JP5517316B2 - Rotating electric machine, bobbin for rotating electric machine, and method for manufacturing bobbin - Google Patents

Description

  Embodiments disclosed herein relate to a rotating electrical machine, a bobbin of the rotating electrical machine, and a method for manufacturing the same.

  In a rotating electrical machine, a bobbin integrally formed of a resin material for electrically insulating a stator winding and an iron core is known (for example, see Patent Document 1).

JP 2004-194458 A

  In order to increase the winding space factor of the stator, it is required to reduce the thickness of the bobbin. However, since the above-described prior art is a molding process using a mold, there is a limit to thinning the bobbin, and there is a problem that the winding space factor is restricted.

  The present invention has been made in view of such problems, and the object of the present invention is to provide a rotating electrical machine that can improve the winding space factor by making the bobbin thin, a bobbin for the rotating electrical machine, and It is to provide a manufacturing method.

In order to solve the above-described problems, according to one aspect of the present invention, a bobbin attached to a protrusion of a stator core, the bobbin has a rectangular frame-shaped body around which a winding is wound. an electric motor having a four side surfaces sac Chi three sides constituting the body portion of the rectangular frame, constituted respectively by integrated 3 sheet-like insulation film of each other it et three thin films is disposed so as to be U-shaped constitute the three sides that are part of the four sides, of the four sides, shaped of the co One side surface on the open side of the shape is disposed on any axial end surface of the protrusion with respect to the axial direction of the rotating electrical machine, and faces one side surface on the open side and one side surface on the open side. one aspect that, among the one side of at least the open side, the resin portion Rotating electric machine, characterized in that provided integrally joined beforehand by molding before mounting of the bobbin is provided.

  According to the present invention, the winding space factor of the rotating electrical machine can be improved by making the bobbin thin.

It is a longitudinal section showing the whole rotary electric machine composition of this embodiment. It is a cross-sectional view equivalent to the II-II cross section in FIG. It is a cross-sectional view which expands and shows a part of stator of a rotary electric machine. It is a perspective view showing the detailed structure of the bobbin of this embodiment. It is a longitudinal cross-sectional view of the bobbin equivalent to the VV cross section in FIG. It is explanatory drawing for demonstrating an example of the process which forms a substantially U-shaped thin film body using an insulating sheet. It is sectional drawing which shows an example of the metal mold | die which installed the substantially U-shaped thin film body. It is a longitudinal cross-sectional view of the bobbin which concerns on the modification which arrange | positions a thin film body only to the side surface which the one side of a trunk | drum opposes. It is a longitudinal cross-sectional view of the bobbin which concerns on the modification which arrange | positions the resin part only to one side of a trunk | drum. It is a longitudinal cross-sectional view of the bobbin which concerns on the modification which forms a thin film body in a square shape.

  Hereinafter, embodiments will be described with reference to the drawings.

<Configuration of rotating electrical machine>
First, the configuration of the rotating electrical machine 1 according to the present embodiment will be described with reference to FIGS. 1 to 3. As shown in FIGS. 1 and 2, the rotating electrical machine 1 is an inner rotor type motor that includes a stator 2 and a rotor 3, and the rotor 3 is provided inside the stator 2. The rotating electrical machine 1 may be a generator instead of a motor. The stator 2 is provided on the inner peripheral surface of the frame 4 via an annular laminated core ring 20 so as to face the rotor 3 in the radial direction. The stator 2 includes a laminated core 5 (stator core), a bobbin 6 attached to the laminated core 5, a coil wire 7 (winding) wound around the bobbin 6, and a laminated core ring 20. have. The bobbin 6 is made of an insulating material in order to electrically insulate the laminated core 5 and the coil wire 7. A substrate 8 is provided on one axial side of the bobbin 6 (left side in FIG. 1), and a circuit provided on the substrate 8 and a coil wire 7 wound around the bobbin 6 are connected to two pin terminals 9. It is electrically connected via. A winding start end and a winding end end 7 a of the coil wire 7 are wound around corresponding pin terminals 9 and fixed by solder H.

  The rotor 3 is made of a permanent magnet and is provided on the outer peripheral surface of the shaft 10. The shaft 10 includes a load-side bearing 12 in which an outer ring is fitted to a load-side bracket 11 provided on the load side (right side in FIG. 1) of the frame 4, and an anti-load side (opposite side of the load side) of the frame 4. 1 is supported rotatably by a non-load-side bearing 14 in which an outer ring is fitted. An encoder 15 is provided at the opposite end of the shaft 10 on the opposite side. The encoder 15 is covered with an encoder cover 16.

