JP2008131810A - Split core for motor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a split core for motor in which the winding can be introduced from the yoke side and the dead space can be reduced. <P>SOLUTION: The split core 10 comprises a columnar teeth 11 around which a winding making a coil is wound, and a yoke 12 provided over the entire circumference of the teeth 11 while projecting on one end side of the teeth 11. As for the split core 10, the first core side angle θ<SB>s1</SB>made by the coil side face 11s of the teeth 11 and the side intersection face 12<SB>fs</SB>of the yoke 12 is an obtuse angle, and the coil side face 11s of the teeth 11 is parallel with the coil side face 12s of the yoke 12. The core 10 has a flat end face 12F flush with the coil end face 11e of the teeth 11 at the yoke 12. The flat end face 12F has a first region 12<SB>I</SB>for arranging the winding making a coil on the teed 11 side, and has a second region 12<SB>II</SB>for arranging the starting end of the winding on the side remote from the teeth 11. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a split core used for a constituent member of a motor. In particular, the present invention relates to a split core for a motor in which a winding can be introduced from the yoke portion side and dead space can be reduced.

Conventionally, a rotor or a stator having a core made of a magnetic material and a coil disposed on the core has been used as a component of a motor. FIG. 4 (I) is a schematic configuration diagram illustrating an example of a stator, and (II) is a cross-sectional view illustrating a schematic configuration of a divided stator that constitutes the stator. In FIG. 4 (II), the coil is shown only on the left side, and the right side coil is omitted. The stator S is configured by annularly combining a plurality of divided stators m each having a divided core 100 and a coil C. The split core 100 is a T-shaped body in which a plurality of T-shaped steel plates are laminated, and the coil side of the tooth 101 on the one end side (the upper side in FIG. 4 (II)) of the tooth 101 having a rectangular parallelepiped shape. The yoke 102 protrudes from the surface 101 _s and the flange 103 protrudes from the coil side surface 101 _s on the other end side (lower side). Further, the coil end side of the split core 100 is configured by a flat surface extending from the yoke 102 to the entire area of the flange 103. The outer peripheral surface of the tooth 101 including the coil side surface 101 _s , the surface 102 _f facing the flange in the yoke 102, and the surface 103 _f facing the yoke in the flange 103 are covered with an insulator 110 made of an insulating material (Patent Document 1). (See Figure 16). The coil C is formed by winding the winding w around the outer periphery of the tooth 101, and is housed in a space (slot) 104 surrounded by the three surfaces 101 _s , 102 _f , 103 _f covered with the insulator 110. An extension surface 102 _se of the coil side surface 102 _s of the yoke 102 _forms an outer shape on the coil side side of the slot 104.

Here, in the split core, when the motor is assembled, the side adjacent to the other split core is called the coil side, and the surface arranged on this side is called the coil side surface. Also, here, in the split core, the side facing the motor rotation axis _Cm direction when the motor is assembled is called the coil end side, and the surface arranged on this side (see FIG. Surface) is called the coil end surface.

Split core 100 opposing surface 102 _f and builds corners of the coil side surface 101 _s and the yoke 102 of the teeth 101 (hereinafter, this angle is referred to as a core angle) when the a theta, a θ = 90 °. When such the outer periphery of the teeth 101 of the split core 100 and winding aligning windings w multilayer forming the coil C, the opposing surface 103 between the opposing surfaces 102 _f and the windings w of the yoke 102, and flange 103 _A dead space (a space in which no winding can be disposed) 105 is formed between _f and the winding w. In order to reduce the dead space 105, the cited document 1 discloses that the core angle θ is 120 °. Further, cited document 1 also discloses that iron loss can be reduced by setting the core angle to 120 °.

  As another split core, a split core having a yoke protruding over the entire circumference of the teeth has been developed (see Patent Document 2). Since this split core has a yoke protruding from the teeth on the coil end side, the coil side surface of the yoke is large and the magnetic path area can be increased.

JP 2000-324728 JP 2004-328971 A

However, even a split core with a core angle of 120 ° still has a lot of dead space.
Even if the core angle is 120 °, the split core in which the coil side surface 101 _s of the tooth 101 and the coil side surface 102 _s (extension surface 102 _se ) of the yoke 102 are non-parallel as shown in FIG. When the coil is formed, the outer shape of the coil becomes stepped (see Patent Document 1 FIG. 2). Therefore, a stepped dead space 106 is formed in the slot 104. A split core with a lot of dead space has a reduced space factor and causes a reduction in motor torque.

On the other hand, a split core having a yoke that protrudes over the entire circumference of the teeth has a large coil side surface of the yoke that forms the magnetic path, so that it is easy to increase the amount of passing magnetic flux and increase the torque. However, it is difficult for this core to introduce a winding from the yoke side.
The winding is usually introduced on the coil end side. Therefore, it is difficult to introduce a winding into the split core in which the yoke protruding to the coil end side exists. Even if the winding is introduced from the yoke side, the starting end of the winding is disposed on the coil end surface of the tooth. Then, when winding the winding in multiple layers, a part of the starting end portion of the winding arranged on the coil end surface of the teeth comes into contact with the winding forming each layer, and the winding is wound in multiple layers. Disturb. In consideration of the insertion direction of the rotor when the rotor is arranged on the inner peripheral side of the annularly arranged divided core, it may be desired to arrange both ends of the winding on the yoke side. If the winding is introduced from the yoke side of the split core and wound so that the terminal end of the winding is on the yoke side, both ends of the winding can be arranged on the yoke side. In addition, the start and end portions of the winding are the portions connected to the bus bar member and used to supply power to the winding portion forming the coil, and are included in the number of turns of the coil. It is a part that cannot.

