JP2005027442A

JP2005027442A - Motor and method of manufacturing the same

Info

Publication number: JP2005027442A
Application number: JP2003190951A
Authority: JP
Inventors: Masayuki Takada; 昌亨高田
Original assignee: Matsushita Electric Industrial Co Ltd
Current assignee: Panasonic Holdings Corp
Priority date: 2003-07-03
Filing date: 2003-07-03
Publication date: 2005-01-27
Anticipated expiration: 2023-07-03
Also published as: JP4367030B2

Abstract

<P>PROBLEM TO BE SOLVED: To provide a motor where the downsizing and thinning can be achieved and also the reliability is improved, by suppressing the height of a coil end to be low, and a method of manufacturing the motor. <P>SOLUTION: The axial sectional form of the wound part 7a of an insulator 7 covering a pole tooth 8 is constituted to form approximately a parallelogram where the thickness of the insulator for the amount of the space ΔG which arises by inertia when a winding nozzle shifts from a rectilinear track to a circular track is reduced, whereby even if the winding speed of the winding nozzle is increased, the winding form after winding of a drive coil 2 can be made roughly rectangular, so the height of a coil end projected axially from a stator iron core can be made low. Therefore, a thinned motor can be obtained. Moreover, since the peripheral length of a coil can be shortened, an efficient motor by the reduction of copper loss can be obtained. Moreover, since the winding speed can be increased, processing cost can be reduced. Therefore, the cost reduction of the motor can be achieved. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

