JP7621131B2 - Rotating Electric Machine - Google Patents

Description

The present invention relates to rotating electrical machines, and in particular to the winding structure of the core that constitutes the stator of a motor.

One known type of motor is an epicyclic motor, in which a rotor supported by bearings on the outer periphery of a stator rotates. The stator is made up of multiple cores (split cores) assembled in the circumferential direction. A bobbin made of insulating material is attached to the split core, and a coil of enameled wire with a round or square cross section is wound around the bobbin to form split magnetic poles. The stator is made up of these multiple split magnetic poles assembled in a ring shape. Meanwhile, the rotor is made up of a permanent magnet such as a rare earth or ferrite fixed to the inside of the ring member. The rotor rotates when different phase currents are passed through the stator coils, converting electrical energy into mechanical energy.
The winding structure of the stator and the bobbin is disclosed in, for example, Japanese Patent Application Laid-Open No. 2003-233996.

JP 2005-20875 A

In a split-core concentrated winding motor using rectangular cross-section wire for the coil, the split cores 3 are arranged so that the rectangular cross-section wire is at its maximum density within the trapezoidal cross section defined by the three planes defined by the bobbin 4 and the insulation boundary line 9 of the adjacent split cores 3, as shown in Fig. 1. In this case, jump lines 10a, 10b (collectively indicated as 10) that skip the wire by several turns are formed at the axial end of the split core 3. (Fig. 1(b) is a view taken along the line A-A in (a).)
In the winding structure of the bobbin, in the case of a round cross-section electric wire, the position of the coil surface can be controlled by the valleys of the electric wires that make up the coils in the lower layer, but in the case of a rectangular cross-section electric wire, there is no means to control the position of the coil surface. Therefore, due to the tension during winding, the jump wires 10 are stretched to take the shortest route, and deviations from the ideal position occur, as shown in jump wires 10a and 10b in Figure 1(a). As a result, as shown in Figure 1(b), a protrusion 91 is generated in which the jump wires 10 protrude beyond the insulation boundary line 9 of the split core 3. In this state, the insulation performance required for the motor cannot be satisfied, and in the worst case, the split magnetic poles cannot even be assembled in the circumferential direction.

The object of the present invention is to prevent misalignment of the wires of a split core using a rectangular cross-section electric coil. More specifically, the object is to suppress movement of the rectangular cross-section electric coil due to jump wires in a split core motor with concentrated winding.

A preferred example of a rotating electric machine according to the present invention is a rotating electric machine including a stator having teeth including a bobbin and a multilayer coil in which a rectangular cross-section electric wire is wound around the bobbin, and a rotor,
The multi-layer coil has a first layer and a second layer formed adjacent to an outer side of the first layer,
A depression or a protrusion is formed at a predetermined location of the first layer,
This is a rotating electric machine in which the initial turn of the second layer is located outside the terminal turn of the first layer, and the depression or protrusion of the first layer limits the movement of at least a portion of the initial turn of the second layer in the extension direction of the teeth.

In a preferred example, protrusions are provided at least at the corners of the bobbin, and the recesses or protrusions in the first layer are formed by the protrusions.

In a preferred embodiment, multiple protrusions are provided in parallel on both opposing side surfaces of the bobbin in the winding direction of the multilayer coil.

In a preferred example, the terminal turn of the first layer of the rectangular cross-section electric wire is connected to the initial turn of the second layer via a jump wire, and the jump wire is in contact with the recess or protrusion.

According to the present invention, it is possible to prevent misalignment of the rectangular cross-section wire on the side of the coil, and to arrange the flying wire spanning multiple turns on one end face of the coil in the axial direction. This allows the wire on the side of the coil, which is an extension of the flying wire, to be contained within the insulation boundary line, and a coil of rectangular cross-section wire wound densely within the trapezoidal winding range can be obtained, resulting in a highly efficient, high-output motor.