  The laminated core 5 includes a plurality of radial protrusions 18 (nine in this example) protruding outward in the radial direction, and the bobbin 6 around which the coil wire 7 is wound is attached to each protrusion 18 from the outside. . As shown in FIG. 3, in the concave portion 19 between the two adjacent projecting portions 18, the opposite side portions of the wound layers of the coil wire 7 of the bobbin 6 attached to each projecting portion 18 have a gap. Be placed. The stator 2 is assembled by fixing the bobbin 6 around which the coil wire 7 is wound to the laminated iron core body 5, fixing it to the inner circumference of the annular laminated iron core ring 20, and attaching it to the inner circumferential surface of the frame 4. . Thereafter, resin is press-fitted into the recess 19 and the bobbin 6, the coil wire 7 and the like are molded with resin.

<Bobbin configuration>
Next, the detailed structure of the bobbin 6 is demonstrated using FIG.4 and FIG.5. The bobbin 6 includes a substantially square frame-shaped body portion 21 around which the coil wire 7 is wound. The trunk portion 21 has two side surfaces 21U and 21D in the axial direction (up and down direction in FIG. 5) of the stator 2 and two side surfaces 21L and 21R in a direction orthogonal to the axial direction (left and right direction in FIG. 5). The body portion 21 has a thin film body 22a made of an insulating material on one of the two side surfaces 21L, 21R, which is opposed to one of the four side surfaces 21U, 21D, 21L, 21R, and the other two of the two side surfaces arranged opposite to each other. A thin film body 22b made of an insulating material is provided on one of the side surfaces 21U and 21D. The thin film body 22b and the two thin film bodies 22a are connected to each other, and the thin film body 22b and the two thin film bodies 22a form a substantially U-shaped thin film body 22.

  Moreover, the trunk | drum 21 has resin part 23A in one side 21U among the other two side surfaces 21U and 21D, and has resin part 23B in the other side 21D. The thin film body 22 and the resin portion 23 are integrally joined by molding (for example, injection molding or the like). Specifically, the thin film body 22b is bonded to the lower surface 23a of the resin portion 23A, and the two thin film bodies 22a are bonded to the side surface 23b of the resin portion 23B. As a result, the thin film body 22b and the resin portion 23A constitute the side surface 21U of the body portion 21, the resin portion 23B constitutes the side surface 21D, and the two thin film bodies 22a constitute the side surfaces 21L and 21R. The two thin film bodies 22a are exposed laterally as the side surfaces 21L and 21R of the bobbin 6. The outer surfaces of the resin portions 23A and 23B are formed in a curved surface so that the stress acting on the wound coil wire 7 can be reduced.

  The body 21 is further provided at both ends on the opening side, that is, the outer peripheral side (the back side in FIG. 5) of the stator 2 in the opening 25 and the inner peripheral side on the rotor 3 side in the opening 25 (FIG. 5). A plurality of (four in this example) collar portions 24 are provided at the end on the middle side. In this example, the collar portion 24 is connected to the thin film body 22a, and is formed of a thin film made of an insulating material. The collar portion 24 is provided on both sides of the end portion of the body portion 21 on the thin film body 22a side so as to protrude to the outside of the opening portion 25. Each collar portion 24 has a substantially rectangular shape, and the length in the longitudinal direction (vertical direction in FIG. 5) is longer than the length in the longitudinal direction of the thin film body 22a. As a result, both end portions of the collar portion 24 extend in the longitudinal direction (vertical direction in FIG. 4) from the resin portion 23A. In addition, it is good also as a structure which extended only the longitudinal direction one end part of the collar part 24 rather than the resin part 23A.

  The coil wire 7 of the stator 2 starts to be wound from one side (the upper side in FIGS. 4 and 5) of the barrel portion 21 in the axial direction, and passes through the thin film body 22a, the resin portion 23B, the thin film body 22a, and the resin portion 23A. The part 21 is made a round, and this is repeated a predetermined number of times to be wound around the body part 21, and the winding is finished on one side of the body part 21 in the axial direction.

  The resin portion 23A includes a resin substrate placement portion 26 (see FIGS. 1 and 4) on which the substrate 8 is placed. The substrate platform 26 is formed of a rectangular parallelepiped block formed on the outer peripheral side of the resin portion 23A, and is formed integrally with the resin portion 23A. An extended portion of the collar portion 24 is joined to the inner peripheral surface 26 a of the substrate platform 26. The substrate 8 is placed on the end surface 26b on one side in the axial direction of the substrate platform 26, and the substrate 8 is positioned in the axial direction. The end face 26b is provided with two pin terminal holes 27 for holding the two pin terminals 9 (see FIG. 1). A terminal 7 a (see FIG. 1) at the beginning of winding of the coil wire 7 is wound around the pin terminal 9 driven into one pin terminal hole 27, and the pin terminal 9 driven into the other pin terminal hole 27 includes The terminal 7a at the end of winding of the coil wire 7 is wound and fixed by solder H, respectively. The circuit of the substrate 8 placed on the substrate placement unit 26 and the coil wire 7 are electrically connected via the pin terminal 9.

