WO2012131776A1 - Electric motor and method for producing electric motor - Google Patents

Electric motor and method for producing electric motor Download PDF

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Publication number
WO2012131776A1
WO2012131776A1 PCT/JP2011/001917 JP2011001917W WO2012131776A1 WO 2012131776 A1 WO2012131776 A1 WO 2012131776A1 JP 2011001917 W JP2011001917 W JP 2011001917W WO 2012131776 A1 WO2012131776 A1 WO 2012131776A1
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WO
WIPO (PCT)
Prior art keywords
stator
mold
electric motor
coil
stator core
Prior art date
Application number
PCT/JP2011/001917
Other languages
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 PCT/JP2011/001917 priority Critical patent/WO2012131776A1/en
Priority to JP2013505012A priority patent/JP5269270B2/en
Publication of WO2012131776A1 publication Critical patent/WO2012131776A1/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
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
    • H02K11/30—Structural association with control circuits or drive circuits
    • H02K11/33—Drive circuits, e.g. power electronics
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/46—Fastening of windings on the stator or rotor structure
    • H02K3/52—Fastening salient pole windings or connections thereto
    • H02K3/521—Fastening salient pole windings or connections thereto applicable to stators only
    • H02K3/522—Fastening salient pole windings or connections thereto applicable to stators only for generally annular cores with salient poles
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K2201/00—Specific aspects not provided for in the other groups of this subclass relating to the magnetic circuits
    • H02K2201/12—Transversal flux machines

Definitions

  • the present invention relates to an electric motor having a stator having a U-shaped coil mounted on a tooth, and a manufacturing method thereof.
  • a U-shaped coil formed in advance in a U-shape is inserted into an adjacent slot with a stator tooth interposed therebetween, and ends of adjacent U-shaped coils are connected to TIG (Tungsten). Inert Gas) was connected by welding or the like (for example, see Patent Document 1).
  • TIG welding if the positional relationship (height and gap) of the U-shaped coil ends to be welded varies, the weldability deteriorates, and in the worst case, welding cannot be performed, leading to poor conduction. Therefore, conventionally, in order to suppress variations in the height direction, TIG welding has been performed after aligning the heights of the end portions of the respective U-shaped coils using a dedicated jig.
  • the conventional electric motor Since the conventional electric motor is configured as described above, it takes time to insert a U-shaped coil into the stator slot.
  • a dedicated jig is required to suppress the variation in the height direction of the U-shaped coil during welding, and it takes time and effort to adjust the height by installing the U-shaped coil on the jig. For this reason, there is a problem that the number of parts increases and work efficiency is poor.
  • the present invention has been made to solve the above-described problems.
  • the present invention simplifies the assembly process of the U-shaped coil including the welding operation, ensures the insulating property of the U-shaped coil, and eliminates the gap from the gap.
  • the purpose is to prevent liquid intrusion.
  • 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 projecting from the inner peripheral portion of the annular body toward the center, an annular magnetomotive force generating portion that magnetizes the rotor portion in the rotation axis direction, and each tooth of the stator core
  • It consists of a U-shaped coil that is mounted and generates the rotational force of the rotor part, and a resin member that is sandwiched between stator coils provided on both sides of the magnetomotive force generating part, and that is integrally formed by arranging the coil on each tooth. It has a generating part, a stator core, and a mold part for holding a coil.
  • the method of manufacturing an electric motor according to the present invention is arranged such that a coil formed by bending a plate member into a U shape is disposed at a predetermined position of a mold in a state where the magnetomotive force generating portion is sandwiched between stator cores provided on both sides.
  • the stator core and the coil integrally to form the stator portion, it is possible to save the trouble of inserting the U-shaped coil into the slot of the stator core at the time of welding and the trouble of adjusting the height using a dedicated jig. Therefore, the assembly process can be simplified. Moreover, since a mold part isolate
  • 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. 6 is a cross-sectional view showing a modification of the electric motor according to 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.
  • 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 shows a cross-sectional view of the stator ASSY 3 in FIG. 3B cut along the line BB.
  • the stator ASSY 3 includes two stator cores 4, 5, a magnet part (magnetomotive force generating part) 6 disposed between the stator cores 4, 5, a plurality of U-shaped coils 8, and a mold part for integrating them. 7.
  • 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 and 5, the magnet part 6, and the six U-shaped coils 8.
  • the procedure of integral molding will be described later.
  • the U-shaped coil 8 is a one-turn coil obtained by bending a copper plate into a U-shape. As shown in FIGS. 3A and 4, the U-shaped coil 8 penetrates the mold portion 7 in the rotation axis direction X, and the bent portion is A tip portion protrudes on the stator core 4 side and on the stator core 5 side. As shown in a region A surrounded by a solid line in FIG. 1, the tip portions of the six U-shaped coils 8 are adjusted to the same height in the integrally formed stator ASSY 3. This region A becomes a TIG weld.