  Therefore, a main object of the present invention is to provide a split core for a motor that can introduce a winding from the yoke portion side and can reduce dead space.

The inventors of the present invention have studied a shape capable of reducing dead space for a split core including a yoke portion protruding over the entire circumference of the teeth. As a result, the present inventors obtained knowledge that the following shapes are preferable.
I. When the angle formed by the coil side surface of the teeth and the side crossing surface connected to the coil side surface of the teeth in the yoke portion is defined as the core side angle, the core side angle is an obtuse angle.
II. The coil side surface of the teeth and the coil side surface of the yoke part are parallel.

  The split core with an obtuse core side angle makes it easier to place the windings in contact with the side crossing surfaces when winding the windings in multiple layers, reducing the dead space between the side crossing surfaces and the windings. can do.

  The split core, in which the coil side surface of the teeth and the coil side surface of the yoke part are parallel, has a smooth shape parallel to the coil side surface, when the winding is aligned in multiple layers, the outer shape of the coil is not stepped. It becomes. Therefore, this core does not generate a step-like dead space in the slot, and the dead space can be reduced.

  Since the dead space is small, this core can increase the space factor and further improve the torque. Also, this core can increase the number of turns.

  In addition, as a result of investigations by the present inventors, the split core having a shape satisfying the above I and II has a smaller magnetic flux density region than the split core having a core side angle (core angle θ) of 90 °, It was found that the iron loss was small and the torque and output were large.

  It is considered that this split core is formed by forming teeth so as to spread toward the yoke portion and making the core side angle an obtuse angle, so that the magnetic flux easily passes through the tooth portion and the magnetic flux density is reduced. It is considered that due to the decrease in magnetic flux density, the core loss of this split core is reduced, and the output is increased due to the reduction of iron loss. In addition, it is considered that this split core has a high torque because the magnetic flux density can be effectively utilized within a range where the magnetic flux density is small as described above and the magnetic flux is not saturated. Moreover, the improvement in torque is considered to be a cause of the improvement in output.

  From the above, while making the core side angle an obtuse angle and forming the split core so that the coil side surface of the teeth and the coil side surface of the yoke part are parallel, the dead space is reduced and only the torque is improved. In addition, the output can be improved.

  Therefore, the split core of the present invention has a shape satisfying the above I and II, and a portion where the starting end portion of the winding is disposed when the winding forming the coil is introduced from the yoke portion side. Specifically, the split core for a motor of the present invention includes a columnar tooth around which a winding is wound, and a yoke portion that protrudes over the entire circumference of the tooth on one end side of the tooth. The teeth have a coil side surface and a coil end surface. The yoke portion has a coil side surface, a side intersection surface connected to the coil side surface of the tooth, and a flat end surface that is flush with the coil end surface of the tooth. The core has an obtuse core side angle, and the coil side surface of the teeth and the coil side surface of the yoke part are parallel to each other. The flat end surface includes a first region on the tooth side and a second region connected to the first region and away from the tooth. The first area is a place where a winding for forming the coil and the starting end of the winding connected to the winding are arranged, and the second area is a place where the starting end of the winding is arranged.

  The core of the present invention is a T-shaped body including a columnar tooth around which a winding is wound on the outer periphery, and a yoke portion projecting over the entire periphery of the tooth on one end side of the tooth. In particular, the teeth and the yoke portion are provided such that the (first) core side angle is an obtuse angle (over 90 °).

  The teeth typically include a pair of coil side surfaces arranged to face each other and a pair of coil end surfaces arranged to face each other. Both coil side surfaces of the teeth are provided so that their extended surfaces intersect, that is, so as to be inclined with respect to a bisector that bisects the two coil side surfaces. The coil end surface of the teeth is provided such that the width (distance between both coil side surfaces) decreases from one end side having the yoke portion toward the other end side. The inclination angle is changed according to the size of the core side angle. If the coil side surfaces of the teeth are parallel to the bisector, the area of the coil side surface of the yoke portion that becomes the magnetic path may be reduced in order to make the core side angle an obtuse angle. Therefore, this invention core inclines the coil side surface of teeth.

  The coil end surfaces of the teeth may be provided so as to be parallel to each other, or may be provided so as to be inclined with respect to a bisector that bisects the space between the coil end surfaces. That is, the coil end surface is provided so that the width (distance between both coil end surfaces) of the tooth coil side surface increases from one end side having the yoke portion to the other end side. Such teeth can make the magnetic flux density uniform by making the cross-sectional area substantially equal across the entire region from one end side to the other end side.

  Further, the teeth may have a step. The number of turns of the winding can be increased or decreased by adjusting the size of the step.

  The yoke portion includes, on the coil side, a coil side surface and a side crossing surface that is connected to the coil side surface of the tooth and forms a core side angle. The core of the present invention includes a yoke portion that also protrudes on the coil end side, so that the coil side surface of the yoke portion that forms the magnetic path is large, and the amount of magnetic flux passing therethrough can be increased to improve the torque. The side crossing surface is preferably provided over the entire coil side surface of the tooth. Windings forming a coil are arranged on the outer periphery of the side crossing surface.

  The yoke portion includes a flat end surface that is flush with the coil end surface of the tooth on the coil end side. The yoke portion is formed so as to have a projecting end surface projecting from the flat end surface and an end intersecting surface connected to the flat end surface.

