Armature module and linear motor

Abstract

An armature module (2A) comprises: an iron core (3) having a core back (30) and a plurality of teeth (31) extending from the core back (30) toward a field (1); an insulator (4) provided in the iron core (3); a coil (5) wound around the teeth (31) with the insulator (4) therebetween; and a resin mold (6) for sealing the periphery of the core back (30) and the teeth (31). The core back (30) is configured such that, of two end surfaces (30b) along the direction of travel of the armature (2), at least a portion of each end surface (30b) is exposed from the resin mold (6) and becomes the outermost surface in the direction of travel. Resin surfaces (61) of the part of the resin mold (6) that seal the coil (5), being both end surfaces of the resin mold (6) along the direction of travel of the armature (2), each have at least a portion that is positioned closer to the coil (5) than the end surface (30b) of the core back (30) exposed in the direction of travel of the armature (2).

Description

Armature module and linear motor

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

[0002] Conventionally, an armature is known that is arranged to face a field magnet across an air gap and is movable relative to the field magnet. For example, the armature of a linear motor disclosed in Patent Document 1 has a configuration in which a plurality of armature blocks arranged along the traveling direction are interconnected. Each armature block is composed of an armature core and an armature coil. Both end faces of the armature core along the traveling direction of the armature are entirely exposed including the teeth portions. When connecting adjacent armature blocks, the exposed end faces of the armature cores are butted against each other, and a positioning convex portion formed on the teeth of one armature core is fitted into a positioning recess formed on the teeth of the other armature core.

[0003] Japanese Unexamined Patent Application Publication No. 2004-23954

[0004] In general, mass-produced iron cores for motors are manufactured by punching electromagnetic steel sheets with a press, and residual press stress remains around the outer peripheral contour, which degrades magnetic properties and increases magnetic resistance. In the technique disclosed in Patent Document 1, the entire end faces of the armature cores that have magnetically deteriorated and increased magnetic resistance are joined to each other via concave and convex portions, so the magnetically deteriorated region through which magnetic flux passes becomes large, which may cause deterioration of motor characteristics such as reduction of motor thrust, increase of cogging thrust, and iron loss due to increased eddy current.

[0005] The present disclosure has been made in view of the above, and an object thereof is to obtain an armature module capable of suppressing deterioration of motor characteristics.

[0006] To solve the above-mentioned problems and achieve the objective, the armature module according to the present disclosure is an armature module that is mounted on a mounting site and arranged facing the field with an air gap between them, and constitutes an armature that is movable relative to the field, comprising: an iron core having a core back extending in the direction of travel and a plurality of teeth arranged in parallel along the direction of travel and extending from the core back toward the field; an insulator provided on the iron core; a coil wound around the teeth via the insulator; and a resin mold having an upper surface facing the mounting site and sealing the periphery of the core back and teeth. The core back is configured such that at least a portion of both end faces along the direction of travel of the armature is exposed from the resin mold and becomes the outermost surface in the direction of travel. The resin mold has both end faces along the direction of travel of the armature, and at least a portion of the resin surface of the part that seals the coil is located on the coil side of the exposed end face of the core back in the direction of travel of the armature.

[0007] The armature module described herein has the effect of suppressing the deterioration of motor characteristics.

[0008] A schematic front view showing the linear motor according to Embodiment 1 A schematic side view showing the linear motor according to Embodiment 1 A schematic perspective view showing the armature module constituting the linear motor according to Embodiment 1 A schematic cross-sectional view showing the armature module constituting the linear motor according to Embodiment 1 A schematic cross-sectional view showing a different form of resin mold for the armature module constituting the linear motor according to Embodiment 1 A schematic cross-sectional view showing the armature constituting the linear motor according to Embodiment 1 A schematic cross-sectional view showing the armature according to Embodiment 1 mounted on a mounting site with an obstacle A schematic perspective view showing a modified example 1 of the armature module constituting the linear motor according to Embodiment 1 A schematic cross-sectional view showing a modified example 1 of the armature module constituting the linear motor according to Embodiment 1 A schematic cross-sectional view showing a modified example 2 of the armature module constituting the linear motor according to Embodiment 1 Figure 15 shows a schematic cross-sectional view of the armature module 1, which is configured to be mounted on a mounting site. Figure 18 shows a schematic cross-sectional view of the armature module 3, which is configured to be mounted on a mounting site.