  The substantially U-shaped thin film body 22 having the four collar portions 24 is formed by performing processing similar to origami work using an insulating sheet or insulating tape made of an insulating material such as polyimide, for example. be able to. An example of processing for forming the substantially U-shaped thin film body 22 using an insulating sheet will be described with reference to FIG.

  As shown in FIG. 6, a rectangular insulating sheet 28 cut to a predetermined size is prepared. Two longitudinal fold lines h1 indicated by broken lines are drawn in the central region in the width direction (vertical direction in FIG. 6) of the insulating sheet 28, and two rectangular regions 28a having substantially the same width are provided on both sides in the width direction of the insulating sheet 28. And a rectangular central region 28b having a large width therebetween. Further, a cut line h2 in the width direction indicated by a solid line is drawn at a substantially central position in the longitudinal direction (left and right direction in FIG. 6) of each region 28a, and each region 28a on both sides in the width direction is divided into two rectangular regions 28a1 having substantially the same length. Divide into Further, the central region in the longitudinal direction of the central region 28b is spaced apart by a predetermined interval, and two widthwise fold lines h3 indicated by broken lines are drawn, so that the central region 28b is divided into a rectangular region 28b1 in the central portion and 2 on both sides thereof. A rectangular region 28b2 having substantially the same length is partitioned, and longitudinal cut lines h4 are drawn at both ends in the width direction of the central region 28b1. Further, a rectangular cut line h5 is drawn at both ends in the longitudinal direction of the central region 28b.

  Then, when the insulating sheet 28 is cut along the cut lines h2, h4, and h5, and is folded along the fold line h3 and valley-folded along the fold line h1, two regions 28b2 in the center in the width direction of the insulating sheet 28 are obtained. And the U-shaped body formed by the region 28b1 therebetween, and the outer bent pieces continuously provided on both sides of the U-shaped body by the two regions 28a1 on both sides in the width direction of the insulating sheet 28. It is formed. The region 28b3 surrounded by the rectangular cut line h5 is cut off. The two regions 28b2 of the U-shaped body become the two thin film bodies 22a arranged opposite to the body portion 21, and the U-shaped region 28b1 becomes the thin film body 22b between the two thin film bodies 22a, which are bent. The region 28a1 becomes the collar portion 24.

  The bobbin 6 is formed by integrally bonding the insulating sheet 28 and the resin portions 23A and 23B (including the substrate placement portion 26) formed in a substantially U shape as described above, for example, by injection molding. Is done. FIG. 7 shows an example of a cross section of a mold used in injection molding. First, an insulating sheet 28 formed in a substantially U-shape is installed in a mold 30 composed of two molds. This procedure corresponds to the first procedure. A portion corresponding to the flange portion 24 of the insulating sheet 28 is disposed outside the mold 30 except for a portion joined to the substrate placement portion 26. In the mold 30 on which the insulating sheet 28 is installed, a cavity 31b for forming the resin portion 23B is defined on one side (left side in FIG. 7), and the resin portion 23A is formed on the other side (right side in FIG. 7). A cavity 31a to be formed is defined. Note that illustration of the cavity forming the substrate platform 26 is omitted. Next, the mold 30 is clamped, and resin is pressed into the mold 30 from a runner (not shown) to be solidified, and resin molding is performed. Thereby, the bobbin 6 integrally provided with the body portion 21 having the thin film body 22a and the resin portions 23A and 23B on the side surface, the four collar portions 24 and the substrate placement portion 26 is formed. This procedure corresponds to the second procedure.

<Effect of embodiment>
According to the embodiment described above, the following effects are obtained. That is, in general, in the bobbin 6 of the rotating electrical machine 1, the influence of the thickness of the surfaces (corresponding to the side surfaces 21U and 21D of the present embodiment) located on both axial sides of the body portion 21 on the number of turns of the coil wire 7 is compared. However, if the thickness of the surfaces (corresponding to the side surfaces 21L and 21R of the present embodiment) located on both sides in the circumferential direction of the body portion 21 is large, the number of turns of the coil wire 7 will decrease, and the number of turns will be reduced. The impact is relatively large.

