Linear motor armature, linear motor, and method for producing linear motor armature
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- MITSUBISHI ELECTRIC CORP
- Filing Date
- 2025-11-13
- Publication Date
- 2026-06-25
Smart Images
Figure JP2025039742_25062026_PF_FP_ABST
Abstract
Description
Linear motor armature, linear motor, and method for manufacturing a linear motor armature
[0001] The present disclosure relates to a linear motor armature, a linear motor, and a method for manufacturing a linear motor armature.
[0002] A linear motor of a gap facing type is configured such that the gap surfaces of each of the field magnet and the linear motor armature face each other. The linear motor armature includes a linear motor armature core and is fixed with a molding resin so as to entirely cover the armature winding (see, for example, Patent Document 1).
[0003] Japanese Patent Application Laid-Open No. 2010-115042
[0004] In the above conventional technique, when the linear motor armature core and the armature winding are fixed with a molding resin, since the linear motor armature core is exposed on the gap surface, when used in an environment where rust is likely to occur, in order to keep the appearance clean, there is a problem that a step of applying an anti-rust agent to the exposed linear motor armature core is required.
[0005] Therefore, an object of the present disclosure is to provide an armature of a linear motor, a linear motor, and a method for manufacturing a linear motor armature in which a linear motor armature core is not exposed on a gap surface.
[0006] The armature of the linear motor according to the present disclosure includes: 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; a plurality of insulators attached to the tooth portions around which the armature windings are wound; and a molding resin for fixing the plurality of armature cores, the plurality of armature windings, and the plurality of insulators. The plurality of back yoke portions are arranged side by side in a first direction and abut against each other. Each of the tooth portions protrudes from the back yoke portion to one side in a second direction orthogonal to the first direction. Each of the insulators protrudes to one side in the second direction more than an end surface on one side in the second direction of the tooth portion. An end surface on one side in the second direction of each of the tooth portions is covered with the molding 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 used as a stator and the other as a movable element, and the linear motor armature and the magnetic field are moved relative to each other.
[0008] A first linear motor armature manufacturing method according to the present disclosure comprises: a preparation step of preparing a plurality of armature cores, each having a back yoke portion and a tooth portion protruding from the back yoke portion, and a plurality of armature windings wound around each of the tooth portions; a connection step of arranging the plurality of back yoke portions in a first direction perpendicular to the second direction and connecting them to each other, with each tooth portion protruding from the back yoke portion to one side in a second direction; a fixing step of attaching an upper jig to the other side of the plurality of back yoke portions in the second direction, with one side in the second direction facing vertically downward, inserting the plurality of armature cores and the plurality of armature windings into a bottomed cylindrical mold opening vertically upward, and fixing the upper jig to the mold with a gap provided between the end face of each tooth portion on one side in the second direction and the bottom surface of the mold; and a molding step of injecting mold resin before hardening into the mold and then hardening the mold resin. It is equipped with these features.
[0009] A second linear motor armature manufacturing method according to the present disclosure comprises: a preparation step of preparing a plurality of armature cores each having a back yoke portion and a tooth portion protruding from the back yoke portion; a plurality of insulators protruding to one side in the second direction from one end face of the tooth portion in the second direction; and a plurality of armature windings wound around each of the tooth portions via the insulators; and a connection step of arranging the plurality of back yoke portions in a first direction perpendicular to the second direction and connecting them to each other, with each tooth portion protruding to one side in the second direction from the back yoke portion; The invention comprises: a fixing step of inserting a plurality of armature cores, a plurality of armature windings, and a plurality of insulators into a bottomed cylindrical mold with an opening to the vertical upward, with one side of the second direction facing vertically downward, and fixing a plurality of back yoke portions by pressing them to one side of the second direction with an upper jig so that the end face of one side of each insulator in the second direction contacts the bottom surface of the mold; and a molding step of injecting mold resin before hardening into the mold and then hardening the mold resin.
[0010] According to the linear motor armature and linear motor described herein, since one end face in the second direction of each tooth portion is covered with molded resin, the linear motor armature core is not exposed to the gap surface. Therefore, there is no need to apply a rust inhibitor to the linear motor armature core, which has the effect of reducing costs.
[0011] According to the first linear motor armature manufacturing method described herein, each tooth portion is fixed with a gap between one end face in the second direction and the bottom surface of the mold. Molding resin is injected into the mold before curing and cured, so that the gap is filled with molding resin, and one end face in the second direction of each tooth portion is covered with molding resin. Therefore, since the linear motor armature core is not exposed on one side in the second direction, there is no need to apply a rust inhibitor to the linear motor armature core, which has the effect of reducing costs.
[0012] According to the second linear motor armature manufacturing method described herein, the end face of each insulator that protrudes to one side in the second direction beyond the end face of the teeth portion in the second direction is in contact with the bottom surface of the mold, and a gap is provided between the bottom surface of the mold and the end face of the teeth portion in the second direction. As the mold resin is injected into the mold and cured, the gap is filled with the mold resin, and the end face of each tooth portion in the second direction is covered with the mold resin. Therefore, since the linear motor armature core is not exposed to one side in the second direction, there is no need to apply a rust inhibitor to the linear motor armature core, which has the effect of reducing costs. In addition, the thickness of the mold resin covering the end face of the teeth portion in the second direction can be controlled by the protrusion height of the insulator on one side in the second direction, and variations can be suppressed. Therefore, variations in the position of the end face of each linear motor armature core in the second direction relative to the end face of the linear motor armature in the second direction can be suppressed. This can suppress variations in motor performance.
[0013] 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 of the insulator according to Embodiment 1. This is a flowchart for explaining the manufacturing method of the linear motor armature according to Embodiment 1. This is a perspective view of each linear motor armature core after welding according to Embodiment 1. This is a front view for explaining the warping of the connected linear motor armature cores after welding according to Embodiment 1. This is a perspective view of the linear motor armature after the fixing process according to Embodiment 1. This is a cross-sectional view of the linear motor armature cut at the III-III cross-sectional position in Figure 9 according to Embodiment 1. This is a perspective view of the linear motor armature cut at the same position as the II-II cross-sectional position in Figure 2 according to Embodiment 2. This is a perspective view of the insulator according to Embodiment 2. This is a perspective view of the linear motor armature after the fixing process according to Embodiment 2. This is a cross-sectional view of the linear motor armature, upper jig, and mold cut at the same cross-sectional position as the III-III cross-sectional position in Figure 9, for explaining the fixing process according to Embodiment 2. This is a perspective view of the linear motor armature cut at the same cross-sectional position as the II-II cross-sectional position in Figure 2, for Embodiment 3. This is a perspective view of the insulator according to Embodiment 3. This is a side view of the insulator according to Embodiment 3. This is a cross-sectional view of the linear motor armature, upper jig, and mold cut at the same cross-sectional position as the III-III cross-sectional position in Figure 9, for explaining the fixing process according to Embodiment 3. This is a perspective view of the linear motor armature cut at the same cross-sectional position as the II-II cross-sectional position in Figure 2, for Embodiment 4. This is a perspective view of the insulator according to Embodiment 4. This is a perspective view of the linear motor armature cut at the same cross-sectional position as the II-II cross-sectional position in Figure 2, for Embodiment 5. This is a perspective view of the insulator according to Embodiment 5. This is a side view of the insulator according to Embodiment 5. This is a side view of the insulator according to Embodiment 5.This is a perspective view of the linear motor armature cut at the same cross-sectional position as the II-II cross-sectional position in Figure 2, according to Embodiment 7. This is a perspective view of the linear motor armature, upper jig, and mold (partially cut) after the fixing process, according to Embodiment 7. This is a perspective view of the insulator, according to Embodiment 7. This is a perspective view of the insulator, according to Embodiment 7. This is a perspective view of the insulator, according to Embodiment 7. This is a perspective view of the linear motor armature cut at the same cross-sectional position as the II-II cross-sectional position in Figure 2, according to Embodiment 11. This is a cross-sectional view of the linear motor armature, upper jig, and mold cut at the same cross-sectional position as the III-III cross-sectional position in Figure 9, for explaining the fixing process, according to Embodiment 11. This is a flowchart for explaining the manufacturing method of the linear motor armature, according to Embodiment 11. This is a perspective view of the linear motor armature cut at the same cross-sectional position as the II-II cross-sectional position in Figure 2, according to Embodiment 6. This is a perspective view of the insulator, according to Embodiment 6. This is a perspective view of the insulator according to a modified example of Embodiment 7. This is a perspective view of the insulator according to a modified example of Embodiment 7. This is a perspective view of the linear motor armature according to Embodiment 8, cut at the same cross-sectional position as the II-II cross-sectional position in Figure 2. This is a perspective view of the insulator according to Embodiment 8. This is a perspective view of the insulator according to Embodiment 8. This is a perspective view of the insulator according to Embodiment 8. This is a perspective view of the linear motor armature according to Embodiment 9, cut at the same cross-sectional position as the II-II cross-sectional position in Figure 2. This is a perspective view of the insulator according to Embodiment 9. This is a side view of the insulator according to Embodiment 9. This is a perspective view of the insulator according to Embodiment 10. This is a side view of the insulator according to Embodiment 10.