[0009] Hereinafter, an armature module and a linear motor according to the embodiments of this disclosure will be described in detail with reference to the drawings.

[0010] Embodiment 1. Figure 1 is a schematic front view showing a linear motor according to Embodiment 1. Figure 1 shows the linear motor 100 attached to the base member 200 and the mounting site 300. Figure 2 is a schematic side view showing the linear motor according to Embodiment 1. In Figure 2, the base member 200 shown in Figure 1 is omitted. As shown in Figures 1 and 2, the linear motor 100 comprises a field 1 and an armature 2 which is positioned opposite the field 1 with an air gap in between and is movable relative to the field 1. The armature 2 is configured in which a plurality of armature modules 2A, each having the same configuration, are arranged and connected along the direction of travel (y-direction). As shown in Figure 1, the linear motor 100 has the field 1 attached to the base member 200 and the armature 2 attached to the mounting site 300. The base member 200 has a bottom surface portion 200a extending along the direction of travel (y-direction) of the armature 2, and side surfaces 200b rising upward from both side edges of the bottom surface portion 200a and extending along the direction of travel (y-direction) of the armature 2, and has a concave cross-sectional shape. A rail member 200c is provided on the upper surface of the side surfaces 200b along the direction of travel (y-direction) of the armature 2. The mounting destination 300 is, as an example, a user's device, slider mechanism, or gantry mechanism configured in combination with the base member 200. The mounting destination 300 is provided with a plate-shaped portion 300a to which the armature 2 is attached, and a guide portion 300b such as a bearing attached to the plate-shaped portion 300a and movably fitted into the rail member 200c.

[0011] The field magnet 1 comprises a mounting base 10 and a plurality of permanent magnets 11 arranged alternately with south poles and north poles along the direction of travel (y-direction) of the armature 2. The mounting base 10 is fixed to the upper surface of the bottom surface portion 200a, which is the inner bottom surface of the base member 200, using a joining member such as a bolt. The permanent magnets 11 are provided on the upper surface of the mounting base 10. The armature 2 will be attached to a plate-shaped portion 300a provided at the mounting destination 300. The transported object 400 is placed on the upper surface of the plate-shaped portion 300a.

[0012] Figure 3 is a schematic perspective view showing the armature module constituting the linear motor according to Embodiment 1. Figure 4 is a schematic cross-sectional view showing the armature module constituting the linear motor according to Embodiment 1. As shown in Figures 3 and 4, the armature module 2A comprises an iron core 3, an insulator 4, a coil 5, and a resin mold 6.

[0013] The core 3 is formed by laminating multiple core pieces, each made by press-forming a thin sheet of electromagnetic steel, for example, a magnetic material. The core 3 comprises a core back 30 and multiple teeth 31. The core back 30 extends in the direction of travel (y-direction) of the armature 2, and its upper surface 30a is attached to the plate-shaped portion 300a of the mounting site 300 using a joining member such as a bolt. Multiple screw holes 32 are formed on the upper surface 30a of the core back 30 for attachment to the plate-shaped portion 300a of the mounting site 300. The core back 30 is divided into multiple sections along the direction of travel (y-direction). The multiple teeth 31 are arranged in parallel along the direction of travel (y-direction) of the armature 2 and extend from the core back 30 toward the field 1. Each tooth 31 is provided on a divided section of the divided core back 30. The tip surface 31a of each tooth 31 faces the field 1. Furthermore, the core back 30 is not limited to a configuration in which it is divided in the direction of travel of the armature 2 (y-direction), but may also be an integrated configuration without division. If the core back 30 is not divided, no gaps will occur at the divided parts, which can improve the motor output.

[0014] The insulator 4 is provided on the iron core 3 to ensure electrical insulation between the iron core 3 and the coil 5. This is because a ground fault would occur if the iron core 3 and the coil 5 came into contact. The insulator 4 is made of a material with excellent electrical insulation properties, such as polyimide, polyethylene terephthalate (PET), polyphenylene sulfide (PPS), or polybutylene terephthalate (PBT).

[0015] The coil 5 is formed by winding a conductor, such as copper or aluminum, around each tooth 31 via an insulator 4. The winding method for the coil 5 around the teeth 31 of the iron core 3 includes concentrated winding, where the coil 5 is concentrated around one tooth 31. Concentrated winding can be further divided into a structure where the coil 5 is concentrated around all teeth 31, and a structure where the coil 5 is wound around every other tooth 31. In the electrical design of a motor, both the structure where the coil 5 is wound around all teeth 31 and the structure where the coil 5 is wound around every other tooth 31 have their own advantages and disadvantages, and are selected based on the application and required specifications.