  The flat end surface has a first region existing on the tooth side and a second region connected to the first region and existing on the side away from the tooth. Specifically, the first region is connected to the side intersecting surface of the yoke part, and a straight line connecting both ends of the side intersecting surface on both coil side sides away from the teeth (side approaching the outer surface of the yoke part). The region sandwiched between the teeth and the boundary between the yoke portions. The second region is a region that exists on the side closer to the outer surface of the yoke part than the straight line.

  On the outer periphery of the first region, windings that mainly form coils are arranged similarly to the side crossing surfaces. In addition, the outer periphery of the first region is provided with a starting end portion of a winding connected to the winding forming the coil. On the other hand, the starting end of the winding is disposed on the outer periphery of the second region. Therefore, the second region only needs to have a size such that the starting end of the winding can be arranged.

For example, as shown in FIG. 3 (I), parallel to a straight line Ly connecting the ends of the side crossing surface Y _fs of the yoke part Y that is away from the tooth T (side approaching the outer surface _Yo of the yoke part Y). As described above, when the end crossing surface _Yfe of the yoke portion Y is provided, the second region is a region sandwiched between the straight line Ly and the end crossing surface _Yfe . At this time, the distance h _II between the straight line Ly and the end crossing surface Y _fe is adjusted in accordance with the size of the winding (for example, the diameter and the cross-sectional area), so that the starting end of the winding can be securely in the second region. Can be arranged. If the interval h _II is too large, the area of the coil side surface Y _s of the yoke portion Y is reduced, which is not preferable. Width of the second region may have a (one size from the coil-side toward the other coil-side) w _II also beginning level allowing placement of the winding. In particular, as shown in FIG. 3 (I), when both coil side sides of the second region are in contact with the coil side surface Y _s of the yoke portion Y, that is, the width w _II is equal to the width of the coil end side of the yoke portion Y. It is preferable to easily arrange the start end. In FIG. 3, arrows indicate examples of the winding introduction direction.

The end intersection plane Y _fe may be provided so as to have an inclination with respect to the straight line Ly as shown in FIG. 3 (II). Since the end crossing surface Y _fe is inclined, the starting end portion of the winding can be arranged along the end crossing surface Y _fe . The core shown in FIG. 3 (II) is formed so that the end crossing surface Y _fe is V-shaped when viewed from the coil end side. At this time, the second region has a triangular shape symmetrical about the bisector B that bisects both coil side surfaces Y _s of the yoke portion Y. It is sufficient that at least a part of the end crossing surface Y _fe is inclined. For example, with the bisector B as the center, the end crossing surface Y _fe on one coil side is inclined, and the end crossing surface Y _fe on the other coil side is parallel to the straight line Ly as shown by a thick broken line Also good. At this time, the second region has a triangular shape. Thus, the core of the present invention can have an asymmetric shape when viewed from the coil end side. On the other hand, when viewed from the coil end side as in the core shown by the solid line in FIG. 3, when the core is compacted, the moldability is excellent.

  The core of the present invention is formed so that the coil side surface of the yoke part and the coil side surface of the teeth are parallel to each other. Here, the slot on the coil side is formed in a space sandwiched between the coil side surface of the tooth and the extension surface of the coil side surface of the yoke portion. That is, the extension surface of the coil side surface of the yoke portion forms the outer shape of the slot. Therefore, in the core of the present invention, the coil side surface of the tooth and the surface that forms the outer shape of the slot are parallel to each other. Therefore, when the winding is aligned and wound along the outer periphery of the tooth, the outer shape of each layer formed by the winding is Parallel to the outline of the slot. That is, the outer shape of the coil is also parallel to the outer shape of the slot. Therefore, the core of the present invention can effectively reduce the dead space in the slot and increase the space factor.

  Further, in the core of the present invention, the first core side angle is an obtuse angle. If the area of the coil side surface of the yoke portion is made constant and the first core side angle is increased so as not to reduce the slot, the teeth may be reduced. Therefore, the first core side angle is preferably more than 90 ° and not more than 135 °. In particular, in a split core with a first core side angle of 120 °, when windings are arranged in multiple layers, the windings at the end of each layer can be placed in contact with the side crossing surface. There is almost no dead space between.

  The first core side angle may be an obtuse angle on at least one coil side side, but is preferably an obtuse angle on both coil end sides. Further, if the first core side angle is made equal on both coil sides to make a symmetrical core, for example, when the core of the present invention is compacted, the moldability is excellent. This also applies to the second core side angle described later.

  When the angle formed by the flat end surface and the end crossing surface is the core end angle, the core end angle is preferably 90 °. That is, the yoke portion is formed so that the flat end surface and the end crossing surface are orthogonal to each other. In the split core having a core end angle of 90 °, it is easy to arrange the start end of the winding in the second region of the flat end surface. Moreover, this core can apply pressure uniformly, for example, when compacting a core, and is excellent in a moldability. The core end angle on at least one of the coil ends may be 90 °, but the core end angle on both coil ends is preferably 90 °.

  The core of the present invention may further include a collar portion so as to face the yoke portion. The collar portion is provided so as to project from the other end side opposite to the one end side from which the yoke portion projects in the teeth. The collar portion may be provided only on the coil side side or on both the coil side side and the coil end side.

  When the core of the present invention has a flange on the coil side, and the angle formed by the flange side crossing surface connected to the coil coil side surface of the tooth and the coil coil side surface of the tooth is the second core side angle, The two-core side angle is preferably 90 ° or more and 135 ° or less. In particular, a core having a second core side angle of 90 ° has a large slot, and a core having a 120 ° angle can reduce dead space in the same manner as in the case where the first core side angle is 120 °.