[0014] 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 showing the configuration 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 in Embodiment 1. Figure 3 is a perspective view of a cross section cut at the I-I cross-sectional position in Figure 2 by a plane parallel to the first direction X and the second direction Z (hereinafter referred to as the XZ plane), which will be described later. Figure 4 is a perspective view of a cross section cut at the II-II cross-sectional position in Figure 2 by a plane parallel to the third direction Y and the second direction Z (hereinafter referred to as the YZ plane).
[0015] 1-1. Configuration of the Linear Motor Armature The linear motor armature 3 comprises a plurality of linear motor armature cores 6, each having a back yoke portion 25 and a tooth portion 26 protruding from the back yoke portion 25; a plurality of armature windings 8 wound around each of the tooth portions 26; and a molded resin 9 that fixes the plurality of linear motor 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 26 around which the armature windings 8 are wound. The plurality of back yoke portions 25 are arranged in a first direction X and are in contact with each other. Each tooth portion 26 protrudes from the back yoke portion 25 to one side Z1 in a second direction perpendicular to the first direction X.
[0016] In this disclosure, the direction in which the multiple back yoke portions 25 are arranged is defined as the first direction X. The direction in which each tooth portion 26 protrudes from the back yoke portion 25 is defined as the second direction Z. 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.
[0017] 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 X and Y directions, and a plurality of permanent magnets 5 arranged at predetermined intervals along the X direction 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.
[0018] <Linear Motor Armature Core> As described above, each linear motor armature core 6 is composed of a back yoke portion 25 and a teeth portion 26. Each linear motor armature core 6 is made of electromagnetic steel sheets laminated in the third direction Y. Multiple back yoke portions 25 are arranged in the first direction X and come into contact with each other to form a connected linear motor armature core 14. That is, the back yoke portion 25 plays the role of a contact portion when multiple linear motor armature cores 6 are connected to form a connected linear motor armature core 14. The back yoke portion 25 is formed in a rectangular parallelepiped shape, with a width in the Y direction being longer than the width in the X direction.
[0019] In the manufacturing process described later, the armature core 14 of the connected linear motor is attached to an upper jig 15 in order to correct the warping in the X direction of the armature core 14 caused by thermal shrinkage. The jig is fastened and fixed to the armature core 14 by screws 29, so screw holes 12 are provided on the Z2 end faces of the multiple back yoke portions 25. In order to correct the warping in the X direction, screw holes 12 are provided in at least two back yoke portions 25 at both ends in the X direction and in one or two back yoke portions 25 closest to the center in the X direction. Screw holes 12 may also be provided in the other back yoke portions 25.
[0020] Recesses 11 extending in the first direction X are formed on both sides of the end of the other side Z2 in the second direction of each back yoke portion 25 in the third direction Y. When multiple linear motor armature cores 6 are lined up in the first direction X, the rectangular cross-sectional recesses 11 of the back yoke portion 25 are connected in a line.
[0021] The teeth portions 26 protruding from the back yoke portion 25 serve as winding portions 30 around which the armature winding 8 is wound. Each tooth portion 26 protrudes from each back yoke portion 25 to one side Z1 in the second direction. The Y-direction width of each tooth portion 26 is equal to the first-direction X-direction width of each back yoke portion 25. The X-direction width of each tooth portion 26 is shorter than the X-direction width of each back yoke portion 25, and each tooth portion 26 is positioned at the center of each back yoke portion 25 in the X direction. A gap is formed between two adjacent tooth portions 26 in the X direction, and the armature winding 8 is positioned in this gap.
[0022] <Insulator> The insulator 7 is inserted into each linear motor armature core 6, and the armature winding 8 is wound around it. As shown in Figure 5, the insulator 7 is made of an insulating resin material. The insulator 7 has a winding section 30 around which the armature winding 8 is wound, a first flange section 22 connected to one side Z1 in the second direction of the winding section 30, and a second flange section 23 connected to the other side Z2 in the second direction.
[0023] In this embodiment, the thickness of the first flange portion 22 in the second direction Z is thin, and the first flange portion 22 of the insulator 7 is positioned closer to one side Z1 in the second direction than the end face of one side Z1 in the second direction of the teeth portion 26.
[0024] The insulator 7 is made of an insulating material. An insulator 7 is attached to both sides of each linear motor armature core 6 in the Y direction. The cross-sectional shape of the winding portion 30 and the first flange portion 22 in the XY plane is concave, recessed on the opposite side from the teeth portion 26, and is fitted into the teeth portion 26.
[0025] <Molding Resin> As described above, the molding resin 9 fixes the multiple linear motor armature cores 6 and the multiple armature windings 8. The molding resin 9 covers one end face Z1 in the second direction of each tooth portion 26.
[0026] With this configuration, the linear motor armature core 6 is not exposed on one side Z1 in the second direction, so there is no need to apply a rust inhibitor to the linear motor armature core 6, which has the effect of reducing costs.
[0027] In this embodiment, the molded resin 9 covers both sides in the Y direction and both sides in the X direction of the multiple linear motor armature cores 6 and the multiple armature windings 8. In the Z2 of the multiple linear motor armature cores 6, the molded resin 9 is filled into the recesses 11, and the parts other than the recesses 11 are not covered by the molded resin 9 and are exposed. As will be described later, the recesses 11 of the multiple back yoke portions 25 are welded to each other, but the welded parts are covered and protected by the molded resin 9. The screw holes 12 provided on the end face of the Z2 of the back yoke portion 25 are not covered by the molded resin 9. During the manufacturing process, the upper jig 15 is attached.
