WO2012131775A1 - Electric motor - Google Patents

Electric motor Download PDF

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Publication number
WO2012131775A1
WO2012131775A1 PCT/JP2011/001916 JP2011001916W WO2012131775A1 WO 2012131775 A1 WO2012131775 A1 WO 2012131775A1 JP 2011001916 W JP2011001916 W JP 2011001916W WO 2012131775 A1 WO2012131775 A1 WO 2012131775A1
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WO
WIPO (PCT)
Prior art keywords
stator
magnet
stator core
electric motor
rotor
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Application number
PCT/JP2011/001916
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French (fr)
Japanese (ja)
Inventor
後藤　隆
Original Assignee
三菱電機株式会社
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Filing date
Publication date
Application filed by 三菱電機株式会社 filed Critical 三菱電機株式会社
Priority to JP2013506836A priority Critical patent/JP5518253B2/en
Priority to PCT/JP2011/001916 priority patent/WO2012131775A1/en
Publication of WO2012131775A1 publication Critical patent/WO2012131775A1/en

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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K21/00—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets
    • H02K21/38—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with rotating flux distributors, and armatures and magnets both stationary
    • H02K21/44—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with rotating flux distributors, and armatures and magnets both stationary with armature windings wound upon the magnets

Definitions

  • This invention relates to an electric motor having a stator with a permanent magnet sandwiched between two stator cores.
  • FIG. 10 shows a cross-sectional structure of a conventional electric motor (for example, see Patent Document 1).
  • the electric motor 100 includes a saliency stator 104 in which stator steel cores 102 and 103 are formed by laminating electromagnetic steel plates on both sides of an axially magnetized permanent magnet 101, and an electromagnetically installed in a central portion of the stator 104. And a saliency rotor 105 in which steel plates are laminated.
  • the rotor 105 has a structure in which the salient pole direction is twisted by 90 degrees in electrical angle, and is integrated with the shaft 107.
  • the permanent magnet 101 for magnetizing the rotor is bonded to the inner peripheral surface of the housing 106, and the stator cores 102 and 103 are press-fitted from both sides of the permanent magnet 101 to fix the permanent magnet 101.
  • stator cores 102 and 103 are press-fitted, it is necessary to position the teeth between the stator cores 102 and 103. Therefore, as shown in FIGS. 11A and 11B, positioning pins 111 are provided between the housing 106 and the stator 104, and the teeth 108 are positioned at the time of assembly.
  • stator cores 102 and 103 are press-fitted into the housing 106 from one direction.
  • the outer diameter of the stator core 102 is increased and the outer diameter of the other stator core 103 is decreased so that the two stator cores 102 and 103 sandwich the permanent magnet 101 after being press-fitted and fixed to the housing 106.
  • a press-fit portion 112 having a large inner diameter and a press-fit portion 113 having a small inner diameter are also formed on the inner peripheral surface of the housing 106.
  • stator cores 102 and 103 When the stator cores 102 and 103 are press-fitted from both sides of the permanent magnet 101, clearances 109 and 110 (shown in FIG. 10) are generated between the stator cores 102 and 103 and the permanent magnet 101, and demagnetization occurs during rotor magnetization. This causes a problem that the motor characteristics (torque) are reduced. Further, if the clearances 109 and 110 are to be eliminated, it is necessary to bring the permanent magnet 101 and the stator cores 102 and 103 into contact with each other, and there is a possibility that the permanent magnet 101 may be damaged due to the load of press-fitting the stator core.
  • stator cores 102 and 103 having the same outer diameter are press-fitted into the housing 106 from two directions, there is a problem that workability is deteriorated.
  • stator cores 102 and 103 having different outer diameters are press-fitted into the housing 106 from one direction, two types of stator cores are required. Therefore, the number of parts is increased, and the press-fitting portions 112 and 113 having different inner diameters are added to the housing 106. Therefore, there is a problem that the housing cutting cost also increases.
  • the present invention has been made to solve the above-described problems, and aims to eliminate the clearance between the permanent magnet and the stator core and reduce the cost required for assembling the permanent magnet and the stator core to the housing.
  • the electric motor of the present invention includes a cylindrical housing, a rotor portion that is rotatably held in a central portion of the housing, and a stator portion that is press-fitted and fixed at a position surrounding the outer periphery of the rotor portion of the housing,
  • a stator core formed with an annular body and a plurality of teeth protruding toward the center from the inner peripheral portion of the annular body, an annular magnet portion that magnetizes the rotor portion in the direction of the rotation axis, and magnet portions are provided on both sides It is made of a resin member that is integrally formed by being sandwiched between stator cores, and has a magnet part and a mold part that holds the stator core at least on the inner peripheral side.
  • the present invention by integrally molding the magnet portion and the stator cores on both sides thereof to form the stator portion, the clearance between the magnet portion and the stator core can be eliminated and the motor characteristics can be improved. Further, since the integrally molded stator portion can be press-fitted into the housing from one direction and assembled, the cost required for the assembly can be reduced.
  • FIG. 1 is an exploded perspective view showing a configuration of an electric motor according to Embodiment 1.
  • FIG. 3 (a) is an external appearance perspective view
  • FIG.3 (b) is a side view.
  • FIG.3 is a plan view showing a configuration of a stator core of the electric motor according to Embodiment 1.
  • FIG. It is the figure which expanded the stator ASSY press-fit part of the electric motor shown in FIG.
  • FIG. It is a figure explaining rotation operation of the electric motor concerning Embodiment 1.
  • FIG. It is sectional drawing of the metal mold
  • FIG. It is the figure which expanded the stator core of the electric motor which concerns on Embodiment 1, and the positioning part of a permanent magnet.
  • Fig.11 (a) is sectional drawing
  • FIG.11 (b) is a top view.
  • FIG. drawing which shows another structural example of the conventional electric motor.
  • FIG. An electric motor 1 shown in FIGS. 1 and 2 constitutes a three-phase AC synchronous motor, and mainly includes a cylindrical housing 2, a stator ASSY (stator portion) 3 press-fitted and fixed to the housing 2, and a shaft (not shown). And a rotor (rotor part) 9 to be rotated.
  • the rotor 9 has two protrusions protruding radially outward at intervals of 180 degrees, and the protrusions are shifted by 90 degrees in the middle of the rotation axis direction X (protrusions 9a and 9b).
  • the rotor 9 may be composed of a permanent magnet.
  • the electric motor 1 when the electric motor 1 is exposed to a high temperature, the magnetic characteristics are deteriorated. For example, it is better to construct a structure in which, for example, electromagnetic steel sheets are punched out and stacked in the rotation axis direction X. preferable. Even when the rotor 9 is formed of laminated steel plates, the protrusions are shifted by 90 degrees in the middle of the rotation axis direction X (protrusions 9a and 9b).
  • the electric motor 1 is applied to an automobile turbocharger, an electric compressor, or the like, a shaft fixed to the rotor 9 is connected to a rotating shaft of a turbine (so-called impeller), and the electric motor 1 rotates the turbine.
  • FIG. 3A is an external perspective view showing the configuration of the stator ASSY 3, and FIG. 3B shows a side view.
  • FIG. 4 is a cross-sectional view of the stator ASSY 3 in FIG. 3B cut along the line AA.
  • the stator ASSY 3 includes two stator cores 4 and 5, a magnet portion 6 disposed between the stator cores 4 and 5, and a mold portion 7 that integrates them.
  • FIG. 5 shows a plan view of the stator core 4.
  • the stator core 4 is formed by stacking electromagnetic steel plates in the rotation axis direction X of the rotor 9.
  • the stator core 4 includes an annular body and six projecting portions (hereinafter referred to as teeth 4a) projecting from the inner peripheral portion of the annular body toward the center.
  • a U-shaped coil 8 is attached to each of the teeth 4a.
  • electromagnetic steel sheets are punched out to provide six protruding teeth 4a in the circumferential direction at intervals of 60 degrees, and further, caulking protrusions 4b are formed at 60 degrees in each of six recesses formed alternately with the teeth 4a. Provide at intervals.