  • one end of the U-shaped coil 8 that has penetrated the mold part 7 penetrates the connection plate ASSY 10 and protrudes toward the control circuit board 12, and is an energizing member molded on the connection plate ASSY 10. It is connected to a certain copper plate coil 11 (U phase, V phase, W phase).
  • 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. 8A is a schematic view showing a cross section of a mold for molding the stator ASSY 3 and corresponds to a cross section cut along the CC line of FIG.
  • 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 portion 6 are installed, a U-shaped coil 8 and resin are injected.
  • the gap 24 for molding the mold part 7 is 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.
  • FIG. 8B is a diagram showing the relationship between the U-shaped coil 8 and the mold as seen from the direction of the arrow in FIG.
  • the upper mold 20 is provided with a pair of positioning guides 28 that sandwich the bent portion of the U-shaped coil 8.
  • FIG. 8A shows a mold structure of a portion where the U-shaped coil 8 positioned on the farthest side in the drawing among the six U-shaped coils 8 is actually installed. Although illustration is omitted, the same structure is provided for the remaining five U-shaped coils 8, and positioning portions 25 for positioning the U-shaped coils 8 are respectively formed at the same height position.
  • 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 six U-shaped coils 8 are fitted into the gap 24 of the lower mold 22 from the front end portion and brought into contact with the abutting portion 25. Since the U-shaped coil 8 is a plate member having a width, the tip end portion comes into contact with the abutting portion 25 and becomes self-supporting. Even if there is a dimensional variation in the longitudinal direction of the U-shaped coil 8, it is absorbed by the clearance 26 of the upper mold 20. Thus, by applying the U-shaped coil 8 to the mold, the height position of the tip of each U-shaped coil 8 is aligned, and the weldability is improved.
  • tip parts of each U-shaped coil 8 can also be made into the clearance gap suitable for welding.
  • the stator cores 4 and 5, the magnet portion 6, and the U-shaped coil 8 are installed, the upper mold 20, the lower mold 21, and the middle shaft 22 are fitted.
  • the positioning pin 27 of the upper mold 20 is fitted into the positioning pin insertion hole 8 a of the U-shaped coil 8, and the positioning guide 28 sandwiches the bent portion of the U-shaped coil 8. Therefore, even if the U-shaped coil 8 has dimensional variations, the rotational movement of the arrow D and the deviation of the arrow E shown in FIG. 8B are regulated by the two positioning pins 27, and the deviation of the arrow F is a pair of It is regulated by the positioning guide 28 and fits in the mold gap.
  • 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 molded stator ASSY 3 When the integrally molded stator ASSY 3 is installed in the housing 2, it is press-fitted from one end side of the housing 2 and fixed 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 connection plate ASSY 10 is press-fitted and fixed to the housing 2, and the tip end portion of the U-shaped coil 8 and the copper plate coil 11 are connected by TIG welding. Since the height direction of the front end portion of each U-shaped coil 8 and the interval between the U-shaped coils 8 are adjusted during the integral molding, welding can be reliably performed without using a conventional dedicated jig during welding. it can.
  • 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.
  • the U-shaped coil 8 works as a core material of the mold part 7 and the strength against vibration increases. Thereby, when the vibration of the direction orthogonal to the rotating shaft direction X of the rotor 9 is applied, it can suppress that a mold part 7 cracks.
  • FIG. 10 is a cross-sectional view showing a configuration in which the electric motor 1 is applied to an electric compressor motor.
  • the electric motor 1 is fastened to a bearing housing 30 of an electric compressor, and the shaft 31 and the rotor 9 are connected.
  • the bearing housing 30 is provided with a bearing 32 that rotatably holds the shaft 31 and an oil reservoir 33 that supplies lubricating oil to the bearing 32.
  • a seal structure is formed on the bearing housing 30 side.
  • the seal structure needs to be inserted through the shaft 31, it cannot be a complete seal structure. Therefore, it can be an oil intrusion route indicated by an arrow G. If the oil in the oil reservoir 33 enters the inside of the electric motor 1, particularly the control circuit board 12, there is a possibility that problems such as damage to elements and defective energization may occur.
  • the oil that has entered the inside of the electric motor 1 enters the clearance between the housing 2 and the stator ASSY 3, but since the press-fitting portion 2 a is sealed by the O-ring 17, the direction toward the control circuit board 12 (arrow H shown in FIG. 10). Oil intrusion can be prevented.
  • an O-ring may be installed and sealed in the press-fitting portion 2b of the housing 2 and the connection plate ASSY 10 to prevent oil intrusion in the direction of the arrow H.
  • an O-ring may be installed in each of the press-fit portions 2a and 2b to enhance the sealing function.
  • 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, a U-shaped coil 8 that is attached to each tooth 4a of the stator cores 4 and 5 and generates the rotational force of the rotor 9, and the magnet portion 6 on both sides
  • the molded portion 7 is composed of a resin member that is sandwiched between the provided stator cores 4 and 5 and that is integrally formed by arranging the U-shaped coils 8 in the respective teeth 4 a and holds the magnet portion 6, the stator cores 4 and 5, and the U-shaped coils 8.