[0016] As shown in Figures 3 and 4, the resin mold 6 has an upper surface 60 facing the mounting surface 300, and seals the periphery of the core back 30 and teeth 31 with the upper surface 30a of the core back 30 and the tip surface 31a of the teeth 31 facing the field 1 exposed. However, a thin layer of resin mold 6 may adhere to the upper surface 30a of the core back 30 and the tip surface 31a of the teeth 31 facing the field 1. The core back 30 is configured such that both end surfaces 30b of the core back 30, along the direction of travel of the armature 2 (y-direction), are exposed from the resin mold 6 and become the outermost surfaces in the direction of travel (y-direction). Furthermore, the core back 30 is not limited to a configuration in which all of both end faces 30b of the core back 30 along the direction of travel of the armature 2 (y-direction) are exposed from the resin mold 6. It may also be a configuration in which at least a part of the end faces 30b are exposed from the resin mold 6, and the exposed end faces 30b are the outermost surfaces in the direction of travel (y-direction). The resin mold 6 has both end faces along the direction of travel of the armature 2 (y-direction), and the resin surface 61 of the portion that seals the coil 5 is located on the coil 5 side of the exposed end face 30b of the core back 30 in the direction of travel of the armature 2 (y-direction). Specifically, the resin surface 61 of the resin mold 6 in the portion that seals the coil 5 is tapered in a way that it is inclined toward the coil 5 side toward the field 1 side.

[0017] Figure 5 is a schematic cross-sectional view illustrating different forms of the resin mold in an armature module constituting a linear motor according to Embodiment 1. As shown in Figure 5, the resin surface 61 of the resin mold 6 in the portion sealing the coil 5 may be recessed in a rectangular shape so as to be located toward the coil 5 toward the field 1. Note that the shape of the resin surface 61 of the resin mold 6 in the portion sealing the coil 5 is not limited to the tapered shape shown in Figure 4 or the recessed rectangular shape shown in Figure 5. The resin surface 61 of the resin mold 6 may have any other shape as long as it is located toward the coil 5 toward the end face 30b of the core back 30 that is exposed in the direction of travel (y direction) of the armature 2. Furthermore, it is preferable that all of the resin surfaces 61 of the resin mold 6 are located toward the coil 5 toward the end face 30b of the core back 30, but a portion of the resin surface 61 may be flush with the end face 30b of the core back 30.

[0018] Figure 6 is a schematic cross-sectional view showing the armature constituting the linear motor according to Embodiment 1. As shown in Figure 6, the armature 2 is configured such that multiple armature modules 2A, each with the same configuration, are arranged along the direction of travel (y-direction), and the exposed end faces 30b of the core backs 30 of adjacent armature modules 2A are in contact with each other. By having the end faces 30b of the core backs 30 in contact with each other, the iron core 3 can be made continuous along the direction of travel (y-direction) of the armature 2. This allows the magnetic field generated by passing current through the coil 5 to be transmitted to adjacent iron core 3, thereby increasing the motor thrust and reducing the cogging thrust. When manufacturing the armature 2 by connecting adjacent armature modules 2A, the iron core 3 is robust, so even if the core backs 30 collide strongly with each other, it will not cause the armature 2 to fail. On the other hand, if the resin molds 6 collide strongly with each other, the resin may crack, which may cause the armature 2 to fail. Of the resin mold 6, the portion that seals around the coil 5 is particularly important, and it is necessary to ensure the insulating function of the armature 2.

[0019] In the armature module 2A according to Embodiment 1, the resin surfaces 61 of the resin mold 6 that seal the coil 5, located at both ends along the direction of travel (y-direction) of the armature 2, are positioned closer to the coil 5 than the end surface 30b of the core back 30 that is exposed in the direction of travel (y-direction) of the armature 2. This prevents or reduces collisions between the resin surfaces 61 of the resin mold 6 when manufacturing the armature 2 by connecting adjacent armature modules 2A, thereby suppressing situations in which the armature 2 may fail due to cracking of the resin or other reasons.