FIG. 1 is a diagram showing a winding structure of a bobbin in the prior art. FIG. 1 is a diagram showing the configuration of an epidural type motor. FIG. 2 is a cross-sectional view of the stator taken along a direction perpendicular to the rotation axis of the rotor. FIG. 2 is a perspective view showing a bobbin according to the first embodiment. FIG. 2 is a perspective view showing a winding structure of a bobbin in the first embodiment. 5A to 5C are diagrams showing a process of winding a wire around a bobbin in the first embodiment. FIG. 4 is a diagram for explaining the width dimension of a protrusion of a bobbin in the first embodiment. 10A to 10C are diagrams showing a process of winding a winding around a bobbin in the second embodiment. FIG. 10 is a diagram for explaining the width dimension of a protrusion of a bobbin in the second embodiment. FIG. 4 is a diagram for explaining the height dimension of a bobbin protrusion. FIG. 4 is a diagram for explaining the dimensions of the corner radius of a bobbin protrusion. FIG. 4 is a diagram for explaining the dimensions of corners of a bobbin protrusion. 13A to 13C are diagrams showing a winding procedure in the third embodiment. FIG. 11 is a diagram illustrating the width dimension of a winding in the third embodiment.

A preferred embodiment of the present invention will now be described with reference to the drawings.

Figure 2 shows the structure of an epidromic motor. An epidromic motor is composed of a stator 1 and a rotor 2 that rotates and is supported by bearings on the outer periphery of the stator 1.

As shown in Figure 3, the stator 1 has multiple split magnetic poles 6 arranged in the circumferential direction, and the coils 5 are housed in a trapezoidal cross-section space defined by three flat surfaces defined by the bobbin 4 and the insulating boundary line 9 of the adjacent split core 3. The split cores 3 are generally made by punching out electromagnetic steel sheets with a thickness of about 0.1 mm to 0.5 mm (the surface has an insulating film to prevent electrical current passing through it) and laminating them by crimping, welding, or bonding with resin.

In a split-core concentrated winding motor using a square cross-section wire for the coil 5, the square cross-section wire is arranged in this trapezoidal cross-section so as to be at maximum density. At the axial end (direction A in Fig. 2) of the split core 3, a jump line 10 (two points 10a and 10b in Fig. 6) is formed, which moves the wire by skipping several turns. The more wire with a larger unit conductor cross-sectional area is wound in the trapezoidal space with the same number of turns, the less copper loss there is, and the more efficient the motor becomes. On the other hand, the more turns are increased for the same unit conductor area, the more ampere turns can be obtained, and the more the motor output increases. Therefore, the efficiency and output of the motor can be increased by increasing the ratio of the conductor area within the trapezoidal cross-section formed by the three planes that make up the bobbin 4 and the insulation boundary 9 of the adjacent split core 3.

FIG. 4 shows the structure of the bobbin 4 .
The bobbin 4 is quadrilaterally made of an insulating material such as PBT or LCP, and an electric wire (winding) such as an enameled wire is wound around the outer periphery to form a quadrilateral coil (rectangular cross-section electric wire coil), and the hollow portion 42 is assembled to the split core 3. Figure 5 shows the bobbin 4 with the rectangular cross-section electric wire coil 5 formed thereon attached to the split core 3.

A distinctive feature is that two protrusions 411, 413, 412, 414 (collectively referred to as 41) are provided on each of the two opposing outer sides of the bobbin 4, parallel to the axial direction (i.e., the direction of the rotation axis of the rotor 2). These protrusions 4 form protrusions on the winding layers of the rectangular cross-section electric wire, suppressing misalignment of the coil side, particularly the movement of the flying wires of the rectangular cross-section electric wire coil in the extension direction of the teeth. The number of protrusions formed on one side corresponds to the number of flying wires 10 occurring on that side. For example, the two protrusions 412, 414 engage with the two flying wires 10a, 10b (Figure 5) to limit their misalignment.

The reason for forming protrusions 41 on the outer surface of each of the two opposing sides of the bobbin 4 is to accommodate winding the wire clockwise from the right and winding counterclockwise from the left. In other words, in the illustrated example, one bobbin 4 can accommodate both clockwise and counterclockwise windings. Note that in the case of only clockwise or only counterclockwise windings, it is sufficient to have a protrusion on only one of the two opposing sides of the bobbin 4.

The protrusions 41 do not need to be continuous in the axial direction, and may be, for example, discontinuous. To significantly prevent misalignment of the jump line, it is preferable to provide the protrusions 41 at least at the corners of the bobbin 4.

Next, the process of winding the wire around the bobbin will be described with reference to FIG.
Here, the position of the protrusion 41 in the winding direction is set at a position one turn before the end position of the flying wire 10. The winding process is carried out in the following steps (1) to (8). Note that (1) to (8) indicate the state of the coil end at each stage.