  • the trouble of mounting the U-shaped coil 8 on each of the teeth 4a of the stator cores 4 and 5 at the time of welding can be saved, and the assembly process can be simplified.
  • separates between the stator cores 4 and 5 and the U-shaped coil 8 insulation can be ensured, without performing an insulation process at another process.
  • the mold part 7 seals the gap between the U-shaped coils 8, the intrusion of liquids such as oil and water can be prevented.
  • the U-shaped coil 8 is integrally formed in the mold part 7 and works as a core material, the strength of the stator ASSY 3 can be improved.
  • the resin member of the mold part 7 has thermosetting properties, 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 plate member is bent into a U shape to form the U-shaped coil 8, and the height position of the bent distal end portion of each U-shaped coil 8 held by the mold portion 7 is made the same. Therefore, the variation in the height direction of the TIG welded portion can be reduced without using a dedicated jig during TIG welding.
  • the magnet portion 6 is disposed in the gap 23 of the lower mold 21 with the stator cores 4, 5 provided on both sides, and the U-shaped coil is disposed. 8 is arranged around each tooth 4a in a state in which the bent end portion of 8 is applied to the abutting portion 25 provided on the inner wall of the bottom surface of the lower die 21, and the upper die 20, the lower die 21 and the middle shaft 22 are fitted. Then, the resin member is injected to integrally mold the stator assembly 3 to form the mold portion 7.
  • the magnet part 6 in which a plurality of permanent magnets are annularly arranged between the stator cores 4 and 5 is used.
  • an exciting coil (magnetomotive force generating portion) 42 in which a conductive material 41 is wound in a radial direction around an annular bobbin 40 having a U-shaped cross section may be used.
  • a yoke 43 is provided on the outer periphery of the stator cores 4 and 5 and the exciting coil 42 to form a field magnetic path.
  • 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 stator ASSY including the U-shaped coil is integrally formed with the thermosetting resin member, so that the turbocharger for automobiles and the electric compressor exposed to high temperatures are rotationally driven. Suitable for use in electric motors.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Manufacture Of Motors, Generators (AREA)
  • Iron Core Of Rotating Electric Machines (AREA)
  • Insulation, Fastening Of Motor, Generator Windings (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 member 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); a U-shaped coil (8) that is mounted to each of the teeth of the stator cores (4, 5) and that generates the rotary force of the rotor (9); and a molded section (7) that is formed by integrally molding the stator cores (4, 5), the magnet (6), and the U-shaped coil (8) by means of a resin member. The stator assembly (3) is press-fitted to the housing (2) from one direction.

Description

電動機および電動機の製造方法Electric motor and method of manufacturing electric motor
　この発明は、ティースにＵ字コイルを装着したステータを有する電動機、およびその製造方法に関する。 The present invention relates to an electric motor having a stator having a U-shaped coil mounted on a tooth, and a manufacturing method thereof.
　従来の電動機は、ハウジングにステータを固定した後、あらかじめＵ字型に成形したＵ字コイルをステータのティースを挟んで隣接するスロットに挿入し、隣接するＵ字コイルの端部同士をＴＩＧ（Ｔｕｎｇｓｔｅｎ　Ｉｎｅｒｔ　Ｇａｓ）溶接などにより接続していた（例えば、特許文献１参照）。ＴＩＧ溶接の場合、溶接対象となるＵ字コイル端部の位置関係（高さおよび隙間）にばらつきが生じると溶接性が悪化し、最悪の場合には溶接することが出来なくなり通電不良につながる。そこで、高さ方向のばらつきを抑制するために、従来は専用の冶具を用いて各Ｕ字コイルの端部の高さを揃えた後にＴＩＧ溶接を実施していた。 In a conventional electric motor, after fixing a stator to a housing, a U-shaped coil formed in advance in a U-shape is inserted into an adjacent slot with a stator tooth interposed therebetween, and ends of adjacent U-shaped coils are connected to TIG (Tungsten). Inert Gas) was connected by welding or the like (for example, see Patent Document 1). In the case of TIG welding, if the positional relationship (height and gap) of the U-shaped coil ends to be welded varies, the weldability deteriorates, and in the worst case, welding cannot be performed, leading to poor conduction. Therefore, conventionally, in order to suppress variations in the height direction, TIG welding has been performed after aligning the heights of the end portions of the respective U-shaped coils using a dedicated jig.
　また、従来はステータの電気的絶縁強化のために、エナメル導線の外周に熱可塑性樹脂を焼き付けた自己融着線を作成しＵ字コイルに用いていた。 In the past, in order to strengthen the electrical insulation of the stator, a self-bonding wire in which a thermoplastic resin was baked on the outer periphery of the enamel lead was created and used for the U-shaped coil.