  • a plurality of positioning recesses 4c are provided on the outer periphery of the electromagnetic steel sheet.
  • a plurality of the electromagnetic steel sheets are laminated, and the protrusions 4b are caulked and bound to form the stator core 4.
  • the stator core 5 is also formed.
  • the magnet unit 6 has an annular shape and is configured by combining a plurality of permanent magnets.
  • six fan-shaped permanent magnets having a central angle of 60 degrees are used, which is the same number as the teeth 4a.
  • the outer peripheral portion 6b of one permanent magnet 6a is arranged so as to cover the outer side in the radial direction corresponding to the teeth 4a forming portion of the stator core 4 (the same applies to the stator core 5).
  • each of the six permanent magnets is arranged in the same manner as the permanent magnet 6a shown in FIG.
  • Each permanent magnet is positioned such that both end portions on the inner peripheral side are in contact with the projections 4 a of the stator cores 4, 5.
  • the divided portions of the permanent magnets do not overlap the teeth 4a when viewed from the rotation axis direction X, the magnetic characteristics can be improved.
  • the mold part 7 is composed of a resin member that integrally molds the stator cores 4, 5 and the magnet part 6. The procedure of integral molding will be described later.
  • a total of 12 coil insertion holes 7 a for inserting the U-shaped coil 8 are formed in the mold portion 7, two for each U-shaped coil 8. .
  • the U-shaped coil 8 is a one-turn coil obtained by bending a copper plate into a U-shape, and penetrates the coil insertion hole 7a in the rotation axis direction X as shown in FIGS. 1 and 2, and the bent portion is on the stator core 4 side. Further, the tip portion protrudes toward the stator core 5 side.
  • the copper plate coil 11 is connected to the control circuit board 12.
  • the control circuit board 12 has an inverter, converts an external power source (not shown) input from the connector unit 14 into an alternating current, and based on the position signal input from the position detection sensor 15, the U phase of the copper plate coil 11, A current is passed through the U-shaped coil 8 by sequentially switching the three phases of the V phase and the W phase.
  • the U-shaped coil 8 and the stator cores 4 and 5 are insulated from each other by the mold portion 7.
  • the position detection sensor 15 includes a Hall element IC (Integrated Circuit) that detects the position of a sensor target 16 (for example, a magnet) that rotates integrally with the rotor 9.
  • the position detection sensor 15 detects the rotational position of the rotor 9 by detecting the position of the sensor target 16 and outputs a position signal to the control circuit board 12.
  • the opening surface of the housing 2 on the control circuit board 12 side is covered with a cover 13 to protect the control circuit board 12 and the position detection sensor 15 and the like.
  • an O-ring 17 is provided and sealed in the press-fitting portion of the housing 2 and the stator ASSY 3.
  • FIG. 6 is an enlarged view of the stator ASSY3 press-fitting portion of the electric motor 1 shown in FIG.
  • Magnetic flux (magnet magnetic flux) generated by the magnet portion 6 magnetized in the rotation axis direction X flows out of the teeth 4a of the stator core 4 arranged on the N pole side of the magnet portion 6 to the protrusion of the rotor 9, and the rotation of the rotor 9
  • the magnetic field magnetic flux flows in the axial direction X, exits from the protrusion on the S pole side of the magnet portion 6, and flows into the teeth 4 a of the stator core 5 disposed on the S pole side of the magnet portion 6.
  • FIG. 7 is a plan view of the electric motor 1 shown in FIG. 1 as viewed from the left side of the drawing. However, illustration of the housing 2 and the U-shaped coil 8 is omitted.
  • a current flows through the U-shaped coil 8 via the copper plate coil 11
  • each tooth of the stator ASSY 3 is magnetized according to the direction of the flowing current, and a rotating magnetic field is generated to generate torque.
  • the NS polarities of the teeth rotate as shown in FIGS. 7A to 7C, and the rotor 9 rotates due to the magnetic action. .
  • FIG. 8 is a cross-sectional view of a mold for molding the stator ASSY 3.
  • the mold is composed of a combination of an upper mold 20, a lower mold 21, and a middle shaft 22, and a gap 23 in which the stator cores 4, 5 and the magnet part 6 are installed, and a gap in which a mold 7 is formed by injecting resin. 24 are provided concentrically.
  • the partition of the upper mold 20 and the lower mold 21 may be arbitrary.
  • the middle shaft 22 is a mold that forms a space for disposing the rotor 9, and has a shape in which the outer peripheral surface of the middle shaft 22 is in contact with the tips of the teeth 4 a of the stator cores 4, 5. Note that the cross section of the stator assembly 3 shown in FIG. 8 corresponds to a cross section cut along the line BB in FIG.
  • a plurality of positioning protrusions (not shown) in the same direction as the axial direction of the middle shaft 22 are formed on the wall surface of the gap 23 of the lower mold 21 so that the positioning protrusions engage with the positioning recesses 4 c of the stator core 5.
  • the stator core 5 is installed in the gap 23.
  • the magnet portion 6 is disposed on the upper side of the stator core 5.
  • the six permanent magnets are arranged in an annular shape, but since the caulking projections 4b protrude from the stator core 5 every 60 degrees, the respective projections 4b are arranged as a guide.
  • FIG. 9A shows an enlarged side view of a divided portion of the projection 4b and the permanent magnet 6a provided on the inner peripheral portion of the stator core 5, and FIG. 9B shows a plan view thereof.
  • each permanent magnet 6a is positioned in contact with the caulking projection 4b.
  • the stator core 4 is installed on the upper side of the magnet portion 6 so that the positioning concave portion 4 c of the stator core 4 engages with the positioning convex portion of the gap 23. Thereby, the phase alignment of each tooth 4a of the stator cores 4 and 5 can be easily performed.
  • the upper mold 20, the lower mold 21 and the middle shaft 22 are fitted, resin is injected from the resin injection port 25 into the gap 24, and the stator ASSY 3 is integrally molded, and the mold Part 7 is formed.
  • the resin member forming the mold part 7 preferably has at least thermosetting properties, for example, polyphenylene sulfide resin (PPS) is used. .
  • PPS polyphenylene sulfide resin
  • the integrally formed stator ASSY 3 When the integrally formed stator ASSY 3 is installed in the housing 2, it is pressed and fixed from one end side of the housing 2 as shown in FIG. 6.
  • the housing 2 is provided with a press-fit portion 2a having a slightly smaller inner diameter, and the press-fit portion 2a holds the press-fitted stator core 5.
  • the U-shaped coil 8 is inserted into the coil insertion hole 7a of the mold part 7, and the connection plate ASSY 10 is installed to connect the coils.
  • the rotor 9 fixed to the shaft (not shown) is inserted into the central opening portion of the stator ASSY 3. Since the inner peripheral surface of the mold portion 7 and the tip end surface of the teeth are flush with each other, the central opening portion of the stator ASSY 3 is not uneven and the rotor 9 can be easily inserted.
  • stator cores 102 and 103 are press-fitted in two directions, so that the clearances 109 and 110 are necessary between the permanent magnets 101.
  • the stator assembly 3 is integrally formed, so that the stator cores are integrally formed. Clearance between 4, 5 and the magnet portion 6 can be eliminated.
  • press-fitting is performed from one direction, workability can be improved as compared with the case of press-fitting from two directions.
  • FIG. 12 described above it is necessary to press-fit the stator cores 102 and 103 having different outer diameters into the press-fit portions 112 and 113 having different inner diameters, but in the first embodiment, one stator core 4 is held.
  • the press-fitting portion does not increase, and the housing cutting cost can be reduced.
  • the cost of preparing stator cores having different outer diameters can be reduced.
  • a mold is used at the time of integral molding. Since the teeth of the stator cores 4 and 5 are positioned, the cost for using the positioning pins can be reduced. Further, the phase alignment of the teeth 4a of the stator cores 4 and 5 can be performed simultaneously with the integral molding.
  • the stator ASSY 3 of the electric motor 1 includes the stator cores 4 and 5 in which the annular body and the six teeth 4a protruding from the inner peripheral portion of the annular body toward the center are formed.