  In the present embodiment, the body portion 21 of the bobbin 6 has a thin film body 22a made of an insulating material on at least one of the two side surfaces 21L, 21R arranged to face each other among the four side surfaces 21U, 21D, 21L, 21R. Thereby, since the part with a large influence on the number of turns of the coil wire 7 in the bobbin 6 can be made thin, the number of turns of the coil wire 7 can be increased, and the space factor can be improved. Therefore, motor characteristics can be improved. In addition, since the body portion 21 has the resin portions 23A and 23B on the other two side surfaces 21U and 21D arranged to face each other, it is possible to ensure necessary strength and improve the reliability of the bobbin 6.

  In the present embodiment, in particular, the thin film body 22 and the resin portions 23A and 23B (including the substrate mounting portion 26) are integrally joined by injection molding. Thereby, for example, when the thin film body 22 and the resin portions 23A and 23B are configured as separate bodies, the thin film body 22 and the resin portions 23A and 23B are mounted when the bobbin 6 is mounted on the protruding portion 18 of the laminated iron core body 5. However, since this embodiment is integrally joined, such assembling work is not necessary. Therefore, workability when the bobbin 6 is mounted on the protrusion 18 can be improved.

  In the present embodiment, in particular, since the bobbin 6 has the flange portions 24 provided at both end portions on the opening side of the trunk portion 21, the insulation between the laminated core 5 and the coil wire 7 can be further improved. Moreover, since the collar part 24 is comprised with a thin film body, the thickness of the collar part 24 can be made small. Thereby, the number of turns of the coil wire 7 can be further increased, and the space factor can be further improved.

  Furthermore, the following effects are also obtained. That is, as described above, the stator 2 is molded with a resin material in a state where the bobbin 6 around which the coil wire 7 is wound is mounted on the protruding portion 18 of the laminated iron core body 5. At this time, for example, when the body portion 6 and the collar portion 24 are bobbins integrally formed of a resin material, stress is concentrated near the base of the collar portion 24 due to pressure during molding, and the collar portion 24 is cracked. there is a possibility. In this embodiment, since the collar part 24 is comprised with a thin film body, it is possible to comprise the thin film body 22a and the collar part 24 of the trunk | drum 21 by bending the insulating sheet 28. FIG. As a result, since the collar portion 24 is flexibly joined to the body portion 21, stress is not concentrated near the base of the collar portion 24 due to pressure applied during molding. Therefore, it is possible to prevent cracks in the collar portion 24 and improve the reliability.

  In the present embodiment, in particular, the thin film body 22 is installed in the mold 30 in a substantially U-shape. Thereby, compared with the case where a plurality of plate-like thin film bodies are individually installed in a mold, for example, the operation of installing the thin film body 22 in the mold 30 is facilitated, and workability can be improved. Further, since the entire lower surface 23a of the resin portion 23A is bonded to the thin film body 22 on the side surface 21U, the bonding area is greatly increased as compared with the case where plate-like thin film bodies are simply arranged on both sides of the resin portion 23A and bonded. The bonding strength between the thin film body 22 and the resin portion 23A can be increased. Therefore, the reliability can be further improved.

  In the present embodiment, in particular, the resin portion 23 </ b> A includes the substrate mounting portion 26, whereby the substrate 18 can be positioned. Further, by providing the pin mounting hole 27 in the substrate mounting portion 26, the pin terminal 9 to which the winding start terminal 7a and the winding end terminal 7a of the coil wire 7 are fixed can be held. Therefore, the bobbin 6 can have the same function as a conventional bobbin formed integrally with a resin material.

<Modification>
The present invention is not limited to the above-described embodiment, and various modifications can be made without departing from the spirit and technical idea of the present invention. Hereinafter, such modifications will be described in order.

(1) When a thin film body is disposed only on the side surfaces 21L and 21R of the body portion 21 In the above embodiment, the body portion 21 of the bobbin 6 has two side surfaces 21L and 21R that are disposed to face each other out of the four side surfaces. Is provided with a thin film body 22b on one side surface 21U of the other two side surfaces 21U and 21D arranged opposite to each other. However, as shown in FIG. It is good also as a structure which does not have a body and has the thin film body 22a only in two side surfaces 21L and 21R.

  Also according to this modification, the portion of the bobbin 6 that has a great influence on the number of turns of the coil wire 7 can be made thin, so that the number of turns of the coil wire 7 can be increased and the space factor can be improved.