特開２００２－２３３０８９号公報JP 2002-233089 A
　従来の電動機は以上のように構成されているので、ステータのスロットにＵ字コイルを挿入する手間がかかっていた。また、溶接時にＵ字コイルの高さ方向のばらつきを抑制するために専用の冶具が必要となり、かつ、Ｕ字コイルを冶具に設置して高さ調整を行う手間もかかっていた。そのため、部品点数が増加すると共に作業効率が悪いという課題があった。 Since the conventional electric motor is configured as described above, it takes time to insert a U-shaped coil into the stator slot. In addition, a dedicated jig is required to suppress the variation in the height direction of the U-shaped coil during welding, and it takes time and effort to adjust the height by installing the U-shaped coil on the jig. For this reason, there is a problem that the number of parts increases and work efficiency is poor.
　また、ステータのスロットにＵ字コイルを挿入した構成であるため、スロットとＵ字コイルの隙間から水および油等の液体が浸入するという課題があった。これを防ぐためには、シール機能を有する部品を追加する工程（例えばワニス処理）が必要となる。 Further, since the U-shaped coil is inserted into the slot of the stator, there is a problem that liquid such as water and oil enters from the gap between the slot and the U-shaped coil. In order to prevent this, a step of adding a part having a sealing function (for example, varnish treatment) is required.
　さらに、従来はＵ字コイルに絶縁処理が必要となる課題があった。 Furthermore, there has been a problem that the U-shaped coil needs to be insulated.
　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、Ｕ字コイルの、溶接作業を含めた組立工程を簡略化し、また、Ｕ字コイルの絶縁性を確保すると共に隙間からの液体浸入を防止することを目的とする。 The present invention has been made to solve the above-described problems. The present invention simplifies the assembly process of the U-shaped coil including the welding operation, ensures the insulating property of the U-shaped coil, and eliminates the gap from the gap. The purpose is to prevent liquid intrusion.
　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起磁力発生部と、ステータコアの各ティースに装着され、ロータ部の回転力を発生させるＵ字形のコイルと、起磁力発生部を両側に設けたステータコアで挟みこむと共に、各ティースにコイルを配置して一体成形した樹脂部材から成り、起磁力発生部、ステータコアおよびコイルを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 projecting from the inner peripheral portion of the annular body toward the center, an annular magnetomotive force generating portion that magnetizes the rotor portion in the rotation axis direction, and each tooth of the stator core It consists of a U-shaped coil that is mounted and generates the rotational force of the rotor part, and a resin member that is sandwiched between stator coils provided on both sides of the magnetomotive force generating part, and that is integrally formed by arranging the coil on each tooth. It has a generating part, a stator core, and a mold part for holding a coil.
　また、この発明の電動機の製造方法は、金型の所定位置に、起磁力発生部を両側に設けたステータコアで挟み込んだ状態に配置すると共に、板部材をＵ字形に折り曲げて成るコイルを、当該折り曲げた先端部を金型の底面内壁に当てた状態で、各ティースの周囲に配置する工程と、金型に樹脂部材を注入してステータ部を一体成形し、モールド部を形成する工程とを有するようにしたものである。 Further, the method of manufacturing an electric motor according to the present invention is arranged such that a coil formed by bending a plate member into a U shape is disposed at a predetermined position of a mold in a state where the magnetomotive force generating portion is sandwiched between stator cores provided on both sides. A process of placing the bent tip portion around each tooth in a state where the front end of the mold is applied to the inner wall of the bottom of the mold, and a process of injecting a resin member into the mold and integrally forming the stator part to form a mold part. It is what you have.
　この発明によれば、ステータコアとコイルを一体成形してステータ部にすることにより、溶接時にステータコアのスロットにＵ字コイルを挿入する手間および専用の冶具を用いて高さ調整を行う手間を省くことができるので、組立工程を簡略化することができる。また、Ｕ字コイルとステータコアの間をモールド部が隔絶するので、別工程で絶縁処理を行うことなく絶縁性を確保できる。さらに、Ｕ字コイルの隙間をモールド部が封止するので液体浸入を防止することができる。 According to the present invention, by forming the stator core and the coil integrally to form the stator portion, it is possible to save the trouble of inserting the U-shaped coil into the slot of the stator core at the time of welding and the trouble of adjusting the height using a dedicated jig. Therefore, the assembly process can be simplified. Moreover, since a mold part isolate | separates between a U-shaped coil and a stator core, insulation can be ensured, without performing an insulation process at another process. Furthermore, since the mold part seals the gap between the U-shaped coils, liquid intrusion can be prevented.
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ＢＢ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 BB 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. 実施の形態１に係る電動機のステータ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 which concerns on Embodiment 1. 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. 実施の形態１に係る電動機を電動コンプレッサ用モータに適用した構成を示す断面図である。It is sectional drawing which shows the structure which applied the electric motor which concerns on Embodiment 1 to the motor for electric compressors. 実施の形態１に係る電動機の変形例を示す断面図である。FIG. 6 is a cross-sectional view showing a modification of the electric motor according to Embodiment 1.
　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ＢＢ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（起磁力発生部）６と、複数のＵ字コイル８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 shows a cross-sectional view of the stator ASSY 3 in FIG. 3B cut along the line BB. The stator ASSY 3 includes two stator cores 4, 5, a magnet part (magnetomotive force generating part) 6 disposed between the stator cores 4, 5, a plurality of U-shaped coils 8, and a mold part for integrating them. 7.