  • An annular magnet portion 6 that magnetizes the rotor 9 in the rotation axis direction X, and a resin member that is integrally formed by sandwiching the magnet portion 6 between stator cores 4 and 5 provided on both sides.
  • the magnet portion 6 and the stator cores 4 and 5 are The mold portion 7 is held at least on the inner peripheral side, and is press-fitted and fixed at a position surrounding the outer periphery of the rotor 9 of the cylindrical housing 2.
  • the clearance between the magnet portion 6 and the stator cores 4 and 5 can be eliminated, the influence of demagnetization due to the clearance is eliminated, and the motor characteristics (torque) are improved. Further, since it is not necessary to press the magnet portion 6 with the stator cores 4 and 5 so as to eliminate the clearance when the stator ASSY 3 is press-fitted into the housing 2, the magnet portion 6 is not damaged. In addition, the assembly to the housing 2 only needs to press-fit the stator ASSY 3 from one direction, and the phase alignment of the teeth 4a is unnecessary, so that the cost required for the assembly can be reduced.
  • the resin member of the mold portion 7 is thermosetting, the heat resistance of the stator ASSY 3 is improved and thermal deformation can be suppressed. For this reason, the electric motor 1 can be used at high temperatures by using it for automobile parts and the like.
  • PPS excellent in heat resistance and water resistance is suitable as the resin member.
  • the mold portion 7 has a shape that closes the gap between the teeth 4a of the stator cores 4 and 5 and is flush with the tip surface of the teeth 4a. Sinking and sagging of members can be prevented.
  • the magnet portion 6 has the same number of fan-shaped permanent magnets as the teeth 4 a of the stator cores 4, 5 arranged in an annular shape, and the outer peripheral portion of the permanent magnets is the teeth 4 a of the stator cores 4, 5. Since the radially outer portion corresponding to the formation portion is covered, the magnetic characteristics can be improved.
  • a plurality of steel plates are laminated in the rotation axis direction X of the rotor 9 and are caulked together to form the stator cores 4, 5. Since positioning is performed by the crimped protrusion 4b, the number of parts does not increase for positioning the magnet portion 6. Further, since the permanent magnet is not displaced, good magnetic characteristics can be maintained.
  • the coil wound around each tooth of the stator core is a one-turn U-shaped coil.
  • the present invention is not limited to this.
  • a total of six teeth for the stator core, two each for the U phase, the V phase, and the W phase, are provided, the present invention is not limited to this.
  • the present invention can be modified in any component of the embodiment or omitted in any component within the scope of the invention.
  • the electric motor according to the present invention is used for an electric motor that rotationally drives an automobile turbocharger and an electric compressor that are exposed to high temperatures. Suitable for

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Iron Core Of Rotating Electric Machines (AREA)
  • Permanent Field Magnets Of Synchronous Machinery (AREA)

Abstract

In the present invention, a stator assembly (3) is provided with: stator cores (4, 5) wherein a ring body and a plurality of teeth that protrude from the inner periphery of the ring body towards the center are formed; an annular magnet (6) that is sandwiched between the stator cores (4, 5) and that magnetizes a rotor (9) in the rotary axis direction (X); and a molded section (7) that is formed by integrally molding the magnet (6) and the stator cores (4, 5) by means of a resin member. The stator assembly (3) is press-fit affixed to a housing (2) from one direction.

Description

電動機Electric motor
　この発明は、２つのステータコアの間に永久磁石を挟んだステータを有する電動機に関する。 This invention relates to an electric motor having a stator with a permanent magnet sandwiched between two stator cores.
　従来の電動機（例えば、特許文献１参照）の断面構造を図１０に示す。電動機１００は、軸方向に着磁された永久磁石１０１の両側に電磁鋼板を積層してステータコア１０２，１０３を形成した突極性のステータ１０４と、このステータ１０４の中心部に回転自在に設置され電磁鋼板が積層されてなる突極性のロータ１０５とを有する。このロータ１０５は突極方向を電気角で９０度ひねった構造であり、シャフト１０７と一体化されている。ステータ１０４を組み付ける際には、ハウジング１０６の内周面にロータ着磁用の永久磁石１０１を接着し、永久磁石１０１の両側からステータコア１０２，１０３をそれぞれ圧入して永久磁石１０１を固定する。 FIG. 10 shows a cross-sectional structure of a conventional electric motor (for example, see Patent Document 1). The electric motor 100 includes a saliency stator 104 in which stator steel cores 102 and 103 are formed by laminating electromagnetic steel plates on both sides of an axially magnetized permanent magnet 101, and an electromagnetically installed in a central portion of the stator 104. And a saliency rotor 105 in which steel plates are laminated. The rotor 105 has a structure in which the salient pole direction is twisted by 90 degrees in electrical angle, and is integrated with the shaft 107. When the stator 104 is assembled, the permanent magnet 101 for magnetizing the rotor is bonded to the inner peripheral surface of the housing 106, and the stator cores 102 and 103 are press-fitted from both sides of the permanent magnet 101 to fix the permanent magnet 101.
　また、ステータコア１０２，１０３をそれぞれ圧入する場合、ステータコア１０２，１０３同士の各ティースを位置決めする必要がある。そこで、図１１（ａ）および図１１（ｂ）に示すように、ハウジング１０６とステータ１０４との間に位置決めピン１１１を設け、組み付けの際に各ティース１０８を位置決めしていた。 Further, when the stator cores 102 and 103 are press-fitted, it is necessary to position the teeth between the stator cores 102 and 103. Therefore, as shown in FIGS. 11A and 11B, positioning pins 111 are provided between the housing 106 and the stator 104, and the teeth 108 are positioned at the time of assembly.
　上記組み付け方法の他にも、例えば図１２に示すように、ステータコア１０２，１０３をそれぞれ一方向からハウジング１０６に圧入する方法があった。この場合、ハウジング１０６へ圧入固定した後で２つのステータコア１０２，１０３が永久磁石１０１を挟持するように、ステータコア１０２の外径を大きくし、もう一方のステータコア１０３の外径を小さくし、これに合わせてハウジング１０６の内周面にも内径の大きい圧入部１１２と内径の小さい圧入部１１３を形成する。 Besides the above assembling method, for example, as shown in FIG. 12, there is a method in which the stator cores 102 and 103 are press-fitted into the housing 106 from one direction. In this case, the outer diameter of the stator core 102 is increased and the outer diameter of the other stator core 103 is decreased so that the two stator cores 102 and 103 sandwich the permanent magnet 101 after being press-fitted and fixed to the housing 106. In addition, a press-fit portion 112 having a large inner diameter and a press-fit portion 113 having a small inner diameter are also formed on the inner peripheral surface of the housing 106.
特開平８－２１４５１９号公報JP-A-8-214519
　永久磁石１０１の両側からステータコア１０２，１０３を圧入する場合、ステータコア１０２，１０３と永久磁石１０１の間にクリアランス１０９，１１０（図１０に示す）が発生してしまい、ロータ着磁の際に減磁が生じてモータ特性（トルク）が減少してしまうという課題があった。また、クリアランス１０９，１１０を無くそうとすると、永久磁石１０１とステータコア１０２，１０３とを接触させる必要があり、ステータコア圧入の荷重が掛かって永久磁石１０１が損傷する可能性があった。 When the stator cores 102 and 103 are press-fitted from both sides of the permanent magnet 101, clearances 109 and 110 (shown in FIG. 10) are generated between the stator cores 102 and 103 and the permanent magnet 101, and demagnetization occurs during rotor magnetization. This causes a problem that the motor characteristics (torque) are reduced. Further, if the clearances 109 and 110 are to be eliminated, it is necessary to bring the permanent magnet 101 and the stator cores 102 and 103 into contact with each other, and there is a possibility that the permanent magnet 101 may be damaged due to the load of press-fitting the stator core.