  The core of the present invention is formed of a soft magnetic material such as steel or iron. The core of the present invention can be formed of a laminate of plate materials, a compacted product obtained by pressure-molding powder, or a combination of a laminate of plate materials and a compacted product. In particular, the core of the present invention is easy to manufacture when a green compact is used. Moreover, when setting it as a compacting body, the symmetrical division | segmentation core can make the pressure at the time of manufacture uniform, and is excellent in a moldability. The green compact has a greater degree of freedom in magnetic direction and excellent magnetic properties compared to a laminate of plate materials having a constant magnetic direction.

  In order to improve the insulation between the core of the present invention and the winding, it is preferable to place an insulator made of an insulating material at least at a location where the winding contacts on the outer periphery of the core of the present invention. For example, in the case of a split core having an outer peripheral surface of a tooth, a side crossing surface / end crossing surface / flat end surface of a yoke part, and a collar part, the insulator covers the side crossing surface. The insulator may be either a similar shape or a non-similar shape along the outer shape of the core. Examples of the insulating material include resins such as PPS (Poly Phenylene Sulfide) and LCP (Liquid Crystal Polymer).

  The insulator has a cylindrical portion that covers the outer periphery of the teeth, a yoke end covering portion that covers a corner portion formed by the flat end surface and the end crossing surface, and further covers a yoke side covering surface that covers the side crossing surface. Suppose you have By filling the corner with the yoke end covering portion, the outer peripheral surface of the yoke end covering portion can be smoothly connected to the yoke side covering surface. Therefore, this insulator can easily transfer the winding wire between the coil side and the coil end. However, by filling the corners, the starting end of the winding cannot be disposed on the outer periphery of the flat end surface. Therefore, a part of the yoke end covering portion is cut out to provide a groove in which at least one of the coil side and the cylindrical portion is opened. In particular, the groove is cut out so that the start end portion of the winding can be arranged, and this groove is used as an introduction groove for introducing the winding. Then, one end side of the starting end portion of the winding is extended from the opening on the coil side side of the introduction groove to the yoke side, and the other end side is extended from the opening on the cylindrical portion side to the cylindrical portion side. Is disposed in the introduction groove. The opening groove can open the starting end of the winding from either arbitrary side to the yoke part side when both coil side sides are opened. Such an introduction groove is provided on at least one coil end side.

  When the insulator includes a side covering surface that covers the coil side surface of the tooth and a yoke side covering surface, the first insulating side angle is defined as the angle formed by the side covering surface and the yoke side covering surface. The side angle is also obtuse, similar to the first core side angle, specifically, more than 90 ° and not more than 135 °. In particular, an insulator having a first insulating side angle of 120 ° can reduce dead space in the same manner as a split core having a first core side angle of 120 °.

  When the insulator is formed so that the first insulating side angle becomes equal to the first core side angle, it is possible to suppress the local vicinity of the portion covering the side crossing surface in the insulator from being locally thick. Here, since the split core also functions as a heat radiating member, if the insulator is thick, it is difficult for the heat of the coil to be transmitted to the core, and heat dissipation is reduced. Therefore, it is desirable that the insulator is as thin as possible. For example, when the first insulating side angle is set to 120 ° when the first core side angle is more than 90 ° and less than 120 °, the insulator is formed so as to fill the corner portion of the core. Becomes thicker. Therefore, it is preferable that the side covering surface is provided so as to be parallel to this surface along the coil side surface of the tooth, and the yoke side covering surface is provided so as to be parallel to this surface along the side crossing surface.

  When the insulator includes an end covering surface that covers the coil end surface of the tooth and a yoke end covering surface that is connected to the end covering surface in the yoke end covering portion, the angle formed by the end covering surface and the yoke end covering surface is the first angle. When it is set as one insulation end angle, the first insulation end angle is preferably an obtuse angle, and particularly preferably 100 ° to 135 °. In particular, an insulator in which the first insulating end angle is equal to the first insulating side angle is likely to transfer the winding between the coil side and the coil end.

  In the case where the core of the present invention has a collar part and the insulator includes the side covering surface and a collar side covering surface that covers the collar side crossing surface of the collar part, the side covering surface and the collar side covering surface are formed. When the corner is the second insulating side angle, the second insulating side angle is preferably 90 ° to 135 °. Insulators having a second insulating side angle of 120 ° can reduce dead space in the same manner as a split core having a first core side angle of 120 °. An insulator having a second insulating side angle of 90 ° can have a large slot. An insulator having the same second insulating side angle and second core side angle is not locally thick but can be formed thin overall.

  The insulator preferably includes a flange on the flange side so as to protrude from the flange side (the other end side of the teeth) of the cylindrical portion regardless of the presence or absence of the flange portion. By providing the flange on the heel side, it is easy to wind the winding in multiple layers. The said heel side coating | coated surface comprises a part of heel side flange.

  When the angle formed between the end covering surface and the flange on the flange side is the second insulating end angle, the second insulating end angle is preferably 90 to 135 °. In particular, when the second insulating end angle is made equal to the second insulating side angle, the winding is easily transferred between the coil side and the coil end.

  The core of the present invention is used for motor parts such as a divided stator constituting a motor. The motor component is obtained by forming a coil by winding a winding around the outer periphery of the tooth (insulator) of the core of the present invention. In particular, a coil formed by winding windings in multiple layers can improve the space factor. As the winding, various types such as a square wire as well as a round wire can be used. As the winding, one having an insulation coating on the outer periphery of the conductor is used.