　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。
　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、マグネット部６および６個のＵ字コイル８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。
　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３（ａ）および図４に示すように、モールド部７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。図１に実線で囲った領域Ａに示すように、一体成形されたステータＡＳＳＹ３において、６個のＵ字コイル８の先端部分は同一高さに調整されている。この領域ＡがＴＩＧ溶接部になる。 The mold part 7 is composed of a resin member that integrally molds the stator cores 4 and 5, the magnet part 6, and the six U-shaped coils 8. The procedure of integral molding will be described later.
The U-shaped coil 8 is a one-turn coil obtained by bending a copper plate into a U-shape. As shown in FIGS. 3A and 4, the U-shaped coil 8 penetrates the mold portion 7 in the rotation axis direction X, and the bent portion is A tip portion protrudes on the stator core 4 side and on the stator core 5 side. As shown in a region A surrounded by a solid line in FIG. 1, the tip portions of the six U-shaped coils 8 are adjusted to the same height in the integrally formed stator ASSY 3. This region A becomes a TIG weld.
　モールド部７を貫通した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 that has penetrated the mold part 7 penetrates the connection plate ASSY 10 and protrudes toward the control circuit board 12, and is an energizing member molded on the connection plate ASSY 10. It is connected to a certain copper plate coil 11 (U phase, V phase, W phase). 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（ａ）は、ステータＡＳＳＹ３を成形する金型の断面を示す模式図であり、図３（ｂ）のＣＣ線に沿って切断した断面に相当する。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、Ｕ字コイル８を設置すると共に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。 Next, the assembly procedure of the stator ASSY 3 will be described.
FIG. 8A is a schematic view showing a cross section of a mold for molding the stator ASSY 3 and corresponds to a cross section cut along the CC line of FIG. 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 portion 6 are installed, a U-shaped coil 8 and resin are injected. The gap 24 for molding the mold part 7 is 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.
　また、Ｕ字コイル８を設置する空隙２４として、下金型２１の底面内壁には、Ｕ字コイル８の一対の先端部と当接してＵ字コイル８の高さ方向を位置決めする一対の当て部２５が設けられている。一方、上金型２０にはＵ字コイル８の折り曲げ部を収容するための所定のクリアランス２６が設けられており、このクリアランス２６の天面から２個の位置決めピン２７が突出している。
　図８（ｂ）は、図８（ａ）の矢印方向から見たＵ字コイル８と金型の関係を示す図である。上金型２０には、２個の位置決めピン２７に加え、Ｕ字コイル８の折り曲げ部を挟持する一対の位置決めガイド２８が設けられている。一方、Ｕ字コイル８の折り曲げ部には、２個の位置決めピン２７を挿入する２箇所の位置決めピン挿入孔８ａが予め開設されている。
　なお、図８（ａ）では、実際には６個あるＵ字コイル８のうち図面上で見て一番奥側に位置するＵ字コイル８を設置する部分の金型構造を示している。図示は省略するが、残り５個のＵ字コイル８に関しても同様の構造が設けられ、各Ｕ字コイル８の位置決め用の当て部２５がそれぞれ同じ高さ位置に形成されている。 In addition, as a gap 24 for installing the U-shaped coil 8, a pair of abutments for positioning the height direction of the U-shaped coil 8 by contacting the pair of tip ends of the U-shaped coil 8 on the inner wall of the bottom surface of the lower mold 21. A portion 25 is provided. On the other hand, the upper mold 20 is provided with a predetermined clearance 26 for accommodating the bent portion of the U-shaped coil 8, and two positioning pins 27 protrude from the top surface of the clearance 26.
FIG. 8B is a diagram showing the relationship between the U-shaped coil 8 and the mold as seen from the direction of the arrow in FIG. In addition to the two positioning pins 27, the upper mold 20 is provided with a pair of positioning guides 28 that sandwich the bent portion of the U-shaped coil 8. On the other hand, in the bent portion of the U-shaped coil 8, two positioning pin insertion holes 8a for inserting the two positioning pins 27 are opened in advance.
FIG. 8A shows a mold structure of a portion where the U-shaped coil 8 positioned on the farthest side in the drawing among the six U-shaped coils 8 is actually installed. Although illustration is omitted, the same structure is provided for the remaining five U-shaped coils 8, and positioning portions 25 for positioning the U-shaped coils 8 are respectively formed at the same height position.
　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.