　また、組み付けの際に位置決めピン１１１などを使用してステータコア１０２，１０３のティース１０８同士を位置決めする場合、組み付けに要するコストが増加するという課題があった。具体的には、位置決めピン１１１の部品点数増加、ステータコア１０２，１０３への位置決めピン１１１圧入用の凹部加工の追加、位置決めピン１１１の圧入作業工程の追加などがある。 Further, when positioning the teeth 108 of the stator cores 102 and 103 using the positioning pins 111 or the like during the assembly, there is a problem that the cost required for the assembly increases. Specifically, there are an increase in the number of parts of the positioning pin 111, addition of a recess processing for press-fitting the positioning pin 111 into the stator cores 102 and 103, addition of a press-fitting work process of the positioning pin 111, and the like.
　さらに、同じ外径のステータコア１０２，１０３を二方向からハウジング１０６に圧入するため、作業性が悪化するという課題があった。
　他方、異なる外径のステータコア１０２，１０３を一方向からハウジング１０６に圧入する場合は、ステータコアが二種類必要となるため、部品点数が増加し、かつ、ハウジング１０６に異なる内径の圧入部１１２，１１３を形成する必要があるため、ハウジング切削コストも増加するという課題があった。 Furthermore, since the stator cores 102 and 103 having the same outer diameter are press-fitted into the housing 106 from two directions, there is a problem that workability is deteriorated.
On the other hand, when the stator cores 102 and 103 having different outer diameters are press-fitted into the housing 106 from one direction, two types of stator cores are required. Therefore, the number of parts is increased, and the press-fitting portions 112 and 113 having different inner diameters are added to the housing 106. Therefore, there is a problem that the housing cutting cost also increases.
　この発明は、上記のような課題を解決するためになされたもので、永久磁石とステータコアの間のクリアランスを無くし、かつ、永久磁石とステータコアをハウジングへ組み付けるために要するコストを削減することを目的とする。 The present invention has been made to solve the above-described problems, and aims to eliminate the clearance between the permanent magnet and the stator core and reduce the cost required for assembling the permanent magnet and the stator core to the housing. And
　この発明の電動機は、円筒状のハウジングと、ハウジングの中央部に回転自在に保持されるロータ部と、ハウジングのロータ部外周を囲う位置に圧入固定されるステータ部とを備え、ステータ部が、環状体および当該環状体の内周部から中心へ向かって突出する複数のティースが形成されたステータコアと、ロータ部を回転軸方向に着磁する環状のマグネット部と、マグネット部を両側に設けたステータコアで挟み込んで一体成形した樹脂部材から成り、マグネット部およびステータコアを少なくとも内周側で保持するモールド部とを有するようにしたものである。 The electric motor of the present invention includes a cylindrical housing, a rotor portion that is rotatably held in a central portion of the housing, and a stator portion that is press-fitted and fixed at a position surrounding the outer periphery of the rotor portion of the housing, A stator core formed with an annular body and a plurality of teeth protruding toward the center from the inner peripheral portion of the annular body, an annular magnet portion that magnetizes the rotor portion in the direction of the rotation axis, and magnet portions are provided on both sides It is made of a resin member that is integrally formed by being sandwiched between stator cores, and has a magnet part and a mold part that holds the stator core at least on the inner peripheral side.
　この発明によれば、マグネット部とその両側のステータコアとを一体成形してステータ部にすることにより、マグネット部とステータコアとの間のクリアランスを無くしてモータ特性を向上させることができる。また、一体成形したステータ部を一方向からハウジングへ圧入して組み付けできるので、組み付けに要するコストを削減することができる。 According to the present invention, by integrally molding the magnet portion and the stator cores on both sides thereof to form the stator portion, the clearance between the magnet portion and the stator core can be eliminated and the motor characteristics can be improved. Further, since the integrally molded stator portion can be press-fitted into the housing from one direction and assembled, the cost required for the assembly can be reduced.
この発明の実施の形態１に係る電動機の構成を示す断面図である。It is sectional drawing which shows the structure of the electric motor which concerns on Embodiment 1 of this invention. 実施の形態１に係る電動機の構成を示す分解斜視図である。1 is an exploded perspective view showing a configuration of an electric motor according to Embodiment 1. FIG. 実施の形態１に係る電動機のステータＡＳＳＹの構成を示し、図３（ａ）は外観斜視図、図３（ｂ）は側面図である。The structure of the stator ASSY of the electric motor which concerns on Embodiment 1 is shown, Fig.3 (a) is an external appearance perspective view, FIG.3 (b) is a side view. 実施の形態１に係る電動機のステータＡＳＳＹを、図３（ｂ）のＡＡ線に沿って切断した断面図である。It is sectional drawing which cut | disconnected the stator ASSY of the electric motor which concerns on Embodiment 1 along the AA line of FIG.3 (b). 実施の形態１に係る電動機のステータコアの構成を示す平面図である。3 is a plan view showing a configuration of a stator core of the electric motor according to Embodiment 1. FIG. 図１に示す電動機のステータＡＳＳＹ圧入部分を拡大した図である。It is the figure which expanded the stator ASSY press-fit part of the electric motor shown in FIG. 実施の形態１に係る電動機の回転動作を説明する図である。It is a figure explaining rotation operation of the electric motor concerning Embodiment 1. FIG. 実施の形態１に係る電動機のステータＡＳＳＹを一体成形する金型の断面図である。It is sectional drawing of the metal mold | die which integrally molds the stator ASSY of the electric motor which concerns on Embodiment 1. FIG. 実施の形態１に係る電動機のステータコアと永久磁石の位置決め部分を拡大した図である。It is the figure which expanded the stator core of the electric motor which concerns on Embodiment 1, and the positioning part of a permanent magnet. 従来の電動機の構成例を示す断面図である。It is sectional drawing which shows the structural example of the conventional electric motor. 従来の電動機の別の構成例を示す図であり、図１１（ａ）は断面図、図１１（ｂ）は平面図である。It is a figure which shows another structural example of the conventional electric motor, Fig.11 (a) is sectional drawing, FIG.11 (b) is a top view. 従来の電動機の別の構成例を示す断面図である。It is sectional drawing which shows another structural example of the conventional electric motor.
　以下、この発明をより詳細に説明するために、この発明を実施するための形態について、添付の図面に従って説明する。
実施の形態１．
　図１および図２に示す電動機１は三相交流シンクロナスモータを構成し、主に、円筒状のハウジング２と、ハウジング２に圧入固定されたステータＡＳＳＹ（ステータ部）３と、図示しないシャフトを回転させるロータ（ロータ部）９とを備える。ロータ９は、径方向外側に突出する突部を１８０度間隔に２箇所形成し、回転軸方向Ｘの途中で突部を９０度ずらした状態にする（突部９ａ，９ｂ）。ロータ９を永久磁石で構成してもよいが、電動機１が高温に晒される場合には磁気特性が低下するので、例えば電磁鋼板を突状に打ち抜いて回転軸方向Ｘに積層して構成するほうが好ましい。積層鋼板でロータ９を構成する場合も、回転軸方向Ｘの途中で突部を９０度ずらした状態にする（突部９ａ，９ｂ）。
　このロータ９にシャフトを固着して、ロータ９と一体にシャフトを回転させることにより、ロータ９に発生した回転力を外部出力する。電動機１を自動車用ターボチャージャおよび電動コンプレッサ等に適用する場合、ロータ９に固着したシャフトをタービン（いわゆるインペラ）の回転軸に連結して、電動機１によりタービンを回転駆動する。 Hereinafter, in order to explain the present invention in more detail, modes for carrying out the present invention will be described with reference to the accompanying drawings.
Embodiment 1 FIG.
An electric motor 1 shown in FIGS. 1 and 2 constitutes a three-phase AC synchronous motor, and mainly includes a cylindrical housing 2, a stator ASSY (stator portion) 3 press-fitted and fixed to the housing 2, and a shaft (not shown). And a rotor (rotor part) 9 to be rotated. The rotor 9 has two protrusions protruding radially outward at intervals of 180 degrees, and the protrusions are shifted by 90 degrees in the middle of the rotation axis direction X ( protrusions 9a and 9b). The rotor 9 may be composed of a permanent magnet. However, when the electric motor 1 is exposed to a high temperature, the magnetic characteristics are deteriorated. For example, it is better to construct a structure in which, for example, electromagnetic steel sheets are punched out and stacked in the rotation axis direction X. preferable. Even when the rotor 9 is formed of laminated steel plates, the protrusions are shifted by 90 degrees in the middle of the rotation axis direction X ( protrusions 9a and 9b).