  By preparing a predetermined number of the motor parts, arranging the motor parts in an annular shape, and holding the motor parts in an annular shape by using an annular member, the motor parts can be used, for example, as an outer rotor or an inner rotor. Each motor component arranged in an annular shape preferably has a concentrated winding structure by connecting ends of windings that form a coil.

  The motor split core according to the present invention can reduce the dead space and improve the space factor, and can introduce the winding from the yoke portion side.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
[Split core]
FIG. 1 (I) is a front view of the split core for a motor of the present invention as viewed from the coil end side, (II) is a front view of the core of the present invention as viewed from the coil side, and (III) is a perspective view of the core of the present invention. It is. The split core 10 includes a columnar tooth 11, a yoke portion 12 protruding from one end side (the upper side in FIG. 1 (I)) of the tooth 11, and a flange portion 13 protruding from the other end side (the lower side). Yeah. The yoke portion 12 is provided over the entire circumference of the tooth 11. Therefore, the split core 10 is T-shaped when viewed from either the coil side side or the coil end side. In the split core 10, an insulator (described later) is mainly disposed on the outer periphery of the tooth 11, and a winding is wound thereon to form a split stator. A plurality of such divided stators are prepared, and the motor stator is formed by holding the coil side surfaces 12s of the yoke portions 12 of the divided stators in an annular shape.

The most characteristic feature of the split core 10 is that the angle (first core side angle) θ _s1 formed by the coil side surface 11s of the tooth 11 and the side crossing surface 12 _fs connected to the coil side surface 11s of the tooth 11 in the yoke portion 12 is The obtuse angle, the coil side surface 11s of the tooth 11 and the coil side surface 12s of the yoke part 12 are parallel, and the yoke part 12 has a flat end surface 12F that is flush with the coil end surface 11e of the tooth 11. In the point.

  The teeth 11 are composed of a pair of coil end surfaces 11e and a pair of coil side surfaces 11s. Each of the coil side surfaces 11s is a rectangular surface that is inclined with respect to a bisector B that bisects the two coil side surfaces 11s, and is disposed so as to cross the extended surfaces. Each coil end surface 11e is a trapezoidal surface extending from the flange portion 13 side toward the yoke portion 12 side, and is disposed to face each other so as to be parallel to each other.

Yoke portion 12 comprises the two coils-side, and the coil side surface 12s which is bonded to the other split core, and a side intersecting surfaces 12 _fs connected to the coil side surface 11s of the teeth 11. In the split core 10, the angle (first core side angle) θ _s1 formed by the coil side surface 11s and the side crossing surface 12 _{fs of} the tooth 11 is 120 °.

The side crossing surface 12 _fs is provided over the entire area of the coil side surface 11s of the tooth 11, one peripheral edge is connected to the coil side surface 11s of the tooth 11, and the other peripheral edge is a surface facing the flange portion in the yoke portion 12. It leads to. You may provide a side crossing surface so that the other periphery may be connected with the coil side surface of a yoke part.

Further, the yoke portion 12 has a flat end surface 12F flush with the coil end surface 11e of the teeth 11, a protruding end surface 12P protruding from the flat end surface 12F, a protruding end surface 12P and a flat end on both coil end sides. End crossing surface 12 _fe connected to surface 12F. As shown in FIG. 1 (I), the end crossing surface 12 _fe is parallel to a straight line Ly connecting the end portions on the side away from the teeth 11 at both side crossing surfaces 12 _fs of the yoke portion 12 when viewed from the coil end side. It is provided as follows. Further, the end crossing surface 12 _fe is located on the side approaching the outer surface 12o of the yoke portion 12 from the straight line Ly (upper side in FIG. 1 (I)). The angle (core end angle) θ _e formed by the flat end surface 12F and the end crossing surface 12 _fe is 90 °. That is, both surfaces 12F and _12fe are orthogonal.

Flat end surface 12F has a first region 12 _I positioned on the teeth 11 side, connected to the first region 12 _I, and a second region 12 _II located on the side away from the teeth 11. The first region 12 _I includes a boundary L _b of the teeth 11 and the yoke portion 12 is an area sandwiched between the straight line Ly, a surface leading to both sides intersecting surfaces 12 _fs. The first region 12 _I is a spread trapezoidal towards the boundary line L _b on the outer surface 12o of the yoke portion 12. On the outer periphery of the first region 12 _I, a portion of the winding that makes a turn of the coil and a portion that is connected to the winding and does not make a turn (start end portion) are arranged. The second region 12 _II is a region sandwiched between the boundary between the flat end surface 12F and the end crossing surface 12 _fe and the straight line Ly, and is provided from one coil side to the other coil side, and has a yoke portion. This is a surface connected to 12 coil side surfaces 12s. On the outer periphery of the second region 12 _II , the starting end of the winding is disposed. The distance between the boundary between the flat end surface 12F and the end intersecting surface _12fe and the straight line Ly is adjusted according to the size of the winding, and is a size that allows the start end of the winding to be arranged.

Flat end surface 12F made of the first region 12 _I and the second region 12 _II may if either one of the coil end side. That is, any one of the flat end surfaces on the coil end side may be the first region. The split core 10 has a symmetrical shape with a flat end surface 12F composed of both regions 12 _I and 12 _II on both coil end sides. Therefore, the split core 10 is excellent in moldability. Further, the core 10 can arbitrarily select a flat end surface on one of the coil end sides and arrange the start end portion of the winding.