[0020] Furthermore, in the linear motor 100 according to Embodiment 1, only one type of armature module 2A is used, and a large-sized motor can be formed by connecting only the required number of armature modules 2A for the user's desired thrust. In this case, since only one type of armature module 2A needs to be handled, inventory management of armature modules 2A becomes easier for both the manufacturer and the user. Also, the manufacturer can significantly reduce investment in manufacturing equipment and reduce the type and size of manufacturing equipment that needs to be prepared. Moreover, manufacturing errors of armature modules 2A are suppressed, and the lead time for delivery of armature modules 2A can be shortened. On the other hand, the user can easily select armature modules 2A.

[0021] Furthermore, generally, the core 3 of mass-produced motors is manufactured by stamping out electromagnetic steel sheets with a press. Residual stress from the press remains around the outer contour, which degrades the magnetic properties and increases magnetic resistance. Therefore, it is desirable to reduce the exposed surface area of ​​the core 3 exposed from the resin mold 6 in the armature module 2A. For example, if there are many magnetically degraded magnetic property regions through which magnetic flux passes in the connecting surfaces of adjacent armature modules 2A, motor characteristics will deteriorate, such as a decrease in motor thrust, an increase in cogging thrust, and an increase in iron loss.

[0022] In the first embodiment, the armature module 2A exposes only the end face 30b of the core back 30 at the connecting surface of adjacent armature modules 2A, thus minimizing the magnetic degradation region. In other words, in the first embodiment, the armature module 2A has reduced magnetic resistance, which increases motor thrust, stabilizes the magnetic properties of the iron core 3, reduces cogging thrust affected by changes in the magnetic properties of the iron core 3, and reduces iron loss because the region with a large hysteresis area of ​​magnetic properties decreases. In other words, deterioration of motor characteristics can be suppressed.

[0023] Furthermore, since the iron core 3 rusts when exposed to air, measures to suppress rust are necessary. One way to suppress rust on the iron core 3 is to apply rust-preventive oil to the surface of the electrical steel sheet. In this case, if a large portion of the iron core 3 is exposed on the connecting surfaces of adjacent armature modules 2A, the amount of rust-preventive oil required will increase, and the burden of application will also increase, potentially leading to higher manufacturing costs. On the other hand, in the armature module 2A according to Embodiment 1, only both end faces 30b of the core back 30 along the direction of travel (y-direction) of the armature 2 are exposed from the resin mold 6. Therefore, compared to a configuration in which the teeth 31 are also exposed in addition to the core back 30, the area where rust must be suppressed is smaller. In other words, in the armature module 2A according to Embodiment 1, when rust prevention treatment is performed with rust-preventive oil, a small amount of rust-preventive oil is required, reducing the burden of application, and thus contributing to a reduction in manufacturing costs.

[0024] Furthermore, in conventional armature modules, both end faces along the direction of armature travel are sealed with resin molding. In this case, the resin molds of multiple armature modules arranged along the direction of armature travel are butted together and connected, so the size in the direction of travel increases due to the thickness of the resin molding. On the other hand, in the armature module 2A according to Embodiment 1, both end faces 30b of the core back 30 along the direction of travel (y direction) of the armature 2 are exposed from the resin molding 6. The resin surface 61 of the resin molding 6, which is the part that seals the coil 5 at both end faces along the direction of travel (y direction) of the armature 2, is located on the coil 5 side than the end face 30b of the core back 30 that is exposed in the direction of travel (y direction) of the armature 2. In other words, in the armature module 2A according to Embodiment 1, when multiple armature modules 2A are connected, the core backs 30 come into contact with each other, making it possible to reduce the size in the direction of travel (y direction).

[0025] Furthermore, the winding method of the coil 5 wound around the teeth 31 of the iron core 3 includes concentrated winding, where the coil 5 is wound intensively around one tooth 31. Concentrated winding has two structures: one in which the coil 5 is wound intensively around all teeth 31, and another in which the coil 5 is wound around every other tooth 31. In the electrical design of the motor, the structure in which the coil 5 is wound around all teeth 31 and the structure in which the coil 5 is wound around every other tooth 31 each have their own advantages and disadvantages, and the choice depends on the application and required specifications. The armature module 2A according to Embodiment 1 has core backs 30 configured on both end faces along the direction of travel (y-direction) of the armature 2, and is separated by the core backs 30. Therefore, it can accommodate both the structure in which the coil 5 is wound intensively around all teeth 31 and the structure in which the coil 5 is wound around every other tooth 31, providing a high degree of freedom in the electrical design of the motor. In addition, a conventional technology is known in which one armature module 2A is divided in the middle of the teeth 31. In this case, it is not possible to wind coils around the divided teeth, and it can only be applied to a structure in which coils 5 are wound around every other tooth 31, thus limiting the flexibility of the motor's electrical design.