[0028] 1-2. Method for Manufacturing a Linear Motor Armature Figure 6 shows a flowchart illustrating the method for manufacturing the linear motor armature 3. <Preparation Step S1> First, in preparation step S1, a plurality of linear motor armature cores 6, each having a back yoke portion 25 and a tooth portion 26 protruding from the back yoke portion 25, and a plurality of armature windings 8 wound around each of the tooth portions 26 are prepared. In this embodiment, a plurality of insulators 7 are also prepared, which are attached to the tooth portions 26, around which the armature windings 8 are wound, and which protrude to one side Z1 in the second direction. The configuration of each prepared component is as described above, so the explanation is omitted.
[0029] <Connecting Process S2> As shown in Figure 7, in connecting process S2, with each tooth portion 26 protruding from the back yoke portion 25 toward one side Z1 in the second direction, the multiple back yoke portions 25 are lined up in the first direction X perpendicular to the second direction Z and connected to each other.
[0030] At least two back yoke sections 25 at both ends in the X direction and one or two back yoke sections 25 closest to the center in the X direction are provided with screw holes 12. Other back yoke sections 25 may also be provided with screw holes 12. Back yoke sections 25 with screw holes 12 may be provided in advance, or they may be drilled after they are connected.
[0031] An engagement portion 13 is formed by aligning the recesses 11 in Z2 of multiple back yoke portions 25 so that they are connected. By welding the engagement portion 13, a connected linear motor armature core 14 is formed by fixing each linear motor armature core 6 to it. As shown in Figure 8, when the engagement portion 13 is welded, thermal shrinkage occurs, causing the connected linear motor armature core 14 to warp in the other side Z2 of the second direction.
[0032] <Fixing Process S3> As shown in Figures 9 and 10, in fixing process S3, the upper jig 15 is attached to the other side Z2 of the second direction of the multiple back yoke portions 25. When attaching, the upper jig 15a and the multiple linear motor armature cores 6 are fixed with screws 29 using the screw holes 12 provided in the connecting process.
[0033] By attaching the upper jig 15 to the other side Z2 in the second direction of multiple back yoke sections 25, the warping that occurs during welding can be corrected.
[0034] Specifically, a through hole is provided in the upper jig 15 at a position corresponding to the screw hole 12 in the back yoke portion 25, extending in the second direction Z. The upper jig 15 is then positioned on the other side Z2 of the linked linear motor armature core 14 in the second direction, and each screw 29 is inserted from the other side Z2 in the second direction into the through hole of the upper jig 15 and screwed into the screw hole 12 of the back yoke portion 25 and tightened. The tensile force of the screws 29 causes the linked linear motor armature core 14 to be tightly pressed against the upper jig 15, correcting any warping of the linked linear motor armature core 14. In this case, as described above, the screw holes 12 are provided in at least two back yoke portions 25 at both ends in the first direction X and in one or two back yoke portions 25 closest to the center in the X direction. This allows the connecting linear motor armature core 14 to be brought into close contact with the upper jig 15 over the entire length of the first direction X, thereby correcting warping.
[0035] Next, in the fixing process S3, with one side Z1 in the second direction facing vertically downward, the multiple linear motor armature cores 6 and multiple armature windings 8 are inserted into a bottomed cylindrical mold 16 that opens vertically upward, and the upper jig 15 is fixed to the mold 16 with a gap provided between the end face of one side Z1 in the second direction of each tooth portion 26 and the bottom surface of the mold 16.
[0036] In this embodiment, the mold 16 is fixed by providing a gap of a certain size not only on the bottom surface but also around the linear motor armature core 6. When fixing, the side surface of the mold 16 and both ends of the upper jig 15 are fixed with screws 31. By fixing with screws 31, the mold 16, the upper jig 15, and the multiple linear motor armature cores 6 can be fixed together.
[0037] <Molding Process S4> In molding process S4, the mold resin 9 before curing is injected into the mold 16, and then the mold resin 9 is cured.
[0038] With the portions of the back yoke 25 of multiple linear motor armature cores 6, excluding the recesses 11, exposed, the mold resin 9 is filled to a height that fills the recesses 11. After filling is complete, the mold resin 9 is heated to harden. After heating until the mold resin 9 hardens, the upper jig 15 and the mold dies 16 are removed, and the linear motor armature 3 of the present disclosure, as shown in Figures 2 to 4, is completed.
[0039] According to the above manufacturing method, each tooth portion 26 is fixed with a gap between the end face of one side Z1 in the second direction and the bottom surface of the mold 16. When the mold resin 9 before hardening is injected into the mold 16 and hardens, the mold resin 9 fills the gap, and the end face of one side Z1 in the second direction of each tooth portion 26 is covered with the mold resin 9.
[0040] Therefore, since the linear motor armature core 6 is not exposed on one side of the second direction Z, there is no need to apply a rust inhibitor to the linear motor armature core 6, which has the effect of reducing costs.
[0041] 2. Embodiment 2 The linear motor armature 3a according to Embodiment 2 will be described with reference to the drawings. The same components as in Embodiment 1 will not be described. The basic configuration of the linear motor armature 3a according to this embodiment is the same as in Embodiment 1, but the configuration of the insulator 7a is slightly different. Figure 11 is a perspective view of the linear motor armature 3a cut in the YZ plane at the same position as the II-II cross section in Figure 2. Figure 12 is a perspective view of the insulator 7a in Embodiment 2.
[0042] Similar to Embodiment 1, the mold resin 9 covers one end face Z1 in the second direction of each tooth portion 26.
[0043] <Insulator> In Embodiment 2, the insulator 7a (in this example, the first flange portion 22) protrudes toward one side Z1 in the second direction from the end surface on one side Z1 in the second direction of the teeth portion 26. The position in the second direction Z of the end surface on one side Z1 in the second direction of the molded resin 9 covering the end surface on one side Z1 in the second direction of each teeth portion 26 is the same as the position in the second direction Z of the tip portion (in this example, the end surface) on one side Z1 in the second direction of each insulator 7a. The tip portion (end surface) on one side Z1 in the second direction of each insulator 7a (first flange portion 22) is not covered with the molded resin 9 and is exposed to the outside.
[0044] According to this configuration, the thickness of the molded resin 9 covering the end surface on one side Z1 in the second direction of the teeth portion 26 can be controlled by the protruding height of the insulator 7a (first flange portion 22) on one side Z1 in the second direction, and variations can be suppressed. Variations in the position of the end surface on one side Z1 in the second direction of each linear motor armature core 6 with respect to the end surface on one side Z1 in the second direction of the linear motor armature 3a can be suppressed. Therefore, variations in the performance of the motor can be suppressed. Even if the tip portion (end surface) on one side Z1 in the second direction of each insulator 7a is exposed to the outside from the molded resin 9, each insulator 7a is formed of a resin member having insulating properties, and there is no need to apply an anti-rust agent.
[0045] As shown in FIG. 12, the thickness of the first flange portion 22 of the insulator 7a in the second direction Z is thicker than that in Embodiment 1, and the first flange portion 22 protrudes toward one side Z1 in the second direction from the end surface on one side Z1 in the second direction of the teeth portion 26. The protruding height of the insulator 7a on one side Z1 in the second direction can be adjusted by the thickness of the first flange portion 22 in the second direction Z.