【０００１】
【発明の属する技術分野】
本発明は、主に集中巻巻線を有する固定子を用いた電動機およびその製造方法に関するものである。
【０００２】
【従来の技術】
近年、電気機器に搭載するファン駆動用の電動機においては、小型化、薄型化、軽量化、高効率化が強く求められており、このため、固定子の巻線密度を高める必要があり、固定子を構成する極歯毎に駆動コイルを巻装する構成が増えてきている。そして、さらなる薄型化を図るためには、固定子鉄心から軸方向に突出するコイルエンドの高さを低くすることが不可欠となってきている。
【０００３】
従来、この種の電動機は、巻線の巻き乱れを抑制して、整列巻きを容易にする構成が知られている（例えば、特許文献１参照）。
【０００４】
以下、その電動機について図２３〜図２５を参照しながら説明する。
【０００５】
図に示すように、コアの径方向に突出するティース５０に装着され、ティース５０の軸方向端面および両側面を覆う被巻線部５１を備える。ティース５０の根元側および先端側に相当する被巻線部５１の縁からそれぞれ軸方向のみに突出して、この被巻線部５１の周りに巻回された巻線５２が径方向に移動するのを禁止する根元側係止部５３および先端側係止部５４を備え、被巻線部５１の周りに巻線５２を巻回するとき、巻線ノズルが各ティース５０の側面および軸方向端面に対してさらに接近した軌道を通して、巻線５２の整列巻きを実現するために、先端側係止部５４が軸方向に突出する先端のコーナにＲ（アール）または面取りを施し、ティース５０の側方で巻線５２とインシュレータ表面との距離（ワイヤの膨らみ）を小さくするために、被巻線部５１のうちティース５０の軸方向端面を覆う部分の表面は、中央部５１Ｇが両側の端部５１Ｇｃよりも軸方向に突出した構造としている。また、被巻線部５１のうちティース５０の軸方向端面を覆う部分は、両側のコーナに面取りを設ける構造や、両側のコーナが切り取られて階段状に凹んだ構造も開示されている。
【０００６】
また、この種の電動機にはコイルを成形しているものもある（例えば、特許文献２参照）。
【０００７】
以下、その電動機について図２６を参照しながら説明する。
【０００８】
図に示すように、ステータコア６１に形成されるスロット６２をスリット状として、ティース６３の幅を広くし、各スロット６２に挿入される成形コイル体６４を所定巻数の角型コイル６５によって形成し、その角型コイル６５を断面略正方形で一辺がスリット状のスロット幅にほぼ等しい形状とし、この角型コイル６５をスロットの奥行方向に１列に整列し、コイルエンド６４ａは折り曲げ成形する構造である。
【０００９】
また、この種の電動機には固定子鉄心の磁極の幅を変更しているものもある（例えば、特許文献３参照）。
【００１０】
以下、その電動機について図２７〜図３０を参照しながら説明する。
【００１１】
図に示すように、固定子鉄心７０に固定子巻線７５が集中巻に巻回された固定子７６と、この固定子７６に対向して回転可能に保持された回転子７７より構成された電動機であって、固定子鉄心７０は、その中央部に配置された中央部固定子鉄心７１と、この中央部固定子鉄心７１の両側の端部に配置された端部固定子鉄心７２とから構成され、中央部固定子鉄心７１は、薄板鋼板を積層して構成されるとともに、端部固定子鉄心７２は、その固定子磁極部７４の幅が中央部固定子鉄心の固定子磁極部７３と接する側の幅に比べて、端部側の幅が狭い断面形状を有する構造である。また、端部固定子鉄心７２の固定子磁極部７４の断面形状が、半円形状としたものや、台形形状としたもの、端部固定子鉄心７２を構成する薄板鋼板の固定子磁極の幅が端部側に行くに従って、順次狭くなるようにしたものも開示されている。
【００１２】
【特許文献１】
特開２００１−９５１８８号公報
【特許文献２】
特開平７−２９８５２８号公報
【特許文献３】
特開２００３−９４３３号公報
【００１３】
【発明が解決しようとする課題】
このような従来の電動機によれば、特許文献１に記載されているものにおいては、整列巻線を実現するために、巻線ノズルの軌道はティースの側方は直線軌道、軸方向端面側は円弧軌道として巻装しているので、特にティースの幅が狭かったり、スロット開口幅が狭かったり、スロット数が多かったり、軸方向の長さが長い場合などは、巻線の巻回時において、巻線ノズルが直線軌道から円弧軌道に移行する時には、慣性力によって、それまでの直線方向に巻線が膨らんで巻装されるため、図３１に示すような被巻線部の軸方向端面側には被巻線部と巻線の間に隙間ΔＧを生じることとなり、巻装形状は略平行四辺形となって、固定子鉄心から軸方向に突出するコイルエンドの高さを低くすることができないという課題があり、薄型化が図れるとともに、信頼性の向上した電動機を提供することが要求されている。
【００１４】
また、巻線の巻回速度を早くすると、一段と慣性力によって生じる隙間が大きくなり、固定子鉄心から軸方向に突出するコイルエンドの高さを低くすることができないという課題があり、巻線の巻回速度を早くしても、薄型化が図れるとともに、信頼性の向上した電動機を提供することが要求されている。
【００１５】
また、特許文献２に記載されているものにおいては、成形されたコイル形状を角形としているので、角形コイルを強制的に成形するため、コイル絶縁被覆の厚さのバラツキや傷が生じ、信頼性が低下するという課題があり、小型・軽量化が図れるとともに、信頼性の向上した電動機を提供することが要求されている。
【００１６】
また、特許文献３に記載されているものにおいては、特許文献１同様に整列巻線を実現するために、巻線ノズルの軌道は固定子磁極部の側方は直線軌道、軸方向端面側は円弧軌道として巻装しているので、特に固定子磁極部の幅が狭く、スロット開口幅が狭く、軸方向の長さが長い場合は、コイルの巻回時において、巻線ノズルが直線軌道から円弧軌道に移行する時には、慣性力によって、それまでの直線方向にコイルが膨らんで巻装されるため、被巻線部の軸方向端面側には被巻線部とコイルの間に隙間を生じることとなり、巻装形状は略平行四辺形となって、固定子鉄心から軸方向に突出するコイルエンドの高さを低くすることができないという課題があり、薄型化が図れるとともに、信頼性の向上した電動機を提供することが要求されている。
【００１７】
本発明は、このような従来の課題を解決するものであり、コイルエンドの高さを低く抑えることにより、小型化、薄型化が図れるとともに、信頼性の向上した電動機およびその製造方法を提供することを目的としている。
【００１８】
【課題を解決するための手段】
本発明のブラシレスＤＣモータは上記目的を達成するために、スロットを有する固定子鉄心と、この固定子鉄心の極歯単位毎に駆動コイルを巻装した固定子と、この固定子に対向して回転可能に保持された回転子と、前記固定子鉄心と前記駆動コイルとを絶縁するインシュレータとを備え、前記固定子鉄心の前記極歯を覆う前記インシュレータの被巻装部の軸方向断面形状は略平行四辺形としたことを特徴とする電動機の構成としたものである。
【００１９】
本発明によれば、極歯を覆うインシュレータの被巻装部の軸方向断面形状は、巻線ノズルが直線軌道から円弧軌道に移行する時に生じる隙間分のインシュレータの肉厚を削った略平行四辺形となっているので、駆動コイル巻装後の巻形状は略長方形にでき、固定子鉄心から軸方向に突出するコイルエンドの高さを低くすることができるため、薄型化した電動機が得られる。また、コイル周長を短くできるので、銅損の低減による高効率化した電動機が得られる。
【００２０】
また他の手段は、スロットを有する固定子鉄心と、この固定子鉄心の極歯単位毎に駆動コイルを巻装した固定子と、この固定子に対向して回転可能に保持された回転子と、前記固定子鉄心と前記駆動コイルとを絶縁するインシュレータとを備え、前記固定子鉄心の前記極歯を覆う前記インシュレータの被巻装部の角部には丸みを設け、一方の対角を成す前記丸みの曲率は、他方の対角を成す前記丸みの曲率よりも大きく形成したことを特徴とする電動機の構成としたものである。
【００２１】
本発明によれば、極歯を覆うインシュレータの被巻装部の角部には丸みを設け、巻線ノズルが直線軌道から円弧軌道に移行する時に生じる隙間分のインシュレータの肉厚を削った丸みの曲率となっているので、固定子鉄心から軸方向に突出するコイルエンドの高さを低くすることができるため、薄型化した電動機が得られる。また、コイル周長を短くできるので、銅損の低減による高効率化した電動機が得られる。
【００２２】
また他の手段は、スロットを有する固定子鉄心と、この固定子鉄心の極歯単位毎に駆動コイルを巻装した固定子と、この固定子に対向して回転可能に保持された回転子と、前記固定子鉄心と前記駆動コイルとを絶縁するインシュレータとを備え、前記固定子鉄心の前記極歯を覆う前記インシュレータの被巻装部の角部には面取りを設け、一方の対角を成す前記面取りの大きさは、他方の対角を成す前記面取りの大きさよりも大きく形成したことを特徴とする電動機の構成としたものである。
【００２３】
本発明によれば、極歯を覆うインシュレータの被巻装部の角部には面取りを設け、巻線ノズルが直線軌道から円弧軌道に移行する時に生じる隙間分のインシュレータの肉厚を削った面取りの大きさとなっているので、固定子鉄心から軸方向に突出するコイルエンドの高さを低くすることができるため、薄型化した電動機が得られる。また、コイル周長を短くできるとともに、駆動コイルの過度の屈折を防止するので、銅損の低減による高効率化した電動機が得られる。
【００２４】
また他の手段は、スロットを有する固定子鉄心と、この固定子鉄心の極歯単位毎に駆動コイルを巻装した固定子と、この固定子に対向して回転可能に保持された回転子と、前記固定子鉄心と前記駆動コイルとを絶縁する絶縁体とを備え、この絶縁体は前記各極歯の側面を絶縁する絶縁フィルムと、この絶縁フィルムを前記固定子鉄心の軸方向から挟み込む樹脂製のインシュレータより構成され、このインシュレータの被巻装部の軸方向端部角は片側を鈍角に形成し、他方は鋭角に形成するとともに、一方の対角は鈍角に、他方の対角は鋭角に形成したことを特徴とする電動機の構成としたものである。
【００２５】
本発明によれば、被巻装部の軸方向断面の形状は、巻線ノズルが直線軌道から円弧軌道に移行する時に生じる隙間分のインシュレータの肉厚を削った略平行四辺形となっているので、駆動コイル巻装後の巻形状は略長方形にでき、固定子鉄心から軸方向に突出するコイルエンドの高さを低くすることができるため、薄型化した電動機が得られる。また、コイル周長を短くできるので、銅損の低減による高効率化した電動機が得られる。
【００２６】
また他の手段は、スロットを有する固定子鉄心と、この固定子鉄心の極歯単位毎に駆動コイルを巻装した固定子と、この固定子に対向して回転可能に保持された回転子と、前記固定子鉄心と前記駆動コイルとを絶縁する絶縁体とを備え、この絶縁体は前記各極歯の側面を絶縁する絶縁フィルムと、この絶縁フィルムを前記固定子鉄心の軸方向から挟み込む樹脂製のインシュレータより構成され、このインシュレータの被巻装部の軸方向端部角には丸みを設け、この丸みは片側の曲率を大きく形成し、他方の丸みの曲率は小さく形成するとともに、一方の対角を成す前記丸みの曲率は大きく形成し、他方の対角を成す前記丸みの曲率は小さく形成したことを特徴とする電動機の構成としたものである。
【００２７】
本発明によれば、被巻装部の角部には丸みを設け、巻線ノズルが直線軌道から円弧軌道に移行する時に生じる隙間分のインシュレータの肉厚を削った丸みの曲率となっているので、固定子鉄心から軸方向に突出するコイルエンドの高さを低くすることができるため、薄型化した電動機が得られる。また、コイル周長を短くできるとともに、駆動コイルの過度の屈折を防止するので、銅損の低減による高効率化した電動機が得られる。
【００２８】
また他の手段は、スロットを有する固定子鉄心と、この固定子鉄心の極歯単位毎に駆動コイルを巻装した固定子と、この固定子に対向して回転可能に保持された回転子と、前記固定子鉄心と前記駆動コイルとを絶縁する絶縁体とを備え、この絶縁体は前記各極歯の側面を絶縁する絶縁フィルムと、この絶縁フィルムを前記固定子鉄心の軸方向から挟み込む樹脂製のインシュレータより構成され、このインシュレータの被巻装部の軸方向端部角には面取りを設け、この面取りの片側は大きく形成し、他方の面取りは小さく形成するとともに、一方の対角を成す前記面取りは大きく形成し、他方の対角を成す前記面取りは小さく形成したことを特徴とする電動機の構成としたものである。
【００２９】
本発明によれば、被巻装部の角部には面取りを設け、巻線ノズルが直線軌道から円弧軌道に移行する時に生じる隙間分のインシュレータの肉厚を削った面取りの大きさとなっているので、固定子鉄心から軸方向に突出するコイルエンドの高さを低くすることができるため、薄型化した電動機が得られる。また、コイル周長を短くできるので、銅損の低減による高効率化した電動機が得られる。
【００３０】
また他の手段は、スロットを有する薄板鋼板を積層した固定子鉄心と、この固定子鉄心の極歯単位毎に駆動コイルを巻装した固定子と、この固定子に対向して回転可能に保持された回転子とを備え、前記固定子鉄心の軸方向端部には前記極歯の被巻装部の幅が漸減する端部積層鉄心部を設け、この端部積層鉄心部における被巻装部の幅の漸減量は、一方の対角は大きく形成し、他方の対角は小さく形成したことを特徴とする電動機の構成としたものである。
【００３１】
本発明によれば、被巻装部の軸方向断面の形状は、巻線ノズルが直線軌道から円弧軌道に移行する時に生じる隙間分の極歯を削った形状となっているので、固定子鉄心から軸方向に突出するコイルエンドの高さを低くすることができるため、薄型化した電動機が得られる。
【００３２】
また他の手段は、粉末磁性材料を成形固化して形成したスロットを有する固定子鉄心と、この固定子鉄心の極歯単位毎に駆動コイルを巻装した固定子と、この固定子に対向して回転可能に保持された回転子とを備え、前記極歯の被巻装部の軸方向断面形状は略平行四辺形としたことを特徴とする電動機の構成としたものである。
【００３３】
本発明によれば、被巻装部の軸方向断面の形状は、巻線ノズルが直線軌道から円弧軌道に移行する時に生じる隙間分の極歯を削った略平行四辺形となっているので、駆動コイル巻装後の巻形状は略長方形にでき、固定子鉄心から軸方向に突出するコイルエンドの高さを低くすることができるため、薄型化した電動機が得られる。また、コイル周長を短くできるので、銅損の低減による高効率化した電動機が得られる。
【００３４】
また他の手段は、粉末磁性材料を成形固化して形成したスロットを有する固定子鉄心と、この固定子鉄心の極歯単位毎に駆動コイルを巻装した固定子と、この固定子に対向して回転可能に保持された回転子とを備え、前記固定子鉄心の極歯の被巻装部角には丸みを設け、一方の対角を成す前記丸みの曲率は、他方の対角を成す前記丸みの曲率よりも大きく形成したことを特徴とする電動機の構成としたものである。
【００３５】
本発明によれば、被巻装部の軸方向断面の形状は、巻線ノズルが直線軌道から円弧軌道に移行する時に生じる隙間分の極歯を削った形状となっているので、固定子鉄心から軸方向に突出するコイルエンドの高さを低くすることができるため、薄型化した電動機が得られる。また、コイル周長を短くできるとともに、駆動コイルの過度の屈折を防止するので、銅損の低減による高効率化した電動機が得られる。
【００３６】
また他の手段は、粉末磁性材料を成形固化して形成したスロットを有する固定子鉄心と、この固定子鉄心の極歯単位毎に駆動コイルを巻装した固定子と、この固定子に対向して回転可能に保持された回転子とを備え、前記固定子鉄心の前記極歯の被巻装部角には面取りを設け、一方の対角を成す前記面取りの大きさは、他方の対角を成す前記面取りの大きさよりも大きく形成したことを特徴とする電動機の構成としたものである。
【００３７】
本発明によれば、被巻装部の軸方向断面の形状は、巻線ノズルが直線軌道から円弧軌道に移行する時に生じる隙間分の極歯を削った形状となっているので、固定子鉄心から軸方向に突出するコイルエンドの高さを低くすることができるため、薄型化した電動機が得られる。
【００３８】
また他の手段は、インシュレータには前記回転子側への駆動コイルの崩れを防止する鍔部を設け、この鍔部の角部は円弧状とし、この円弧部の曲率は前記被巻装部の角部が鈍角を形成する側、または前記被巻装部の角部丸みの曲率が大きい側、または前記被巻装部の角部面取りが大きい側は、前記被巻装部の角部が鋭角を形成している側、または前記被巻装部の角部丸みの曲率が小さい側、または前記被巻装部の角部面取りが小さい側の前記円弧部曲率よりも大きくしたことを特徴とする電動機の構成としたものである。
【００３９】
本発明によれば、鍔部の円弧部の曲率が大きい側の巻線ノズルの軌道は、直線軌道から円弧軌道への移行が早くできることから、駆動コイルとインシュレータの間の隙間が小さくなるので、固定子鉄心から軸方向に突出するコイルエンドの高さを低くすることができるため、薄型化した電動機が得られる。
【００４０】
また他の手段は、インシュレータには前記回転子側への駆動コイルの崩れを防止する鍔部を設け、この鍔部の角部には面取り部を設け、この面取り部の大きさは前記被巻装部の角部が鈍角を形成する側、または前記被巻装部の角部丸みの曲率が大きい側、または前記被巻装部の角部面取りが大きい側は、前記被巻装部の角部が鋭角を形成している側、または前記被巻装部の角部丸みの曲率が小さい側、または前記被巻装部の角部面取りが小さい側の面取りよりも大きくしたことを特徴とする電動機の構成としたものである。
【００４１】
本発明によれば、鍔部角の面取り部の面取りが大きい側の巻線ノズルの軌道は、直線軌道から円弧軌道への移行が早くできることから、駆動コイルとインシュレータの間の隙間が小さくなるので、固定子鉄心から軸方向に突出するコイルエンドの高さを低くすることができるため、薄型化した電動機が得られる。
【００４２】
また他の手段は、インシュレータには前記回転子側への駆動コイルの崩れを防止する鍔部を設け、この鍔部には切欠きを設け、この切欠きは前記被巻装部の角部が鈍角を形成する側、または前記被巻装部の角部丸みの曲率が大きい側、または前記被巻装部の角部面取りが大きい側に設けたことを特徴とする電動機の構成としたものである。
【００４３】
本発明によれば、鍔部の切欠きを有する側の巻線ノズルの軌道は、直線軌道から円弧軌道への移行が早くできることから、駆動コイルとインシュレータの間の隙間が小さくなるので、固定子鉄心から軸方向に突出するコイルエンドの高さを低くすることができるため、薄型化した電動機が得られる。
【００４４】
また他の手段は、極歯には回転子側への駆動コイルの崩れを防止する鍔部を設け、この鍔部の角部は円弧状とし、この円弧部の曲率は前記被巻装部の幅の漸減量が大きい側、または前記被巻装部の角部が鈍角を形成する側、または前記被巻装部の角部丸みの曲率が大きい側、または前記被巻装部の角部面取りが大きい側は、前記被巻装部の幅の漸減量が小さい側、または前記被巻装部の角部が鋭角を形成する側、または前記被巻装部の角部丸みの曲率が小さい側、または前記被巻装部の角部面取りが小さい側の円弧部曲率よりも大きくしたことを特徴とする電動機の構成としたものである。
【００４５】
本発明によれば、鍔部の円弧状角部の曲率が大きい側の巻線ノズルの軌道は、直線軌道から円弧軌道への移行が早くできることから、駆動コイルと固定子鉄心の間の隙間が小さくなるので、固定子鉄心から軸方向に突出するコイルエンドの高さを低くすることができるため、薄型化した電動機が得られる。
【００４６】
また他の手段は、極歯には回転子側への駆動コイルの崩れを防止する鍔部を設け、この鍔部の角部には面取り部を設け、この面取り部の大きさは前記被巻装部の幅の漸減量が大きい側、または前記被巻装部の角部が鈍角を形成する側、または前記被巻装部の角部丸みの曲率が大きい側、または前記被巻装部の角部面取りが大きい側は、前記被巻装部の幅の漸減量が小さい側、または前記被巻装部の角部が鋭角を形成する側、または前記被巻装部の角部丸みの曲率が小さい側、または前記被巻装部の角部面取りが小さい側の面取りよりも大きくしたことを特徴とする電動機の構成としたものである。
【００４７】
本発明によれば、鍔部の面取りが大きい側の巻線ノズルの軌道は、直線軌道から円弧軌道への移行が早くできることから、駆動コイルと固定子鉄心の間の隙間が小さくなるので、固定子鉄心から軸方向に突出するコイルエンドの高さを低くすることができるため、薄型化した電動機が得られる。
【００４８】
また他の手段は、極歯には回転子側への駆動コイルの崩れを防止する鍔部を設け、この鍔部には切欠きを設け、この切欠きは前記被巻装部の幅の漸減量が大きい側、または前記被巻装部の角部が鈍角を形成する側、または前記被巻装部の角部丸みの曲率が大きい側、または前記被巻装部の角部面取りが大きい側に設けたことを特徴とする電動機の構成としたものである。
【００４９】
本発明によれば、鍔部の切欠きを有する側の巻線ノズルの軌道は、直線軌道から円弧軌道への移行が早くできることから、駆動コイルと固定子鉄心の間の隙間が小さくなるので、固定子鉄心から軸方向に突出するコイルエンドの高さを低くすることができるため、薄型化した電動機が得られる。
【００５０】
また他の手段は、巻線ノズルがスロット開口部を通過して、各極歯の周りを回転して駆動コイルを巻装する電動機の製造方法であって、前記巻線ノズルの軌道は固定子鉄心のスロット内は直線状に、固定子鉄心の軸方向端面側は円弧状とするとともに、直線状軌道から円弧状軌道に移る側の円弧の曲率は、円弧状軌道から直線状軌道に移る側の円弧の曲率よりも大きくしたことを特徴とする電動機の製造方法としたものである。
【００５１】
本発明によれば、直線軌道から円弧軌道への移行が早くできることから、駆動コイルと固定子鉄心の間の隙間が小さくなるので、固定子鉄心から軸方向に突出するコイルエンドの高さを低くすることができるため、薄型化した電動機の製造方法が得られる。
【００５２】
【発明の実施の形態】
請求項１に記載の発明は、固定子鉄心の極歯単位毎に駆動コイルを巻装した固定子と、この固定子に対向して回転可能に保持された回転子と、前記固定子鉄心と前記駆動コイルとを絶縁するインシュレータとを備え、前記固定子鉄心の前記極歯を覆う前記インシュレータの被巻装部の軸方向断面の形状は略平行四辺形としたことを特徴とする電動機の構成とすることにより、巻線巻装後の巻形状は略長方形になり、固定子鉄心から軸方向に突出するコイルエンドの高さが低くなるとともに、コイル周長が短くなるという作用を有する。
【００５３】
請求項２に記載の発明は、固定子鉄心の極歯単位毎に駆動コイルを巻装した固定子と、この固定子に対向して回転可能に保持された回転子と、前記固定子鉄心と前記駆動コイルとを絶縁するインシュレータとを備え、前記固定子鉄心の前記極歯を覆う前記インシュレータの被巻装部の角部には丸みを設け、一方の対角を成す前記丸みの曲率は、他方の対角を成す前記丸みの曲率よりも大きく形成したことを特徴とする電動機の構成とすることにより、固定子鉄心から軸方向に突出するコイルエンドの高さが低くなるとともに、コイル周長が短くなるという作用を有する。
【００５４】
請求項３に記載の発明は、固定子鉄心の極歯単位毎に駆動コイルを巻装した固定子と、この固定子に対向して回転可能に保持された回転子と、前記固定子鉄心と前記駆動コイルとを絶縁するインシュレータとを備え、前記固定子鉄心の前記極歯を覆う前記インシュレータの被巻装部の角部には面取りを設け、一方の対角を成す前記面取りの大きさは、他方の対角を成す前記面取りの大きさよりも大きく形成したことを特徴とする電動機の構成とすることにより、固定子鉄心から軸方向に突出するコイルエンドの高さが低くなるとともに、コイル周長が短くなるという作用を有する。
【００５５】
請求項４に記載の発明は、固定子鉄心の極歯単位毎に駆動コイルを巻装した固定子と、この固定子に対向して回転可能に保持された回転子と、前記固定子鉄心と前記駆動コイルとを絶縁する絶縁体とを備え、この絶縁体は前記各極歯の側面を絶縁する絶縁フィルムと、この絶縁フィルムを前記固定子鉄心の軸方向から挟み込む樹脂製のインシュレータより構成され、このインシュレータの被巻装部の軸方向端部角は片側を鈍角に形成し、他方は鋭角に形成するとともに、一方の対角は鈍角に、他方の対角は鋭角に形成したことを特徴とする電動機の構成とすることにより、巻線巻装後の巻形状は略長方形になり、固定子鉄心から軸方向に突出するコイルエンドの高さが低くなるとともに、コイル周長が短くなるという作用を有する。
【００５６】
請求項５に記載の発明は、固定子鉄心の極歯単位毎に駆動コイルを巻装した固定子と、この固定子に対向して回転可能に保持された回転子と、前記固定子鉄心と前記駆動コイルとを絶縁する絶縁体とを備え、この絶縁体は前記各極歯の側面を絶縁する絶縁フィルムと、この絶縁フィルムを前記固定子鉄心の軸方向から挟み込む樹脂製のインシュレータより構成され、このインシュレータの被巻装部の軸方向端部角には丸みを設け、この丸みは片側の曲率を大きく形成し、他方の丸みの曲率は小さく形成するとともに、一方の対角を成す前記丸みの曲率を大きく形成し、他方の対角を成す前記丸みの曲率は小さく形成したことを特徴とする電動機の構成とすることにより、固定子鉄心から軸方向に突出するコイルエンドの高さが低くなるとともに、コイル周長が短くなるという作用を有する。
【００５７】
請求項６に記載の発明は、スロットを有する固定子鉄心と、この固定子鉄心の極歯単位毎に駆動コイルを巻装した固定子と、この固定子に対向して回転可能に保持された回転子と、前記固定子鉄心と前記駆動コイルとを絶縁する絶縁体とを備え、この絶縁体は前記各極歯の側面を絶縁する絶縁フィルムと、この絶縁フィルムを前記固定子鉄心の軸方向から挟み込む樹脂製のインシュレータより構成され、このインシュレータの被巻装部の軸方向端部角には面取りを設け、この面取りの片側は大きく形成し、他方の面取りは小さく形成するとともに、一方の対角を成す面取りは大きく形成し、他方の対角を成す面取りは小さく形成したことを特徴とする電動機の構成とすることにより、固定子鉄心から軸方向に突出するコイルエンドの高さが低くなるとともに、コイル周長が短くなるという作用を有する。
【００５８】
請求項７に記載の発明は、スロットを有する薄板鋼板を積層した固定子鉄心と、この固定子鉄心の極歯単位毎に駆動コイルを巻装した固定子と、この固定子に対向して回転可能に保持された回転子とを備え、前記固定子鉄心の軸方向端部には前記極歯の被巻装部の幅が漸減する端部積層鉄心部を設け、この端部積層鉄心部における被巻装部の幅の漸減量は、一方の対角は大きく形成し、他方の対角は小さく形成したことを特徴とする電動機の構成とすることにより、固定子鉄心から軸方向に突出するコイルエンドの高さが低くなるとともに、コイル周長が短くなるという作用を有する。
【００５９】
請求項８に記載の発明は、粉末磁性材料を成形固化して形成したスロットを有する固定子鉄心と、この固定子鉄心の極歯単位毎に駆動コイルを巻装した固定子と、この固定子に対向して回転可能に保持された回転子とを備え、前記極歯の被巻装部の軸方向断面形状は略平行四辺形としたことを特徴とする電動機の構成とすることにより、固定子鉄心から軸方向に突出するコイルエンドの高さが低くなるとともに、コイル周長が短くなるという作用を有する。
【００６０】
請求項９に記載の発明は、粉末磁性材料を成形固化して形成したスロットを有する固定子鉄心と、この固定子鉄心の極歯単位毎に駆動コイルを巻装した固定子と、この固定子に対向して回転可能に保持された回転子とを備え、前記固定子鉄心の前記極歯の被巻装部角には丸みを設け、一方の対角を成す前記丸みの曲率は、他方の対角を成す前記丸みの曲率よりも大きく形成したことを特徴とする電動機の構成とすることにより、固定子鉄心から軸方向に突出するコイルエンドの高さが低くなるとともに、コイル周長が短くなるという作用を有する。
【００６１】
請求項１０に記載の発明は、粉末磁性材料を成形固化して形成したスロットを有する固定子鉄心と、この固定子鉄心の極歯単位毎に駆動コイルを巻装した固定子と、この固定子に対向して回転可能に保持された回転子とを備え、前記固定子鉄心の前記極歯の被巻装部角には面取りを設け、一方の対角を成す前記面取りの大きさは、他方の対角を成す前記面取りの大きさよりも大きく形成したことを特徴とする電動機の構成とすることにより、固定子鉄心から軸方向に突出するコイルエンドの高さが低くなるとともに、コイル周長が短くなるという作用を有する。
【００６２】
請求項１１に記載の発明は、インシュレータには回転子側への駆動コイルの崩れを防止する鍔部を設け、この鍔部の角部は円弧状とし、この円弧部の曲率は前記被巻装部の角部が鈍角を形成する側、または前記被巻装部の角部丸みの曲率が大きい側、または前記被巻装部の角部面取りが大きい側は、前記被巻装部の角部が鋭角を形成している側、または前記被巻装部の角部丸みの曲率が小さい側、または被巻装部の角部面取りが小さい側の円弧部曲率よりも大きくしたことを特徴とする電動機の構成とすることにより、鍔部の円弧部の曲率が大きい側の巻線ノズルの軌道は、直線軌道から円弧軌道への移行が早くできるため、駆動コイルとインシュレータの間の隙間が小さくなるので、固定子鉄心から軸方向に突出するコイルエンドの高さを低くなるとともに、コイル周長が短くなるという作用を有する。
【００６３】
請求項１２に記載の発明は、インシュレータには回転子側への駆動コイルの崩れを防止する鍔部を設け、この鍔部の角部には面取り部を設け、この鍔部角面取り部の面取りの大きさは前記被巻装部の角部が鈍角を形成する側、または前記被巻装部の角部丸みの曲率が大きい側、または前記被巻装部の角部面取りが大きい側は、前記被巻装部の角部が鋭角を形成している側、または前記被巻装部の角部丸みの曲率が小さい側、または前記被巻装部の角部面取りが小さい側の前記鍔部角面取り部の面取りよりも大きくしたことを特徴とする電動機の構成により、鍔部角の面取り部の面取りが大きい側の巻線ノズルの軌道は、直線軌道から円弧軌道への移行が早くできるため、駆動コイルとインシュレータの間の隙間が小さくなるので、固定子鉄心から軸方向に突出するコイルエンドの高さを低くなるとともに、コイル周長が短くなるという作用を有する。
【００６４】
請求項１３に記載の発明は、インシュレータには回転子側への駆動コイルの崩れを防止する鍔部を設け、この鍔部には切欠きを設け、この切欠きは前記被巻装部の角部が鈍角を形成する側、または前記被巻装部の角部丸みの曲率が大きい側、または前記被巻装部の角部面取りが大きい側に設けたことを特徴とする電動機の構成とすることにより、鍔部の切欠きを有する側の巻線ノズルの軌道は、直線軌道から円弧軌道への移行が早くできるため、駆動コイルとインシュレータの間の隙間が小さくなるので、固定子鉄心から軸方向に突出するコイルエンドの高さを低くなるとともに、コイル周長が短くなるという作用を有する。
【００６５】
請求項１４に記載の発明は、極歯には回転子側への駆動コイルの崩れを防止する鍔部を設け、この鍔部の角部は円弧状とし、この円弧部の曲率は前記被巻装部の幅の漸減量が大きい側、または前記被巻装部の角部が鈍角を形成する側、または前記被巻装部の角部丸みの曲率が大きい側、または前記被巻装部の角部面取りが大きい側は、前記被巻装部の幅の漸減量が小さい側、または前記被巻装部の角部が鋭角を形成する側、または前記被巻装部の角部丸みの曲率が小さい側、または前記被巻装部の角部面取りが小さい側の円弧部曲率よりも大きくしたことを特徴とする電動機の構成とすることにより、鍔部の円弧部の曲率が大きい側の巻線ノズルの軌道は、直線軌道から円弧軌道への移行が早くできるため、駆動コイルと固定子鉄心の間の隙間が小さくなるので、固定子鉄心から軸方向に突出するコイルエンドの高さを低くなるとともに、コイル周長が短くなるという作用を有する。
【００６６】
請求項１５に記載の発明は、極歯には回転子側への駆動コイルの崩れを防止する鍔部を設け、この鍔部の角部には面取り部を設け、この面取り部の大きさは前記被巻装部の幅の漸減量が大きい側、または前記被巻装部の角部が鈍角を形成する側、または前記被巻装部の角部丸みの曲率が大きい側、または前記被巻装部の角部面取りが大きい側は、前記被巻装部の幅の漸減量が小さい側、または前記被巻装部の角部が鋭角を形成する側、または前記被巻装部の角部丸みの曲率が小さい側、または前記被巻装部の角部面取りが小さい側の面取りよりも大きくしたことを特徴とする電動機の構成とすることにより、鍔部の面取りが大きい側の巻線ノズルの軌道は、直線軌道から円弧軌道への移行が早くできるため、駆動コイルと固定子鉄心の間の隙間が小さくなるので、固定子鉄心から軸方向に突出するコイルエンドの高さを低くなるとともに、コイル周長が短くなるという作用を有する。
【００６７】
請求項１６に記載の発明は、極歯には回転子側への駆動コイルの崩れを防止する鍔部を設け、この鍔部には切欠きを設け、この切欠きは前記被巻装部の幅の漸減量が大きい側、または前記被巻装部の角部丸みの曲率が大きい側、または前記被巻装部の角部が鈍角を形成する側、または前記被巻装部の角部面取りが大きい側に設けたことを特徴とする電動機の構成とすることにより、鍔部の切欠きを有する側の巻線ノズルの軌道は、直線軌道から円弧軌道への移行が早くできるため、駆動コイルと固定子鉄心の間の隙間が小さくなるので、固定子鉄心から軸方向に突出するコイルエンドの高さを低くなるとともに、コイル周長が短くなるという作用を有する。
【００６８】
請求項１７に記載の発明は、巻線ノズルがスロット開口部を通過して、各極歯の周りを回転して駆動コイルを巻装する電動機の製造方法であって、前記巻線ノズルの軌道は固定子鉄心のスロット内は直線状に、固定子鉄心の軸方向端面側は円弧状とするとともに、直線状軌道から円弧状軌道に移る側の円弧の曲率は、円弧状軌道から直線状軌道に移る側の円弧の曲率よりも大きくしたことを特徴とする電動機の製造方法とすることにより、巻線ノズルが直線軌道から円弧軌道への移行が早くできるので、駆動コイルと固定子鉄心の間の隙間が小さくなるという作用を有する。
【００６９】
以下、本発明の実施例について図１〜図２２を参照しながら説明する。
【００７０】
【実施例】
（実施例１）
図１〜図４に示すように、１は電動機で、１０は複数のスロットを有する珪素鋼板などの薄板鋼板を積層した固定子鉄心１０ａに絶縁材にて形成されたインシュレータ７を介して駆動コイル２を巻装した固定子で、固定子１０は熱硬化性樹脂１２にてモールド成形されて外被を形成しており、１１はブラケットで軸受け６を保持している。３はプラスチックマグネットを射出成形時に極配向させてシャフト９と一体成形して形成した磁石回転子であり、固定子１０内周側に回転自在に配置されている。４は磁石回転子３の磁極位置を検知するホールＩＣで、１５はホールＩＣ４の出力信号に基づいて駆動コイル２への通電を制御する駆動ＩＣである。１４はホールＩＣ４、駆動ＩＣ１５、その他電子部品を実装したプリント基板で、電動機１に内蔵されている。８は極歯で、この極歯８単位毎にインシュレータ７を介して駆動コイル２が集中巻線されている。そして、極歯８の先端部には磁石回転子３の回転方向に張り出したポールピース部８ａが配置されており、このポールピース部８ａのインシュレータ７には駆動コイル２が磁石回転子３側への崩れを防止する鍔部１３を設け、この鍔部１３の角部は円弧状となっている。そして、極歯８を覆うインシュレータ７の被巻装部７ａの軸方向断面形状は略平行四辺形となっており、鈍角部７ｂと鋭角部７ｃには丸みを設けてある。そして、鍔部１３角の円弧部１６において、鈍角部７ｂ側の鍔部１３角は曲率の大きな円弧部１６ａを形成し、鋭角部７ｃ側の鍔部１３角は曲率の小さな円弧部１６ｂを形成した構成である。
【００７１】
このような本発明の電動機１によれば、極歯８を覆うインシュレータ７の被巻装部７ａの軸方向断面形状は、巻線ノズルが直線軌道から円弧軌道に移行する時に慣性力によって生じる隙間分ΔＧのインシュレータの肉厚を削った略平行四辺形となっているので、巻線ノズルの巻回速度を早くしても、駆動コイル２の巻装後の巻形状は略長方形にでき、固定子鉄心から軸方向に突出するコイルエンドの高さを低くすることができるため、薄型化した電動機が得られる。また、コイル周長を短くできるので、銅損の低減による高効率化した電動機が得られる。また、巻装速度が早くできることから加工コストの削減ができることから電動機の低コスト化が実現できる。
【００７２】
また、鍔部１３角の円弧部１６において、極歯８を覆うインシュレータ７の被巻装部７ａの角が鈍角を形成している鈍角部７ｂ側の円弧部１６ａの曲率を大きく形成しているので、巻線ノズルが直線軌道から円弧軌道に移行するタイミングを早くできることから、駆動コイル２とインシュレータ７の間の隙間が小さくなるので、固定子鉄心１０ａから軸方向に突出するコイルエンドの高さが、さらに低くなるとともに、コイル周長も短くなるため、駆動コイル２の抵抗値が低くなり、銅損がさらに低減できるので、一層の薄型化、高効率化が実現できる電動機が得られる。
【００７３】
なお、本実施例１では固定子の内周側に配置された回転子が回転する内転型の電動機としたが、固定子の外周側に配置された回転子が回転する外転型の電動機としても良く、その作用効果に差異を生じない。
【００７４】
また、本実施例１では駆動回路を内蔵する電動機の構成としたが、駆動回路を内蔵しないセンサレス型の電動機としても良く、その作用効果に差異を生じない。
【００７５】
また、本実施例１では回転子に永久磁石を配した直流電動機の構成としたが、永久磁石を使用しない誘導電動機や、リラクタンスモータとしても良く、集中巻線を施す電動機であれば、その作用効果に差異を生じない。
【００７６】
また、図５に示すように、極歯８を覆うインシュレータ７の被巻装部７ａの角に丸み５を設け、一方の対角を成す丸み５ａの曲率を、他方の対角を成す丸み５ｂの曲率よりも大きく形成するとともに、巻線ノズルが直線軌道から円弧軌道に移行する時に慣性力によって生じる隙間分ΔＧを丸みの曲率に差を設けた構成としても、固定子鉄心１０ａと駆動コイル２の距離が短くなるので、固定子鉄心から軸方向に突出するコイルエンドの高さが低くなり、薄型化した電動機が得られる。また、コイル周長を短くできるとともに、駆動コイルの屈折による抵抗値の増加を抑制できるので、銅損の低減による一層の高効率化を実現した電動機が得られる。
【００７７】
また、図６に示すように、極歯８を覆うインシュレータ７の被巻装部７ａの角に面取り１７を設け、一方の対角を成す面取り１７ａの大きさを、他方の対角を成す面取り１７ｂの大きさよりも大きく形成するとともに、巻線ノズルが直線軌道から円弧軌道に移行する時に慣性力によって生じる隙間分ΔＧを面取りの大きさに差を設けた構成としても、固定子鉄心１０ａと駆動コイル２の距離が短くなるので、固定子鉄心から軸方向に突出するコイルエンドの高さが低くなり、薄型化した電動機が得られる。また、コイル周長を短くできるので、銅損の低減による高効率化した電動機が得られる。
【００７８】
また、図７に示すように、駆動コイル２と固定子鉄心１０ａの絶縁手段において、極歯８の側方はポリエステルフィルムなどの絶縁フィルム１８を配し、この絶縁フィルム１８を軸方向から樹脂製のインシュレータ１９にて挟み込む構造とし、このインシュレータ１９の被巻装部１９ａの軸方向端部角は片側を鈍角１９ｂに形成し、他方は鋭角１９ｃに形成するとともに、一方の対角は鈍角に、他方の対角は鋭角に形成する構成としても、被巻線部の軸方向断面の形状は、巻線ノズルが直線軌道から円弧軌道に移行する時に慣性力によって生じる隙間分ΔＧのインシュレータの肉厚を削った略平行四辺形となっているので、駆動コイル２の巻装後の巻形状は略長方形にでき、固定子鉄心から軸方向に突出するコイルエンドの高さを低くすることができるため、薄型化した電動機が得られる。また、コイル周長を短くできるので、銅損の低減による高効率化した電動機が得られる。
【００７９】
また、図８に示すように、駆動コイル２と固定子鉄心１０ａの絶縁手段において、極歯８の側方はポリエステルフィルムなどの絶縁フィルム１８を配し、この絶縁フィルム１８を軸方向から樹脂製のインシュレータ２０にて挟み込む構造とし、このインシュレータ２０の被巻装部２０ａの軸方向端部角には丸み２１を設け、この丸み２１の曲率は片側を大きく形成し、他方は小さく形成するとともに、一方の対角の丸み２１ａの曲率は大きく、他方の対角の丸み２１ｂの曲率は小さく形成する構成としても、巻線ノズルが直線軌道から円弧軌道に移行する時に慣性力によって生じる隙間分ΔＧを丸みの曲率に差を設けてあるので、固定子鉄心１０ａと駆動コイル２の距離が短くなるので、固定子鉄心から軸方向に突出するコイルエンドの高さが低くなり、薄型化した電動機が得られる。また、コイル周長を短くできるとともに、駆動コイルの屈折による抵抗値の増加を抑制できるので、銅損の低減による一層の高効率化を実現した電動機が得られる。
【００８０】
また、図９に示すように、駆動コイル２と固定子鉄心１０ａの絶縁手段において、極歯８の側方はポリエステルフィルムなどの絶縁フィルム１８を配し、この絶縁フィルム１８を軸方向から樹脂製のインシュレータ２２にて挟み込む構造とし、このインシュレータ２２の被巻装部２２ａの軸方向端部角には面取り２３を設け、この面取り２３の大きさは片側を大きく形成し、他方は小さく形成するとともに、一方の対角の面取り２３ａの大きさは大きく、他方の対角の面取り２３ｂの大きさは小さく形成する構成としても、巻線ノズルが直線軌道から円弧軌道に移行する時に慣性力によって生じる隙間分ΔＧを面取りの大きさに差を設けてあるので、固定子鉄心１０ａと駆動コイル２の距離が短くなるので、固定子鉄心から軸方向に突出するコイルエンドの高さが低くなり、薄型化した電動機が得られる。また、コイル周長を短くできるので、銅損の低減による高効率化した電動機が得られる。
【００８１】
また、図１０に示すように、ポールピース部８ａのインシュレータ７，１９，２０，２２には駆動コイル２が磁石回転子３側への崩れを防止する鍔部２４を設け、鍔部２４の角に面取りを配し、この鍔部２４角の面取り部において、極歯８を覆うインシュレータ７，１９の被巻装部７ａ，１９ａ角が鈍角を形成している鈍角部７ｂ，１９ｂ側、もしくは極歯８を覆うインシュレータ７，２０の被巻装部７ａ，２０ａ角の曲率が大きい丸み５ａ，２１ａ側、もしくは極歯８を覆うインシュレータ７，２２の被巻線部７ａ，２２ａ角の大きい面取り１７ａ，２３ａ側の鍔部２４角の面取り部２４ａを大きく形成した構成とすることによっても、巻線ノズルが直線軌道から円弧軌道に移行するタイミングを早くできることから、駆動コイル２とインシュレータ７の間の隙間が小さくなるので、固定子鉄心１０ａから軸方向に突出するコイルエンドの高さが、さらに低くなるとともに、コイル周長も短くなるため、駆動コイル２の抵抗値が低くなり、銅損がさらに低減できるので、一層の薄型化、高効率化が実現できる電動機が得られる。
【００８２】
また、図１１に示すように、ポールピース部８ａのインシュレータ７，１９，２０，２２には駆動コイル２が磁石回転子３側への崩れを防止する鍔部２５を設け、この鍔部２５において、極歯８を覆うインシュレータ７，１９の被巻装部７ａ，１９ａ角が鈍角を形成している鈍角部７ｂ，１９ｂ側、もしくは極歯８を覆うインシュレータ７，２０の被巻装部７ａ，２０ａ角の曲率が大きい丸み５ａ，２１ａ側、もしくは極歯８を覆うインシュレータ７，２２の被巻装部７ａ，２２ａ角の大きい面取り１７ａ，２３ａ側の鍔部２５角に切欠き２６を配した構成とすることによっても、巻線ノズルが直線軌道から円弧軌道に移行するタイミングを早くできることから、駆動コイル２と固定子鉄心１０ａの間の隙間が小さくなるので、固定子鉄心１０ａから軸方向に突出するコイルエンドの高さが、さらに低くなるとともに、コイル周長も短くなるため、駆動コイル２の抵抗値が低くなり、銅損がさらに低減できるので、一層の薄型化、高効率化が実現できる電動機が得られる。
【００８３】
（実施例２）
図１２および図１３に示すように、２７は複数のスロットを有する珪素鋼板などの薄板鋼板を積層した固定子鉄心２７ａに駆動コイル２を巻装した固定子で、２８は極歯で、この極歯２８単位毎に駆動コイル２が集中巻線されている。固定子鉄心２７ａにおいて、軸方向両端部には極歯２８の被巻装部３０の幅が漸減する端部積層鉄心部２９を設け、この端部積層鉄心部２９において、被巻装部３０の幅における漸減量は、一方の対角の漸減量ΔＷ１は大きくし、他方の対角の漸減量ΔＷ２は小さく形成し、極歯２８における先端のポールピース部２８ａの幅は同一としている。そして、その他の構成は実施例１と同じであり、詳細な説明は省略する。
【００８４】