　続いて、６個のＵ字コイル８を、先端部から下金型２２の空隙２４に嵌合して当て部２５に当接させる。Ｕ字コイル８は幅のある板部材なので、先端部が当て部２５に当接して自立した状態になる。Ｕ字コイル８の長手方向の寸法ばらつきがあっても、上金型２０のクリアランス２６で吸収される。このように、Ｕ字コイル８を金型当てすることで各Ｕ字コイル８の先端部の高さ位置が揃い、溶接性が向上する。さらに、Ｕ字コイル８同士の間隔も当て部２５により規制されるので、各Ｕ字コイル８の先端部同士の隙間も溶接に適した隙間にできる。
　ステータコア４，５、マグネット部６およびＵ字コイル８を設置した後、上金型２０、下金型２１および中軸２２を嵌合する。このとき、上金型２０の位置決めピン２７がＵ字コイル８の位置決めピン挿入孔８ａに嵌合し、位置決めガイド２８がＵ字コイル８の折り曲げ部を挟持する。よって、Ｕ字コイル８に寸法のばらつきがあっても、図８（ｂ）に示す矢印Ｄの回転移動および矢印Ｅのずれは２個の位置決めピン２７により規制され、矢印Ｆのずれは一対の位置決めガイド２８により規制されて金型空隙内に収まる。 Subsequently, the six U-shaped coils 8 are fitted into the gap 24 of the lower mold 22 from the front end portion and brought into contact with the abutting portion 25. Since the U-shaped coil 8 is a plate member having a width, the tip end portion comes into contact with the abutting portion 25 and becomes self-supporting. Even if there is a dimensional variation in the longitudinal direction of the U-shaped coil 8, it is absorbed by the clearance 26 of the upper mold 20. Thus, by applying the U-shaped coil 8 to the mold, the height position of the tip of each U-shaped coil 8 is aligned, and the weldability is improved. Furthermore, since the space | interval of U-shaped coils 8 is also controlled by the contact part 25, the clearance gap between the front-end | tip parts of each U-shaped coil 8 can also be made into the clearance gap suitable for welding.
After the stator cores 4 and 5, the magnet portion 6, and the U-shaped coil 8 are installed, the upper mold 20, the lower mold 21, and the middle shaft 22 are fitted. At this time, the positioning pin 27 of the upper mold 20 is fitted into the positioning pin insertion hole 8 a of the U-shaped coil 8, and the positioning guide 28 sandwiches the bent portion of the U-shaped coil 8. Therefore, even if the U-shaped coil 8 has dimensional variations, the rotational movement of the arrow D and the deviation of the arrow E shown in FIG. 8B are regulated by the two positioning pins 27, and the deviation of the arrow F is a pair of It is regulated by the positioning guide 28 and fits in the mold gap.
　続いて、不図示の樹脂注入口から空隙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。 Subsequently, resin is injected into the gap 24 from a resin injection port (not shown) to integrally mold the stator ASSY 3 to form the mold part 7. 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、ハウジング２に結線板ＡＳＳＹ１０を圧入固定し、Ｕ字コイル８の先端部と銅板コイル１１とをＴＩＧ溶接にて接続する。一体成形の際に各Ｕ字コイル８の先端部の高さ方向およびＵ字コイル８同士の間隔を調整しているので、溶接時に従来のような専用冶具を用いることなく確実に溶接することができる。
　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 molded stator ASSY 3 is installed in the housing 2, it is press-fitted from one end side of the housing 2 and fixed 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 connection plate ASSY 10 is press-fitted and fixed to the housing 2, and the tip end portion of the U-shaped coil 8 and the copper plate coil 11 are connected by TIG welding. Since the height direction of the front end portion of each U-shaped coil 8 and the interval between the U-shaped coils 8 are adjusted during the integral molding, welding can be reliably performed without using a conventional dedicated jig during welding. it can.
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.
　モールド部７とＵ字コイル８を一体成形するので、Ｕ字コイル８がモールド部７の芯材として働き、振動に対する強度が増加する。これにより、ロータ９の回転軸方向Ｘに直交する方向の振動が印加された場合にモールド部７にクラックが入ることを抑制できる。 Since the mold part 7 and the U-shaped coil 8 are integrally formed, the U-shaped coil 8 works as a core material of the mold part 7 and the strength against vibration increases. Thereby, when the vibration of the direction orthogonal to the rotating shaft direction X of the rotor 9 is applied, it can suppress that a mold part 7 cracks.
　図１０は、電動機１を電動コンプレッサ用モータに適用した構成を示す断面図である。電動機１は電動コンプレッサのベアリングハウジング３０に締結され、シャフト３１とロータ９とが連結されている。ベアリングハウジング３０には、シャフト３１を回転自在に保持するベアリング３２と、このベアリング３２に潤滑用のオイルを供給するオイル溜り３３とが設けられている。オイル溜り３３のオイル漏れを防止するために、ベアリングハウジング３０側にシール構造が形成されているが、このシール構造はシャフト３１を挿通する必要があるので完全シール構造にはできない。よって、矢印Ｇで示すオイル浸入経路となり得る。オイル溜り３３のオイルが電動機１の内部、特に制御回路基板１２に浸入すると、素子の損傷および通電不良等の不具合が発生する可能性がある。 FIG. 10 is a cross-sectional view showing a configuration in which the electric motor 1 is applied to an electric compressor motor. The electric motor 1 is fastened to a bearing housing 30 of an electric compressor, and the shaft 31 and the rotor 9 are connected. The bearing housing 30 is provided with a bearing 32 that rotatably holds the shaft 31 and an oil reservoir 33 that supplies lubricating oil to the bearing 32. In order to prevent oil leakage from the oil reservoir 33, a seal structure is formed on the bearing housing 30 side. However, since the seal structure needs to be inserted through the shaft 31, it cannot be a complete seal structure. Therefore, it can be an oil intrusion route indicated by an arrow G. If the oil in the oil reservoir 33 enters the inside of the electric motor 1, particularly the control circuit board 12, there is a possibility that problems such as damage to elements and defective energization may occur.