[0046] A method for manufacturing the linear motor armature 3a according to this embodiment will be described. <Preparation step S1> First, in the preparation step S1, a plurality of linear motor armature cores 6 each having a back yoke portion 25 and a tooth portion 26 protruding from the back yoke portion 25, a plurality of armature windings 8 wound around each of the tooth portions 26, and a plurality of insulators 7a attached to the tooth portions 26 around which the armature windings 8 are wound and protruding in one side Z1 in the second direction from the end face on one side Z1 in the second direction of the tooth portion 26 are prepared.
[0047] <Connection step S2> In the connection step S2, with each tooth portion 26 protruding from the back yoke portion 25 in one side Z1 in the second direction, the plurality of back yoke portions 25 are arranged in the first direction X orthogonal to the second direction Z and connected to each other.
[0048] In this embodiment, different from the first embodiment, no screw hole 12 is provided in the back yoke portion 25. Since the rest is the same as the first embodiment, the description is omitted.
[0049] <Fixing step S3> As shown in FIGS. 13 and 14, in the fixing step S3, with one side Z1 in the second direction facing vertically downward, the plurality of linear motor armature cores 6, the plurality of armature windings 8, and the plurality of insulators 7a are inserted into a bottomed cylindrical mold 16 having an opening on the vertically upper side, and the plurality of back yoke portions 25 are pressed and fixed in one side Z1 in the second direction by the upper jig 15a so that the end face on one side Z1 in the second direction of each insulator 7a (first flange portion 22) abuts against the bottom surface of the mold 16.
[0050] According to this configuration, different from the first embodiment, there is no need to cut a screw hole 12 for attaching the upper jig 15a to the linear motor armature core 6 before molding, and it is possible to suppress metal chips during the machining of the screw hole 12 from being mixed into the product and the insulation performance from deteriorating.
[0051] Since the end faces of each insulator 7a (first flange portion 22) that protrude further in the second direction Z1 than the end face of the tooth portion 26 in the second direction Z1 are in contact with the bottom surface of the mold 16, a gap is created between the bottom surface of the mold 16 and the end face of the tooth portion 26 in the second direction Z1.
[0052] In Embodiment 2, the pressing jig 19 is used as a means to correct the warping of the linear motor armature core 6. After placing the pressing jig 19 on the connected linear motor armature core 14, the upper jig 15a is fixed to the mold dies 16 above it with screws 31. The upper jig 15a has a plurality of screw holes 32 that penetrate in the second direction Z. The plurality of screw holes 32 are provided at positions corresponding to the two back yoke portions 25 at both ends in the first direction X and the one or two back yoke portions 25 closest to the center in the X direction. Multiple screws 29 are screwed into each screw hole 32 of the upper jig 15a from top to bottom, and the plurality of screws 29 press the pressing jig 19 and the linear motor armature core 6 downward against the upper jig 15a.
[0053] <Molding Process S4> In molding process S4, the mold resin 9 before curing is injected into the mold 16, and then the mold resin 9 is cured.
[0054] With the portions of the back yoke 25 of multiple linear motor armature cores 6, excluding the recesses 11, exposed, the mold resin 9 is filled to a height that fills the recesses 11. After filling is complete, the mold resin 9 is heated to harden. After heating until the mold resin 9 hardens, the upper jig 15a and the mold dies 16 are removed, and the linear motor armature 3a of the present disclosure, as shown in Figure 11, is completed.
[0055] According to the above manufacturing method, the end faces of each insulator 7a (first flange portion 22) that protrude further in the second direction Z1 than the end face of the tooth portion 26 in the second direction Z1 are in contact with the bottom surface of the mold 16, and a gap is provided between the bottom surface of the mold 16 and the end faces of the tooth portion 26 in the second direction Z1. When the mold resin 9 is injected into the mold 16 before curing and cured, the gap is filled with the mold resin 9, and the end faces of each tooth portion 26 in the second direction Z1 are covered with the mold resin 9. Therefore, the linear motor armature core 6 is not exposed on the second direction Z1, and there is no need to apply a rust inhibitor to the linear motor armature core 6, which has the effect of reducing costs.
[0056] Furthermore, the thickness of the molded resin 9 covering the end face of the tooth portion 26 on one side Z1 in the second direction can be controlled by the protrusion height of one side Z1 in the second direction of the insulator 7a (first flange portion 22), thereby suppressing variations. Therefore, variations in the position of the end face of one side Z1 in the second direction of each linear motor armature core 6 relative to the end face of one side Z1 in the second direction of the linear motor armature 3a can be suppressed. This suppresses variations in motor performance. Note that even if the tip (end face) of one side Z1 in the second direction of each insulator 7a is exposed to the outside from the molded resin 9, each insulator 7a is formed of an insulating resin material, so there is no need to apply a rust inhibitor.
[0057] 3. Embodiment 3 The linear motor armature 3b according to Embodiment 3 will be described with reference to the drawings. The same components as in Embodiment 2 will not be described. The basic configuration of the linear motor armature 3b according to this embodiment is the same as in Embodiment 2, but the structure of the insulator 7b is slightly different. Figure 15 is a perspective view of the linear motor armature 3b cut in the YZ plane at the same cross-sectional position as the II-II cross-sectional position in Figure 2. Figure 16 is a perspective view of the insulator 7b in Embodiment 3, and Figure 17 is a side view of the insulator 7b in Embodiment 3.
[0058] Similar to Embodiment 2, the insulator 7b (first flange portion 22) protrudes further in the second direction Z1 than the end face of the tooth portion 26 in the second direction Z1. The position in the second direction Z of the end face of the molded resin 9 covering the end face of the tooth portion 26 in the second direction Z1 is equivalent to the position in the second direction Z of the tip portion of the insulator 7b in the second direction Z1 (in this example, the top of the taper). The tip portion of the insulator 7b in the second direction Z1 (the top of the taper) is not covered by the molded resin 9 and is exposed to the outside.
[0059] In the third embodiment, the end of one side Z1 in the second direction of the insulator 7b (first flange portion 22 in this example) is formed in a tapered shape 27, where the protruding height of one side Z1 in the second direction increases as it approaches the center in the first direction X.
[0060] With this configuration, as will be described later, when the end of one side Z1 in the second direction of the insulator 7b (first flange portion 22) is pressed against a plane to correct the warping of the connecting linear motor armature core 14, one of the two inclined surfaces of one side Z1 in the second direction of the insulator 7b (first flange portion 22) comes into contact with the plane, increasing the contact surface area. This allows the pressing force applied to each insulator 7b to be distributed, thereby suppressing deformation and a decrease in rigidity of the insulator 7b.
[0061] Unlike Embodiment 2, the insulator 7b prepared in preparation step S1 has a tapered shape 27 at one end Z1 in the second direction of the insulator 7b (first flange portion 22), where the protruding height of one end Z1 in the second direction increases as it approaches the center in the first direction X.
[0062] Embodiment 2 differs in how stress is applied to the insulator 7b when the screw 29 presses the pressing jig 19 and the linear motor armature core 6 downward against the upper jig 15a during the fixing process S3. Figure 18 shows the state at the start of pressing by the screw 29 and the pressing jig 19. During the connection process, the linear motor armature core 14 connected by welding is warped. One side of the two inclined surfaces 33 on one side Z1 of the two central insulators 7b1 and 7b2 in the first direction X contacts the bottom surface of the mold 16, increasing the contact surface area and thus distributing the pressing force applied to each insulator 7b1 and 7b2. Therefore, for example, the stress on the corners 20 of each insulator 7b1 and 7b2 that contact the linear motor armature core 6 is reduced, and deformation and rigidity reduction of the insulator 7b can be suppressed. The corner 20 is the corner 20 on the linear motor armature core 6 side (inner side) at the connection point between the winding section 30 and the first flange section 22.