このような本発明の電動機によれば、極歯２８における被巻装部３０の軸方向断面の形状は、巻線ノズルが直線軌道から円弧軌道に移行する時に生じる隙間分ΔＧの極歯を削った形状となっているので、固定子鉄心２７ａから軸方向に突出するコイルエンドの高さを低くすることができ、コイル周長も短くなるため、駆動コイル２の抵抗値が低くなり、銅損の低減ができるので、一層の薄型化を実現できる電動機が得られる。ここで、固定子鉄心２７ａの体積は減少するので、磁束が小さくなり、発生できるトルクは小さくなるが、銅損の低減量と相殺できるので、必要とするトルクが同一であれば、薄型化が可能となる。
【００８５】
なお、実施例２では極歯２８の被巻装部３０に対して直に駆動コイル２を巻装したが、略均一の肉厚となる絶縁体を介して巻装しても良く、その作用効果に差異を生じない。
【００８６】
また、実施例１と同様に外転型の電動機の構成としても良く、その作用効果に差異を生じない。
【００８７】
また、実施例１と同様にセンサレス型の電動機としても良く、その作用効果に差異を生じない。
【００８８】
また、実施例１と同様に誘導電動機やリラクタンスモータとしても良く、その作用効果に差異を生じない。
【００８９】
また、図１４（ａ）に示すように、ポールピース部２８ａには駆動コイル２が磁石回転子３側への崩れを防止する鍔部１３を設け、この鍔部１３の角部には円弧部１６を設け、この鍔部１３角の円弧部１６において、被巻装部３０の幅の漸減量が多い（ΔＷ１）側は曲率の大きな円弧部１６ａを形成し、被巻装部３０の幅の漸減量が少ない（ΔＷ２）側は曲率の小さな円弧部１６ｂ形成した構成としても、図１４（ｂ）に示すように、ポールピース部２８ａには駆動コイル２が磁石回転子３側への崩れを防止する鍔部２４を設け、この鍔部２４の角部には面取りを設け、この鍔部２４角の面取り部において、被巻装部３０の幅の漸減量が多い（ΔＷ１）側は大きな面取り部２４ａを形成し、被巻装部３０の幅の漸減量が少ない（ΔＷ２）側は小さな面取り部２４ｂを形成した構成としても、図１４（ｃ）に示すように、ポールピース部２８ａには駆動コイル２が磁石回転子３側への崩れを防止する鍔部２５を設け、この鍔部２５の角部において、被巻装部３０の幅の漸減量が多い（ΔＷ１）側には切欠き２６を形成した構成としても、巻線ノズルが直線軌道から円弧軌道に移行するタイミングを早くできることから、駆動コイル２と固定子鉄心２７ａの間の隙間が小さくなるので、固定子鉄心２７ａから軸方向に突出するコイルエンドの高さが、さらに低くなるとともに、コイル周長も短くなるため、駆動コイル２の抵抗値が低くなり、銅損がさらに低減できるので、一層の薄型化、高効率化が実現できる電動機が得られる。
【００９０】
また、実施例２では被巻線部３０の幅を両端とも（ΔＷ１，ΔＷ２）削った構成としたが、片側のみ削った構成としても良く、その作用効果に大きな差異を生じない。
【００９１】
（実施例３）
図１５および図１６に示すように、３１は粉末磁性材料である酸化物で表面を絶縁処理した磁性粉末と樹脂の複合材料を成形固化して形成した複数のスロットを有する固定子鉄心３１ａに駆動コイル２を巻装した固定子で、３３は極歯で、この極歯３３単位毎に駆動コイル２が集中巻線されている。そして、極歯３３の先端部には磁石回転子３の回転方向に張り出したポールピース部３３ａが配置されており、このポールピース部３３ａには駆動コイル２が磁石回転子３側への崩れを防止する鍔部３２を一体的に設け、この鍔部３２の角部は円弧状となっている。そして、極歯３３の被巻装部３３ｂの軸方向断面形状は略平行四辺形となっており、鈍角部３３ｃと鋭角部３３ｄには丸みを設けてある。そして、鍔部３２角の円弧部３４において、鈍角部３３ｃ側の鍔部３２角は曲率の大きな円弧部３４ａを形成し、鋭角部３３ｄ側の鍔部３４角は曲率の小さな円弧部３４ｂを形成した構成としている。そして、その他の構成は実施例１と同じであり、詳細な説明は省略する。
【００９２】
このような本発明の電動機によれば、極歯３３の被巻装部３３ｂの軸方向断面形状は、巻線ノズルが直線軌道から円弧軌道に移行する時に慣性力によって生じる隙間分ΔＧのインシュレータの肉厚を削った略平行四辺形となっているので、駆動コイル２の巻装後の巻形状は略長方形にでき、固定子鉄心３１ａから軸方向に突出するコイルエンドの高さを低くすることができるため、薄型化した電動機が得られる。また、コイル周長を短くできるので、銅損の低減による高効率化した電動機が得られる。
【００９３】
また、鍔部３２角の円弧部３４において、被巻装部３３ｂの角が鈍角を形成している鈍角部３３ｃ側の円弧部３４ａの曲率を大きく形成しているので、巻線ノズルが直線軌道から円弧軌道に移行するタイミングを早くできることから、駆動コイル２と固定子鉄心３１ａの間の隙間が小さくなるので、固定子鉄心３１ａから軸方向に突出するコイルエンドの高さが、さらに低くなるとともに、コイル周長も短くなるため、駆動コイル２の抵抗値が低くなり、銅損がさらに低減できるので、一層の薄型化、高効率化が実現できる電動機が得られる。
【００９４】
なお、実施例１と同様に外転型の電動機の構成としても良く、その作用効果に差異を生じない。
【００９５】
また、図１７に示すように、被巻装部３３ｂの角に丸み３５を設け、一方の対角を成す丸み３５ａの曲率を、他方の対角を成す丸み３５ｂの曲率よりも大きく形成するとともに、巻線ノズルが直線軌道から円弧軌道に移行する時に慣性力によって生じる隙間分ΔＧを丸みの曲率に差を設けた構成としても、固定子鉄心と駆動コイル２の距離が短くなるので、固定子鉄心から軸方向に突出するコイルエンドの高さが低くなり、薄型化した電動機が得られる。また、コイル周長を短くできるとともに、駆動コイルの屈折による抵抗値の増加を抑制できるので、銅損の低減による一層の高効率化を実現した電動機が得られる。
【００９６】
また、図１８に示すように、被巻装部３３ｂの角に面取り３６を設け、一方の対角を成す面取り３６ａの大きさを、他方の対角を成す面取り３６ｂの大きさよりも大きく形成するとともに、巻線ノズルが直線軌道から円弧軌道に移行する時に慣性力によって生じる隙間分ΔＧを面取りの大きさに差を設けた構成としても、固定子鉄心と駆動コイル２の距離が短くなるので、固定子鉄心から軸方向に突出するコイルエンドの高さが低くなり、薄型化した電動機が得られる。また、コイル周長を短くできるので、銅損の低減による高効率化した電動機が得られる。
【００９７】
また、図１９に示すように、ポールピース部３３ａには駆動コイル２が磁石回転子３側への崩れを防止する鍔部３７を一体的に設け、この鍔部３７の角に面取りを配し、この鍔部３７角の面取り部において、被巻装部３３ｂ角が鈍角を形成している鈍角部３３ｃ側、もしくは被巻装部３３ｂ角の曲率が大きい丸み３５ａ側、もしくは被巻装部３３ｂ角の大きい面取り３６ａ側の鍔部３７角の面取り部３７ａを大きく形成する構成としても、図２０に示すように、ポールピース部３３ａには駆動コイル２が磁石回転子３側への崩れを防止する鍔部３８を一体的に設け、この鍔部３８において、被巻装部３３ｂ角が鈍角を形成している鈍角部３３ｃ側、もしくは被巻装部３３ｂ角の曲率が大きい丸み３５ａ側、もしくは被巻装部３３ｂ角の大きい面取り３６ａ側の鍔部３８角に切欠き３８ａを配す構成としても、巻線ノズルが直線軌道から円弧軌道に移行するタイミングを早くできることから、駆動コイル２と固定子鉄心３１ａの間の隙間が小さくなるので、固定子鉄心３１ａから軸方向に突出するコイルエンドの高さが、さらに低くなるとともに、コイル周長も短くなるため、駆動コイル２の抵抗値が低くなり、銅損がさらに低減できるので、一層の薄型化、高効率化が実現できる電動機が得られる。
【００９８】
（実施例４）
図２１および図２２に示すように、４１はスロット４０を有する固定子鉄心であり、この固定子鉄心４１のスロット開口部４３を巻線ノズル３９が通過して、各極歯４２の周りを回転して駆動コイル２を巻装する電動機の製造方法であって、前記巻線ノズル３９の軌道は固定子鉄心４１のスロット４０内は直線状に、固定子鉄心の軸方向端面側は円弧状とするとともに、直線状軌道から円弧状軌道に移る側の円弧の曲率Ｒａは、円弧状軌道から直線状軌道に移る側の円弧の曲率Ｒｂよりも大きくした軌道で所定回数巻回することによって電動機の巻線工程の製造が完了する。それ以降の組み立ては通常の電動機の製造方法と同じである。
【００９９】
このような本発明の電動機の製造方法によれば、巻線ノズル３９の軌道において、直線軌道から円弧軌道に移行する側の円弧軌道の曲率Ｒａを、円弧軌道から直線軌道に移行する側の円弧軌道の曲率Ｒｂよりも大きくした製造方法としたことによって、直線軌道から円弧軌道への移行が早くできることから、慣性力によって生じる駆動コイル２と固定子鉄心４１の間の隙間が小さくなるので、スロット数の多い固定子鉄心への巻装であっても、スロット開口部の狭い固定子鉄心への巻装であっても、軸方向長さの長い固定子鉄心への巻装であっても、極歯の被巻装部の幅が狭い固定子鉄心への巻装であっても、固定子鉄心から軸方向に突出するコイルエンドの高さを低くすることができるため、薄型化を可能とする電動機の製造方法が得られる。
【０１００】
【発明の効果】
以上の実施例から明らかなように、本発明によれば、固定子鉄心の極歯単位毎に駆動コイルを巻装した固定子と、この固定子に対向して回転可能に保持された回転子と、前記固定子鉄心と前記駆動コイルとを絶縁するインシュレータとを備え、前記固定子鉄心の前記極歯を覆う前記インシュレータの軸方向断面の形状は、巻線ノズルが直線軌道から円弧軌道に移行する時に生じる隙間分のインシュレータの肉厚を削った略平行四辺形としたことを特徴とする電動機の構成とすることにより、巻線ノズルの巻回速度を早くしても、駆動コイル巻装後の巻形状は略長方形になり、固定子鉄心から軸方向に突出するコイルエンドの高さを低くすることができるため、薄型化した電動機が得られる。また、コイル周長を短くできるので、銅損の低減による高効率化した電動機が得られる。
【０１０１】
また、極歯の被巻線部を覆うインシュレータの角に丸みを設け、一方の対角を成す丸みの曲率を、他方の対角を成す丸みの曲率よりも大きく形成するとともに、巻線ノズルが直線軌道から円弧軌道に移行する時に慣性力によって生じる隙間分を丸みの曲率に差を設けた構成としても、固定子鉄心と駆動コイルの距離が短くなるので、固定子鉄心から軸方向に突出するコイルエンドの高さが低くなり、薄型化した電動機が得られる。また、コイル周長を短くできるとともに、駆動コイルの屈折による抵抗値の増加を抑制できるので、銅損の低減による一層の高効率化を実現した電動機が得られる。ここで、一層の高効率化を実現したことによって、同一出力であれば、固定子鉄心の積層厚を薄くできるので、さらなる薄型化を実現した電動機を提供できる。
【０１０２】
また、極歯の被巻線部を覆うインシュレータの角に面取りを設け、一方の対角を成す面取りの大きさを、他方の対角を成す面取りの大きさよりも大きく形成するとともに、巻線ノズルが直線軌道から円弧軌道に移行する時に慣性力によって生じる隙間分を面取りの大きさに差を設けた構成としても、固定子鉄心と駆動コイルの距離が短くなるので、固定子鉄心から軸方向に突出するコイルエンドの高さが低くなり、薄型化した電動機が得られる。また、コイル周長を短くできるので、銅損の低減による高効率化した電動機が得られる。
【０１０３】
また、駆動コイルと固定子鉄心の絶縁手段において、極歯の被巻線部の側方は絶縁フィルムを配し、この絶縁フィルムを軸方向から樹脂製のインシュレータにて挟み込む構造とし、このインシュレータの軸方向端部の角は片側を鈍角に形成し、他方は鋭角に形成するとともに、一方の対角は鈍角に形成し、他方の対角は鋭角に形成する構成としても、被巻線部の軸方向断面の形状は、巻線ノズルが直線軌道から円弧軌道に移行する時に慣性力によって生じる隙間分のインシュレータの肉厚を削った略平行四辺形となっているので、駆動コイルの巻装後の巻形状は略長方形にでき、固定子鉄心から軸方向に突出するコイルエンドの高さを低くすることができるため、薄型化した電動機が得られる。また、コイル周長を短くできるので、銅損の低減による高効率化した電動機が得られる。
【０１０４】
また、絶縁フィルムを軸方向から挟み込む樹脂製インシュレータの軸方向端部角には丸みを設け、この丸みの曲率は片側を大きく形成し、他方は小さく形成するとともに、一方の対角を成す丸みの曲率は大きく形成し、他方の対角を成す丸みの曲率は小さく形成する構成としても、巻線ノズルが直線軌道から円弧軌道に移行する時に慣性力によって生じる隙間分を丸みの曲率に差を設けてあるので、固定子鉄心と駆動コイルの距離が短くなるので、固定子鉄心から軸方向に突出するコイルエンドの高さが低くなり、薄型化した電動機が得られる。また、コイル周長を短くできるとともに、駆動コイルの屈折による抵抗値の増加を抑制できるので、銅損の低減による一層の高効率化を実現した電動機が得られる。ここで、一層の高効率化を実現したことによって、同一出力であれば、固定子鉄心の積層厚を薄くできるので、さらなる薄型化を実現した電動機を提供できる。
【０１０５】
また、絶縁フィルムを軸方向から挟み込む樹脂製インシュレータの軸方向端部角には面取りを設け、この面取りの大きさは片側を大きく形成し、他方は小さく形成するとともに、一方の対角を成す面取りの大きさは大きく形成し、他方の対角を成す面取りの大きさは小さく形成する構成としても、巻線ノズルが直線軌道から円弧軌道に移行する時に慣性力によって生じる隙間分を面取りの大きさに差を設けてあるので、固定子鉄心と駆動コイルの距離が短くなるので、固定子鉄心から軸方向に突出するコイルエンドの高さが低くなり、薄型化した電動機が得られる。また、コイル周長を短くできるので、銅損の低減による高効率化した電動機が得られる。
【０１０６】
また、固定子鉄心において、軸方向両端部には極歯の被巻装部の幅が漸減する端部積層鉄心部を設け、この端部積層鉄心部において、被巻装部の幅における漸減量は、一方の対角の漸減量は大きくし、他方の対角の漸減量は小さく形成することにより、極歯における被巻装部の軸方向断面の形状は、巻線ノズルが直線軌道から円弧軌道に移行する時に生じる隙間分の極歯を削った形状となっているので、固定子鉄心から軸方向に突出するコイルエンドの高さを低くすることができ、コイル周長も短くなるため、駆動コイルの抵抗値が低くなり、銅損の低減ができるので、一層の薄型化を実現できる電動機が得られる。ここで、固定子鉄心の体積は減少するので、磁束が小さくなり、発生できるトルクは小さくなるが、銅損の低減量と相殺できるので、必要とするトルクが同一であれば、薄型化が可能となる。
【０１０７】
また、粉末磁性材料である酸化物で表面を絶縁処理した磁性粉末と樹脂の複合材料を成形固化して形成した複数のスロットを有する固定子鉄心の極歯単位毎に駆動コイルを巻装した固定子と、この固定子に対向して回転可能に保持された回転子とを備え、前記固定子鉄心の軸方向断面の形状は、巻線ノズルが直線軌道から円弧軌道に移行する時に生じる隙間分の固定子鉄心の肉厚を削った略平行四辺形としたことを特徴とする電動機の構成とすることにより、巻線巻装後の巻形状は略長方形になり、固定子鉄心から軸方向に突出するコイルエンドの高さを低くすることができるため、薄型化した電動機が得られる。また、コイル周長を短くできるので、銅損の低減による高効率化した電動機が得られる。
【０１０８】
また、粉末磁性材料を成形固化して形成した複数のスロットを有する固定子鉄心の被巻装部の角に丸みを設け、一方の対角を成す丸みの曲率を、他方の対角を成す丸みの曲率よりも大きく形成するとともに、巻線ノズルが直線軌道から円弧軌道に移行する時に慣性力によって生じる隙間分を丸みの曲率に差を設けた構成としても、固定子鉄心と駆動コイルの距離が短くなるので、固定子鉄心から軸方向に突出するコイルエンドの高さが低くなり、薄型化した電動機が得られる。また、コイル周長を短くできるとともに、駆動コイルの屈折による抵抗値の増加を抑制できるので、銅損の低減による一層の高効率化を実現した電動機が得られる。
【０１０９】
また、粉末磁性材料を成形固化して形成した複数のスロットを有する固定子鉄心の被巻装部の角に面取りを設け、一方の対角を成す面取りの大きさを、他方の対角を成す面取りの大きさよりも大きく形成するとともに、巻線ノズルが直線軌道から円弧軌道に移行する時に慣性力によって生じる隙間分を面取りの大きさに差を設けた構成としても、固定子鉄心と駆動コイルの距離が短くなるので、固定子鉄心から軸方向に突出するコイルエンドの高さが低くなり、薄型化した電動機が得られる。また、コイル周長を短くできるので、銅損の低減による高効率化した電動機が得られる。
【０１１０】
また、極歯には駆動コイルが磁石回転子側への崩れを防止する鍔部を設け、この鍔部の角部は円弧状とし、この鍔部の円弧部において、駆動コイル巻装時の巻線ノズルが直線軌道から円弧軌道に移行する側の円弧部曲率を、巻線ノズルが円弧軌道から直線軌道に移行する側の円弧部曲率よりも大きくした構成により、巻線ノズルが直線軌道から円弧軌道に移行するタイミングを早くできることから、駆動コイルと固定子鉄心の間の隙間が小さくなるので、固定子鉄心から軸方向に突出するコイルエンドの高さが、さらに低くなるとともに、コイル周長も短くなることから、駆動コイルの抵抗値が低くなり、銅損がさらに低減できるので、一層の薄型化、高効率化が実現できる電動機が得られる。
【０１１１】
また、極歯には駆動コイルが磁石回転子側への崩れを防止する鍔部を設け、この鍔部の角部には面取りを設け、この鍔部の面取り部において、駆動コイル巻装時の巻線ノズルが直線軌道から円弧軌道に移行する側の面取りの大きさを、巻線ノズルが円弧軌道から直線軌道に移行する側の面取りの大きさよりも大きくした構成としても、巻線ノズルが直線軌道から円弧軌道に移行するタイミングを早くできることから、駆動コイルと固定子鉄心の間の隙間が小さくなるので、固定子鉄心から軸方向に突出するコイルエンドの高さが、さらに低くなるとともに、コイル周長も短くなるため、駆動コイルの抵抗値が低くなり、銅損がさらに低減できるので、一層の薄型化、高効率化が実現できる電動機が得られる。
【０１１２】
また、極歯には駆動コイルが磁石回転子側への崩れを防止する鍔部を設け、駆動コイル巻装時の巻線ノズルが直線軌道から円弧軌道に移行する側の鍔部の角部に切欠きを設けた構成としても、巻線ノズルが直線軌道から円弧軌道に移行するタイミングを早くできることから、駆動コイルと固定子鉄心の間の隙間が小さくなるので、固定子鉄心から軸方向に突出するコイルエンドの高さが、さらに低くなるとともに、コイル周長も短くなるため、駆動コイルの抵抗値が低くなり、銅損がさらに低減できるので、一層の薄型化、高効率化が実現できる電動機が得られる。
【０１１３】
また、固定子鉄心のスロット開口部を巻線ノズルが通過して、各極歯の周りを回転して駆動コイルを巻装する電動機の製造方法であって、前記巻線ノズルの軌道は固定子鉄心のスロット内は直線状に、固定子鉄心の軸方向端面側は円弧状とするとともに、直線状軌道から円弧状軌道に移る側の円弧の曲率は、円弧状軌道から直線状軌道に移る側の円弧の曲率よりも大きくした軌道で所定回数巻回することによって、巻線工程の製造を行う電動機の製造方法とすることにより、巻線ノズルの軌道において、直線軌道から円弧軌道への移行が早くできることから、慣性力によって生じる駆動コイルと固定子鉄心の間の隙間が小さくなるので、スロット数の多い固定子鉄心への巻装であっても、スロット開口部の狭い固定子鉄心への巻装であっても、軸方向長さの長い固定子鉄心への巻装であっても、極歯の被巻装部の幅が狭い固定子鉄心への巻装であっても、固定子鉄心から軸方向に突出するコイルエンドの高さを低くすることができるため、薄型化を可能とする電動機の製造方法が得られる。
【図面の簡単な説明】
【図１】本発明の実施例１における電動機を示す断面図
【図２】同電動機の被巻装部を示す断面図
【図３】同電動機の鍔部を示す図
【図４】同電動機の固定子を示す平面図
【図５】同電動機の被巻装部における他の構成を示す断面図
【図６】同電動機の被巻装部における他の構成を示す断面図
【図７】同電動機の被巻装部における他の構成を示す断面図
【図８】同電動機の被巻装部における他の構成を示す断面図
【図９】同電動機の被巻装部における他の構成を示す断面図
【図１０】同電動機の鍔部における他の構成を示す図
【図１１】同電動機の鍔部における他の構成を示す図
【図１２】本発明の実施例２の電動機における固定子鉄心を示す斜視図
【図１３】同電動機の被巻装部を示す断面図
【図１４】（ａ）同電動機の他の構成における鍔部を示す図
（ｂ）同図
（ｃ）同図
【図１５】本発明の実施例３の電動機における被巻装部を示す断面図
【図１６】同電動機の鍔部を示す図
【図１７】同電動機の被巻装部における他の構成を示す断面図
【図１８】同電動機の被巻装部における他の構成を示す断面図
【図１９】同電動機の鍔部における他の構成を示す図
【図２０】同電動機の鍔部における他の構成を示す図
【図２１】本発明の実施例４における電動機の製造方法による駆動コイル巻装時の状態を示す図
【図２２】同電動機の製造方法における巻線ノズルの軌道を示す図
【図２３】（ａ）従来の電動機における概略構成を示す正面図
（ｂ）同側断面図
【図２４】（ａ）同電動機の先端係止部を示す図
（ｂ）同図
【図２５】（ａ）同電動機における被巻線部のうちティースの軸方向端面を覆う部分を示す図
（ｂ）同図
（ｃ）同図
（ｄ）同図
【図２６】（ａ）従来の電動機における他の構成のステータを示す概略図
（ｂ）同巻線を示す概略図
【図２７】従来の電動機における他の構成を示す側断面図
【図２８】同電動機の巻線巻装前の構成を示す平面図
【図２９】同電動機の固定子鉄心を示す分解斜視図
【図３０】（ａ）同電動機の被巻装部を示す断面図
（ｂ）同図
【図３１】従来の電動機における被巻装部の実際の状態を示す断面図
【符号の説明】
１電動機
２駆動コイル
３磁石回転子
４ホールＩＣ
５丸み
５ａ丸み（曲率大）
５ｂ丸み（曲率小）
６軸受け
７インシュレータ
７ａ被巻装部
７ｂ鈍角部
７ｃ鋭角部
８極歯
８ａポールピース部
９シャフト
１０固定子
１０ａ固定子鉄心
１１ブラケット
１２熱硬化性樹脂
１３鍔部
１４プリント基板
１５駆動ＩＣ
１６円弧部
１６ａ円弧部（曲率大）
１６ｂ円弧部（曲率小）
１７面取り
１７ａ面取り（大）
１７ｂ面取り（小）
１８絶縁フィルム
１９インシュレータ
１９ａ被巻装部
１９ｂ鈍角部
１９ｃ鋭角部
２０インシュレータ
２０ａ被巻装部
２１丸み
２１ａ丸み（曲率大）
２１ｂ丸み（曲率小）
２２インシュレータ
２２ａ被巻装部
２３面取り
２３ａ面取り（大）
２３ｂ面取り（小）
２４鍔部
２４ａ鍔部角面取り部（大）
２４ｂ鍔部角面取り部（小）
２５鍔部
２６切欠き
２７固定子
２７ａ固定子鉄心
２８極歯
２８ａポールピース部
２９端部積層鉄心部
３０被巻線部
３１固定子
３１ａ固定子鉄心
３２鍔部
３３極歯
３３ａポールピース部
３３ｂ被巻線部
３３ｃ鈍角部
３３ｄ鋭角部
３４円弧部
３４ａ円弧部（曲率大）
３４ｂ円弧部（曲率小）
３５丸み
３５ａ丸み（曲率大）
３５ｂ丸み（曲率小）
３６面取り
３６ａ面取り（大）
３６ｂ面取り（小）
３７鍔部
３７ａ鍔部角面取り部（大）
３８鍔部
３８ａ切欠き
３９巻線ノズル
４０スロット
４０ａスロット開口部
４１固定子鉄心
４２極歯
４３軸方向端面側[0001]
BACKGROUND OF THE INVENTION
The present invention mainly relates to an electric motor using a stator having concentrated windings and a manufacturing method thereof.
[0002]
[Prior art]
In recent years, there has been a strong demand for miniaturization, thinning, weight reduction, and high efficiency in motors for driving fans mounted on electrical equipment. For this reason, it is necessary to increase the winding density of the stator, The structure which winds a drive coil for every pole tooth which comprises a child has increased. In order to further reduce the thickness, it is indispensable to reduce the height of the coil end protruding in the axial direction from the stator core.
[0003]
Conventionally, this type of electric motor is known to have a configuration that facilitates aligned winding by suppressing winding disturbance (see, for example, Patent Document 1).
[0004]
Hereinafter, the electric motor will be described with reference to FIGS.
[0005]
As shown in the figure, a wound portion 51 is provided that is attached to a tooth 50 protruding in the radial direction of the core and covers the axial end surface and both side surfaces of the tooth 50. The winding 52 wound around the to-be-winded portion 51 moves in the radial direction by projecting only from the edge of the to-be-winded portion 51 corresponding to the root side and the tip side of the tooth 50. , And when the winding 52 is wound around the wound portion 51, the winding nozzle is provided on the side surface and the axial end surface of each tooth 50. On the other hand, in order to achieve aligned winding of the winding 52 through a closer track, the distal end side locking portion 54 applies R (R) or chamfering to the corner of the distal end protruding in the axial direction, and the side of the tooth 50 In order to reduce the distance between the winding 52 and the insulator surface (bulge of the wire), the surface of the portion of the wound portion 51 that covers the axial end surface of the tooth 50 has a central portion 51G at both end portions 51Gc. Structure that protrudes more axially than It is set to. Moreover, the structure which provides the chamfering to the corner of both sides and the structure which cut off the corner of both sides and was dented in the step shape is also disclosed for the part which covers the axial direction end surface of the teeth 50 among the to-be-wound parts 51.
[0006]
Some of this type of electric motor has a coil formed (see, for example, Patent Document 2).
[0007]
Hereinafter, the electric motor will be described with reference to FIG.
[0008]
As shown in the figure, a slot 62 formed in the stator core 61 is formed into a slit shape, the width of the teeth 63 is widened, and a molded coil body 64 inserted into each slot 62 is formed by a square coil 65 having a predetermined number of turns, The rectangular coil 65 has a substantially square cross section and a side substantially equal to the slit-shaped slot width, the rectangular coil 65 is aligned in a line in the depth direction of the slot, and the coil end 64a is bent. .
[0009]
In addition, there is a motor of this type in which the width of the magnetic pole of the stator core is changed (see, for example, Patent Document 3).
[0010]
Hereinafter, the electric motor will be described with reference to FIGS.
[0011]
As shown in the figure, the stator core 70 is composed of a stator 76 in which a stator winding 75 is wound in a concentrated manner and a rotor 77 that is rotatably held facing the stator 76. The stator core 70 is an electric motor, and includes a center stator core 71 disposed at the center thereof and end stator cores 72 disposed at both ends of the center stator core 71. The center stator core 71 is configured by laminating thin steel plates, and the end stator core 72 has a stator magnetic pole portion 73 whose width of the stator magnetic pole portion 74 is the center stator core 73. The width of the end portion side is narrower than the width on the side in contact with the cross section. Further, the stator magnetic pole portion 74 of the end stator core 72 has a cross-sectional shape that is semicircular, trapezoidal, or the width of the stator magnetic pole of the thin steel plate constituting the end stator core 72. There is also disclosed a configuration in which the width gradually decreases toward the end side.
[0012]
[Patent Document 1]
JP 2001-95188 A
[Patent Document 2]
JP-A-7-298528
[Patent Document 3]
JP 2003-9433 A
[0013]
[Problems to be solved by the invention]
According to such a conventional electric motor, in the one described in Patent Document 1, in order to realize the aligned winding, the winding nozzle track is a straight track on the side of the teeth, and the axial end surface side is on the side. Since it is wound as an arc track, especially when the width of the teeth is narrow, the slot opening width is narrow, the number of slots is long, or the axial length is long, when winding the winding, When the winding nozzle moves from the linear track to the circular track, the winding is swelled and wound in the linear direction up to that time due to the inertial force, so the axial end face side of the wound portion as shown in FIG. In this case, a gap ΔG is generated between the wound portion and the winding, and the winding shape is a substantially parallelogram, so that the height of the coil end protruding in the axial direction from the stator core can be reduced. There is a problem that it can not be done, so you can reduce the thickness Together, to provide a motor with improved reliability is required.
[0014]
Further, when the winding speed of the winding is increased, the gap generated by the inertial force is further increased, and there is a problem that the height of the coil end protruding in the axial direction from the stator core cannot be reduced. There is a demand to provide an electric motor that can be thinned and improved in reliability even if the winding speed is increased.
[0015]
Moreover, in what is described in Patent Document 2, since the formed coil shape is a square, since the square coil is forcibly formed, variations in the thickness of the coil insulation coating and scratches occur, resulting in reliability. Therefore, there is a demand for providing an electric motor that can be reduced in size and weight and improved in reliability.
[0016]
Moreover, in what is described in Patent Document 3, in order to realize aligned winding as in Patent Document 1, the winding nozzle track is a straight track on the side of the stator magnetic pole part, and the axial end surface side is on the side. Since it is wound as an arc track, especially when the stator magnetic pole part is narrow, the slot opening width is narrow, and the axial length is long, the winding nozzle is moved from the straight track when winding the coil. When shifting to the arcuate track, the coil swells and winds in the linear direction up to that time due to inertial force, so that a gap is created between the coiled part and the coil on the axial end face side of the coiled part. As a result, the winding shape becomes a substantially parallelogram, and there is a problem that the height of the coil end protruding in the axial direction from the stator core cannot be lowered, and the thickness can be reduced and the reliability can be improved. Is required to provide There.
[0017]
The present invention solves such a conventional problem, and provides a motor and a method for manufacturing the same that can be reduced in size and thickness by reducing the height of a coil end and can be reduced in thickness. The purpose is that.
[0018]
[Means for Solving the Problems]
In order to achieve the above object, the brushless DC motor of the present invention has a stator core having a slot, a stator in which a drive coil is wound for each pole tooth unit of the stator core, and the stator. An axial cross-sectional shape of a wound portion of the insulator that includes a rotor held rotatably and an insulator that insulates the stator core and the drive coil, and covers the pole teeth of the stator core. The electric motor is characterized by having a substantially parallelogram.
[0019]
According to the present invention, the axial cross-sectional shape of the wound portion of the insulator that covers the pole teeth is substantially parallel to the thinned portion of the insulator corresponding to the gap generated when the winding nozzle moves from the linear track to the arc track. Since it is shaped, the winding shape after winding the drive coil can be made substantially rectangular, and the height of the coil end protruding in the axial direction from the stator core can be reduced, so that a thin motor can be obtained. . Further, since the coil circumference can be shortened, a highly efficient electric motor can be obtained by reducing copper loss.
[0020]
Another means is a stator core having a slot, a stator having a drive coil wound for each pole tooth unit of the stator core, and a rotor held rotatably against the stator. An insulator that insulates the stator core from the drive coil, and a corner of the wound portion of the insulator that covers the pole teeth of the stator core is rounded to form one diagonal. The curvature of the roundness is formed to be larger than the curvature of the roundness that forms the other diagonal.