(1) The state of the bobbin 4 before winding.
(2) The first layer is wound from the bottom (split core 3 side) to the top (winding direction (X direction)). At this time, protrusions 12 are formed by the winding on top of the four protrusions 41.
(3) The winding is folded back at the upper end, and the second layer is wound from top to bottom (Y direction (opposite to X direction)). The second layer of projections 13 are formed on top of the projections of the first layer.
(4) A first flying line 10a is formed from the lower end. Here, the end of the first flying line 10a is hooked onto the protrusion 13a of the second layer and positioned.
(5) From the end position of the first flying line 10a, the third layer is wound from below to above (in the X direction). At this time, the protrusions 14 of the third layer are formed on the protrusions 13b of the second layer.
(6) The winding is folded back at the top end, and the fourth layer is wound from top to bottom. At this time, the fourth layer projection 15 is formed on the third layer projection 14.
(7) A second jump line 10b is formed from the lower folded end. Here, the end of the second jump line 10b is hooked onto the protrusion 15b of the fourth layer and positioned.
(8) Finally, wind from the end position of the second flying wire 10b upwards and finish at the upper end. The final winding of the bobbin 4 is completed as shown in FIG.

As described above, the end of the jump wire 10 is hooked onto the protrusions 13a and 15b formed by winding the coil 5 around the protrusion 41 on the side of the bobbin 4, thereby regulating the position of the coil and suppressing misalignment of the rectangular cross-section wire. This allows the jump wires 10a and 10b to be formed on one end face in the axial direction of the coil 5, and the wire on the side of the coil to be contained inside the insulation boundary line.

Here, as shown in FIG. 7, by setting the width Wp of the protrusion 41 of the bobbin 4 smaller than the minimum width Wc of the rectangular cross-section electric wire 16, it becomes possible to wind the coil on the upper layer of the bobbin without any gaps, in response to the manufacturing dimensional error of the rectangular cross-section electric wire 16.

A second embodiment will be described with reference to FIGS.
The second embodiment uses the same bobbin 4 (FIG. 4) as the first embodiment, but differs in that the position of the projection 41 in the winding direction is set at the end position of the flying wire 10. The other configurations are the same as those of the first embodiment.
The winding process will be described below with reference to Figure 8. (1) to (8) show the state of the coil end at each stage.

(1) The state of the bobbin 4 before winding.
(2) The first layer is wound from the bottom (split core 3 side) to the top (X direction). At this time, protrusions 12 are formed by the winding above the four protrusions 41.
(3) The winding is folded back at the top end, and the second layer is wound from top to bottom (Y direction). Here, after the second layer is wound, the flying wire 10a is formed, and the recess 17a is formed avoiding the protrusion 12a which is the end position of the flying wire 10a. In the third layer, the rectangular cross-section wire is wound around the protrusion 41 in the location where the flying wire 10a is not formed, to form the protrusion 13 of the second layer.
(4) The first flying line 10a is formed from the lower end. Here, the end of the first flying line 10a is embedded and positioned in the depression 17a of the first layer.
(5) From the end position of the first flying line 10a, the third layer is wound from below to above (in the X direction). At this time, the protrusions 14 of the third layer are formed on the protrusions 13 of the second layer.
(6) The winding is turned back at the upper end, and the fourth layer is wound from top to bottom. At this time, a jump line is formed after the fourth layer is wound, and a recess 18b is formed to avoid the protrusion 14b which is the end position of the jump line.
(7) The second jump line 10b is formed from the lower folded end. Here, the end of the second jump line 10b is embedded and positioned in the depression 18b of the third layer.
(8) Finally, wind upward (in the X direction) from the end position of the second jump wire 10b and finish at the upper end.

As described above, the end ends of the jump wires 10a, 10b are embedded in the recesses 17a, 18b formed by winding the coil 5 around the protrusions 41 on the side of the bobbin 4, avoiding the protrusions 12a, 14b, thereby restricting their position and preventing misalignment of the rectangular cross-section wire. This allows the jump wire 10 to be formed on one end face in the axial direction of the coil 5, and the wire on the side of the coil to be contained inside the insulation boundary line.