[0063] 4. Embodiment 4 The linear motor armature 3c according to Embodiment 4 will be described with reference to the drawings. The same components as in Embodiment 1 will not be described. The basic configuration of the linear motor armature 3c according to this embodiment is the same as in Embodiment 2, but the structure of the insulator 7c is slightly different. Figure 19 is a perspective view of the linear motor armature 3c cut in the YZ plane at the same cross-sectional position as the II-II cross-sectional position in Figure 2. Figure 20 is a perspective view of the insulator 7c in Embodiment 4.
[0064] Similar to Embodiment 2, the insulator 7c protrudes further in the second direction Z1 than the end face of the tooth portion 26 in the second direction Z1. The position in the second direction Z of the end face of the molded resin 9 covering the end face of the tooth portion 26 in the second direction Z1 is equivalent to the position in the second direction Z of the tip portion (end face in this example) of the insulator 7c in the second direction Z1. The tip portion (end face) of the insulator 7c in the second direction Z1 is not covered by the molded resin 9 and is exposed to the outside.
[0065] Unlike Embodiment 2, the insulator 7c (first flange portion 22 in this example) has a rounded structure at the corners 34 facing the corners on both sides of the first direction X of the teeth portion 26.
[0066] With this configuration, as will be described later, when the end of one side Z1 in the second direction of the insulator 7c (first flange portion 22) is pressed against a plane to correct the warping of the connecting linear motor armature core 14, stress concentration can be alleviated and deformation and reduction in rigidity of the insulator 7c can be suppressed.
[0067] Unlike Embodiment 2, the insulator 7c (first flange portion 22) prepared in preparation step S1 has a rounded structure at the corners on both sides of the first direction X of the teeth portion 26 and the corner 34 facing it.
[0068] As described in Embodiment 3, in the fixing step S3, when the screw 29 presses the pressing jig 19 and the linear motor armature core 6 downward against the upper jig 15a, a pressing force is applied to one end Z1 of the insulator 7c (first flange portion 22) in the second direction. The insulator 7c (first flange portion 22) according to Embodiment 4 has a structure with rounded corners 34, which reduces stress concentration and suppresses deformation and reduction in rigidity of the insulator 7c.
[0069] 5. Embodiment 5 The linear motor armature 3d according to Embodiment 5 will be described with reference to the drawings. The same components as in Embodiment 2 will not be described. The basic configuration of the linear motor armature 3d according to this embodiment is the same as in Embodiment 2, but the structure of the insulator 7d is slightly different. Figure 21 is a perspective view of the linear motor armature 3d cut in the YZ plane at the same cross-sectional position as the II-II cross-sectional position in Figure 2. Figure 22 is a perspective view of the insulator 7d in Embodiment 5, and Figure 23 is a side view of the insulator 7d in Embodiment 5. Figure 24 is a side view of a modified example of the insulator 7d in Embodiment 5.
[0070] Similar to Embodiment 2, the insulator 7d has a winding portion 30 and a first flange portion 22 connected to one side Z1 in the second direction of the winding portion 30. Unlike Embodiment 2, the connection portion between the winding portion 30 and the first flange portion 22 has a rib structure 21 with increased thickness on the outside.
[0071] With this configuration, as will be described later, when the end of one side Z1 of the insulator 7d in the second direction is pressed against a plane to correct the warping of the connecting linear motor armature core 14, the rib structure 21 is provided on the opposite side of the corner 20 to suppress the stress on the corner 20 of each insulator 7b1, 7b2 that contacts the linear motor armature core 6. This suppresses deformation and reduction in rigidity of the corner 20.
[0072] Unlike Embodiment 2, the insulator 7d prepared in preparation step S1 has a rib structure 21 with increased thickness on the outside at the connection between the winding portion 30 and the first flange portion 22.
[0073] As described in Embodiment 3, in the fixing step S3, when the screw 29 presses the pressing jig 19 and the linear motor armature core 6 downward against the upper jig 15a, a pressing force is applied to one end Z1 of the insulator 7d in the second direction. This pressing force applies stress to the corners 20 of each insulator 7b1 and 7b2 that are in contact with the linear motor armature core 6. Since a rib structure 21 is provided on the opposite side of the corners 20, deformation and rigidity reduction of the corners 20 can be suppressed.
[0074] 6. Embodiment 6 The linear motor armature 3g according to Embodiment 6 will be described with reference to the drawings. The same components as in Embodiment 2 will not be described. The basic configuration of the linear motor armature 3g according to this embodiment is the same as in Embodiment 2, but the configuration of the insulator 7g is slightly different. Figure 33 is a perspective view of the linear motor armature 3g cut in the YZ plane at the same cross-sectional position as the II-II cross-sectional position in Figure 2. Figure 34 is a perspective view of the insulator 7g in Embodiment 6.
[0075] Unlike Embodiment 2, the portion of the insulator 7g that protrudes further toward one side Z1 in the second direction than the end face of one side Z1 in the second direction of the teeth portion 26 has a bottom portion 35 that partially covers the end face of one side Z1 in the second direction of the teeth portion 26.
[0076] Similar to Embodiment 2, the insulator 7g has a winding portion 30 and a first flange portion 22 connected to one side Z1 in the second direction of the winding portion 30. Unlike Embodiment 2, the first flange portion 22 has a bottom portion 35 that covers one or the other end in the first direction X at the end face of the tooth portion 26 on one side Z1 in the second direction.
[0077] With this configuration, as will be described later, when the end of one side Z1 of the insulator 7g in the second direction is pressed against a plane to correct the warping of the connecting linear motor armature core 14, stress concentration can be alleviated and deformation and reduction in rigidity of the insulator 7g can be suppressed.
[0078] Unlike Embodiment 2, in the insulator 7g prepared in preparation step S1, the portion of the insulator 7g that protrudes further in the second direction Z1 than the end face of the tooth portion 26 in the second direction Z1 has a bottom portion 35 that partially covers the end face of the tooth portion 26 in the second direction Z1.
[0079] As described in Embodiment 3, in the fixing step S3, when the screw 29 presses the pressing jig 19 and the linear motor armature core 6 downward against the upper jig 15a, a pressing force is applied to one end of the insulator 7g in the second direction Z1. The insulator 7g according to Embodiment 6 has a structure in which a bottom portion 35 is provided on one side Z1 in the second direction, thereby mitigating stress concentration and suppressing deformation and reduction in rigidity of the insulator 7g.
[0080] 7. Embodiment 7 The linear motor armature 3e according to Embodiment 7 will be described with reference to the drawings. The same components as in Embodiment 2 described above will be omitted from the description. The basic configuration of the linear motor armature 3e according to this embodiment is the same as in Embodiment 1, but the structure of the insulator 7e is slightly different. Figure 25 is a perspective view of the linear motor armature 3e cut in the YZ plane at the same cross-sectional position as the II-II cross-sectional position in Figure 2. Figure 26 is a perspective view of the linear motor armature, upper jig, and mold (partially cut) after the fixing process. Figure 27 is a perspective view showing the configuration of the insulator 7e according to Embodiment 7. Figure 28 is a perspective view showing the configuration of the insulator 7e according to Embodiment 7. Figure 29 is a perspective view showing the configuration of the insulator 7e according to Embodiment 7. Figure 35 is a perspective view of the insulator according to a modified example of Embodiment 7. Figure 36 is a perspective view of the insulator according to a modified example of Embodiment 7.