[0021]
According to the present invention, the corner of the wound portion of the insulator that covers the pole teeth is rounded, and the thickness of the insulator corresponding to the gap generated when the winding nozzle moves from the linear track to the arc track is rounded. Therefore, since the height of the coil end protruding in the axial direction from the stator core can be reduced, a thin motor can be obtained. Further, since the coil circumference can be shortened, a highly efficient electric motor can be obtained by reducing copper loss.
[0022]
Another means is a stator core having a slot, a stator having a drive coil wound for each pole tooth unit of the stator core, and a rotor held rotatably against the stator. And an insulator that insulates the stator core from the drive coil, the corner of the wound portion of the insulator covering the pole teeth of the stator core is chamfered to form one diagonal The size of the chamfer is configured to be larger than the size of the chamfer forming the other diagonal.
[0023]
According to the present invention, chamfering is provided at the corner of the wound portion of the insulator covering the pole teeth, and the thickness of the insulator corresponding to the gap generated when the winding nozzle moves from the linear track to the arc track is cut off. Therefore, the height of the coil end protruding in the axial direction from the stator core can be reduced, and a thin motor can be obtained. Moreover, since the coil circumference can be shortened and excessive refraction of the drive coil is prevented, a highly efficient electric motor can be obtained by reducing copper loss.
[0024]
Another means is a stator core having a slot, a stator having a drive coil wound for each pole tooth unit of the stator core, and a rotor held rotatably against the stator. And an insulator that insulates the stator core from the drive coil, the insulator being an insulating film that insulates the side surfaces of the pole teeth, and a resin that sandwiches the insulating film from the axial direction of the stator core. The angle of the axial direction of the wound portion of this insulator is formed as an obtuse angle, the other is formed as an acute angle, one diagonal is an obtuse angle, and the other diagonal is an acute angle. It is set as the structure of the electric motor characterized by having formed in this.
[0025]
According to the present invention, the shape of the section in the axial direction of the wound portion is a substantially parallelogram obtained by cutting the thickness of the insulator corresponding to the gap generated when the winding nozzle moves from the linear track to the arc track. Therefore, the winding shape after winding the drive coil can be made substantially rectangular, and the height of the coil end protruding in the axial direction from the stator core can be reduced, so that a thin motor can be obtained. Further, since the coil circumference can be shortened, a highly efficient electric motor can be obtained by reducing copper loss.
[0026]
Another means is a stator core having a slot, a stator having a drive coil wound for each pole tooth unit of the stator core, and a rotor held rotatably against the stator. And an insulator that insulates the stator core from the drive coil, the insulator being an insulating film that insulates the side surfaces of the pole teeth, and a resin that sandwiches the insulating film from the axial direction of the stator core. This insulator is made of an insulator, and a round end is provided at a corner in an axial direction of the wound portion of the insulator. The roundness has a large curvature on one side and a small curvature on the other side. The curvature of the roundness forming the diagonal is formed large, and the curvature of the rounding forming the other diagonal is formed small.
[0027]
According to the present invention, the corner of the wound portion is rounded, and the curvature of the rounded shape is obtained by reducing the thickness of the insulator corresponding to the gap generated when the winding nozzle moves from the linear track to the arc track. Therefore, since the height of the coil end protruding in the axial direction from the stator core can be reduced, a thin motor can be obtained. Moreover, since the coil circumference can be shortened and excessive refraction of the drive coil is prevented, a highly efficient electric motor can be obtained by reducing copper loss.
[0028]
Another means is a stator core having a slot, a stator having a drive coil wound for each pole tooth unit of the stator core, and a rotor held rotatably against the stator. And an insulator that insulates the stator core from the drive coil, the insulator being an insulating film that insulates the side surfaces of the pole teeth, and a resin that sandwiches the insulating film from the axial direction of the stator core. This insulator is made of an insulator, and a chamfer is provided at the axial end corner of the wound portion of the insulator. One side of the chamfer is formed large, the other chamfer is formed small, and one diagonal is formed. The motor has a configuration in which the chamfer is formed large and the other diagonal chamfer is formed small.
[0029]
According to the present invention, a chamfer is provided at the corner of the wound portion, and the thickness of the insulator corresponding to the gap generated when the winding nozzle moves from the linear track to the circular track is reduced. Therefore, since the height of the coil end protruding in the axial direction from the stator core can be reduced, a thin motor can be obtained. Further, since the coil circumference can be shortened, a highly efficient electric motor can be obtained by reducing copper loss.
[0030]
Another means is that a stator core in which thin steel plates having slots are laminated, a stator in which a drive coil is wound for each pole tooth unit of the stator core, and rotatably held facing the stator. An end laminated core portion in which the width of the wound portion of the pole teeth is gradually reduced at the axial end portion of the stator core, and the wrapped portion in the end laminated core portion is provided. The gradually decreasing amount of the width of the part is a configuration of an electric motor characterized in that one diagonal is formed large and the other diagonal is formed small.
[0031]
According to the present invention, the shape of the section in the axial direction of the wound portion is a shape in which the pole teeth corresponding to the gap generated when the winding nozzle moves from the linear track to the arc track are cut off. Since the height of the coil end protruding in the axial direction can be reduced, a thin motor can be obtained.
[0032]
Another means is a stator core having a slot formed by molding and solidifying a powder magnetic material, a stator having a drive coil wound for each pole tooth unit of the stator core, and the stator facing the stator core. And a rotor that is rotatably held, and an axial sectional shape of the wound portion of the pole teeth is a substantially parallelogram.
[0033]
According to the present invention, the shape of the section in the axial direction of the wound part is a substantially parallelogram in which the pole teeth corresponding to the gap generated when the winding nozzle moves from the linear orbit to the arc orbit, Since the winding shape after the drive coil is wound can be made substantially rectangular and the height of the coil end protruding in the axial direction from the stator core can be lowered, a thin motor can be obtained. Further, since the coil circumference can be shortened, a highly efficient electric motor can be obtained by reducing copper loss.
[0034]
Another means is a stator core having a slot formed by molding and solidifying a powder magnetic material, a stator having a drive coil wound for each pole tooth unit of the stator core, and the stator facing the stator core. And the rotor core held so as to be rotatable, the winding angle of the pole teeth of the stator core is rounded, and the curvature of the round that forms one diagonal forms the other diagonal The motor is configured to have a larger curvature than the round curvature.
[0035]
According to the present invention, the shape of the section in the axial direction of the wound portion is a shape in which the pole teeth corresponding to the gap generated when the winding nozzle moves from the linear track to the arc track are cut off. Since the height of the coil end protruding in the axial direction can be reduced, a thin motor can be obtained. Moreover, since the coil circumference can be shortened and excessive refraction of the drive coil is prevented, a highly efficient electric motor can be obtained by reducing copper loss.
[0036]
Another means is a stator core having a slot formed by molding and solidifying a powder magnetic material, a stator having a drive coil wound for each pole tooth unit of the stator core, and the stator facing the stator core. And the rotor core held rotatably, the chamfered portion of the pole tooth of the stator core is chamfered, and the size of the chamfer forming one diagonal is the other diagonal It is set as the structure of the electric motor characterized by forming larger than the magnitude | size of the said chamfering which comprises.
[0037]
According to the present invention, the shape of the section in the axial direction of the wound portion is a shape in which the pole teeth corresponding to the gap generated when the winding nozzle moves from the linear track to the arc track are cut off. Since the height of the coil end protruding in the axial direction can be reduced, a thin motor can be obtained.
[0038]
According to another means, the insulator is provided with a flange portion for preventing the drive coil from collapsing toward the rotor side, and the corner portion of the flange portion is formed in an arc shape, and the curvature of the arc portion is the same as that of the wound portion. On the side where the corner forms an obtuse angle, or on the side where the curvature of the rounded corner of the wound part is large, or on the side where the corner is chamfered, the corner of the wound part is acute. Is larger than the curvature of the arc part on the side where the curvature is small, or on the side where the curvature of the rounded corner of the wound part is small, or on the side where the corner chamfer of the wound part is small. This is a configuration of an electric motor.
[0039]
According to the present invention, since the path of the winding nozzle on the side where the curvature of the arc portion of the flange portion is large can be quickly shifted from the linear track to the arc track, the gap between the drive coil and the insulator is reduced. Since the height of the coil end protruding in the axial direction from the stator core can be reduced, a thin motor can be obtained.
[0040]
According to another means, the insulator is provided with a flange portion that prevents the drive coil from collapsing toward the rotor side, and a chamfered portion is provided at a corner portion of the flange portion, and the size of the chamfered portion is determined by the size of the wound portion. The side where the corner portion of the covering portion forms an obtuse angle, the side where the curvature of the corner portion roundness of the wound portion is large, or the side where the corner portion is chamfered is the corner of the wound portion. It is characterized in that it is larger than the chamfer on the side where the part forms an acute angle, the side where the curvature of the corner roundness of the wound part is small, or the side where the corner of the wound part is small is chamfered. This is a configuration of an electric motor.
[0041]
According to the present invention, the winding nozzle track on the side where the chamfered portion of the chamfered corner has a large chamfer can quickly transition from the linear track to the circular track, so the gap between the drive coil and the insulator is reduced. Since the height of the coil end protruding in the axial direction from the stator core can be reduced, a thin motor can be obtained.
[0042]
Another means is that the insulator is provided with a flange portion that prevents the drive coil from collapsing toward the rotor side, and this notch portion is provided with a notch, and this notch is provided at the corner of the wound portion. The motor has a configuration in which the obtuse angle is formed, the corner portion of the wound portion has a larger curvature of the corner roundness, or the corner portion of the wound portion has a larger chamfer. is there.
[0043]
According to the present invention, since the track of the winding nozzle on the side having the notch of the flange portion can be quickly shifted from the linear track to the arc track, the gap between the drive coil and the insulator is reduced, so that the stator Since the height of the coil end protruding in the axial direction from the iron core can be reduced, a thin motor can be obtained.
[0044]
As another means, a pole portion is provided with a hook portion for preventing the drive coil from collapsing to the rotor side, and a corner portion of the hook portion is formed in an arc shape, and the curvature of the arc portion is the same as that of the wound portion. The side where the width gradually decreases, the side where the corner of the wound part forms an obtuse angle, the side where the curvature of the rounded corner of the wound part is large, or the corner chamfer of the wound part The side where the winding portion is large is the side where the gradually decreasing amount of the width of the wound portion is small, the side where the corner portion of the wound portion forms an acute angle, or the side where the curvature of the corner roundness of the wound portion is small Alternatively, the configuration of the electric motor is characterized in that the corner portion chamfer of the wound portion is larger than the arc portion curvature on the smaller side.
[0045]
According to the present invention, the path of the winding nozzle on the side with a large curvature of the arcuate corner of the flange can be quickly transferred from the linear track to the arc track, so that there is a gap between the drive coil and the stator core. Since the coil end becomes smaller, the height of the coil end protruding in the axial direction from the stator core can be reduced, and a thin motor can be obtained.
[0046]
As another means, a pole portion is provided with a flange portion for preventing the drive coil from collapsing toward the rotor side, and a chamfered portion is provided at a corner portion of the flange portion, and the size of the chamfered portion is the same as that of the wound portion. The side where the gradually decreasing amount of the width of the mounting part is large, the side where the corner of the wound part forms an obtuse angle, the side where the curvature of the corner roundness of the wound part is large, or the side of the wound part The side where the corner chamfer is large is the side where the gradually decreasing amount of the width of the wound part is small, the side where the corner of the wound part forms an acute angle, or the curvature of the corner roundness of the wound part The motor is characterized in that the chamfered portion on the small side or the chamfered corner portion of the wound portion is made larger than the chamfered side on the small side.
[0047]
According to the present invention, the winding nozzle track on the side with the larger chamfered portion of the flange portion can be quickly transferred from the linear track to the circular track, so that the gap between the drive coil and the stator core is reduced. Since the height of the coil end protruding in the axial direction from the core can be reduced, a thin motor can be obtained.
[0048]
As another means, a pole portion is provided on the pole tooth to prevent the drive coil from collapsing toward the rotor side, and a notch is provided in the flange portion, and this notch gradually reduces the width of the wound portion. The side where the amount is large, the side where the corner of the wound part forms an obtuse angle, the side where the curvature of the corner roundness of the wound part is large, or the side where the corner is chamfered is large It is set as the structure of the electric motor characterized by providing in.
[0049]
According to the present invention, since the trajectory of the winding nozzle on the side having the notch of the flange portion can be quickly shifted from the linear track to the circular arc track, the gap between the drive coil and the stator core becomes small. Since the height of the coil end protruding in the axial direction from the stator core can be reduced, a thin motor can be obtained.
[0050]
Another means is a method of manufacturing an electric motor in which a winding nozzle passes through a slot opening and rotates around each pole tooth to wind a drive coil, and the track of the winding nozzle is a stator. The slot in the iron core is linear, the axial end surface side of the stator core is arc-shaped, and the curvature of the arc on the side moving from the linear track to the arc-shaped track is the side moving from the arc-shaped track to the linear track The method of manufacturing the electric motor is characterized in that it is larger than the curvature of the arc.
[0051]
According to the present invention, since the transition from the linear track to the circular track can be performed quickly, the gap between the drive coil and the stator core is reduced, so that the height of the coil end protruding in the axial direction from the stator core is reduced. Therefore, a thin motor manufacturing method can be obtained.
[0052]
DETAILED DESCRIPTION OF THE INVENTION
The invention according to claim 1 is a stator in which a drive coil is wound for each pole tooth unit of the stator core, a rotor that is rotatably held facing the stator, and the stator core. A structure of an electric motor comprising an insulator for insulating the drive coil, wherein a shape of an axial section of a wound portion of the insulator covering the pole teeth of the stator core is a substantially parallelogram. As a result, the winding shape after winding is approximately rectangular, and the coil end protruding in the axial direction from the stator core has the effect of reducing the coil peripheral length.
[0053]
According to a second aspect of the present invention, there is provided a stator in which a drive coil is wound for each pole tooth unit of the stator core, a rotor that is rotatably held facing the stator, and the stator core. An insulator that insulates the drive coil, the corner of the wound portion of the insulator that covers the pole teeth of the stator core is rounded, and the curvature of the round that forms one diagonal is: The height of the coil end protruding in the axial direction from the stator core is reduced by the configuration of the electric motor characterized by being formed to be larger than the curvature of the round that forms the other diagonal. Has the effect of shortening.