The flange portion 13 is provided on the coil side side so as to face the yoke portion 12, and includes a flange side crossing surface 13f connected to the coil side surface 11s of the tooth 11. The split core 10 has an angle (second core side angle) θ _{s2 formed} by the heel side crossing surface 13f and the coil side surface 11s of the tooth 11 of 120 °.

  Further, in the split core 10, the coil side surface 11s of the tooth 11 and the coil side surface 12s of the yoke portion 12 are parallel, and the coil end surface 11e of the tooth 11 and the protruding end surface 12P of the yoke portion 12 are parallel. .

  The split core 10 is a compacted body using a powder made of a soft magnetic material, and the teeth 11, the yoke portion 12, and the flange portion 13 are integrally molded. By forming a compacted body, it is possible to easily and accurately form the split core 10 having a complicated shape. The split core 10 has a symmetrical shape on both the coil side side and the coil end side, and is excellent in moldability.

[Insulator]
FIG. 2 is a diagram showing a state in which an insulator is arranged on the outer periphery of the split core 10. (I) is a front view seen from the coil end side, (II) is a front view seen from the coil side side, III) is a perspective view. 2, the same reference numerals as those in FIG. 1 denote the same items. FIG. 2 (I) shows the winding (cross section) only on the left side, and the right side is omitted. Also, the split core 10 shown in FIG. 2 has a flat end surface composed of a first region and a second region on one coil end side, and a flat end surface composed of a first region on the other coil end side. . That is, the split core 10 has an asymmetric shape when viewed from the coil side, and has a symmetrical shape when viewed from the coil end side. Except this point, it is the same as the split core shown in FIG.

  The insulator 20 is a member that insulates the split core 10 and the winding w, and mainly covers the outer periphery of the tooth 11. Specifically, the insulator 20 includes a cylindrical portion 21 that covers the outer peripheral surface of the tooth 11, a yoke-side flange 22 that protrudes from one end of the cylindrical portion 21, and a flange that protrudes from the other end. With side flanges 23.

The cylindrical portion 21 has a side covering surface 21s that covers the coil side surface 11s of the tooth 11, and an end covering surface 21e that covers the coil end surface 11e. The yoke-side flange 22 is provided over the entire circumference of the cylindrical portion 21, and has a yoke-side covering surface 22 _fs that covers the side crossing surface 12 _fs of the yoke portion 12 on both coil sides. A yoke end covering portion 22E that covers the outer periphery of the flat end surface 12F is provided on the end side. The flange side flange 23 is provided over the entire circumference of the cylindrical portion 21, and includes a flange side covering surface 23s that covers the flange side crossing surface 13f of the flange portion 13 on both coil side sides.

The cylindrical portion 21 is formed along the outer peripheral surface of the tooth 11, the coil side surface 11s and the side covering surface 21s of the tooth 11 are parallel, and the coil end surface 11e and the end covering surface 21e are parallel. The yoke side covering surface 22 _fs is formed so as to be parallel to the side crossing surface 12 _fs . Therefore, the angle (first insulating side angle) α _s1 formed by the side covering surface 21s and the yoke side covering surface 22 _fs is 120 °, like the first core side angle θ _s1 . Further, the heel side covering surface 23s is formed so as to be parallel to the heel side crossing surface 13f of the ridge portion 13, and an angle formed by the side covering surface 21s and the heel side covering surface 23s (second insulating side angle). ) α _s2 is 120 °, similar to the second core side angle θ _s2 .

Further, the insulator 20 (the yoke flange 22), as shown in FIG. 2 (II), the yoke end covering portion so as to fill the corners of the flat end surface 12F and the end cross surface 12 _fe is made of the yoke portion 12 22E Have The yoke end covering portion 22E provided on one coil end side (the right side in FIG. 2 (II)) is provided so as to fill the corners from one coil side side to the other coil side side. (See FIG. 2 (I)), it has a yoke end covering surface _22fe connected to the end covering surface 21e. The angle (first insulating end angle) α _e1 formed by the yoke end covering surface 22 _fe and the end covering surface 21 _e is 120 °, like the first insulating side angle α _s1 . The yoke end covering surface 22 _fe is smoothly connected to both yoke side covering surfaces 22 _fs . Further, the yoke end covering portion 22E includes a protruding covering portion 22e that covers the protruding end surface 12P.

Yoke end covering portion 22E provided on the other coil end side (left side in FIG. 2 (II)) is also made and the flat end surface 12F and the end cross surface 12 _fe of the yoke portion 12 similar to the side one described above corner It is provided to fill the part. However, the yoke end covering portion 22E has an introduction groove 24 to place the leading end w _s of the winding to the yoke portion. More specifically, the yoke end covering portion 22E includes a flat covering portion 22F covering the flat end surface 12F, and the end cross covering portion 22 _f that covers a portion of the end cross surface 12 _fe, end cross surface 12 _fe It has a protruding covering portion 22e that covers the other portion and the protruding end surface 12P, and an inclined covering portion 22d that is connected to the protruding covering portion 22e. Note that the starting end portion w _{s of the} winding is a portion that is obliquely arranged from one coil side side (right side) to the side coating surface 21s on the other coil side side (left side) in FIG. is there. A part of the start end portion w _s is disposed on the end covering surface 21e (the coil end surface 11e of the tooth 11). The windings forming the coil are windings shown in cross section in the left slot in FIG. 2 (I).