[0026] Figure 7 is a schematic cross-sectional view showing the armature according to Embodiment 1 mounted on a mounting site having an obstacle. As shown in Figure 7, the armature 2 according to Embodiment 1 may be mounted on a mounting site 300 having an obstacle 301 according to the user's specifications. In this case, the pitch of the magnetic poles on the field 1 side is τ ｐ When n is an integer greater than or equal to 2, the armature 2 has some adjacent armature modules 2A along the direction of travel (y-direction) that are 2nτ ｐ At a distance greater than the specified limit, avoiding the obstacle 301, the upper surface 30a of the core back 30 is attached to the plate-shaped portion 300a of the mounting site 300. This is because all armature modules 2A are energized by the same power supply, and therefore it is necessary to maintain a spacing of an integer distance between the magnetic pole pairs.

[0027] For example, some adjacent armature modules 2A along the direction of travel (y-direction) 2nτ ｐ If the armature modules 2A are placed at a shorter distance than 2nτ, they will magnetically interfere with each other, increasing both cogging thrust and thrust ripple when energized. Therefore, to ensure that the armature modules 2A do not magnetically interfere with each other, the distance between adjacent armature modules 2A along the direction of travel (y-direction) is set to 2nτ. ｐ The above-mentioned space must be left open. Thus, the armature 2 according to Embodiment 1 can be configured not only in a state in which adjacent armature modules 2A are connected in contact, but also in a state that matches the structure of the mounting site 300 having an obstacle 301.

[0028] Figure 8 is a schematic perspective view showing a modified example 1 of the armature module constituting the linear motor according to Embodiment 1. Figure 9 is a schematic cross-sectional view showing a modified example 1 of the armature module constituting the linear motor according to Embodiment 1. As shown in Figures 8 and 9, the insulator 4 may be formed to a length such that the portion facing the core back 30 is exposed from both end faces of the resin mold 6 along the direction of travel (y direction) of the armature 2, and is flush with the exposed end face 30b of the core back 30. As shown in Figure 9, by increasing the length of the insulator 4 facing the core back 30, the creepage distance from the coil 5 to the core back 30 can be increased, so that the amount of coil 5 wound around the teeth 31 can be increased, thereby suppressing the copper loss of the motor and the temperature rise of the motor. It is preferable that the insulator 4 be a length flush with the exposed end face 30b of the core back 30, but it is not necessarily required that it be flush with the exposed end face 30b of the core back 30, and it may be positioned slightly closer to the coil 5 than the end face 30b of the core back 30.

[0029] Figure 10 is a schematic perspective view showing a modified example 2 of the armature module constituting the linear motor according to Embodiment 1. As shown in Figure 10, the armature module 2A may have individual identification markings 7 applied to at least one of the exposed end faces 30b of the core back 30 along the direction of travel (y-direction) of the armature 2. The markings 7 are applied for traceability purposes. The markings 7 can be, for example, a barcode, a QR code (registered trademark), or a two-dimensional data matrix. Note that the area of ​​the exposed end face 30b of the core back 30 is not large. Therefore, a two-dimensional data matrix, which does not require much space and is resistant to noise, is preferred for the markings 7. Methods for applying the markings 7 include, for example, laser printing, label application, or stamping. Since it is desirable that the markings 7 applied to the end face 30b of the core back 30 do not peel off easily, it is preferable to apply the markings 7 by laser printing. The marking 7 includes, for example, manufacturing lot information for the part, manufacturing date information for the part, and manufacturer information for the part. The information contained in the marking 7 can be read within the manufacturing plant where the linear motor 100 is manufactured, and within the factory of the user who uses the linear motor 100.