[0054]
According to a third aspect of the present invention, there is provided a stator in which a drive coil is wound for each pole tooth unit of the stator core, a rotor that is rotatably held facing the stator, and the stator core. An insulator that insulates the drive coil, and a chamfer is provided at a corner of the wound portion of the insulator that covers the pole teeth of the stator core, and the size of the chamfer that forms one diagonal is The height of the coil end protruding in the axial direction from the stator core is reduced by the configuration of the electric motor characterized by being formed larger than the size of the chamfer forming the other diagonal, and the coil circumference It has the effect of shortening the length.
[0055]
According to a fourth aspect of the present invention, there is provided a stator in which a drive coil is wound for each pole tooth unit of the stator core, a rotor that is rotatably held facing the stator, and the stator core. An insulator that insulates the drive coil, and the insulator includes an insulating film that insulates the side surfaces of the pole teeth, and a resin insulator that sandwiches the insulating film from the axial direction of the stator core. The axial end angle of the wrapped portion of this insulator is formed as one obtuse angle, the other is formed as an acute angle, one diagonal is formed as an obtuse angle, and the other diagonal is formed as an acute angle. With the configuration of the electric motor, the winding shape after winding is substantially rectangular, the height of the coil end protruding in the axial direction from the stator core is reduced, and the coil circumference is shortened. Has an effect.
[0056]
According to a fifth aspect of the present invention, there is provided a stator in which a drive coil is wound for each pole tooth unit of the stator core, a rotor that is rotatably held facing the stator, and the stator core. An insulator that insulates the drive coil, and the insulator includes an insulating film that insulates the side surfaces of the pole teeth, and a resin insulator that sandwiches the insulating film from the axial direction of the stator core. The angle of the end portion in the axial direction of the wound portion of the insulator is rounded, and the roundness forms a large curvature on one side, the curvature of the other round is small, and the rounding that forms one diagonal. The coil end protruding in the axial direction from the stator core has a low height by adopting an electric motor structure characterized in that the curvature of the other part is formed large and the curvature of the other diagonal is formed small. Become , An effect that the coil circumference is shortened.
[0057]
The invention according to claim 6 is a stator iron core having a slot, a stator around which a drive coil is wound for each pole tooth unit of the stator iron core, and rotatably held facing the stator. A rotor, an insulator that insulates the stator core and the drive coil, and the insulator is an insulation film that insulates the side surfaces of the pole teeth; The chamfer is provided at the axial end corner of the wound portion of the insulator, and one side of the chamfer is formed large, the other chamfer is formed small, and one pair of chamfers is formed. The height of the coil end protruding in the axial direction from the stator core is reduced by adopting the configuration of the motor characterized in that the chamfer forming the corner is formed large and the chamfer forming the other diagonal is formed small. Together we comprising, an effect that the coil circumference is shortened.
[0058]
According to the seventh aspect of the present invention, there is provided a stator core in which thin steel plates having slots are laminated, a stator in which a drive coil is wound for each pole tooth unit of the stator core, and rotation facing the stator. An end laminated core part in which the width of the wound portion of the pole teeth is gradually reduced at the axial end of the stator core. The gradually decreasing amount of the width of the wound portion projects from the stator core in the axial direction by adopting a configuration of an electric motor characterized in that one diagonal is formed large and the other diagonal is formed small. The coil end height is lowered and the coil peripheral length is shortened.
[0059]
According to an eighth aspect of the present invention, there is provided a stator iron core having a slot formed by molding and solidifying a magnetic powder material, a stator in which a drive coil is wound for each pole tooth unit of the stator iron core, and the stator. And a rotor that is rotatably held opposite to each other, and the axial cross-sectional shape of the wound portion of the pole teeth is a substantially parallelogram. While the height of the coil end protruding in the axial direction from the core is reduced, the coil peripheral length is shortened.
[0060]
According to the ninth aspect of the present invention, there is provided a stator iron core having a slot formed by molding and solidifying a magnetic powder material, a stator in which a drive coil is wound for each pole tooth unit of the stator iron core, and the stator. A rotor that is rotatably held opposite to each other, and a rounded corner is provided at the wound portion corner of the pole tooth of the stator core, and the curvature of the round that forms one diagonal is the other. By configuring the electric motor to be larger than the curvature of the rounded diagonal, the height of the coil end protruding in the axial direction from the stator core is reduced and the coil circumference is shortened. It has the effect of becoming.
[0061]
The invention according to claim 10 includes a stator core having a slot formed by molding and solidifying a powder magnetic material, a stator having a drive coil wound for each pole tooth unit of the stator core, and the stator A chamfered portion of the pole tooth of the stator iron core, the chamfered portion being provided with a chamfer, and the size of the chamfer forming one diagonal is the other. The height of the coil end protruding in the axial direction from the stator core is reduced, and the coil peripheral length is reduced. Has the effect of shortening.
[0062]
According to the eleventh aspect of the present invention, the insulator is provided with a flange portion for preventing the drive coil from collapsing toward the rotor side, and the corner portion of the flange portion is formed in an arc shape, and the curvature of the arc portion is determined by the above-described winding. The side where the corner of the part forms an obtuse angle, the side where the curvature of the corner roundness of the wound part is large, or the side where the corner chamfer of the wound part is large is the corner of the wound part Is larger than the arcuate curvature on the side forming the acute angle, or on the side where the curvature of the rounded corner of the wound part is small, or on the side where the corner chamfer of the wound part is small. By adopting the configuration of the electric motor, the winding nozzle track on the side with the larger curvature of the arc portion of the collar portion can quickly shift from the linear track to the arc track, so the gap between the drive coil and the insulator is reduced. Therefore, the height of the coil end protruding in the axial direction from the stator core With Kunar, an effect that the coil circumference is shortened.
[0063]
According to a twelfth aspect of the present invention, the insulator is provided with a flange portion that prevents the drive coil from collapsing toward the rotor side, and a chamfered portion is provided at a corner portion of the flange portion, and the chamfered portion of the flange corner chamfered portion is provided. Is the side where the corner of the wound part forms an obtuse angle, the side where the curvature of the corner roundness of the wound part is large, or the side where the corner chamfer of the wound part is large, The flange on the side where the corner of the wound part forms an acute angle, the side where the curvature of the rounded corner of the wound part is small, or the side where the corner chamfer of the wound part is small Due to the configuration of the motor that is larger than the chamfer of the corner chamfered part, the winding nozzle trajectory on the side with the larger chamfered part of the chamfered corner corner can quickly transition from a linear track to an arced track. Because the gap between the drive coil and the insulator becomes smaller, the stator core With lower height of the coil end projecting et axis direction, an effect that the coil circumference is shortened.
[0064]
According to a thirteenth aspect of the present invention, the insulator is provided with a flange portion that prevents the drive coil from collapsing toward the rotor side, and the notch portion is provided with a notch, and the notch is provided at a corner of the wound portion. The motor is characterized in that it is provided on the side where the part forms an obtuse angle, on the side where the curvature of the corner roundness of the wound part is large, or on the side where the corner part is chamfered is large. Thus, the track of the winding nozzle on the side having the notch of the flange portion can quickly shift from the linear track to the circular track, so that the gap between the drive coil and the insulator is reduced, so that the shaft from the stator core While the height of the coil end protruding in the direction is lowered, the coil peripheral length is shortened.
[0065]
In a fourteenth aspect of the present invention, the pole teeth are provided with a flange portion that prevents the drive coil from collapsing toward the rotor side, and the corner portion of the flange portion has an arc shape, and the curvature of the arc portion is the winding The side where the gradually decreasing amount of the width of the mounting part is large, the side where the corner of the wound part forms an obtuse angle, the side where the curvature of the corner roundness of the wound part is large, or the side of the wound part The side where the corner chamfer is large is the side where the gradually decreasing amount of the width of the wound part is small, the side where the corner of the wound part forms an acute angle, or the curvature of the corner roundness of the wound part The winding on the side with the larger curvature of the arc portion of the flange portion is made by the configuration of the electric motor characterized in that the curvature is larger than the arc portion curvature on the side with a smaller corner or the corner chamfer of the wound portion. The wire nozzle trajectory allows a quick transition from a linear trajectory to an arc trajectory, so the gap between the drive coil and the stator core. Since smaller, with lower height of the coil end projecting from the stator core in the axial direction, has the effect of coil circumference is shortened.
[0066]
In the invention according to claim 15, the pole teeth are provided with a flange portion for preventing the drive coil from collapsing toward the rotor, and a chamfered portion is provided at a corner portion of the flange portion, and the size of the chamfered portion is The side where the gradually decreasing amount of the width of the wound part is large, the side where the corner of the wound part forms an obtuse angle, the side where the curvature of the corner roundness of the wound part is large, or the wound The side where the chamfered portion of the mounting part is large is the side where the amount of decrease in the width of the wound part is small, the side where the corner part of the wound part forms an acute angle, or the corner part of the wound part The winding nozzle on the side where the chamfer of the flange portion is large by adopting the configuration of the electric motor characterized in that it is larger than the chamfer on the side where the curvature of the roundness is small or the corner portion of the portion to be wound is small. Since the trajectory of the trajectory can move quickly from a straight trajectory to an arc trajectory, the gap between the drive coil and the stator core Since smaller, with lower height of the coil end projecting from the stator core in the axial direction, has the effect of coil circumference is shortened.
[0067]
In the invention described in claim 16, the pole teeth are provided with a flange portion for preventing the drive coil from collapsing toward the rotor side, the notch portion is provided with a notch, and the notch is formed on the wound portion. The side where the amount of taper decrease is large, the side where the curvature of the corner roundness of the wound part is large, the side where the corner of the wound part forms an obtuse angle, or the corner chamfer of the wound part By adopting the configuration of the electric motor characterized by being provided on the larger side, the winding nozzle trajectory on the side having the notch of the collar portion can quickly shift from the linear trajectory to the circular arc trajectory. Since the gap between the stator core and the stator core becomes small, the height of the coil end protruding in the axial direction from the stator core is lowered, and the coil peripheral length is shortened.
[0068]
The invention according to claim 17 is a method of manufacturing an electric motor in which a winding nozzle passes through a slot opening and rotates around each pole tooth to wind a drive coil, and the track of the winding nozzle Is linear in the slot of the stator core, and the axial end surface side of the stator core is arcuate, and the curvature of the arc moving from the linear track to the arcuate track is from the arcuate track to the linear track By making the motor manufacturing method characterized in that it is larger than the curvature of the arc on the moving side, the winding nozzle can make the transition from the linear orbit to the arc orbit faster, so between the drive coil and the stator core. It has the effect | action that the clearance gap between becomes small.
[0069]
Hereinafter, embodiments of the present invention will be described with reference to FIGS.
[0070]
【Example】
(Example 1)
As shown in FIGS. 1 to 4, 1 is an electric motor, 10 is a drive coil via an insulator 7 formed of an insulating material on a stator core 10a in which thin steel plates such as silicon steel plates having a plurality of slots are laminated. 2, a stator 10 is molded with a thermosetting resin 12 to form a jacket, and 11 is a bracket that holds a bearing 6. Reference numeral 3 denotes a magnet rotor formed by integrally orienting a plastic magnet with a shaft 9 in a polar orientation at the time of injection molding, and is arranged rotatably on the inner peripheral side of the stator 10. 4 is a Hall IC that detects the magnetic pole position of the magnet rotor 3, and 15 is a drive IC that controls energization of the drive coil 2 based on the output signal of the Hall IC 4. Reference numeral 14 denotes a printed circuit board on which the Hall IC 4, the drive IC 15, and other electronic components are mounted, and is built in the electric motor 1. 8 is a pole tooth, and the drive coil 2 is concentratedly wound via an insulator 7 for every unit of the pole tooth 8. A pole piece portion 8a projecting in the rotation direction of the magnet rotor 3 is disposed at the tip of the pole tooth 8, and the drive coil 2 is moved to the magnet rotor 3 side in the insulator 7 of the pole piece portion 8a. A flange portion 13 is provided to prevent the collapse of the flange portion, and the corner portion of the flange portion 13 has an arc shape. And the axial direction cross-sectional shape of the to-be-wrapped part 7a of the insulator 7 which covers the pole tooth 8 is a substantially parallelogram, and the obtuse angle part 7b and the acute angle part 7c are rounded. Then, in the arc portion 16 of the flange portion 13 corner, the flange portion 13 corner on the obtuse angle portion 7 b side forms an arc portion 16 a having a large curvature, and the flange portion 13 corner on the acute angle portion 7 c side forms an arc portion 16 b having a small curvature. This is the configuration.
[0071]
According to the electric motor 1 of the present invention as described above, the axial sectional shape of the wound portion 7a of the insulator 7 covering the pole teeth 8 is the gap generated by the inertial force when the winding nozzle moves from the linear track to the arc track. Since it is a substantially parallelogram with the thickness of the insulator ΔG cut, even if the winding speed of the winding nozzle is increased, the winding shape after winding of the drive coil 2 can be made substantially rectangular and fixed. Since the height of the coil end protruding in the axial direction from the core can be reduced, a thin motor can be obtained. Further, since the coil circumference can be shortened, a highly efficient electric motor can be obtained by reducing copper loss. In addition, since the winding speed can be increased, the machining cost can be reduced, so that the cost of the electric motor can be reduced.
[0072]
Further, in the arc portion 16 of the collar portion 13 corner, the curvature of the arc portion 16a on the obtuse angle portion 7b side where the corner of the wound portion 7a of the insulator 7 covering the pole teeth 8 forms an obtuse angle is formed large. Therefore, since the timing at which the winding nozzle shifts from the linear track to the circular track can be made earlier, the gap between the drive coil 2 and the insulator 7 is reduced, so that the height of the coil end protruding in the axial direction from the stator core 10a is reduced. However, since the coil perimeter becomes shorter and the resistance value of the drive coil 2 becomes lower and the copper loss can be further reduced, an electric motor that can be further reduced in thickness and increased in efficiency can be obtained.
[0073]
In the first embodiment, an inner rotation type electric motor in which the rotor arranged on the inner peripheral side of the stator rotates is used. However, an outer rotation type electric motor in which the rotor arranged on the outer peripheral side of the stator rotates. And it does not make a difference in its effects.
[0074]
In the first embodiment, the electric motor has a built-in driving circuit. However, a sensorless electric motor without a driving circuit may be used, and there is no difference in operation and effect.
[0075]
In the first embodiment, the configuration is a DC motor in which permanent magnets are arranged on the rotor. However, an induction motor that does not use permanent magnets or a reluctance motor may be used. There is no difference in effect.
[0076]