As shown in FIG. 9, by setting the width Wp of the protrusion 41 of the bobbin 4 larger than the maximum width Wc of the rectangular cross-section electric wire 16, the width Wg of the recess 17a formed in the second layer can be made smaller than the width Wc of the rectangular cross-section electric wire 16 in response to the manufacturing dimensional error of the rectangular cross-section electric wire 16, and the end of the flying wire 10a can be inserted into the recess to obtain a stable fixing force.

This is true for both Examples 1 and 2, but by making the height hp of the bobbin projection 41 larger (r < hp) relative to the minimum radius r of the corner of the rectangular cross-section electric wire 16 as shown in (a) of Figure 10 compared to (b) of Figure 10, it is possible to reduce the positional deviation of the rectangular cross-section electric wire 16 in the winding advance direction relative to the projection 41.

In addition, as can be said for both Examples 1 and 2, if the corner radius rp of the protrusion 41 of the bobbin 4 is made smaller than the corner radius rb of the surface of the bobbin 4 other than the protrusion, as shown in (a) of Figure 11 compared to (b), the area of the protrusion 41 that restrains the end of the flying line becomes larger, and a stable flying line positioning effect can be obtained.

In addition, if the corner shape of the protrusion 41 of the bobbin 4 is an ellipse with the long side a (= rb + hp) in the height direction of the protrusion and the short side b perpendicular to the height of the protrusion 41, and the short side b is smaller than the corner radius rb of the surface of the bobbin 4 other than the protrusion, the area of the protrusion 41 that restrains the end of the flying line will be increased, thereby improving the positioning effect of the end of the flying line.

Example 3 will be described with reference to Figures 13 and 14. In Example 3, instead of providing the protrusions 41 on the bobbin 4 as in Example 1, a recess is formed in the winding layer by devising the winding structure, and the winding is positioned with respect to the flying wires by using this recess.
The winding process will be described below with reference to Figure 13. (1) to (8) show the state of the coil end at each stage.

(1) The state of the bobbin 4 before winding.
(2) The first layer is wound from the bottom (split core 3 side) to the top (X direction).
(3) The winding is folded back at the top end, and the second layer is wound from top to bottom (Y direction). After the second layer is wound, a jump line 10a is formed, and a recess 17a is formed by avoiding the end position of the jump line 10a. Here, the recess 17a is formed by winding the wire 16 on the side of the bobbin 4 with a gap of one wire, as shown in FIG.
(4) The first flying line 10a is formed from the lower end. Here, the end of the first flying line 10a is embedded in the depression 17a of the second layer for positioning.
(5) From the end position of the first jump line 10a, wind the third layer from bottom to top (X direction).
(6) The winding is turned back at the upper end, and the fourth layer is wound from top to bottom. At this time, a jump line is formed after the fourth layer is wound, and a recess 18b is formed at the end position.
(7) The second flying wire 10b is formed from the lower folded end. Here, the wire is wound around the side surface of the bobbin 4 with a space for one wire to form a recess 18b. The end of the second flying wire 10b is embedded and positioned in the recess 18b of the third layer.
(8) Finally, wind upward (in the X direction) from the end position of the second jump wire 10b and finish at the upper end.

As described above, by embedding the end portions of the jump wires 10a, 10b in the recesses 17a, 18b formed by winding the electric wire on the side of the bobbin 4 with a space between each wire, the end position of the jump wires can be regulated and the electric wires can be prevented from shifting. As a result, the jump wire 10 can be formed on one end face in the axial direction of the coil 5, and the electric wire on the side of the coil can be contained inside the insulation boundary line.

The above embodiment describes a concentrated winding motor with an outer rotor type split core, but it can also be applied to a concentrated winding motor with an inner rotor type split core.

1: Stator
2: Rotor
3: Split core
4: Bobbin 41: Protrusion
5: Coil
6: Split pole
9: Insulation boundary
10: Flying lines
12: Protrusion from first layer winding
13: Protrusion due to second layer winding
14: Protrusion due to third layer winding
15: Protrusion due to fourth layer winding
16: Square cross-section wire
17: Depression of second layer winding
18: Depression of the fourth layer winding

Claims (11)