By fixing the shaft to the rotor 9 and rotating the shaft integrally with the rotor 9, the rotational force generated in the rotor 9 is output to the outside. When the electric motor 1 is applied to an automobile turbocharger, an electric compressor, or the like, a shaft fixed to the rotor 9 is connected to a rotating shaft of a turbine (so-called impeller), and the electric motor 1 rotates the turbine.
　図３（ａ）は、ステータＡＳＳＹ３の構成を示す外観斜視図であり、図３（ｂ）に側面図を示す。また、図３（ｂ）のステータＡＳＳＹ３をＡＡ線に沿って切断した断面図を図４に示す。ステータＡＳＳＹ３は、２個のステータコア４，５と、このステータコア４，５の間に配置されたマグネット部６と、これらを一体化するモールド部７とから構成される。 FIG. 3A is an external perspective view showing the configuration of the stator ASSY 3, and FIG. 3B shows a side view. FIG. 4 is a cross-sectional view of the stator ASSY 3 in FIG. 3B cut along the line AA. The stator ASSY 3 includes two stator cores 4 and 5, a magnet portion 6 disposed between the stator cores 4 and 5, and a mold portion 7 that integrates them.
　図５にステータコア４の平面図を示す。ステータコア４は電磁鋼板をロータ９の回転軸方向Ｘに積層して構成する。このステータコア４は環状体と、この環状体の内周部から中心に向かって突出する６個の突部（以下、ティース４ａ）とからなる。ティース４ａの各々にはＵ字コイル８が装着されることになる。
　図示例では、電磁鋼板を打ち抜いて突状のティース４ａを円周方向に６０度間隔で６個設け、さらに、ティース４ａと互い違いに出来た６箇所の凹部それぞれにかしめ用の突起４ｂを６０度間隔で設ける。また、電磁鋼板の外周部には位置決め凹部４ｃを複数設ける。この電磁鋼板を複数積層し、各々の突起４ｂをかしめて結束してステータコア４にする。同様にしてステータコア５も形成する。 FIG. 5 shows a plan view of the stator core 4. The stator core 4 is formed by stacking electromagnetic steel plates in the rotation axis direction X of the rotor 9. The stator core 4 includes an annular body and six projecting portions (hereinafter referred to as teeth 4a) projecting from the inner peripheral portion of the annular body toward the center. A U-shaped coil 8 is attached to each of the teeth 4a.
In the illustrated example, electromagnetic steel sheets are punched out to provide six protruding teeth 4a in the circumferential direction at intervals of 60 degrees, and further, caulking protrusions 4b are formed at 60 degrees in each of six recesses formed alternately with the teeth 4a. Provide at intervals. A plurality of positioning recesses 4c are provided on the outer periphery of the electromagnetic steel sheet. A plurality of the electromagnetic steel sheets are laminated, and the protrusions 4b are caulked and bound to form the stator core 4. Similarly, the stator core 5 is also formed.
　マグネット部６は環状であり、複数の永久磁石を組み合わせて構成する。図４の例では、中心角６０度の扇形をした永久磁石を、ティース４ａと同一数である６個用いている。永久磁石の配置例として、図５に示すように１個の永久磁石６ａの外周部６ｂがステータコア４（ステータコア５でも同様）のティース４ａ形成部分に相当する径方向外側を覆うように配置する。図５に示す永久磁石６ａと同じように６個の永久磁石それぞれを配置したのが、図４に示す状態である。各永久磁石は、内周側の両端部分がステータコア４，５の各突起４ａに当接して位置決めされている。この配置例の場合、回転軸方向Ｘから見て各永久磁石の分割部分がティース４ａに重ならないので、磁気特性を向上できる。 The magnet unit 6 has an annular shape and is configured by combining a plurality of permanent magnets. In the example of FIG. 4, six fan-shaped permanent magnets having a central angle of 60 degrees are used, which is the same number as the teeth 4a. As an example of the arrangement of the permanent magnets, as shown in FIG. 5, the outer peripheral portion 6b of one permanent magnet 6a is arranged so as to cover the outer side in the radial direction corresponding to the teeth 4a forming portion of the stator core 4 (the same applies to the stator core 5). In the state shown in FIG. 4, each of the six permanent magnets is arranged in the same manner as the permanent magnet 6a shown in FIG. Each permanent magnet is positioned such that both end portions on the inner peripheral side are in contact with the projections 4 a of the stator cores 4, 5. In the case of this arrangement example, since the divided portions of the permanent magnets do not overlap the teeth 4a when viewed from the rotation axis direction X, the magnetic characteristics can be improved.
　モールド部７は、ステータコア４，５およびマグネット部６を一体成形する樹脂部材で構成される。一体成形の手順は後述する。図３（ａ）および図４に示すように、モールド部７にはＵ字コイル８を挿通するためのコイル挿通孔７ａが１個のＵ字コイル８につき２個、合計１２個形成されている。
　Ｕ字コイル８は、銅板をＵ字に折り曲げた１回巻きのコイルであり、図１および図２に示すようにコイル挿通孔７ａを回転軸方向Ｘに貫通して、折り曲げ部分がステータコア４側に、先端部分がステータコア５側に突出している。 The mold part 7 is composed of a resin member that integrally molds the stator cores 4, 5 and the magnet part 6. The procedure of integral molding will be described later. As shown in FIG. 3A and FIG. 4, a total of 12 coil insertion holes 7 a for inserting the U-shaped coil 8 are formed in the mold portion 7, two for each U-shaped coil 8. .
The U-shaped coil 8 is a one-turn coil obtained by bending a copper plate into a U-shape, and penetrates the coil insertion hole 7a in the rotation axis direction X as shown in FIGS. 1 and 2, and the bent portion is on the stator core 4 side. Further, the tip portion protrudes toward the stator core 5 side.
　モールド部７のコイル挿通孔７ａに挿通されたＵ字コイル８の一端部は、図１に示すように、結線板ＡＳＳＹ１０を貫通して制御回路基板１２側へ突出しており、この結線板ＡＳＳＹ１０にモールドされた通電部材である銅板コイル１１（Ｕ相、Ｖ相、Ｗ相）に接続されている。この銅板コイル１１は制御回路基板１２に接続されている。
　制御回路基板１２はインバータを有し、コネクタ部１４から入力される外部電源（不図示）を交流電流に変換し、位置検出センサ１５から入力される位置信号に基づいて銅板コイル１１のＵ相、Ｖ相、Ｗ相の三相を順次切り替えてＵ字コイル８に電流を流す。なお、Ｕ字コイル８とステータコア４，５とはモールド部７により隔絶されて絶縁される。 As shown in FIG. 1, one end of the U-shaped coil 8 inserted into the coil insertion hole 7a of the mold part 7 penetrates the connection plate ASSY 10 and protrudes toward the control circuit board 12 side. It is connected to a copper plate coil 11 (U phase, V phase, W phase) which is a molded energization member. The copper plate coil 11 is connected to the control circuit board 12.
The control circuit board 12 has an inverter, converts an external power source (not shown) input from the connector unit 14 into an alternating current, and based on the position signal input from the position detection sensor 15, the U phase of the copper plate coil 11, A current is passed through the U-shaped coil 8 by sequentially switching the three phases of the V phase and the W phase. The U-shaped coil 8 and the stator cores 4 and 5 are insulated from each other by the mold portion 7.