Further, as shown in FIG. 5, a roundness 5 is provided at the corner of the wound portion 7a of the insulator 7 covering the pole teeth 8, and the curvature of the rounding 5a forming one diagonal is set to the rounding 5b forming the other diagonal. In addition, the gap ΔG generated by the inertial force when the winding nozzle moves from the linear track to the circular track is provided with a difference in rounding curvature. Therefore, the height of the coil end protruding in the axial direction from the stator core is reduced, and a thin motor can be obtained. Further, since the coil circumference can be shortened and an increase in resistance value due to refraction of the drive coil can be suppressed, an electric motor that achieves further high efficiency by reducing copper loss can be obtained.
[0077]
Further, as shown in FIG. 6, chamfers 17 are provided at the corners of the wound portion 7a of the insulator 7 that covers the pole teeth 8, and the size of the chamfer 17a that forms one diagonal is set to the chamfer that forms the other diagonal. Even if it is formed larger than the size of 17b, and the gap ΔG generated by the inertial force when the winding nozzle moves from the linear track to the circular track, the difference between the chamfered sizes is provided. Since the distance of the coil 2 is shortened, the height of the coil end protruding in the axial direction from the stator core is reduced, and a thin motor can be obtained. Further, since the coil circumference can be shortened, a highly efficient electric motor can be obtained by reducing copper loss.
[0078]
Further, as shown in FIG. 7, in the insulating means of the drive coil 2 and the stator core 10a, an insulating film 18 such as a polyester film is disposed on the side of the pole teeth 8, and this insulating film 18 is made of resin from the axial direction. The insulator 19 has a structure sandwiched between them, and an axial end portion angle of the wound portion 19a of the insulator 19 is formed on one side as an obtuse angle 19b, the other is formed at an acute angle 19c, and one diagonal is formed as an obtuse angle. Even if the other diagonal is formed as an acute angle, the shape of the section in the axial direction of the coiled portion is the thickness of the insulator of the gap ΔG generated by the inertial force when the winding nozzle moves from the linear track to the arc track. Therefore, the winding shape after winding of the drive coil 2 can be made substantially rectangular, and the height of the coil end protruding in the axial direction from the stator core can be reduced. Since it is, thinned electric motor is obtained. Further, since the coil circumference can be shortened, a highly efficient electric motor can be obtained by reducing copper loss.
[0079]
Further, as shown in FIG. 8, in the insulating means of the drive coil 2 and the stator core 10a, an insulating film 18 such as a polyester film is disposed on the side of the pole teeth 8, and the insulating film 18 is made of resin from the axial direction. The insulator 20 has a structure sandwiched between them, and a rounded portion 21 is provided at an end corner in the axial direction of the wound portion 20a of the insulator 20, and the curvature of the rounded portion 21 is large on one side and small on the other side, Even in a configuration in which the curvature of one diagonal round 21a is large and the curvature of the other diagonal round 21b is small, the clearance ΔG generated by the inertial force when the winding nozzle moves from the linear track to the circular track is reduced. Since there is a difference in the curvature of roundness, the distance between the stator core 10a and the drive coil 2 is shortened, so the height of the coil end protruding in the axial direction from the stator core Lower, thinner and electric motor can be obtained. Further, since the coil circumference can be shortened and an increase in resistance value due to refraction of the drive coil can be suppressed, an electric motor that achieves further high efficiency by reducing copper loss can be obtained.
[0080]
Further, as shown in FIG. 9, in the insulating means of the drive coil 2 and the stator core 10a, an insulating film 18 such as a polyester film is disposed on the side of the pole teeth 8, and the insulating film 18 is made of resin from the axial direction. The chamfer 23 is provided at the axial end corner of the wound portion 22a of the insulator 22, and the chamfer 23 is formed so that one side is large and the other is small. Even if the diagonal chamfer 23a is large in size and the diagonal chamfer 23b is small in size, the gap generated by the inertial force when the winding nozzle moves from the linear track to the circular track. Since the difference ΔG is provided in the chamfer size, the distance between the stator core 10a and the drive coil 2 is shortened, so that it protrudes axially from the stator core. The height of Iruendo is low, thin the motor is obtained. Further, since the coil circumference can be shortened, a highly efficient electric motor can be obtained by reducing copper loss.
[0081]
Further, as shown in FIG. 10, the insulators 7, 19, 20, and 22 of the pole piece portion 8 a are provided with a flange portion 24 that prevents the drive coil 2 from collapsing toward the magnet rotor 3. In the chamfered portion of the 24 corners of the flange portion, the obtuse angle portions 7b and 19b side where the wound portions 7a and 19a of the insulators 7 and 19 covering the pole teeth 8 form an obtuse angle, or the pole The rounded portions 5a and 21a of the insulators 7 and 20 that cover the teeth 8 have a large curvature at the corners 7a and 20a, or the chamfers 17a and 22a of the insulators 7 and 22 that cover the pole teeth 8 have a large corner. , 23a side chamfered portion 24a of chamfered portion 24a is also formed large, so that the timing at which the winding nozzle shifts from the linear track to the circular track can be made faster. Since the gap between the regulators 7 is reduced, the height of the coil end protruding in the axial direction from the stator core 10a is further reduced and the coil circumferential length is also shortened, so that the resistance value of the drive coil 2 is reduced. In addition, since the copper loss can be further reduced, an electric motor that can be further reduced in thickness and increased in efficiency can be obtained.
[0082]
Further, as shown in FIG. 11, the insulator 7, 19, 20, 22 of the pole piece portion 8a is provided with a flange portion 25 for preventing the drive coil 2 from collapsing toward the magnet rotor 3, and in this flange portion 25, The wrapped portions 7a and 19b of the insulators 7 and 19 covering the pole teeth 8 are formed on the obtuse angle portions 7b and 19b side where the corners form an obtuse angle, or the wound portions 7a of the insulators 7 and 20 covering the pole teeth 8 The notches 26 are arranged on the rounded corners 5a and 21a having a large curvature of the 20a corner, or on the chamfered corners 25a on the chamfered portions 17a and 23a having the large corners of the insulators 7 and 22 covering the pole teeth 8, and on the chamfer 17a and 23a side. Also by adopting the configuration, the timing at which the winding nozzle shifts from the linear track to the circular track can be accelerated, so that the gap between the drive coil 2 and the stator core 10a is reduced, so that the stator core 1 Since the height of the coil end protruding in the axial direction from a is further reduced and the coil peripheral length is also shortened, the resistance value of the drive coil 2 is reduced and the copper loss can be further reduced. An electric motor capable of realizing high efficiency can be obtained.
[0083]
(Example 2)
As shown in FIGS. 12 and 13, reference numeral 27 denotes a stator in which a drive core 2 is wound around a stator core 27a in which thin steel plates such as silicon steel plates having a plurality of slots are laminated, and 28 denotes pole teeth. The drive coil 2 is concentratedly wound every 28 units of teeth. In the stator core 27 a, end laminated core portions 29 in which the width of the wound portion 30 of the pole teeth 28 gradually decrease are provided at both axial ends, and in the end laminated core portion 29, the wound portion 30 of the wound portion 30 is provided. The gradual decrease amount in the width is such that the gradual decrease amount ΔW1 in one diagonal is large, the gradual decrease amount ΔW2 in the other diagonal is small, and the width of the pole piece portion 28a at the tip of the pole tooth 28 is the same. Other configurations are the same as those of the first embodiment, and detailed description thereof is omitted.
[0084]
According to such an electric motor of the present invention, the shape of the axial section of the wound portion 30 in the pole tooth 28 is such that the pole tooth of the gap ΔG generated when the winding nozzle moves from the linear track to the arc track. Therefore, the height of the coil end protruding in the axial direction from the stator core 27a can be reduced, and the coil peripheral length is also shortened. Therefore, the resistance value of the drive coil 2 is reduced, and the copper loss is reduced. Therefore, an electric motor that can be further reduced in thickness can be obtained. Here, since the volume of the stator core 27a is reduced, the magnetic flux is reduced, and the torque that can be generated is reduced, but it can be offset with the reduced amount of copper loss. It becomes possible.
[0085]
In the second embodiment, the drive coil 2 is wound directly around the wound portion 30 of the pole tooth 28. However, the drive coil 2 may be wound via an insulator having a substantially uniform thickness, and the operation thereof. There is no difference in effect.
[0086]
Moreover, it is good also as a structure of an abduction type electric motor similarly to Example 1, and does not produce a difference in the effect.
[0087]
Moreover, it is good also as a sensorless type electric motor similarly to Example 1, and does not produce a difference in the effect.
[0088]
Moreover, it is good also as an induction motor and a reluctance motor similarly to Example 1, and does not produce a difference in the effect.
[0089]
Further, as shown in FIG. 14A, the pole piece portion 28a is provided with a flange portion 13 for preventing the drive coil 2 from collapsing toward the magnet rotor 3, and an arc portion is provided at a corner portion of the flange portion 13. 16, in the arcuate portion 16 of the 13 corners of the flange portion, the side where the gradually decreasing amount of the wound portion 30 is large (ΔW1) forms an arc portion 16a having a large curvature, and the width of the wound portion 30 is increased. As shown in FIG. 14 (b), the drive coil 2 does not collapse to the magnet rotor 3 side in the pole piece portion 28a as shown in FIG. A flange 24 to be prevented is provided, and a chamfer is provided at a corner of the flange 24. In the chamfer at the corner of the flange 24, the side where the width of the wound portion 30 is gradually decreased (ΔW1) is large. Part 24a is formed, and the gradually decreasing amount of the width of the wound part 30 is small (ΔW2) is small. Even in the configuration in which the chamfered portion 24b is formed, as shown in FIG. 14 (c), the pole piece portion 28a is provided with the flange portion 25 for preventing the drive coil 2 from collapsing toward the magnet rotor 3 side. Even when the notch 26 is formed on the side of the portion 25 where the gradually decreasing amount of the wound portion 30 is large (ΔW1), the timing at which the winding nozzle shifts from the linear track to the circular track is accelerated. Since the gap between the drive coil 2 and the stator core 27a is reduced, the height of the coil end protruding in the axial direction from the stator core 27a is further reduced, and the coil circumference is also shortened. Since the resistance value of the drive coil 2 is reduced and the copper loss can be further reduced, an electric motor that can be further reduced in thickness and increased in efficiency can be obtained.
[0090]
Further, in the second embodiment, the configuration is such that the width of the wound portion 30 is cut at both ends (ΔW1, ΔW2). However, the configuration may be such that only one side is cut, and there is no significant difference in the effect.
[0091]
(Example 3)
As shown in FIGS. 15 and 16, 31 is driven by a stator core 31a having a plurality of slots formed by molding and solidifying a composite material of magnetic powder and resin whose surface is insulated with an oxide which is a magnetic powder material. A stator 33 around which the coil 2 is wound, 33 is a pole tooth, and the drive coil 2 is concentratedly wound for each unit of the pole tooth 33. A pole piece portion 33a projecting in the rotation direction of the magnet rotor 3 is disposed at the tip of the pole tooth 33, and the drive coil 2 is prevented from collapsing toward the magnet rotor 3 in this pole piece portion 33a. The collar part 32 to prevent is provided integrally, and the corner part of the collar part 32 has an arc shape. And the axial direction cross-sectional shape of the to-be-wrapped part 33b of the pole tooth 33 is a substantially parallelogram, and the obtuse angle part 33c and the acute angle part 33d are rounded. Further, in the arc portion 34 of the flange portion 32 corner, the flange portion 32 corner on the obtuse angle portion 33c side forms an arc portion 34a having a large curvature, and the flange portion 34 angle on the acute angle portion 33d side forms an arc portion 34b having a small curvature. The configuration is as follows. Other configurations are the same as those of the first embodiment, and detailed description thereof is omitted.
[0092]
According to such an electric motor of the present invention, the axial cross-sectional shape of the wound portion 33b of the pole tooth 33 is the same as that of the insulator of the gap ΔG generated by the inertia force when the winding nozzle moves from the linear track to the arc track. Since it is a substantially parallelogram with a reduced thickness, the winding shape of the drive coil 2 after winding can be made substantially rectangular, and the height of the coil end protruding in the axial direction from the stator core 31a can be reduced. Therefore, a thin motor can be obtained. Further, since the coil circumference can be shortened, a highly efficient electric motor can be obtained by reducing copper loss.
[0093]
In addition, in the arc portion 34 of the collar portion 32 corners, the winding nozzle 33 is formed in a straight track because the angle of the arcuate portion 34a on the obtuse angle portion 33c side where the angle of the wound portion 33b forms an obtuse angle is formed. Since the timing of the transition from the arc to the arc track can be made earlier, the gap between the drive coil 2 and the stator core 31a is reduced, so that the height of the coil end protruding in the axial direction from the stator core 31a is further reduced. Since the coil circumferential length is also shortened, the resistance value of the drive coil 2 is reduced and the copper loss can be further reduced, so that an electric motor that can be further reduced in thickness and increased in efficiency can be obtained.
[0094]
In addition, it is good also as a structure of an abduction-type electric motor similarly to Example 1, and does not produce a difference in the effect.
[0095]
In addition, as shown in FIG. 17, the round portion 35 is provided at the corner of the wound portion 33b, and the curvature of the round portion 35a that forms one diagonal is larger than the curvature of the round portion 35b that forms the other diagonal. The distance between the stator core and the drive coil 2 is shortened even if the gap ΔG generated by the inertial force when the winding nozzle moves from the linear track to the circular track has a difference in rounding curvature. The height of the coil end protruding in the axial direction from the iron core is reduced, and a thin motor can be obtained. Further, since the coil circumference can be shortened and an increase in resistance value due to refraction of the drive coil can be suppressed, an electric motor that achieves further high efficiency by reducing copper loss can be obtained.
[0096]
Further, as shown in FIG. 18, chamfers 36 are provided at the corners of the wound portion 33b, and the size of the chamfer 36a forming one diagonal is formed larger than the size of the chamfer 36b forming the other diagonal. At the same time, even if the gap ΔG generated by the inertial force when the winding nozzle moves from the linear track to the circular track is provided with a difference in the chamfer size, the distance between the stator core and the drive coil 2 is shortened. The height of the coil end protruding in the axial direction from the stator core is reduced, and a thin motor can be obtained. Further, since the coil circumference can be shortened, a highly efficient electric motor can be obtained by reducing copper loss.
[0097]
Further, as shown in FIG. 19, the pole piece portion 33a is integrally provided with a flange portion 37 for preventing the drive coil 2 from collapsing toward the magnet rotor 3, and the corners of the flange portion 37 are chamfered. In the chamfered portion of the flange 37 corner, the obtuse angle portion 33c side where the angle of the wound portion 33b forms an obtuse angle, the roundness 35a side where the curvature of the angle of the wound portion 33b is large, or the wound portion 33b As shown in FIG. 20, the drive coil 2 is prevented from collapsing to the magnet rotor 3 side in the pole piece 33a as shown in FIG. The flange portion 38 is integrally provided, and in this flange portion 38, the obtuse angle portion 33c side where the angle of the wound portion 33b forms an obtuse angle, the round portion 35a side where the curvature of the angle of the wound portion 33b is large, or Wound part 33b corner is large Even when the notch 38a is arranged at the corner 38 of the flange 36a side, the timing at which the winding nozzle shifts from the linear track to the circular track can be accelerated, so that there is a gap between the drive coil 2 and the stator core 31a. Since the coil end becomes smaller, the height of the coil end protruding in the axial direction from the stator core 31a is further reduced, and the coil peripheral length is also shortened, so that the resistance value of the drive coil 2 is reduced and the copper loss can be further reduced. Therefore, an electric motor that can achieve further reduction in thickness and efficiency can be obtained.
[0098]
(Example 4)
As shown in FIGS. 21 and 22, reference numeral 41 denotes a stator core having a slot 40, and a winding nozzle 39 passes through a slot opening 43 of the stator core 41 to rotate around each pole tooth 42. In the method of manufacturing the electric motor in which the drive coil 2 is wound, the track of the winding nozzle 39 is linear in the slot 40 of the stator core 41, and the axial end surface side of the stator core is arcuate. At the same time, the curvature Ra of the arc on the side moving from the linear track to the arcuate track is wound a predetermined number of times on a track larger than the curvature Rb of the arc on the side moving from the arcuate track to the linear track. The winding process is completed. Subsequent assembly is the same as a normal method of manufacturing an electric motor.
[0099]