[0030] Incidentally, the manufacturing process for the armature module 2A is carried out in the following order: assembly of the iron core 3, assembly of the insulator 4, winding of the coil 5, molding of the resin mold 6, and finishing of the mounting surface to be attached to the mounting site 300. Generally, after the resin mold 6 is molded, an individual identification label is attached to the resin mold 6. In this case, since the molding of the resin mold 6 is at the end of the manufacturing process, it is not possible to trace the iron core 3 which is assembled at the beginning. Also, if a marking 7 is applied to the mounting surface of the iron core 3 which is attached to the mounting site 300 at the beginning of the manufacturing process, there is a risk that the marking 7 will disappear during the final finishing process of the mounting surface. On the other hand, a thin layer of the molded resin mold 6 may adhere to the tip surface 31a of the teeth 31 that face the field 1. Therefore, if a marking 7 is applied to the tip surface 31a of the teeth 31, there is a risk that it will be hidden by the resin mold 6.

[0031] In the first embodiment, the armature module 2A has individual identification markings 7 applied to at least one of the end faces 30b of the core back 30, which is exposed at both end faces along the direction of travel (y-direction) of the armature 2. Therefore, in a manufacturing plant that produces linear motors 100, the armature module 2A can be easily traced from the initial assembly of the iron core 3 to the final finishing of the mounting surface before attachment to the mounting site 300.

[0032] Furthermore, the armature module 2A in Embodiment 1 is not limited to a configuration in which the upper surface 30a of the core back 30 is attached to the plate-shaped portion 300a of the mounting destination 300. Figure 11 is a schematic perspective view showing a third modification of the armature module constituting the linear motor according to Embodiment 1. As shown in Figure 11, the armature module 2A may be configured such that, for example, a fastening rod 8 extending along the direction of travel (y-direction) of the armature module 2A is provided on the upper surface 30a of the core back 30, and the fastening rod 8 is attached to the plate-shaped portion 300a of the mounting destination 300 using a joining member such as a bolt. The fastening rod 8 is made of the same material as the iron core 3, for example. The fastening rod 8 is fitted into a recess formed on the upper surface 30a of the core back 30 and fixed by welding or the like. Multiple screw holes 80 for attachment to the plate-shaped portion 300a of the mounting destination 300 are formed on the upper surface of the fastening rod 8. Compared to the core back 30, the fastening rod 8 allows for easier design and processing of the screw holes 80, and the fastening force with the mounting destination 300 can be increased by the joining member screwed into the screw holes 80. The fastening rod 8 is not limited to the rectangular parallelepiped shape shown, and may have other shapes as long as it is provided on the upper surface 30a of the core back 30 and can be attached to the plate-shaped portion 300a of the mounting destination 300. The upper surface 30a of the core back 30 may be exposed or sealed by the resin mold 6.

[0033] Embodiment 2. Next, the armature modules 2B, 2C, and 2D according to Embodiment 2 will be described. Note that components identical to those in Embodiment 1 are denoted by the same reference numerals, and their descriptions are omitted as appropriate. Figure 12 is a schematic perspective view showing the armature modules constituting the linear motor according to Embodiment 2. Figure 13 is a schematic cross-sectional view showing the armature modules constituting the linear motor according to Embodiment 2.

[0034] As shown in Figures 12 and 13, in the second embodiment, the armature module 2B has first grooves 33a and 33b formed on the upper surface 30a of the core back 30, which is exposed from the resin mold 6 and faces the mounting site 300, along a direction (x direction) that intersects with the direction of travel of the armature 2 (y direction). The first grooves 33a and 33b are filled with resin mold 6a. The first grooves 33a and 33b are rectangular in shape as an example. Seven first grooves 33a and 33b are formed at intervals along the direction of travel of the armature 2 (y direction). Of the seven first grooves 33a and 33b, the first grooves 33b located at both ends in the direction of travel of the armature 2 (y direction) are formed by cutting out the ends of the core back 30 in an L-shape when viewed from the x direction. Note that the first grooves 33a and 33b are not limited to the rectangular shape shown and may be of other shapes. Furthermore, the first grooves 33a and 33b are not limited to the seven shown in the figure; one or more are sufficient.

[0035] The resin mold 6 has upper surfaces 60 that extend along the direction of travel (y-direction) of the armature 2, formed on both sides of the upper surface 30a of the core back 30, and these upper surfaces 60 formed on both sides are connected by resin mold 6a filled in the first grooves 33a and 33b.

