second direction, wherein the linear motor armature and the magnetic field are moved relative to each other, with either the linear motor armature or the magnetic field being the stator and the other being the movable element.

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