According to such a method of manufacturing an electric motor of the present invention, the curvature Ra of the circular arc track on the side of transition from the linear track to the circular track in the track of the winding nozzle 39 is changed to the arc on the side of transition from the circular track to the linear track. By making the manufacturing method larger than the curvature Rb of the track, the transition from the linear track to the circular track can be made faster, so the gap between the drive coil 2 and the stator core 41 caused by the inertial force is reduced. Whether it is winding on a large number of stator cores, winding on a stator core with a narrow slot opening, or winding on a stator core with a long axial length, Even when winding on the stator core where the width of the wound portion of the pole teeth is narrow, the height of the coil end protruding in the axial direction from the stator core can be reduced, so that the thickness can be reduced. A method for manufacturing an electric motor is obtained. .
[0100]
【The invention's effect】
As is clear from the above embodiments, according to the present invention, a stator in which a drive coil is wound for each pole tooth unit of the stator core, and a rotor that is rotatably held facing the stator. And an insulator that insulates the stator core from the drive coil, and the shape of the axial cross section of the insulator that covers the pole teeth of the stator core is such that the winding nozzle moves from a linear track to an arc track Even if the winding speed of the winding nozzle is increased by adopting a motor structure characterized by having a substantially parallelogram with the thickness of the insulator for the gap generated when The winding shape of the coil is substantially rectangular, and the height of the coil end protruding in the axial direction from the stator core can be reduced, so that a thin motor can be obtained. Further, since the coil circumference can be shortened, a highly efficient electric motor can be obtained by reducing copper loss.
[0101]
In addition, the corners of the insulator covering the wound portion of the pole teeth are rounded, and the curvature of one of the diagonals is larger than the curvature of the other diagonal, and the winding nozzle Even if the difference between the rounding curvature and the gap generated by the inertial force when moving from the straight track to the circular track, the distance between the stator core and the drive coil is shortened, so that it protrudes from the stator core in the axial direction. The coil end is reduced in height, and a thin motor can be obtained. Further, since the coil circumference can be shortened and an increase in resistance value due to refraction of the drive coil can be suppressed, an electric motor that achieves further high efficiency by reducing copper loss can be obtained. Here, by realizing higher efficiency, the laminated thickness of the stator core can be reduced if the output is the same, so that an electric motor that is further reduced in thickness can be provided.
[0102]
Also, a chamfer is provided at the corner of the insulator that covers the wound portion of the pole teeth, and the chamfer size forming one diagonal is formed larger than the chamfer size forming the other diagonal, and the winding nozzle Even when the gap between the stator core and the drive coil is reduced, the gap between the stator core and the drive coil is shortened in the axial direction. The height of the protruding coil end is reduced, and a thin motor can be obtained. Further, since the coil circumference can be shortened, a highly efficient electric motor can be obtained by reducing copper loss.
[0103]
In addition, in the insulating means of the drive coil and the stator core, an insulating film is provided on the side of the pole tooth winding portion, and this insulating film is sandwiched by a resin insulator from the axial direction. The angle at the end in the axial direction is an obtuse angle on one side, the other is an acute angle, one diagonal is an obtuse angle, and the other diagonal is an acute angle. The shape of the axial cross section is a substantially parallelogram with the thickness of the insulator corresponding to the gap generated by the inertia force being reduced when the winding nozzle moves from the linear orbit to the arc orbit. The coil shape can be made substantially rectangular, and the height of the coil end protruding in the axial direction from the stator core can be reduced, so that a thin motor can be obtained. Further, since the coil circumference can be shortened, a highly efficient electric motor can be obtained by reducing copper loss.
[0104]
In addition, the resin insulator that sandwiches the insulating film from the axial direction is rounded at the end corner in the axial direction, and the curvature of this round is large on one side, small on the other, and rounded on one diagonal. Even if the curvature of the rounding that forms the other diagonal is small, the gap created by the inertial force when the winding nozzle moves from the linear orbit to the arc orbit is provided with a difference in the rounding curvature. As a result, the distance between the stator core and the drive coil is reduced, so that the height of the coil end protruding in the axial direction from the stator core is reduced, and a thin motor can be obtained. Further, since the coil circumference can be shortened and an increase in resistance value due to refraction of the drive coil can be suppressed, an electric motor that achieves further high efficiency by reducing copper loss can be obtained. Here, by realizing higher efficiency, the laminated thickness of the stator core can be reduced if the output is the same, so that an electric motor that is further reduced in thickness can be provided.
[0105]
Also, a chamfer is provided at the end corner in the axial direction of the resin insulator that sandwiches the insulating film from the axial direction, and the chamfer is formed so that one side is large and the other is small, and the other side is chamfered. Even if the size of the chamfer forming the other diagonal is small and the size of the other diagonal chamfer is small, the gap chamfered by the inertial force when the winding nozzle moves from the linear track to the circular track is chamfered. Since the distance between the stator core and the drive coil is shortened, the height of the coil end protruding in the axial direction from the stator core is reduced, and a thin motor can be obtained. Further, since the coil circumference can be shortened, a highly efficient electric motor can be obtained by reducing copper loss.
[0106]
In addition, in the stator core, both end portions in the axial direction are provided with end laminated core portions in which the width of the wound portion of the pole teeth is gradually reduced, and in this end laminated core portion, the gradually decreasing amount in the width of the wound portion is provided. The shape of the axial cross section of the wound part at the pole teeth is such that the winding nozzle has a circular arc from the straight track by forming the gradually decreasing amount of one diagonal and reducing the decreasing amount of the other diagonal. Since it has a shape that has sharpened the teeth of the gap generated when moving to the track, the height of the coil end protruding in the axial direction from the stator core can be reduced, and the coil circumference is also shortened, Since the resistance value of the drive coil is reduced and the copper loss can be reduced, an electric motor capable of realizing further reduction in thickness can be obtained. Here, since the volume of the stator core is reduced, the magnetic flux is reduced and the torque that can be generated is reduced, but it can be offset with the reduced amount of copper loss, so if the required torque is the same, the thickness can be reduced. It becomes.
[0107]
In addition, a fixed structure in which a drive coil is wound for each pole tooth unit of a stator core having a plurality of slots formed by molding and solidifying a composite material of magnetic powder and resin whose surface is insulated with an oxide which is a magnetic powder material. A stator and a rotor held rotatably against the stator, and the shape of the axial cross section of the stator core is a clearance generated when the winding nozzle moves from a linear track to an arc track. With the configuration of an electric motor characterized by having a substantially parallelogram with the thickness of the stator core of the coil wound, the winding shape after winding is approximately rectangular, and the axial direction from the stator core Since the height of the protruding coil end can be reduced, a thin motor can be obtained. Further, since the coil circumference can be shortened, a highly efficient electric motor can be obtained by reducing copper loss.
[0108]
In addition, the corner of the wound portion of the stator core having a plurality of slots formed by molding and solidifying powder magnetic material is rounded, the curvature of one of the diagonals is rounded, the rounding of the other diagonal The gap between the stator core and the drive coil is different even when the winding nozzle is formed to have a difference in rounding curvature due to the inertia generated when the winding nozzle moves from the linear track to the circular track. Since the length becomes shorter, the height of the coil end protruding in the axial direction from the stator core is reduced, and a thin motor can be obtained. Further, since the coil circumference can be shortened and an increase in resistance value due to refraction of the drive coil can be suppressed, an electric motor that achieves further high efficiency by reducing copper loss can be obtained.
[0109]
Also, a chamfer is provided at the corner of the wound portion of the stator core having a plurality of slots formed by molding and solidifying the magnetic powder material, and the size of the chamfer forming one diagonal is the other diagonal. In addition to forming the chamfer larger than the chamfer size, the gap generated by the inertia force when the winding nozzle moves from the linear track to the circular arc track has a difference in the chamfer size. Since the distance becomes shorter, the height of the coil end protruding in the axial direction from the stator core is reduced, and a thin motor can be obtained. Further, since the coil circumference can be shortened, a highly efficient electric motor can be obtained by reducing copper loss.
[0110]
In addition, the pole teeth are provided with a flange portion that prevents the drive coil from collapsing toward the magnet rotor, and the corner portion of the flange portion is formed in an arc shape, and the arc portion of the flange portion is wound when the drive coil is wound. The winding nozzle has a circular arc from the linear track by a configuration in which the arc curvature on the side where the linear nozzle transitions from the linear track to the circular track is larger than the arc curvature on the side where the winding nozzle transitions from the circular track to the linear track. Since the timing of shifting to the track can be made earlier, the gap between the drive coil and the stator core becomes smaller, so the height of the coil end protruding in the axial direction from the stator core is further reduced, and the coil circumference is also reduced. Since it becomes shorter, the resistance value of the drive coil becomes lower, and the copper loss can be further reduced, so that an electric motor that can be made thinner and more efficient can be obtained.
[0111]
In addition, the pole teeth are provided with a hook portion that prevents the drive coil from collapsing toward the magnet rotor side, and a chamfer is provided at the corner portion of the hook portion. Even if the chamfering size on the side where the winding nozzle moves from the linear track to the circular track is larger than the chamfering size on the side where the winding nozzle transitions from the circular track to the linear track, the winding nozzle is linear. Since the timing of transition from the track to the arc track can be made earlier, the gap between the drive coil and the stator core is reduced, so that the height of the coil end protruding in the axial direction from the stator core is further reduced, and the coil Since the circumference is also shortened, the resistance value of the drive coil is reduced and the copper loss can be further reduced, so that an electric motor that can be further reduced in thickness and increased in efficiency can be obtained.
[0112]
In addition, the pole teeth are provided with a flange that prevents the drive coil from collapsing toward the magnet rotor, and the winding nozzle when winding the drive coil is located at the corner of the flange on the side where the transition from the linear track to the arc track occurs. Even when the notch is provided, the winding nozzle can be moved from the linear track to the arc track earlier, so the gap between the drive coil and the stator core is reduced, so that it protrudes from the stator core in the axial direction. As the coil end height is further reduced and the coil circumference is also shortened, the resistance value of the drive coil is reduced and the copper loss can be further reduced, so that the motor can be further reduced in thickness and increased in efficiency. Is obtained.
[0113]
The winding nozzle passes through the slot opening of the stator core, rotates around each pole tooth and winds the drive coil, and the track of the winding nozzle is the stator. The slot in the iron core is linear, the axial end face side of the stator core is arc-shaped, and the curvature of the arc on the side moving from the linear track to the arc-shaped track is the side moving from the arc-shaped track to the linear track In the winding nozzle track, the transition from the linear track to the circular track is achieved in the winding nozzle track by winding a predetermined number of times on the track larger than the curvature of the arc. Since the gap between the drive coil and the stator core caused by the inertial force is reduced because it can be done quickly, even if it is wound around the stator core with a large number of slots, it can be wound around the stator core with a narrow slot opening. Even if Even if it is wound around a stator core with a long axial length, or even if it is wound around a stator core where the width of the pole-wound portion is narrow, it protrudes from the stator core in the axial direction. Since the height of the coil end can be reduced, a method for manufacturing an electric motor that can be reduced in thickness can be obtained.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing an electric motor according to Embodiment 1 of the present invention.
FIG. 2 is a cross-sectional view showing a wound part of the same motor
FIG. 3 is a view showing a buttock of the electric motor
FIG. 4 is a plan view showing a stator of the same motor
FIG. 5 is a cross-sectional view showing another configuration of the wound portion of the electric motor
FIG. 6 is a cross-sectional view showing another configuration of the wound portion of the electric motor
FIG. 7 is a cross-sectional view showing another configuration of the wound portion of the electric motor
FIG. 8 is a cross-sectional view showing another configuration of the wound portion of the electric motor
FIG. 9 is a cross-sectional view showing another configuration of the wound portion of the electric motor
FIG. 10 is a diagram showing another configuration of the buttock of the electric motor
FIG. 11 is a diagram showing another configuration in the buttock of the electric motor
FIG. 12 is a perspective view showing a stator core in the electric motor according to Embodiment 2 of the present invention.
FIG. 13 is a cross-sectional view showing a wound part of the same motor
FIG. 14A is a diagram showing a collar portion in another configuration of the electric motor.
(B) Figure
(C) Figure
FIG. 15 is a sectional view showing a portion to be wound in the electric motor according to the third embodiment of the present invention.
FIG. 16 is a view showing a buttock of the electric motor
FIG. 17 is a cross-sectional view showing another configuration of the wound portion of the electric motor
FIG. 18 is a cross-sectional view showing another configuration of the wound portion of the electric motor
FIG. 19 is a view showing another configuration of the buttock of the electric motor
FIG. 20 is a diagram showing another configuration of the buttock of the electric motor
FIG. 21 is a diagram showing a state when the drive coil is wound by the method for manufacturing the electric motor according to the fourth embodiment of the present invention.
FIG. 22 is a view showing a track of a winding nozzle in the method for manufacturing the same motor
FIG. 23A is a front view showing a schematic configuration of a conventional electric motor.
(B) Cross-sectional side view
FIG. 24A is a view showing a tip locking portion of the same electric motor.
(B) Figure
FIG. 25A is a view showing a portion of the wound portion in the same motor that covers the end face in the axial direction of the teeth.
(B) Figure
(C) Figure
(D) Figure
FIG. 26A is a schematic view showing a stator having another configuration in a conventional electric motor.
(B) Schematic showing the winding
FIG. 27 is a side sectional view showing another configuration of a conventional electric motor.
FIG. 28 is a plan view showing the configuration before winding the winding of the motor.
FIG. 29 is an exploded perspective view showing the stator core of the same motor.
FIG. 30 (a) is a cross-sectional view showing a portion to be wound of the electric motor
(B) Figure
FIG. 31 is a sectional view showing an actual state of a wound part in a conventional electric motor
[Explanation of symbols]
1 Electric motor
2 Drive coil
3 Magnet rotor
4 Hall IC
5 Roundness
5a Roundness (high curvature)
5b Roundness (curvature is small)
6 Bearing
7 Insulator
7a Wound part
7b obtuse corner
7c Sharp corner
8 pole teeth
8a Pole piece part
9 Shaft
10 Stator
10a Stator core
11 Bracket
12 Thermosetting resin
13 Buttocks
14 Printed circuit board
15 Drive IC
16 Arc part
16a Arc part (large curvature)
16b Arc part (small curvature)
17 Chamfer
17a Chamfer (Large)
17b Chamfer (small)
18 Insulating film
19 Insulator
19a Wound part
19b obtuse angle part
19c Sharp corner
20 Insulator
20a Wound part
21 Roundness
21a Roundness (large curvature)
21b Roundness (small curvature)
22 Insulator
22a Wound part
23 Chamfering
23a Chamfer (Large)
23b Chamfer (small)
24 Buttocks
24a Chamfered corner chamfer (large)
24b Chamfered corner chamfer (small)
25 Buttocks
26 Notch
27 Stator
27a Stator core
28 pole teeth
28a Pole piece part
29 End laminated core
30 Winded part
31 Stator
31a Stator core
32 Buttocks
33 pole teeth
33a Pole piece part
33b Winded part
33c obtuse corner
33d acute corner
34 Arc part
34a Arc part (large curvature)
34b Arc part (small curvature)
35 Roundness
35a Roundness (high curvature)
35b Roundness (small curvature)
36 Chamfer
36a Chamfer (Large)
36b Chamfer (small)
37 Buttocks
37a Chamfered corner chamfer (large)
38
38a Notch
39 Winding nozzle
40 slots
40a Slot opening
41 Stator core
42 pole teeth
43 Axial end face side