　位置検出センサ１５は、ロータ９と一体に回転するセンサターゲット１６（例えば磁石）の位置を検出するホール素子ＩＣ（Ｉｎｔｅｇｒａｔｅｄ　Ｃｉｒｃｕｉｔ）などで構成される。この位置検出センサ１５は、センサターゲット１６の位置を検出することによりロータ９の回転位置を検知して、制御回路基板１２へ位置信号を出力する。
　なお、ハウジング２の制御回路基板１２側の開口面をカバー１３で覆い、制御回路基板１２および位置検出センサ１５などを保護する。また、ハウジング２とステータＡＳＳＹ３の圧入部分にＯリング１７を設けてシールする。 The position detection sensor 15 includes a Hall element IC (Integrated Circuit) that detects the position of a sensor target 16 (for example, a magnet) that rotates integrally with the rotor 9. The position detection sensor 15 detects the rotational position of the rotor 9 by detecting the position of the sensor target 16 and outputs a position signal to the control circuit board 12.
The opening surface of the housing 2 on the control circuit board 12 side is covered with a cover 13 to protect the control circuit board 12 and the position detection sensor 15 and the like. Further, an O-ring 17 is provided and sealed in the press-fitting portion of the housing 2 and the stator ASSY 3.
　ここで、電動機１の動作概略を説明する。
　図６は、図１に示す電動機１のステータＡＳＳＹ３圧入部分を拡大した図である。回転軸方向Ｘに着磁されたマグネット部６による磁束（マグネット磁束）は、マグネット部６のＮ極側に配置されたステータコア４のティース４ａからロータ９の突部へ流れ出て、ロータ９の回転軸方向Ｘに進んでマグネット部６のＳ極側にある突部から出て、マグネット部６のＳ極側に配置されたステータコア５のティース４ａへ流れ入る界磁磁束となる。このように、マグネット部６の界磁磁気力がロータ９に作用することで、マグネット部６のＮ極側に対面するロータ９の突部をＮ極に着磁し、マグネット部６のＳ極側に対面するロータ９の突部をＳ極に着磁する。
　図７は、図１に示す電動機１を図面紙上左側から見た平面図である。ただし、ハウジング２およびＵ字コイル８は図示を省略する。銅板コイル１１を経由してＵ字コイル８に電流が流れると、流れた電流の向きに応じてステータＡＳＳＹ３の各ティースが着磁して回転磁界が生じ、トルクが発生する。Ｕ字コイル８に流す電流の向きを順次切り替えることにより、図７（ａ）～図７（ｃ）のように各ティースのＮＳ各極性が回転移動していき、磁気作用によりロータ９が回転する。 Here, an outline of the operation of the electric motor 1 will be described.
FIG. 6 is an enlarged view of the stator ASSY3 press-fitting portion of the electric motor 1 shown in FIG. Magnetic flux (magnet magnetic flux) generated by the magnet portion 6 magnetized in the rotation axis direction X flows out of the teeth 4a of the stator core 4 arranged on the N pole side of the magnet portion 6 to the protrusion of the rotor 9, and the rotation of the rotor 9 The magnetic field magnetic flux flows in the axial direction X, exits from the protrusion on the S pole side of the magnet portion 6, and flows into the teeth 4 a of the stator core 5 disposed on the S pole side of the magnet portion 6. Thus, the magnetic field force of the magnet unit 6 acts on the rotor 9, so that the protrusion of the rotor 9 facing the N pole side of the magnet unit 6 is magnetized to the N pole, and the S pole of the magnet unit 6 The protrusion of the rotor 9 facing the side is magnetized to the S pole.
FIG. 7 is a plan view of the electric motor 1 shown in FIG. 1 as viewed from the left side of the drawing. However, illustration of the housing 2 and the U-shaped coil 8 is omitted. When a current flows through the U-shaped coil 8 via the copper plate coil 11, each tooth of the stator ASSY 3 is magnetized according to the direction of the flowing current, and a rotating magnetic field is generated to generate torque. By sequentially switching the direction of the current flowing through the U-shaped coil 8, the NS polarities of the teeth rotate as shown in FIGS. 7A to 7C, and the rotor 9 rotates due to the magnetic action. .
　次に、ステータＡＳＳＹ３の組み立て手順を説明する。
　図８は、ステータＡＳＳＹ３を成形する金型の断面図である。金型は、上金型２０、下金型２１および中軸２２を組み合わせて成り、内部にステータコア４，５およびマグネット部６を設置する空隙２３と、樹脂を注入してモールド部７を成形する空隙２４とが同心円状に設けられている。上金型２０と下金型２１のパーティションは任意でよい。中軸２２はロータ９を配置するための空間を形成する金型であり、中軸２２の外周面がステータコア４，５の各ティース４ａ先端部分に当接する形状である。なお、図８に示すステータＡＳＳＹ３の断面は、図３（ｂ）のＢＢ線に沿って切断した断面に相当する。 Next, the assembly procedure of the stator ASSY 3 will be described.
FIG. 8 is a cross-sectional view of a mold for molding the stator ASSY 3. The mold is composed of a combination of an upper mold 20, a lower mold 21, and a middle shaft 22, and a gap 23 in which the stator cores 4, 5 and the magnet part 6 are installed, and a gap in which a mold 7 is formed by injecting resin. 24 are provided concentrically. The partition of the upper mold 20 and the lower mold 21 may be arbitrary. The middle shaft 22 is a mold that forms a space for disposing the rotor 9, and has a shape in which the outer peripheral surface of the middle shaft 22 is in contact with the tips of the teeth 4 a of the stator cores 4, 5. Note that the cross section of the stator assembly 3 shown in FIG. 8 corresponds to a cross section cut along the line BB in FIG.
　下金型２１の空隙２３の壁面には中軸２２の軸方向と同一方向の位置決め凸部（不図示）が複数形成されており、この位置決め凸部がステータコア５の位置決め凹部４ｃに係合するように、空隙２３にステータコア５を設置する。続いて、ステータコア５の上側にマグネット部６を配置する。上述したように６個の永久磁石を環状に配置することになるが、ステータコア５には６０度毎にかしめ用の突起４ｂが突出しているので各突起４ｂを目安に配置する。図９（ａ）にステータコア５の内周部に設けた突起４ｂと永久磁石６ａの分割部分を拡大した側面図を示し、その平面図を図９（ｂ）に示す。図示するように、各永久磁石６ａはかしめ用の突起４ｂに当接して位置決めされる。
　続いて、ステータコア４の位置決め凹部４ｃが空隙２３の位置決め凸部と係合するように、マグネット部６の上側にステータコア４を設置する。これにより、ステータコア４，５の各ティース４ａの位相合わせが容易にできる。 A plurality of positioning protrusions (not shown) in the same direction as the axial direction of the middle shaft 22 are formed on the wall surface of the gap 23 of the lower mold 21 so that the positioning protrusions engage with the positioning recesses 4 c of the stator core 5. In addition, the stator core 5 is installed in the gap 23. Subsequently, the magnet portion 6 is disposed on the upper side of the stator core 5. As described above, the six permanent magnets are arranged in an annular shape, but since the caulking projections 4b protrude from the stator core 5 every 60 degrees, the respective projections 4b are arranged as a guide. FIG. 9A shows an enlarged side view of a divided portion of the projection 4b and the permanent magnet 6a provided on the inner peripheral portion of the stator core 5, and FIG. 9B shows a plan view thereof. As shown in the figure, each permanent magnet 6a is positioned in contact with the caulking projection 4b.
Subsequently, the stator core 4 is installed on the upper side of the magnet portion 6 so that the positioning concave portion 4 c of the stator core 4 engages with the positioning convex portion of the gap 23. Thereby, the phase alignment of each tooth 4a of the stator cores 4 and 5 can be easily performed.