[0036] Figure 14 is an explanatory diagram showing the operation of the armature module constituting the linear motor according to Embodiment 2. The arrows shown in Figure 14 indicate the direction in which the resin flows during the molding of the resin mold 6. As shown in Figure 14, by forming first grooves 33a and 33b on the upper surface 30a of the core back 30 along a direction intersecting the direction of travel (y direction) of the armature 2, the first grooves 33a and 33b become paths through which the resin flows during the molding of the resin mold 6. This improves the fluidity of the resin mold 6 and improves the filling of the resin mold 6 up to the corner A of the molding die.

[0037] Figure 15 is a schematic cross-sectional view showing a modified example 1 of the armature module constituting the linear motor according to Embodiment 2. Figure 16 is a schematic cross-sectional view showing the modified example 1 of the armature module shown in Figure 15, mounted on a mounting site. As shown in Figures 15 and 16, the upper surface 60a of the resin mold 6a filled in the first grooves 33a and 33b may be configured to be one step lower than the upper surface 30a of the core back 30 exposed from the resin mold 6. The upper surface of the armature module 2B becomes the mounting surface to the mounting site 300 and greatly affects mounting accuracy and heat dissipation. For this reason, the upper surface of the armature module 2B is often finished to a highly accurate flat surface as the final step in motor manufacturing. By lowering the upper surface 60a of the resin mold 6a filled in the first grooves 33a and 33b by one step lower than the upper surface 30a of the core back 30, the finishing of the upper surface 60a of the resin mold 6a can be omitted. Furthermore, the resin mold 6a is extremely hard. By omitting the finishing process on the upper surface 60a of the resin mold 6a, the lifespan of the cutting tools used for finishing can be ensured. In addition, the generation of dust from the resin mold 6a due to finishing can be prevented.

[0038] Figure 17 is a schematic cross-sectional view showing a modified example 2 of the armature module constituting the linear motor according to Embodiment 2. As shown in Figure 17, in addition to the first grooves 33a and 33b formed on the upper surface 30a of the core back 30, the armature module 2C has second grooves 34a and 34b formed on the lower surface of the core back 30 where the teeth 31 are formed, along a direction (x direction) that intersects with the direction of travel of the armature 2 (y direction). The second grooves 34a and 34b are rectangular in shape as an example. The second grooves 34b located at both ends in the direction of travel of the armature 2 (y direction) are formed by cutting out the ends of the core back 30 in an L-shape when viewed from the x direction. The second grooves 34a and 34b are filled with resin mold 6b.

[0039] The armature module 2C shown in Figure 17 has second grooves 34a and 34b formed on the lower surface of the core back 30 on which the teeth 31 are formed, and resin mold 6b is filled into the second grooves 34a and 34b, so the creepage distance from the coil 5 to the iron core 3 is increased, and the insulation performance to ground can be improved. In other words, the amount of coil 5 wound around the teeth 31 can be increased, thereby suppressing copper loss in the motor and the temperature rise of the motor. Note that the second grooves 34a and 34b are not limited to the rectangular shape shown, but may be of other shapes. Also, the insulator 4 shown in Figure 17 is formed so that the portion facing the core back 30 is exposed from both end faces of the resin mold 6 along the direction of travel (y direction) of the armature 2 and is flush with the end face 30b of the exposed core back 30, but for example, as shown in Figure 13, it may be formed only in the portion facing the coil 5. Furthermore, the armature module 2C is not limited to a configuration in which first grooves 33a and 33b are formed on the upper surface 30a of the core back 30. The first grooves 33a and 33b may be omitted, and second grooves 34a and 34b may be formed only on the lower surface of the core back 30 in which the teeth 31 are formed.

[0040] Figure 18 is a schematic cross-sectional view showing a modification 3 of the armature module constituting the linear motor according to Embodiment 2. Figure 19 is a schematic cross-sectional view showing the modification 3 of the armature module shown in Figure 18 in a state where it is attached to a mounting site. As shown in Figures 18 and 19, the armature module 2D has first grooves 35a and 35b formed in the shape of dovetail grooves, with the opening narrowing toward the upper surface 30a of the core back 30. The first grooves 35b located at both ends in the direction of travel (y direction) of the armature 2 are formed by cutting out the end of the core back 30 in an L-shape when viewed from the x direction. The first grooves 35a and 35b are filled with resin mold 6a. This ensures that the area of ​​the upper surface 30a of the core back 30, which is the mounting surface to the mounting site 300, is secured, and thus ensures heat dissipation from the upper surface 30a of the core back 30. In other words, the armature module 2D is located on the upper surface 30a of the core back 30 and forms groove-shaped first grooves 35a and 35b, thereby achieving both improved filling of the resin mold 6 and ensuring heat dissipation from the upper surface 30a of the core back 30. Although not shown in the diagram, the upper surface 60a of the resin mold 6a filled in the first grooves 35a and 35b may be configured to be one step lower than the upper surface 30a of the core back 30.