Claims

A stator core having a slot, a stator having a drive coil wound around each pole tooth unit of the stator core, a rotor rotatably held facing the stator, and the stator core An electric motor comprising an insulator that insulates the drive coil, wherein an axial section of the wound portion of the insulator that covers the pole teeth of the stator core is a substantially parallelogram.

A stator core having a slot, a stator having a drive coil wound around each pole tooth unit of the stator core, a rotor rotatably held facing the stator, and the stator core An insulator that insulates the drive coil, the corner of the wound portion of the insulator that covers the pole teeth of the stator core is rounded, and the curvature of the round that forms one diagonal is: An electric motor characterized by being formed to be larger than the curvature of the roundness forming the other diagonal.

A stator core having a slot, a stator having a drive coil wound around each pole tooth unit of the stator core, a rotor rotatably held facing the stator, and the stator core An insulator that insulates the drive coil, and a chamfer is provided at a corner of the wound portion of the insulator that covers the pole teeth of the stator core, and the size of the chamfer that forms one diagonal is The electric motor is formed larger than the size of the chamfer forming the other diagonal.

A stator core having a slot, a stator having a drive coil wound around each pole tooth unit of the stator core, a rotor rotatably held facing the stator, and the stator core An insulator that insulates the drive coil, and the insulator includes an insulating film that insulates the side surfaces of the pole teeth, and a resin insulator that sandwiches the insulating film from the axial direction of the stator core. The axial end angle of the wound portion of this insulator is formed with an obtuse angle on one side, the other with an acute angle, one diagonal with an obtuse angle, and the other with an acute angle. Electric motor.

A stator core having a slot, a stator having a drive coil wound around each pole tooth unit of the stator core, a rotor rotatably held facing the stator, and the stator core An insulator that insulates the drive coil, and the insulator includes an insulating film that insulates the side surfaces of the pole teeth, and a resin insulator that sandwiches the insulating film from the axial direction of the stator core. The angle of the end portion in the axial direction of the wound portion of the insulator is rounded, and the roundness forms a large curvature on one side, the curvature of the other round is small, and the rounding that forms one diagonal. The electric motor is characterized in that it has a large curvature, and the curvature of the other rounded corner is small.

A stator core having a slot, a stator having a drive coil wound around each pole tooth unit of the stator core, a rotor rotatably held facing the stator, and the stator core An insulator that insulates the drive coil, and the insulator includes an insulating film that insulates the side surfaces of the pole teeth, and a resin insulator that sandwiches the insulating film from the axial direction of the stator core. In addition, a chamfer is provided at the axial end corner of the wrapped portion of the insulator, one side of the chamfer is formed large, the other chamfer is formed small, and the chamfer forming one diagonal is formed large. The electric motor characterized in that the chamfer forming the other diagonal is formed small.

A stator core in which thin steel plates having slots are laminated, a stator in which a drive coil is wound for each pole tooth unit of the stator core, and a rotor that is rotatably held facing the stator. An end laminated core portion in which the width of the wound portion of the pole teeth is gradually reduced is provided at an axial end portion of the stator core, and the width of the wound portion in the end laminated core portion is gradually reduced. Is an electric motor characterized in that one diagonal is formed large and the other diagonal is formed small.

A stator core having a slot formed by molding and solidifying a magnetic powder material, a stator having a drive coil wound for each pole tooth unit of the stator core, and rotatably held facing the stator. And an axial section of the wound portion of the pole teeth is a substantially parallelogram.

A stator core having a slot formed by molding and solidifying a magnetic powder material, a stator having a drive coil wound for each pole tooth unit of the stator core, and rotatably held facing the stator. And the winding angle of the pole teeth of the stator core is rounded, and the curvature of the round that forms one diagonal is more than the curvature of the round that forms the other diagonal. An electric motor characterized by a large size.

A stator core having a slot formed by molding and solidifying a magnetic powder material, a stator having a drive coil wound for each pole tooth unit of the stator core, and rotatably held facing the stator. The chamfered portion of the pole tooth of the stator core is chamfered, and the size of the chamfer forming one diagonal is the size of the chamfer forming the other diagonal. An electric motor characterized by being formed larger than the above.

The insulator is provided with a flange portion that prevents the drive coil from collapsing toward the rotor. The corner portion of the flange portion has an arc shape, and the curvature of the arc portion is obtuse at the corner portion of the wound portion. On the side where the curvature of the rounded corner of the wound part is large, or on the side where the corner chamfer of the wound part is large, the corner of the wound part forms an acute angle. The curvature of the arcuate portion on the side where the curvature of the corner roundness of the wrapped portion is small, or on the side where the corner chamfer of the wrapped portion is small is larger than the arc portion curvature. 6. The electric motor according to any one of 6.

The insulator is provided with a flange portion that prevents the drive coil from collapsing toward the rotor side, and a chamfered portion is provided at a corner portion of the flange portion. The side where the corner of the winding part forms an obtuse angle, the side where the curvature of the corner roundness of the winding part is large, or the side where the corner chamfering of the winding part is large is the side of the winding part. From the chamfering of the corner chamfered portion on the side where the corner forms an acute angle, the side where the curvature of the rounded corner of the wound portion is small, or the side where the corner chamfer of the wound portion is small The electric motor according to claim 1, wherein the electric motor is also made larger.

The insulator is provided with a flange portion that prevents the drive coil from collapsing toward the rotor side, and this notch portion is provided with a notch, and this notch forms an obtuse angle at the corner of the wound portion. 7. The device according to claim 1, further comprising a side, a side having a large curvature of a corner roundness of the wound portion, or a side having a large corner chamfer of the wound portion. Electric motor.

11. The electric motor according to claim 7, wherein the pole teeth are provided with a flange portion that prevents the drive coil from collapsing toward the rotor, and a corner portion of the flange portion is formed in an arc shape. The curvature of the arc part is the side where the gradually decreasing amount of the width of the wound part is large, or the side where the curvature of the corner roundness of the wound part is large, or the corner part of the wound part forms an obtuse angle. The side where the corner portion chamfer of the wound portion is large, the side where the gradually decreasing amount of the width of the wound portion is small, the side where the corner portion of the wound portion forms an acute angle, or the An electric motor characterized in that it is larger than the curvature of the arc portion on the side where the curvature of the corner roundness of the wound portion is small or the side where the corner chamfer of the wound portion is small.

11. The electric motor according to claim 7, wherein the pole teeth are provided with a flange portion that prevents the drive coil from collapsing toward the rotor, and a chamfered portion is provided at a corner portion of the flange portion. The size of the chamfered portion is such that the gradually decreasing amount of the width of the wound portion is large, the side where the corner portion of the wound portion forms an obtuse angle, or the curvature of the rounded corner of the pole tooth portion. The larger side, or the side where the chamfered portion of the wound part is larger is the side where the gradually decreasing amount of the width of the wound part is small, the side where the corner part of the wound part forms an acute angle, or the An electric motor characterized in that it is larger than the chamfer on the side where the curvature of the rounded corner of the wound part is small, or on the side where the corner of the wound part is small.

The electric motor according to any one of claims 7 to 10, wherein the pole teeth are provided with a flange portion that prevents the drive coil from collapsing toward the rotor, and the flange portion is provided with a notch, This notch is the side where the gradually decreasing amount of the width of the wound part is large, the side where the corner of the wound part forms an obtuse angle, or the side where the curvature of the rounded corner of the wound part is large, Or the electric motor provided in the side with the large corner | angular chamfering of the said to-be-wrapped part.

A method for manufacturing an electric motor in which a winding nozzle passes through a slot opening and rotates around each pole tooth to wind a drive coil, the track of the winding nozzle being straight in the slot of the stator core The axial end surface side of the stator core has an arc shape, and the curvature of the arc on the side moving from the linear track to the arc track is larger than the curvature of the arc on the side moving from the arc track to the linear track. A method of manufacturing an electric motor characterized in that it is enlarged.