(2) In the case where the resin portion is disposed only on the side surface 21D of the body portion 21 In the above embodiment, the body portion 21 of the bobbin 6 has the resin portions 23A and 23B on both of the two side surfaces 21U and 21D. As shown in FIG. 9, it is good also as a structure which has the resin part 23B only in the side surface 21D.

  Also by this modification, the trunk | drum 21 of the bobbin part 6 can be formed in square frame shape, and the structure of the trunk | drum 21 can be simplified. Moreover, since the circumference of the trunk | drum 21 can be shortened, required coil length can be saved.

(3) When providing the resin part and thin film body of a bobbin separately In the said embodiment, although resin part 23A, 23B and thin film body 22a, 22b were integrally formed by resin molding, resin part 23A, 23B and The body 21 may be assembled by forming the thin film bodies 22a and 22b separately.

(4) When the collar portion is only on one side or the collar portion is eliminated In the above embodiment, the body portion 21 of the bobbin 6 has the collar portion 24 at both the outer peripheral side and the inner peripheral side of the opening 25. However, the collar portion 24 may be provided only on one side of the outer peripheral side and the inner peripheral side of the opening 25. Furthermore, it is good also as a structure which does not provide the collar part 24. FIG. In this case, the coil wire 7 may be wound with a gap between the protruding portion 18 and the laminated core ring 20 and insulated by a subsequent resin mold.

(5) In the case where the thin film body is formed in a square shape In the above embodiment, the thin film body 22 used for the body portion 21 of the bobbin 6 is formed in a substantially U shape, but as shown in FIG. The thin film body 22 may be formed in a square shape by disposing the thin film body 22c also on the side surface 21D of the portion 21. Even with such a shape, the work of installing the thin film body 22 on the mold 30 becomes easy, and the workability can be improved.

  In addition to those already described above, the methods according to the above-described embodiments and modifications may be used in appropriate combination.

  In addition, although not illustrated one by one, this embodiment is implemented with various modifications within a range not departing from the gist thereof.

DESCRIPTION OF SYMBOLS 1 Rotating electrical machine 2 Stator 3 Rotor 5 Laminated core (stator core)
6 Bobbin 7 Coil wire (winding)
18 Protrusion part 21 Body part 22a, 22b Thin film body 22 Thin film body 23A, 23B Resin part 24 Collar part 25 Opening part 26 Substrate placing part 27 Pin terminal hole 28 Insulating sheet 30 Mold

Claims (5)

Having a bobbin attached to the protrusion of the stator core;
The bobbin is a rotating electrical machine having a square frame-shaped body around which a winding is wound,
Four sides sac Chi three sides constituting the body portion of the rectangular frame, constituted respectively by mutually integrated 3 sheet-like insulation film of,
It et three thin films constitutes three sides are arranged so as to be U-shaped become part of the four sides,
Among the four side surfaces, one side surface on the open side of the U-shape is disposed on any axial end surface of the protrusion with respect to the axial direction of the rotating electrical machine, and one side surface on the open side, and, one side facing the one side of the open side, out of, on one side of at least the open side, provided with integrally joined beforehand by molding a resin portion before mounting of the bobbin Rotating electric machine characterized by that. The bobbin is
It further comprises a collar portion provided at at least one of both end portions on the opening side of the trunk portion,
The collar portion is
The rotating electrical machine according to claim 1, wherein the rotating electrical machine is constituted by the thin film body. The resin part is
A substrate placement section on which the substrate is placed;
The rotating electrical machine according to claim 1, further comprising: a pin terminal hole provided in the substrate mounting portion. Attached to the protrusion of the stator core of the rotating electrical machine,
A bobbin having a quadrangular frame-like body around which a winding is wound,
Four sides sac Chi three sides constituting the body portion of the rectangular frame, constituted respectively by mutually integrated 3 sheet-like insulation film of,
It et three thin films constitutes three sides are arranged so as to be U-shaped become part of the four sides,
Among the four sides, one side of the open side of the shape of the co, and one side surface opposite to the one side of the open side, out of, on one side of at least the open side, the resin A bobbin for a rotating electrical machine, wherein the parts are integrally joined by molding. A method of manufacturing a bobbin to be mounted on a protrusion of a stator core of a rotating electrical machine,
A first step of installing three sheet-like insulating thin film bodies integrated in a U-shape into a mold;
By resin molding using the mold, three side surfaces of the four side surfaces of the square frame are configured by the three U-shaped thin film bodies, and among the four side surfaces, the U shape one aspect of the open side of the shape, and, one side facing the one side of the open side, among the provided integrally joined by molding the resin portion on one side of at least the open side A bobbin manufacturing method comprising: a second step of forming the rectangular frame-shaped body around which the winding is wound.

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