　ステータコア４，５およびマグネット部６を設置した後、上金型２０、下金型２１および中軸２２を嵌合し樹脂注入口２５から空隙２４へ樹脂を注入してステータＡＳＳＹ３を一体成形し、モールド部７を形成する。自動車用ターボチャージャに適用する等して電動機１が高温に晒されるような場合、モールド部７を形成する樹脂部材は少なくとも熱硬化性を有することが好ましく、例えばポリフェニレンサルファイド樹脂（ＰＰＳ）を使用する。
　なお、マグネット部６の永久磁石間には設計上クリアランスが確保されているため、ステータＡＳＳＹ３のマグネット部６の外周側にも樹脂を流してモールド部７を延長することが可能である。また、モールド部７の内周面はティース４ａの先端面と面一になるので（即ち、モールド部７の内周径とティース４ａ先端部分を繋いだ形の径とが同じになるので）、樹脂のヒケおよびダレを防止できる。 After the stator cores 4 and 5 and the magnet part 6 are installed, the upper mold 20, the lower mold 21 and the middle shaft 22 are fitted, resin is injected from the resin injection port 25 into the gap 24, and the stator ASSY 3 is integrally molded, and the mold Part 7 is formed. When the electric motor 1 is exposed to a high temperature, for example, when applied to a turbocharger for automobiles, the resin member forming the mold part 7 preferably has at least thermosetting properties, for example, polyphenylene sulfide resin (PPS) is used. .
In addition, since a clearance is secured between the permanent magnets of the magnet part 6 by design, it is possible to extend the mold part 7 by flowing resin also on the outer peripheral side of the magnet part 6 of the stator ASSY 3. Moreover, since the inner peripheral surface of the mold part 7 is flush with the tip surface of the teeth 4a (that is, the inner peripheral diameter of the mold part 7 and the diameter of the shape connecting the tip parts of the teeth 4a are the same), Resin sinking and sagging can be prevented.
　一体成形したステータＡＳＳＹ３をハウジング２に設置する際には、図６に示すようにハウジング２の一端側から圧入して固定する。ハウジング２には内径を若干小さくした圧入部２ａが設けられており、この圧入部２ａが圧入されたステータコア５を保持する。その後、Ｕ字コイル８をモールド部７のコイル挿通孔７ａに挿入し、結線板ＡＳＳＹ１０を設置してコイル同士を接続する。また、ステータＡＳＳＹ３の中央開口部分に、シャフト（不図示）に固着したロータ９を挿入する。モールド部７の内周面とティース先端面とを面一にしたので、ステータＡＳＳＹ３の中央開口部分は凹凸がなくロータ９の挿入が容易である。 When the integrally formed stator ASSY 3 is installed in the housing 2, it is pressed and fixed from one end side of the housing 2 as shown in FIG. 6. The housing 2 is provided with a press-fit portion 2a having a slightly smaller inner diameter, and the press-fit portion 2a holds the press-fitted stator core 5. Thereafter, the U-shaped coil 8 is inserted into the coil insertion hole 7a of the mold part 7, and the connection plate ASSY 10 is installed to connect the coils. Further, the rotor 9 fixed to the shaft (not shown) is inserted into the central opening portion of the stator ASSY 3. Since the inner peripheral surface of the mold portion 7 and the tip end surface of the teeth are flush with each other, the central opening portion of the stator ASSY 3 is not uneven and the rotor 9 can be easily inserted.
　先立って説明した図１０では二方向からステータコア１０２，１０３を圧入するので永久磁石１０１との間にクリアランス１０９，１１０が必要であったが、本実施の形態１ではステータＡＳＳＹ３を一体成形するのでステータコア４，５とマグネット部６とのクリアランスを無くすことができる。また、圧入は一方向から行うので、二方向から圧入する場合に比べて作業性を向上できる。
　また、先立って説明した図１２では外径の異なるステータコア１０２，１０３を内径の異なる圧入部１１２，１１３に圧入してそれぞれ保持する必要があったが、本実施の形態１では一方のステータコア４を一体成形した他方のステータコア５により保持するので、圧入部が増えず、ハウジング切削コストを削減できる。また、外径の異なるステータコアを用意するコストも削減できる。
　さらに、先立って説明した図１１ではステータコア１０２，１０３のティースを位置決めするためにハウジング１０６に位置決めピン１１１を設置する必要があったが、本実施の形態１では一体成形時に金型を利用してステータコア４，５のティースを位置決めしてあるので、位置決めピン使用にかかるコストを削減できる。また、ステータコア４，５の各ティース４ａの位相合わせを一体成形と同時にすることができる。 In FIG. 10 described above, the stator cores 102 and 103 are press-fitted in two directions, so that the clearances 109 and 110 are necessary between the permanent magnets 101. However, in the first embodiment, the stator assembly 3 is integrally formed, so that the stator cores are integrally formed. Clearance between 4, 5 and the magnet portion 6 can be eliminated. In addition, since press-fitting is performed from one direction, workability can be improved as compared with the case of press-fitting from two directions.
In addition, in FIG. 12 described above, it is necessary to press-fit the stator cores 102 and 103 having different outer diameters into the press- fit portions 112 and 113 having different inner diameters, but in the first embodiment, one stator core 4 is held. Since it is held by the other stator core 5 that is integrally formed, the press-fitting portion does not increase, and the housing cutting cost can be reduced. In addition, the cost of preparing stator cores having different outer diameters can be reduced.
Further, in FIG. 11 described above, it is necessary to install the positioning pin 111 on the housing 106 in order to position the teeth of the stator cores 102 and 103. In the first embodiment, a mold is used at the time of integral molding. Since the teeth of the stator cores 4 and 5 are positioned, the cost for using the positioning pins can be reduced. Further, the phase alignment of the teeth 4a of the stator cores 4 and 5 can be performed simultaneously with the integral molding.
　以上より、実施の形態１によれば、電動機１のステータＡＳＳＹ３は、環状体およびこの環状体の内周部から中心へ向かって突出する６個のティース４ａが形成されたステータコア４，５と、ロータ９を回転軸方向Ｘに着磁する環状のマグネット部６と、マグネット部６を両側に設けたステータコア４，５で挟み込んで一体成形した樹脂部材から成り、マグネット部６およびステータコア４，５を少なくとも内周側で保持するモールド部７とを有する構成であり、円筒状のハウジング２のロータ９外周を囲う位置に圧入固定するようにした。このため、マグネット部６とステータコア４，５との間のクリアランスを無くすことができるようになり、クリアランスに起因する減磁の影響が無くなり、モータ特性（トルク）が向上する。また、ステータＡＳＳＹ３をハウジング２に圧入する際にクリアランスを無くすようにステータコア４，５でマグネット部６を押圧する必要がないので、マグネット部６が損傷することがない。また、ハウジング２への組み付けはステータＡＳＳＹ３を一方向から圧入するだけでよく、ティース４ａの位相合わせも不要のため、組み付けに要するコストを削減できる。 As described above, according to the first embodiment, the stator ASSY 3 of the electric motor 1 includes the stator cores 4 and 5 in which the annular body and the six teeth 4a protruding from the inner peripheral portion of the annular body toward the center are formed. An annular magnet portion 6 that magnetizes the rotor 9 in the rotation axis direction X, and a resin member that is integrally formed by sandwiching the magnet portion 6 between stator cores 4 and 5 provided on both sides. The magnet portion 6 and the stator cores 4 and 5 are The mold portion 7 is held at least on the inner peripheral side, and is press-fitted and fixed at a position surrounding the outer periphery of the rotor 9 of the cylindrical housing 2. For this reason, the clearance between the magnet portion 6 and the stator cores 4 and 5 can be eliminated, the influence of demagnetization due to the clearance is eliminated, and the motor characteristics (torque) are improved. Further, since it is not necessary to press the magnet portion 6 with the stator cores 4 and 5 so as to eliminate the clearance when the stator ASSY 3 is press-fitted into the housing 2, the magnet portion 6 is not damaged. In addition, the assembly to the housing 2 only needs to press-fit the stator ASSY 3 from one direction, and the phase alignment of the teeth 4a is unnecessary, so that the cost required for the assembly can be reduced.
　また、実施の形態１によれば、モールド部７の樹脂部材は熱硬化性を有するものにしたので、ステータＡＳＳＹ３の耐熱性が向上し、熱変形を抑制できる。このため、電動機１を自動車用部品等に用いて高温下で使用可能である。特に、樹脂部材として、耐熱性と耐水性に優れたＰＰＳが好適である。 Further, according to the first embodiment, since the resin member of the mold portion 7 is thermosetting, the heat resistance of the stator ASSY 3 is improved and thermal deformation can be suppressed. For this reason, the electric motor 1 can be used at high temperatures by using it for automobile parts and the like. In particular, PPS excellent in heat resistance and water resistance is suitable as the resin member.