[0081] Similar to Embodiment 2, the insulator 7e protrudes further in the second direction Z1 than the end face of the tooth portion 26 in the second direction Z1. The position in the second direction Z of the end face of the molded resin 9 covering the end face of the tooth portion 26 in the second direction Z1 is equivalent to the position in the second direction Z of the tip of the insulator 7e in the second direction Z1 (in this example, the tip surface excluding the groove 24 described later). The tip (tip surface) of the insulator 7e in the second direction Z1 is not covered by the molded resin 9 and is exposed to the outside.
[0082] The insulator 7e (first flange portion 22 in this example) has a groove 24 formed on one side Z1 in the second direction, connecting the end face side of the teeth portion 26 on one side Z1 in the second direction to the opposite end face, and molded resin 9 is provided in the groove 24.
[0083] This configuration allows for the creation of a groove 24 between the insulator 7e and the bottom surface of the mold 16, thereby increasing the area of the inflow path for the mold resin 9. This shortens the time required to fill the mold resin 9, resulting in cost reduction. Furthermore, even when using mold resin 9 containing fillers with high thermal conductivity and viscosity, the mold resin 9 can be filled smoothly. Using mold resin 9 containing fillers with high thermal conductivity and viscosity also improves heat dissipation.
[0084] In this embodiment, a groove 24 is formed on one side Z1 of the first flange portion 22 in the second direction, penetrating in the third direction Y. As shown in Figure 27, a groove 24 with a rectangular cross-sectional shape and penetrating in the third direction Y is formed in the center of the first direction X on one side Z1 of the first flange portion 22 in the second direction. As shown in Figure 28, the cross-sectional shape of the groove 24 may be semicircular. Furthermore, as shown in Figure 29, two or more grooves 24 may be provided. Also, as shown in Figure 35, the groove 24 may be provided with a rectangular cross-sectional shape at both ends of the first direction X on one side Z1 of the first flange portion 22 in the second direction. Furthermore, as shown in Figure 36, the groove 24 may be provided with an R shape (semicircular shape) at both ends of the first direction X on one side Z1 of the first flange portion 22 in the second direction. The grooves 24 at both ends in the first direction X shown in Figures 35 and 36 can also be referred to as the notches 40 at the ends in the first direction, which will be described later in Embodiments 9 and 10.
[0085] Unlike Embodiment 2, the insulator 7e prepared in preparation step S1 has a groove 24 formed on one side Z1 in the second direction of the insulator 7e (first flange portion 22), connecting the end face side of one side Z1 in the second direction of the teeth portion 26 to the opposite side of the end face.
[0086] In this embodiment, during the fixing process S3, when the end face of one side Z1 in the second direction of each insulator 7e comes into contact with the bottom surface of the mold 16 due to the pressing force, a groove 24 is formed between the insulator 7e and the bottom surface of the mold 16, connecting the end face side and the opposite side of the end face of one side Z1 in the second direction of the teeth portion 26.
[0087] Then, in the molding process S4, the mold resin 9 can be injected through the groove 24 into the end face side of the second direction Z1 of the teeth portion 26 from the opposite side of the end face. Therefore, the area of the inflow path for the mold resin 9 can be increased. The time required to fill the mold resin 9 is shortened, which has the effect of reducing costs. Furthermore, even when using a mold resin 9 containing fillers with high thermal conductivity and viscosity, the mold resin 9 can be filled smoothly. When using a mold resin 9 containing fillers with high thermal conductivity and viscosity, it has the effect of improving heat dissipation.
[0088] 8. Embodiment 8 The linear motor armature 3h according to Embodiment 8 will be described with reference to the drawings. The same components as in Embodiment 2 described above will be omitted from the description. The basic configuration of the linear motor armature 3h according to this embodiment is the same as in Embodiment 1, but the configuration of the insulator 7h is slightly different. Figure 37 is a perspective view of the linear motor armature 3h cut in the YZ plane at the same cross-sectional position as the II-II cross-sectional position in Figure 2. Figure 38 is a perspective view of the insulator 7h in Embodiment 8. Figure 39 is a perspective view of the insulator 7h in Embodiment 8. Figure 40 is a perspective view of the insulator 7h in Embodiment 8.
[0089] Similar to Embodiment 2, the insulator 7h has a winding portion 30 and a first flange portion 22 connected to one side Z1 in the second direction of the winding portion 30. Unlike Embodiment 2, the first flange portion 22 has a notch 36 (a notch at the opposite end) at the end on one side Z1 in the second direction, opposite to the linear motor armature core 6, and molded resin 9 is provided in the notch 36 at the opposite end. Furthermore, as shown in Figure 40, as in Embodiment 7, the first flange portion 22 may further have a groove 24 (in this example, notches on both sides in the first direction X) penetrating in the third direction Y at the portion on one side Z1 in the second direction.
[0090] With this configuration, even if the other side Z2 of the insulator 7h in the second direction tilts to the opposite side of the linear motor armature core 6 due to the force of the winding during the winding process S1, the notch 36 at the opposite end can be provided during the fixing process S3 to prevent the end on the opposite side Z1 of the first flange portion 22, which is opposite to the linear motor armature core 6, from protruding to the opposite side Z1 of the second direction. This suppresses fluctuations in the distance of the gap between the bottom surface of the mold 16 and the end face of the tooth portion 26 on the opposite side Z1 of the second direction, and reduces variations in the position of the end face on the opposite side of the second direction of each linear motor armature core 6 relative to the end face on the opposite side of the linear motor armature 3, thus having the effect of suppressing variations in motor performance.
[0091] Unlike Embodiment 2, in the insulator 7h prepared in preparation step S1, the first flange portion 22 has a notch 36 at the opposite end on one side Z1 in the second direction, which is the end opposite to the linear motor armature core 6. With this configuration, even if the other side Z2 of the insulator 7h in the second direction tilts to the opposite side of the linear motor armature core 6 due to the force of the winding during winding, fluctuations in the distance of the gap between the bottom surface of the mold 16 and the end surface of one side Z1 in the second direction of the teeth portion 26 can be suppressed during the fixing step S3.
[0092] In this embodiment, in the fixing process S3, when the end face Z1 on one side in the second direction of each insulator 7h is brought into contact with the bottom surface of the mold 16 by the pressing force, the variation in the position of the end face on one side in the second direction of each linear motor armature core 6 relative to the end face on one side in the second direction of the linear motor armature 3 can be suppressed, thus having the effect of suppressing variations in motor performance.
[0093] 9. Embodiment 9 The linear motor armature 3i according to Embodiment 9 will be described with reference to the drawings. The same components as in Embodiment 2 described above will be omitted from the description. The basic configuration of the linear motor armature 3i according to this embodiment is the same as in Embodiment 1, but the configuration of the insulator 7i is slightly different. Figure 41 is a perspective view of the linear motor armature 3i cut in the YZ plane at the same cross-sectional position as the II-II cross-sectional position in Figure 2. Figure 42 is a perspective view of the insulator 7i in Embodiment 9. Figure 43 is a side view of the insulator 7i in Embodiment 9.