　電動機１の内部に浸入したオイルは、ハウジング２とステータＡＳＳＹ３のクリアランスへ浸入するが、圧入部２ａがＯリング１７でシールされるので、制御回路基板１２の方向（図１０に示す矢印Ｈ）へのオイル浸入を防止することができる。あるいは、ハウジング２と結線板ＡＳＳＹ１０の圧入部２ｂにＯリングを設置してシールし、矢印Ｈの方向へのオイル浸入を防止してもよい。もちろん圧入部２ａ，２ｂそれぞれにＯリングを設置してシール機能を強化してもよい。
　また、先立って説明した特許文献１のようにステータのスロットにＵ字コイルを挿入する構成の場合、スロットとＵ字コイルの間にクリアランスが存在するのでそのクリアランスから制御回路基板１２へオイルが浸入する可能性がある（図１０に示す矢印Ｉ）。これに対し、本実施の形態１ではモールド部７とＵ字コイル８を一体成形するので隙間は封止され、矢印Ｉで示す制御回路基板１２の方向へのオイル浸入を防止することができる。
　なお、ステータＡＳＳＹ３の内周部とロータ９の外周部の間からもオイルが浸入するが（図１０に示す矢印Ｊ）、ハウジング２に圧入固定した結線板ＡＳＳＹ１０が隔壁となって制御回路基板１２へのオイル浸入を防止する。 The oil that has entered the inside of the electric motor 1 enters the clearance between the housing 2 and the stator ASSY 3, but since the press-fitting portion 2 a is sealed by the O-ring 17, the direction toward the control circuit board 12 (arrow H shown in FIG. 10). Oil intrusion can be prevented. Alternatively, an O-ring may be installed and sealed in the press-fitting portion 2b of the housing 2 and the connection plate ASSY 10 to prevent oil intrusion in the direction of the arrow H. Of course, an O-ring may be installed in each of the press- fit portions 2a and 2b to enhance the sealing function.
Further, in the case of the configuration in which the U-shaped coil is inserted into the stator slot as described in Patent Document 1 described above, since there is a clearance between the slot and the U-shaped coil, oil enters the control circuit board 12 from the clearance. (Arrow I shown in FIG. 10). On the other hand, in the first embodiment, since the mold portion 7 and the U-shaped coil 8 are integrally formed, the gap is sealed, and oil intrusion in the direction of the control circuit board 12 indicated by the arrow I can be prevented.
Note that oil also enters between the inner peripheral portion of the stator ASSY 3 and the outer peripheral portion of the rotor 9 (arrow J shown in FIG. 10), but the connection plate ASSY 10 press-fitted and fixed to the housing 2 serves as a partition wall to form a control circuit board 12. Prevent oil intrusion into.
　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、ステータコア４，５の各ティース４ａに装着され、ロータ９の回転力を発生させるＵ字コイル８と、マグネット部６を両側に設けたステータコア４，５で挟みこむと共に、各ティース４ａにＵ字コイル８を配置して一体成形した樹脂部材から成り、マグネット部６、ステータコア４，５およびＵ字コイル８を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、溶接時にステータコア４，５の各ティース４ａにＵ字コイル８を装着する手間を省くことができ、組立工程を簡略化できる。また、ステータコア４，５とＵ字コイル８の間をモールド部７が隔絶するので、別工程で絶縁処理を行うことなく絶縁性を確保できる。さらに、Ｕ字コイル８の隙間をモールド部７が封止するので、オイルおよび水などの液体の浸入を防止することができる。
　また、モールド部７にＵ字コイル８が一体成形されて芯材として働くので、ステータＡＳＳＹ３の強度を向上させることができる。 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, a U-shaped coil 8 that is attached to each tooth 4a of the stator cores 4 and 5 and generates the rotational force of the rotor 9, and the magnet portion 6 on both sides The molded portion 7 is composed of a resin member that is sandwiched between the provided stator cores 4 and 5 and that is integrally formed by arranging the U-shaped coils 8 in the respective teeth 4 a and holds the magnet portion 6, the stator cores 4 and 5, and the U-shaped coils 8. 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 trouble of mounting the U-shaped coil 8 on each of the teeth 4a of the stator cores 4 and 5 at the time of welding can be saved, and the assembly process can be simplified. Moreover, since the mold part 7 isolate | separates between the stator cores 4 and 5 and the U-shaped coil 8, insulation can be ensured, without performing an insulation process at another process. Furthermore, since the mold part 7 seals the gap between the U-shaped coils 8, the intrusion of liquids such as oil and water can be prevented.