　また、実施の形態１によれば、モールド部７は、ステータコア４，５それぞれのティース４ａ同士の隙間を塞ぐ形状であって、ティース４ａ先端面と面一にしたので、一体成形した際の樹脂部材のヒケおよびダレを防止できる。 Further, according to the first embodiment, the mold portion 7 has a shape that closes the gap between the teeth 4a of the stator cores 4 and 5 and is flush with the tip surface of the teeth 4a. Sinking and sagging of members can be prevented.
　また、実施の形態１によれば、マグネット部６は、ステータコア４，５のティース４ａと同一数の扇形の永久磁石を環状に配置し、この永久磁石の外周部がステータコア４，５のティース４ａ形成部分に相当する径方向外側部分を覆うようにしたので、磁気特性を向上できる。 Further, according to the first embodiment, the magnet portion 6 has the same number of fan-shaped permanent magnets as the teeth 4 a of the stator cores 4, 5 arranged in an annular shape, and the outer peripheral portion of the permanent magnets is the teeth 4 a of the stator cores 4, 5. Since the radially outer portion corresponding to the formation portion is covered, the magnetic characteristics can be improved.
　また、実施の形態１によれば、複数の鋼板をロータ９の回転軸方向Ｘに積層して互いにかしめてステータコア４，５を形成し、マグネット部６の各永久磁石は、ステータコア４，５のかしめた突起４ｂで位置決めされるようにしたので、マグネット部６の位置決めのために部品点数が増加することがない。また、永久磁石がずれることがないので良好な磁気特性を維持できる。 Further, according to the first embodiment, a plurality of steel plates are laminated in the rotation axis direction X of the rotor 9 and are caulked together to form the stator cores 4, 5. Since positioning is performed by the crimped protrusion 4b, the number of parts does not increase for positioning the magnet portion 6. Further, since the permanent magnet is not displaced, good magnetic characteristics can be maintained.
　なお、図示例では、ステータコアの各ティースに巻回するコイルを１回巻きのＵ字コイルとしたが、これに限定されるものではない。また、ステータコアのティースをＵ相、Ｖ相およびＷ相それぞれ２個ずつ、合計６個設ける構成としたが、これに限定されるものではない。
　これ以外にも、本願発明はその発明の範囲内において、実施の形態の任意の構成要素の変形、もしくは実施の形態の任意の構成要素の省略が可能である。 In the illustrated example, the coil wound around each tooth of the stator core is a one-turn U-shaped coil. However, the present invention is not limited to this. In addition, although a total of six teeth for the stator core, two each for the U phase, the V phase, and the W phase, are provided, the present invention is not limited to this.
In addition to this, the present invention can be modified in any component of the embodiment or omitted in any component within the scope of the invention.
　以上のように、この発明に係る電動機は、永久磁石とステータコアを熱硬化性樹脂部材で一体成形するようにしたので、高温に晒される自動車用ターボチャージャおよび電動コンプレッサなどを回転駆動する電動機に用いるのに適している。 As described above, since the permanent magnet and the stator core are integrally formed of the thermosetting resin member, the electric motor according to the present invention is used for an electric motor that rotationally drives an automobile turbocharger and an electric compressor that are exposed to high temperatures. Suitable for
　１　電動機、２　ハウジング、２ａ　圧入部、３　ステータ、４，５　ステータコア、４ａ　ティース、４ｂ　突起、４ｃ　位置決め凹部、６　マグネット部、７　モールド部、７ａ　コイル挿通孔、８　Ｕ字コイル、９　ロータ、９ａ，９ｂ　突部、１０　結線板ＡＳＳＹ、１１　銅板コイル、１２　制御回路基板、１３　カバー、１４　コネクタ部、１５　位置検出センサ、１６　センサターゲット、１７　Ｏリング、２０　上金型、２１　下金型、２２　中軸、２３，２４　空隙、２５　樹脂注入口、１００　電動機、１０１　永久磁石、１０２，１０３　ステータコア、１０４　ステータ、１０５　ロータ、１０６　ハウジング、１０７　シャフト、１０８　ティース、１０９，１１０　クリアランス、１１１　位置決めピン、１１２，１１３　圧入部。 1 Electric motor, 2 housing, 2a press-fitting part, 3 stator, 4,5 stator core, 4a teeth, 4b protrusion, 4c positioning recess, 6 magnet part, 7 mold part, 7a coil insertion hole, 8 U-shaped coil, 9 rotor, 9a , 9b Projection, 10 Connection plate assembly, 11 Copper plate coil, 12 Control circuit board, 13 Cover, 14 Connector part, 15 Position detection sensor, 16 Sensor target, 17 O-ring, 20 Upper mold, 21 Lower mold, 22 Middle shaft, 23, 24 gap, 25 resin inlet, 100 motor, 101 permanent magnet, 102, 103 stator core, 104 stator, 105 rotor, 106 housing, 107 shaft, 108 teeth, 109, 110 clearance, 111 positioning pin, 1 2,113 press-fit portion.

Claims (5)

  1. 　円筒状のハウジングと、
    　前記ハウジングの中央部に回転自在に保持されるロータ部と、
    　前記ハウジングの前記ロータ部外周を囲う位置に圧入固定されるステータ部とを備え、
    　前記ステータ部は、
    　環状体および当該環状体の内周部から中心へ向かって突出する複数のティースが形成されたステータコアと、
    　前記ロータ部を回転軸方向に着磁する環状のマグネット部と、
    　前記マグネット部を両側に設けた前記ステータコアで挟み込んで一体成形した樹脂部材から成り、前記マグネット部および前記ステータコアを少なくとも内周側で保持するモールド部とを有することを特徴とする電動機。     A cylindrical housing;
    A rotor part rotatably held in a central part of the housing;
    A stator portion press-fitted and fixed at a position surrounding the outer periphery of the rotor portion of the housing,
    The stator portion is
    A stator core formed with a plurality of teeth projecting toward the center from the inner periphery of the annular body and the annular body;
    An annular magnet portion for magnetizing the rotor portion in the rotation axis direction;
    An electric motor comprising a resin member integrally formed by sandwiching the magnet part between the stator cores provided on both sides, and having a magnet part and a mold part for holding the stator core at least on the inner peripheral side.
  2. 　モールド部の樹脂部材は熱硬化性を有することを特徴とする請求項１記載の電動機。 2. The electric motor according to claim 1, wherein the resin member of the mold part has thermosetting properties.
  3. 　モールド部は、ステータコアのティース同士の隙間を塞ぐ形状であって、当該ティース先端面と面一であることを特徴とする請求項１記載の電動機。 2. The electric motor according to claim 1, wherein the mold portion has a shape that closes a gap between the teeth of the stator core and is flush with the tooth tip surface.
  4. 　マグネット部は、ステータコアのティースと同一数の扇形の永久磁石を環状に配置して成り、当該各永久磁石の外周部が前記ステータコアのティース形成部分に相当する径方向外側部分を覆うことを特徴とする請求項１記載の電動機。 The magnet portion is formed by annularly arranging the same number of fan-shaped permanent magnets as the teeth of the stator core, and the outer peripheral portion of each permanent magnet covers a radially outer portion corresponding to the teeth forming portion of the stator core. The electric motor according to claim 1.
  5. 　ステータコアは、複数の鋼板をロータ部の回転軸方向に積層して互いにかしめて成り、
    　マグネット部の各永久磁石は、前記ステータコアのかしめた突起で位置決めされることを特徴とする請求項４記載の電動機。     The stator core is formed by laminating a plurality of steel plates in the direction of the rotation axis of the rotor part and caulking each other,
    The electric motor according to claim 4, wherein each permanent magnet of the magnet portion is positioned by a caulking projection of the stator core.
PCT/JP2011/001916 2011-03-30 2011-03-30 Electric motor WO2012131775A1 (en)

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