[0094] Similar to Embodiment 2, the insulator 7i has a winding portion 30 and a first flange portion 22 connected to one side Z1 in the second direction of the winding portion 30. Also, similar to Embodiment 8, the first flange portion 22 has a notch 36 (also referred to as the notch at the opposite end) at the end on one side Z1 in the second direction, opposite to the linear motor armature core 6, and molded resin 9 is provided in the notch 36 at the opposite end. Unlike Embodiment 8, the portion of the first flange portion 22 with the notch 36 at the opposite end has a rib structure 37 in which the thickness in the second direction Z increases as it approaches the linear motor armature core 6 in the third direction Y.
[0095] With this configuration, even if the other side Z2 of the insulator 7i in the second direction tilts to the opposite side of the linear motor armature core 6 due to the force of the winding during the winding process S1, the notch 36 at the opposite end can be provided during the fixing process S3 to prevent the end of the first flange portion 22 on the opposite side Z1 in the second direction from protruding to the opposite side Z1 in the second direction. This suppresses fluctuations in the distance of the gap between the bottom surface of the mold 16 and the end face of the tooth portion 26 on the opposite side Z1 in the second direction, and reduces variations in the position of the end face of the opposite side Z1 in the second direction of each linear motor armature core 6 relative to the end face of the linear motor armature 3 on the opposite side Z1, thus having the effect of suppressing variations in motor performance.
[0096] The rib structure 37 has the smallest thickness in the second direction Z at the tip 38 opposite to the linear motor armature core 6 in the third direction Y, so that when the insulator 7i is tilted, the first flange portion 22 does not protrude to one side Z1 in the second direction.
[0097] Furthermore, by providing the rib structure 37, the strength of the portion with the notch 36 at the opposite end is increased and stress concentration is reduced, thereby preventing the insulator 7i from being destroyed by the force of the winding during the winding process S1 and reducing its insulating properties.
[0098] Furthermore, similar to Figure 35 of Embodiment 7, the first flange portion 22 has notches 40 (also referred to as notches 40 at the first direction end) at both ends in the first direction X on the surface of one side Z1 in the second direction.
[0099] This configuration prevents both ends of the first direction X on the surface of one side Z1 in the second direction of the first flange portion 22 from protruding to one side Z1 in the second direction due to the force of the winding during the winding process S1. This suppresses fluctuations in the distance of the gap between the bottom surface of the mold 16 and the end face of one side Z1 in the second direction of the teeth portion 26. This suppresses positional variations of the end face of one side Z1 in the second direction of each linear motor armature core 6 relative to the end face of one side Z1 in the second direction of the linear motor armature 3, thus having the effect of suppressing variations in motor performance. Note that the notch 40 at the end in the first direction does not need to be provided.
[0100] 10. Embodiment 10 The linear motor armature 3j according to Embodiment 10 will be described with reference to the drawings. The same components as in Embodiment 2 described above will be omitted from the description. The basic configuration of the linear motor armature 3j according to this embodiment is the same as in Embodiment 1, but the configuration of the insulator 7j is slightly different. Figure 44 is a perspective view of the insulator 7j in Embodiment 10. Figure 45 is a side view of the insulator 7j in Embodiment 10.
[0101] Similar to Embodiment 2, the insulator 7j has a winding portion 30 and a first flange portion 22 connected to one side Z1 in the second direction of the winding portion 30. Also, similar to Embodiment 9 and Embodiment 7 (Figure 35), the first flange portion 22 has notches 40 (also referred to as first-direction end notches 40) at both ends in the first direction X on the surface of one side Z1 in the second direction. Molded resin 9 is provided in each first-direction end notch 40. Unlike Embodiment 9 and Embodiment 7 (Figure 35), the portion of the first flange portion 22 where each first-direction end notch 40 is provided has a rib structure 39 in which the thickness in the second direction Z increases as it approaches the center of the first flange portion 22 in the first direction X. Also, similar to Embodiment 9, a notch 36 and its rib structure 37 are provided at the opposite end.
[0102] This configuration prevents both ends of the first direction X on the surface of one side Z1 in the second direction of the first flange portion 22 from protruding to one side Z1 in the second direction due to the force of the winding during winding in the preparation process S1. This suppresses fluctuations in the distance of the gap between the bottom surface of the mold 16 and the end face of one side Z1 in the second direction of the teeth portion 26. This suppresses positional variations of the end face of one side Z1 in the second direction of each linear motor armature core 6 relative to the end face of one side Z1 in the second direction of the linear motor armature 3, thus having the effect of suppressing variations in motor performance.
[0103] Furthermore, by providing the rib structure 39, the strength of the portion with the notch 40 at the first direction end is increased and stress concentration is reduced, thereby preventing the insulator 7j from being destroyed by the winding force during winding in the preparation process S1 and reducing its insulating properties.
[0104] 11. Embodiment 11 The linear motor armature 3f according to Embodiment 11 will be described with reference to the drawings. The same components as in Embodiment 2 described above will be omitted from the description. The basic configuration of the linear motor armature 3f according to this embodiment is the same as in Embodiment 1, but the structure of the linear motor armature 3f is slightly different. Figure 30 is a perspective view of the linear motor armature 3f cut in the YZ plane at the same cross-sectional position as the II-II cross-sectional position in Figure 2. Figure 31 is a cross-sectional view of the linear motor armature, upper jig, and mold cut in the XZ plane at the same cross-sectional position as the III-III cross-sectional position in Figure 9, for explaining the fixing process.
[0105] Similar to Embodiment 2, the insulator 7f (first flange portion 22 in this example) prepared in preparation step S1 protrudes more from one side Z1 in the second direction than the end face of one side Z1 in the second direction of the teeth portion 26.
[0106] In this embodiment, the projection height of the insulator 7f (first flange portion 22) toward one side Z1 in the second direction relative to the end face of one side Z1 in the second direction of the teeth portion 26 is higher than in Embodiment 2.
[0107] Similar to Embodiment 2, in the fixing step S3, with one side Z1 in the second direction facing vertically downward, a plurality of linear motor armature cores 6, a plurality of armature windings 8, and a plurality of insulators 7f are inserted into a bottomed cylindrical mold 16 that opens vertically upward, and the upper jig 15a presses and fixes the plurality of back yoke portions 25 to one side Z1 in the second direction so that the end face of one side Z1 in the second direction of each insulator 7f contacts the bottom surface of the mold 16.
[0108] Since the projection height of the insulator 7f (first flange portion 22) toward one side Z1 in the second direction is higher than in Embodiment 2, the width of the gap between the end face of one side Z1 in the second direction of each tooth portion 26 and the bottom surface of the mold 16 is increased. Therefore, it is easier to fill with mold resin 9.
[0109] Similar to Embodiment 2, in the molding process S4, the uncured molding resin 9 is injected into the mold 16, and then the molding resin 9 is cured.
[0110] In this embodiment, as shown in the flowchart of Figure 32, a cutting process S5 is provided after the molding process S4. In the cutting process S5, the end face of one side Z1 in the second direction of the linear motor armature 3f removed from the mold 16 is cut so that the end face of one side Z1 in the second direction of each tooth portion 26 is covered with mold resin 9 of a set thickness.