Locations in projecting covering portion 22e covers the end cross surface 12 _fe is provided to project toward the end cross surface 12 _fe the flange side flange 23 side, between the projecting portion and the flat cover portion 22F, a clearance Have. Accordingly, the protruding portion exists on the outer periphery of the flat end surface 12F, that is, on the outer periphery of the flat covering portion 22F. Further, the protruding portion is provided so that the vicinity of one coil side side end portion is exposed in the flat covering portion 22F. The other coil-side of the projecting portion, as well as the yoke end covering portion 22E of the coil end side of one of the above-described, fills the corner to make the flat end surface 12F and the end cross surface 12 _fe is. The gap between the protruding portion and the flat covering portion 22F constitutes an introduction groove 24 in which the starting end portion of the winding is disposed. The introduction groove 24 is open on one coil side (right side in FIG. 2 (I), front right side in (III)), and the other coil side is closed. Further, the introduction groove 24 is also opened on the cylindrical portion 21 side. The opening on the cylindrical portion 21 side is provided so as to extend from one side covering surface 21s of the cylindrical portion 21 to the other side covering surface 21s.

The inclined covering portion 22d is provided so as to protrude from a surface facing the flange side flange 23 in the protruding portion of the protruding covering portion 22e described above, and has a yoke end covering surface _22fe . The angle formed by the extended surface of the yoke end covering surface 22 _fe and the end covering surface 21e is also 120 °. The inclined covering portion 22d is also provided so that the vicinity of one coil side side end portion is exposed in the flat covering portion 22F. Further, there is a gap between the inclined covering portion 22d and the flat covering portion 22F, and this gap is continuous with the gap between the protruding portion of the protruding covering portion 22e and the flat covering portion 22F described above. This gap also constitutes the introduction groove 24.

Furthermore, as shown in FIG. 2 (II), the insulator 20 (the flange side 23) has a portion that covers the flange portion 13 on the coil end side. This portion is provided so as to protrude from the end covering surface 21e, and is smoothly connected to the heel side covering surface 23s. More specifically, when viewed from the coil side, the flange side flange 23 has an inclined portion whose width increases from the end covering surface 21e toward the end surface side of the split core 10 (lower side in FIG. 2 (II)). In addition, the inclined portion has a collar end covering surface 23e connected to the end covering surface 21e. The angle (second insulating end angle) α _e2 formed by the end covering surface 23e and the end covering surface 21e is about 120 °, like the second insulating side angle α _s2 .

In addition, the yoke-side flange 22 has a portion that covers the surface of the yoke portion 12 that faces the flange. When such an insulator 20 is arranged on the split core 10, the coil side surface 12s and the outer side surface 12o of the yoke portion 12 and the end surface of the flange portion 13 are exposed. A space surrounded by the side covering surface 21s, the yoke side covering surface 22 _fs , and the heel side covering surface 23s creates a slot on the coil side, and is surrounded by the end covering surface 21e, the yoke end covering surface 22 _fe , and the heel end covering surface 23e. The space creates a slot on the coil end side.

  The insulator 20 has a configuration in which a pair of divided pieces are combined and integrated, and can be easily arranged on the divided core 10. A configuration in which the joint (not shown) of the split pieces is located at the coil end side, the coil side side, or the boundary between the coil end and the coil side can be mentioned. When the joints of the split pieces are joined with an adhesive or the like, the split pieces are difficult to drop off from the split core. Further, the insulator 20 has a fitting groove in a part of the cylindrical portion 21, so that the windings w can be easily aligned. Furthermore, you may provide a level | step difference over the perimeter of a cylindrical part.

The arrangement insulator 20 comprising a can, for fitting the starting end w _s of the cylindrical portion 21 end cover surface 21e introduction groove 24 wound around the collar flange 23 side along the a. When performing the winding operation, the starting end portion w _s of the winding is fitted into the introduction groove 24 as described above, and the starting end portion w _s is disposed on the flat covering surface 22F. Then, one end portion of the start end portion w _s is fixed from the opening portion on the coil side side of the introduction groove 24. Further, the winding w connected to the starting end w _s to form a coil is taken out from the opening on the cylindrical portion 21 side of the introduction groove 24, arranged on the side covering surface 21s through the end covering surface 21e, and the winding It is good to wind. After winding, the starting end portion may be unfixed and bent toward the yoke portion 12 side by bending the end portion along the coil side surface of the protruding covering portion 22e as shown in FIG. 2 (III). FIG. 2 shows a case where two windings are wound simultaneously, but one winding or three or more windings may be used.

[effect]
Since the split core 10 has an obtuse first core side angle θ _s1 , dead space in the slot can be reduced when winding the windings in multiple layers. In particular, by setting the first core side angle θ _s1 to 120 ° and the first insulating side angle α _s1 of the insulator 20 to 120 °, the windings at the end of each layer can be connected to the yoke side as shown in FIG. It can be in contact with the coated surface 22 _fs . Therefore, the split core 10 has very little dead space between the winding and the yoke side covering surface 22 _fs . Further, since the split core 10 has both the second core side angle θ _s2 and the second insulating side angle α _{s2 set} to 120 °, the winding at the end of each layer can be brought into contact with the heel side covering surface 23s. , Dead space can be further reduced.

  In the split core 10, the coil side surface 11s of the tooth 11 (side covering surface 21s of the insulator 20) and the coil side surface 12s of the yoke portion 12 are parallel to each other. That is, the coil side surface 11s of the tooth 11 is parallel to the outer shape of the slot. Therefore, when winding the windings in multiple layers, the windings forming each layer are arranged along the coil side surface 11s of the tooth 11 and have a linear shape along the outer shape of the slot. Therefore, the split core 10 does not have a step-like dead space caused by the stepped outer shape of the coil, and can reduce the dead space.