[0041] The configurations shown in the above embodiments are merely examples and can be combined with other known technologies, or the embodiments themselves can be combined. Furthermore, it is possible to omit or modify parts of the configuration without departing from the gist of the invention.

[0042] 1 Field, 2 Armature, 2A, 2B, 2C, 2D Armature module, 3 Iron core, 4 Insulator, 5 Coil, 6, 6a, 6b Resin mold, 7 Marking, 8 Fastening rod, 10 Mounting seat, 11 Permanent magnet, 30 Core back, 30a, 60, 60a Top surface, 30b End surface, 31 Teeth, 31a Tip surface, 32, 80 Screw holes, 33a, 33b, 35a, 35b First groove, 34a, 34b Second groove, 61 Resin surface, 100 Linear motor, 200 Base member, 200a Bottom surface, 200b Side surface, 200c Rail member, 300 Mounting point, 300a Plate-shaped part, 300b Guide part, 301 Obstacle, 400 Conveyed object.

Claims

1. An armature module comprising an armature that is mounted to a mounting site and positioned facing a field with an air gap between them, and which is movable relative to the field, the armature module comprising: an iron core having a core back extending in the direction of travel and a plurality of teeth arranged in parallel along the direction of travel and extending from the core back toward the field; an insulator provided on the iron core; a coil wound around the teeth via the insulator; and a resin mold having an upper surface facing the mounting site and sealing the periphery of the core back and the teeth, wherein at least a portion of the end faces of the core back along the direction of travel of the armature is exposed from the resin mold and becomes the outermost surface in the direction of travel, and the resin mold has at least a portion of the resin surface of the portion that seals the coil on both end faces along the direction of travel of the armature, which is located on the coil side than the end face of the core back that is exposed in the direction of travel of the armature.

2. The armature module according to claim 1, characterized in that the resin mold has both end faces along the direction of travel of the armature, and all of the resin surfaces of the portion sealing the coil are located on the coil side of the end face of the core back that is exposed in the direction of travel of the armature.

3. The armature module according to claim 1 or 2, characterized in that the portion of the insulator facing the core back is formed to a length that is exposed from the end face of the resin mold along the direction of travel of the armature.

4. The armature module according to any one of claims 1 to 3, characterized in that at least one of the end faces of the core back exposed at both end faces along the direction of travel of the armature is marked with an individual identification mark.

5. The armature module according to any one of claims 1 to 4, characterized in that the core back has an upper surface exposed from the resin mold and facing the mounting site, and a first groove is formed on the upper surface in a direction intersecting the direction of travel of the armature, and the resin mold has upper surfaces extending in the direction of travel of the armature, arranged on both sides of the core back, and the upper surfaces arranged on both sides are connected by the resin mold filled in the first groove.

6. The armature module according to claim 5, characterized in that the upper surface of the resin mold filled in the first groove is lower than the upper surface of the core back exposed from the resin mold.

7. The armature module according to claim 5 or 6, characterized in that the first groove is dovetail groove-shaped, with the opening narrowing toward the upper surface of the core back.

8. The armature module according to any one of claims 1 to 7, characterized in that the core back has a second groove formed on the lower surface on which the teeth are formed, in a direction intersecting the direction of travel of the armature, and the resin mold is filled into the second groove.

9. A linear motor comprising a field and an armature having a configuration in which a plurality of armature modules according to any one of claims 1 to 8 are arranged and connected along the direction of travel.

10. The linear motor according to claim 9, characterized in that the armature is configured such that a plurality of armature modules having the same configuration are arranged along the direction of travel, and the exposed ends of the core backs of adjacent armature modules are connected in contact with each other.

11. The pitch of the magnetic poles on the field side is τ ｐ When n is an integer of 2 or more, the armature is such that at least some of the armature modules adjacent to each other along the direction of travel are 2nτ ｐ The linear motor according to claim 9 or 10, characterized in that the upper surface of the core back is attached to the mounting site at a distance greater than or equal to the above.

Images