[0111] In this cutting process S5, as shown in Figure 30, the insulator 7f (first flange portion 22) and molded resin 9 that constitute the end face of one side Z1 in the second direction of the linear motor armature 3f are cut until the thickness of the molded resin 9 covering the end face of one side Z1 in the second direction of each tooth portion 26 reaches the set thickness. Therefore, the thickness of the molded resin 9 can be controlled to the set thickness by cutting, and variations can be suppressed. Thus, variations in the position of the end face of one side Z1 in the second direction of each linear motor armature core 6 relative to the end face of one side Z1 in the second direction of the linear motor armature 3f can be suppressed. Variations in motor performance can be suppressed. After cutting, the end face of one side Z1 in the second direction of each insulator 7f (first flange portion 22) is exposed to the outside from the molded resin 9, but each insulator 7f is formed of an insulating resin material, so there is no need to apply a rust inhibitor.
[0112] <Other Embodiments> The configurations of the insulators 7a to 7f, 7h, 7i, and 7j described in embodiments 2 to 10 above may be combined. That is, in embodiments 2 to 7, the insulator 7 may be provided with any two or more of the following: a tapered shape, a rounded corner structure, a rib structure, a bottom 35, a notch 36 at the opposite end, and a notch 40 at the first direction end. Also, in embodiment 11, the insulator 7 on one side Z1 in the second direction, which is cut, may be provided with any two or more of the following: a tapered shape, a rounded corner structure, a rib structure, a bottom 35, a notch 36 at the opposite end, and a notch 40 at the first direction end.
[0113] While this disclosure describes various exemplary embodiments and examples, the various features, aspects, and functions described in one or more embodiments are not limited to the application of a particular embodiment, but are applicable individually or in various combinations to the embodiments. Accordingly, countless variations not illustrated are envisioned within the scope of the art disclosed in this disclosure. For example, these include modifying, adding or omitting at least one component, or extracting at least one component and combining it with a component from another embodiment.
[0114] 1 Linear motor, 2 Field, 3, 3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i Linear motor armature, 4 Stator yoke, 5 Permanent magnet, 6 Linear motor armature core, 7, 7a, 7b, 7b1, 7b2, 7c, 7d, 7e, 7f, 7g, 7h, 7i Insulator, 8 Armature winding, 9 Molded resin, 11 Recess, 12 Screw hole, 13 Engaging part, 14 Connecting linear motor armature core, 15, 15a Upper jig, 16 Molding mold, 19 Pressing jig, 20 Corner (of insulator), 21 Rib structure, 22 First flange, 23 Second flange, 24 Groove (of insulator), 25 Back yoke, 26 Teeth, 27 Tapered shape, 29 Screw, 30 31 Winding section, 32 Screw hole, 33 Inclined surface, 34 Corner section, 35 Bottom section, 36 Notch at the opposite end, 37 Rib structure, 38 Tip section, 39 Rib structure, 40 Notch at the first direction end
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; a plurality of insulators attached to the tooth portions and around which the armature windings are wound; and a molded resin for fixing the plurality of armature cores, the plurality of armature windings, and the plurality of insulators, wherein the plurality of back yoke portions are arranged in a first direction and in contact with each other; each tooth portion protrudes from the back yoke portion to one side in a second direction perpendicular to the first direction; each insulator protrudes to one side in the second direction beyond the end face of the tooth portion on one side in the second direction; and the end face of each tooth portion on one side in the second direction is covered by the molded resin.
2. The linear motor armature according to claim 1, wherein the position in the second direction of the end face in the second direction of the mold resin covering one end face in the second direction of each tooth portion is equivalent to the position in the second direction of the tip portion in the second direction of each insulator.
3. The linear motor armature according to claim 1, wherein one end of each insulator in the second direction is tapered, such that the protruding height on one side in the second direction increases as it approaches the center in the first direction.
4. The linear motor armature according to any one of claims 1 to 3, wherein the insulator has a structure in which the corners on both sides of the teeth portion in the first direction and the corners facing it are rounded.
5. The linear motor armature according to any one of claims 1 to 4, wherein the insulator has a winding portion and a first flange portion connected to one side of the winding portion in the second direction, and the connection portion between the winding portion and the first flange portion has a rib structure with increased thickness.
6. The portion of the insulator that protrudes to one side in the second direction beyond the end face of the teeth portion on one side in the second direction has a bottom portion that partially covers the end face of the teeth portion on one side in the second direction, according to any one of claims 1 to 5.
7. A linear motor armature according to any one of claims 1 to 6, wherein a groove is formed on one side of the insulator in the second direction, connecting the end face side of the teeth portion in the second direction with the opposite end face, and the mold resin is provided in the groove.
8. The linear motor armature according to any one of claims 1 to 7, wherein the insulator has a notch at the opposite end on one side in the second direction that is opposite to the armature core, and the molded resin is provided in the notch at the opposite end.
9. The linear motor armature according to claim 8, wherein the portion of the insulator having a notch at the opposite end has a rib structure in which the thickness in the second direction increases as it approaches the armature core.
10. The linear motor armature according to any one of claims 1 to 9, wherein the insulator has notches at both ends in the first direction on one side surface in the second direction, and the molded resin is provided in each of the notches at the first direction ends.
11. The linear motor armature according to claim 10, wherein the portion of the insulator having a notch at each of the first direction ends has a rib structure in which the thickness in the second direction increases as it approaches the center of the insulator in the first direction.
12. A linear motor comprising: a linear motor armature according to any one of claims 1 to 11; 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.
13. A method for manufacturing a linear motor armature, comprising: a preparation step of preparing a plurality of armature cores, each having a back yoke portion and a tooth portion protruding from the back yoke portion, and a plurality of armature windings wound around each of the tooth portions; a connection step of arranging the plurality of back yoke portions in a first direction perpendicular to the second direction and connecting them to each other, with each tooth portion protruding from the back yoke portion to one side in a second direction; a fixing step of attaching an upper jig to the other side of the plurality of back yoke portions in the second direction, with one side in the second direction facing vertically downward, inserting the plurality of armature cores and the plurality of armature windings into a bottomed cylindrical mold opening vertically upward, and fixing the upper jig to the mold with a gap provided between the end face of each tooth portion on one side in the second direction and the bottom surface of the mold; and a molding step of injecting mold resin before hardening into the mold and then hardening the mold resin.
14. Preparation steps include: preparing a plurality of armature cores, each having a back yoke portion and a tooth portion protruding from the back yoke portion; a plurality of insulators protruding to one side in the second direction beyond the end face of the tooth portion on one side in the second direction; and a plurality of armature windings wound around each of the tooth portions via the insulators; connecting steps include: arranging the plurality of back yoke portions in a first direction perpendicular to the second direction, with each tooth portion protruding to one side in the second direction from the back yoke portion, and connecting them to each other; inserting the plurality of armature cores, the plurality of armature windings, and the plurality of insulators into a bottomed cylindrical mold with an opening on the vertically upward side, with one side in the second direction facing vertically downward, and fixing the plurality of back yoke portions by pressing them to one side in the second direction with an upper jig so that the end face of each insulator on one side in the second direction abuts against the bottom surface of the mold; A method for manufacturing a linear motor armature, comprising: a molding step of injecting a mold resin before curing into the mold; and curing the mold resin.
15. The method for manufacturing a linear motor armature according to claim 14, further comprising a cutting step of cutting the end face on one side in the second direction of the linear motor armature removed from the mold, such that the end face on one side in the second direction of each tooth portion is covered with the mold resin of a set thickness.
16. The method for manufacturing a linear motor armature according to any one of claims 13 to 15, wherein in the coupling step, the ends of the multiple back yoke portions on the other side in the second direction are welded to one another.