  By reducing the dead space, the split core 10 can increase the space factor and improve the torque.

Furthermore, since the split core 10 has an obtuse first core side angle θ _s1 , magnetic flux easily passes through the teeth 11 and iron loss can be reduced. The split core 10 can improve the output by reducing the iron loss. Further, the split core 10 can improve the torque by effectively using the magnetic flux as long as the magnetic flux is not saturated.

  The insulator 20 has the introduction groove 24 in the yoke end covering portion 22E, thereby introducing the starting end portion of the winding from the yoke portion side, and connecting the starting end portion to form a coil from the end covering surface 21s to the side covering surface. Can be placed in 21s. Therefore, in the core 10, both the start end portion and the end end portion of the winding can be arranged on the yoke portion side.

In addition, the insulator 20 is configured such that the first insulating end angle α _e1 and the second insulating end angle α _e2 are equal to the first insulating side angle α _s1 and the second insulating side angle α _s2 , respectively. The winding w can be smoothly transferred between and with excellent winding properties. Further, since the insulator 20 is thin except for a portion covering a corner portion formed by the flat end surface 12F and the end crossing surface _12fe and a protruding portion of the flange side flange 23, the insulator 20 is excellent in heat dissipation.

  The above-described embodiments can be appropriately changed without departing from the gist of the present invention, and are not limited to the above-described configuration. For example, the split core may be provided so that the end crossing surface is V-shaped when viewed from the coil end side. Moreover, you may arrange | position the insulator which has an introductory groove in both coil end sides in a division | segmentation core.

  The split core for a motor of the present invention can be suitably used for a motor component such as a stator. The motor having the split core can be suitably used for a motor that requires high output, such as an electric vehicle or a hybrid vehicle.

(I) is a front view of the split core for a motor of the present invention viewed from the coil end side, (II) is a front view of the core of the present invention viewed from the coil side, and (III) is a perspective view of the core of the present invention. . It is a diagram showing a state in which an insulator is arranged on the outer periphery of the core of the present invention, (I) is a front view seen from the coil end side, (II) is a front view seen from the coil side side, (III) is a perspective view It is. It is the front view which looked at the example of the present invention core from the coil end side, (I) shows an example where an end crossing surface is parallel to straight line Ly, and (II) shows an example where an end crossing surface is V shape. (I) is a front view schematically showing a state in which a plurality of split stators having a conventional split core are combined and arranged in an annular shape, and (II) is a cross-sectional view of a conventional split core.

Explanation of symbols

10 split cores 11 teeth 11e teeth coil end surface
11s Coil side surface of teeth 12 Yoke part 12 _fs side cross surface
12 _fe crossing surface 12s Coil side surface of yoke 12F Flat end surface
12 _I 1st area 12 _II 2nd area 12o Outer surface 12P Projection end surface 13
13f 鍔 Side crossing
20 Insulator 21 Cylindrical part 21e End covering surface 21s Side covering surface
22 Yoke side flange 22 _fs Yoke side coated surface
22E Yoke end cover 22d Inclined cover 22e Protruding cover
22 _f End crossing cover 22F Flat cover 22 _fe Yoke end cover
23 Side flange 23s Side cover surface 23e End cover surface 24 Introduction groove
100 split cores 101 teeth 101 _s teeth coil side surface 102 yoke
102 _f Opposite surface of yoke 102s Coil side surface of yoke
102 _se yoke coil side surface extension surface 103 鍔 103f 対 向 opposite surface
104 Slot 105,106 Dead space 110 Insulator
m Split stator C Coil S Stator w Winding w _s Winding start
T Teeth Y Yoke Y _s Coil side surface of yoke Y _o Outer surface
Y _fs side intersection Y _fe end intersection

Claims (3)

A split core for a motor comprising a columnar tooth around which a winding for forming a coil is wound, and a yoke part protruding over the entire circumference of the tooth on one end side of the tooth,
The teeth have a coil side surface and a coil end surface,
The yoke portion has a coil side surface, a side crossing surface connected to the coil side surface of the tooth, and a flat end surface that is flush with the coil end surface of the tooth.
When the angle formed by the coil side surface of the teeth and the side crossing surface of the yoke portion is the core side angle, the core side angle is an obtuse angle.
The coil side surface of the teeth and the coil side surface of the yoke part are parallel,
The flat end surface includes a first region on the tooth side and a second region connected to the first region and away from the tooth.
The first area is a place where a winding forming a coil and a starting end part of a winding connected to the winding are arranged, and the second area is a place where a starting end part of the winding is arranged. Split core for motors characterized by The yoke portion further has an end crossing surface connected to the flat end surface on the coil end side,
2. The split core for motor according to claim 1, wherein the core end angle is 90 ° when the angle formed by the flat end surface and the end crossing surface is a core end angle. The yoke portion further has an end crossing surface connected to the flat end surface on the coil end side,
An insulator is arranged on the outer periphery of this divided core,
This insulator has a cylindrical portion that covers the outer periphery of the tooth, and a yoke end covering portion that covers the corner portion formed by the flat end surface and the end crossing surface,
The yoke end covering portion is characterized in that at least one of the coil side side and the cylindrical portion side is open, and a winding introduction groove in which the starting end portion of the winding can be arranged on the outer periphery of the flat end surface is provided. 3. The split core for a motor according to claim 1 or 2.

Images