A rotating electric machine having a stator having teeth including a bobbin and a multi-layer coil in which a rectangular cross-section electric wire is wound around the bobbin, and a rotor,
The multi-layer coil has a first layer and a second layer formed adjacent to an outer side of the first layer,
A depression or a protrusion is formed at a predetermined location of the first layer,
The terminal turn of the first layer and the initial turn of the second layer of the rectangular cross-section electric wire are connected via a jump wire, and the jump wire is in contact with the depression or the protrusion,
The initial turn of the second layer is located outside the terminal turn of the first layer, and the depression or protrusion of the first layer limits movement of at least a portion of the initial turn of the second layer in the extension direction of the teeth,
A protrusion is provided at least on a corner of the bobbin,
the protrusions in the first layer are formed by the protrusions provided on the bobbin;
The number of the protrusions generated on the first layer corresponds to the number of the jump lines.
Rotating electric motor. A rotating electric machine having a stator having teeth including a bobbin and a multi-layer coil in which a rectangular cross-section electric wire is wound around the bobbin, and a rotor,
The multi-layer coil has a first layer and a second layer formed adjacent to an outer side of the first layer,
A depression or a protrusion is formed at a predetermined location of the first layer,
The terminal turn of the first layer and the initial turn of the second layer of the rectangular cross-section electric wire are connected via a jump wire, and the jump wire is in contact with the depression or the protrusion,
The initial turn of the second layer is located outside the terminal turn of the first layer, and the depression or protrusion of the first layer limits movement of at least a portion of the initial turn of the second layer in the extension direction of the teeth,
a plurality of projections, the same number of which are provided on each of the opposing side surfaces of the bobbin, in parallel to the winding direction of the multilayer coil;
the protrusions in the first layer are formed by the plurality of protrusions provided on the bobbin;
The number of the protrusions generated on the first layer corresponds to the number of the jump lines.
Rotating electric motor. The end of the flying wire is embedded in a recess formed by winding the square cross-section electric wire around the protrusion formed on the side surface of the bobbin and avoiding the protrusion of the first layer.
The rotating electric machine according to claim 1 . The multilayer coil has a third layer which is a bottom layer located on the inner side adjacent to the first layer,
The initial turn of the third layer is located inside the end turn of the third layer, and the third layer has a protrusion formed by winding the rectangular cross-section electric wire around the protrusion of the bobbin,
3. The rotating electric machine according to claim 1, wherein the projections of the first layer are formed by winding the rectangular cross-section electric wire around the projections of the third layer. The rectangular cross-section wire is a wire whose width varies due to manufacturing errors,
5. The rotating electric machine according to claim 4, wherein the width of said projection of said bobbin is equal to or smaller than the minimum width of said rectangular cross-section electric wire. The multilayer coil includes a third layer, which is a bottom layer located on an inner side adjacent to the first layer,
The initial turn of the third layer is located inside the end turn of the third layer, and the third layer has a protrusion formed by winding the rectangular cross-section electric wire around a protrusion of the bobbin,
2. The rotating electric machine according to claim 1, wherein the turns of the rectangular cross-section electric wire are spaced above the protrusions of the third layer to form the recesses of the first layer. The rectangular cross-section wire is a wire whose width varies due to manufacturing errors,
7. The rotating electric machine according to claim 6, wherein a width of said projection of said bobbin is equal to or greater than a maximum width of said rectangular cross-section electric wire. The corner of the rectangular cross-section wire is rounded with a first radius,
2. The rotating electric machine according to claim 1, wherein the height of said projection of said bobbin is equal to or greater than said first radius. The rotating electric machine of claim 1, wherein the radius of the corners of the protrusions of the bobbin is equal to or smaller than the radius of the corners of the winding body of the bobbin. The rotating electric machine of claim 4, wherein the corner of the protrusion of the bobbin is elliptical, and at least one side of the ellipse is equal to or smaller than the radius of the corner of the winding body of the bobbin. A rotating electric machine having a stator having teeth including a bobbin and a multi-layer coil in which a rectangular cross-section electric wire is wound around the bobbin, and a rotor,
No protrusions are formed on the side surface of the bobbin,
The multi-layer coil has at least a first layer and a second layer formed adjacent to the outside of the first layer,
The terminal turn of the first layer and the initial turn of the second layer of the rectangular cross-section electric wire are connected via a jump wire,
The rectangular cross-section electric wire is wound around a side surface of the bobbin with an interval of one electric wire therebetween to form a recess, and the end portion of the flying wire is embedded in the recess;
A rotating electric machine, wherein the initial turn of the second layer is located outside the terminal turn of the first layer, and the recess of the first layer limits movement of at least a portion of the initial turn of the second layer in the extension direction of the teeth.

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