Moreover, since the U-shaped coil 8 is integrally formed in the mold part 7 and works as a core material, the strength of the stator ASSY 3 can be improved.
　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化で使用可能である。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 part 7 has thermosetting properties, 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、板部材をＵ字形に折り曲げてＵ字コイル８を形成し、モールド部７に保持された各Ｕ字コイル８の折り曲げた先端部の高さ位置を同じにしたので、ＴＩＧ溶接時に専用の冶具を使用することなくＴＩＧ溶接部の高さ方向のばらつきを低減することができる。 Further, according to the first embodiment, the plate member is bent into a U shape to form the U-shaped coil 8, and the height position of the bent distal end portion of each U-shaped coil 8 held by the mold portion 7 is made the same. Therefore, the variation in the height direction of the TIG welded portion can be reduced without using a dedicated jig during TIG welding.
　また、実施の形態１によれば、電動機１の製造方法として、下金型２１の空隙２３に、マグネット部６を両側に設けたステータコア４，５で挟み込んだ状態で配置すると共に、Ｕ字コイル８の折り曲げた先端部を下金型２１の底面内壁に設けた当て部２５に当てた状態で各ティース４ａの周囲に配置する工程と、上金型２０、下金型２１および中軸２２を嵌合して樹脂部材を注入してステータＡＳＳＹ３を一体成形し、モールド部７を形成する工程とを実施するようにした。このため、溶接時にステータコア４，５の各ティース４ａにＵ字コイル８を装着する手間および専用の冶具を用いて高さ調整を行う手間を省くことができ、組立工程を簡略化できる。また、ＴＩＧ溶接部の高さ方向のばらつきを低減することができる。 Further, according to the first embodiment, as a method for manufacturing the electric motor 1, the magnet portion 6 is disposed in the gap 23 of the lower mold 21 with the stator cores 4, 5 provided on both sides, and the U-shaped coil is disposed. 8 is arranged around each tooth 4a in a state in which the bent end portion of 8 is applied to the abutting portion 25 provided on the inner wall of the bottom surface of the lower die 21, and the upper die 20, the lower die 21 and the middle shaft 22 are fitted. Then, the resin member is injected to integrally mold the stator assembly 3 to form the mold portion 7. For this reason, it is possible to save the trouble of attaching the U-shaped coil 8 to each of the teeth 4a of the stator cores 4 and 5 during welding and the trouble of adjusting the height using a dedicated jig, and the assembly process can be simplified. Moreover, the dispersion | variation in the height direction of a TIG welding part can be reduced.
　なお、上記実施の形態１では、ロータ９を着磁する起磁力発生部として、ステータコア４，５の間に、複数の永久磁石を環状に配置したマグネット部６を用いたが、これに限定されるものではなく、図１１に示すように、断面コ字状の環状のボビン４０に導電材４１を径方向に巻回してプリモールドした励磁コイル（起磁力発生部）４２を用いてもよい。この構成の場合には、ステータコア４，５および励磁コイル４２の外周部にヨーク４３を設置して界磁磁路とする。 In the first embodiment, as the magnetomotive force generating part for magnetizing the rotor 9, the magnet part 6 in which a plurality of permanent magnets are annularly arranged between the stator cores 4 and 5 is used. However, the present invention is not limited to this. Instead of this, as shown in FIG. 11, an exciting coil (magnetomotive force generating portion) 42 in which a conductive material 41 is wound in a radial direction around an annular bobbin 40 having a U-shaped cross section may be used. In the case of this configuration, a yoke 43 is provided on the outer periphery of the stator cores 4 and 5 and the exciting coil 42 to form a field magnetic path.
　また、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、Ｕ字コイルを含めてステータＡＳＳＹ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, in the electric motor according to the present invention, the stator ASSY including the U-shaped coil is integrally formed with the thermosetting resin member, so that the turbocharger for automobiles and the electric compressor exposed to high temperatures are rotationally driven. Suitable for use in electric motors.
　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、８ａ　位置決めピン挿入孔、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　当て部、２６　クリアランス、２７　位置決めピン、２８　位置決めガイド、３０　ベアリングハウジング、３１　シャフト、３２　ベアリング、３３　オイル溜り、４０　ボビン、４１　導電材、４２　励磁コイル、４３　ヨーク。 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 coil, 8a positioning pin insertion Hole, 9 rotor, 9a, 9b protrusion, 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 contact part, 26 clearance, 27 positioning pin, 28 positioning guide, 30 bearing housing, 31 shaft, 32 bearing, 33 oil reservoir, 40 bobbin, 41 conductive material, 42 Excitation coil 43 yoke.

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起磁力発生部と、
    　前記ステータコアの各ティースに装着され、前記ロータ部の回転力を発生させるＵ字形のコイルと、
    　前記起磁力発生部を両側に設けた前記ステータコアで挟み込むと共に、前記各ティースに前記コイルを配置して一体成形した樹脂部材から成り、前記起磁力発生部、前記ステータコアおよび前記コイルを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 magnetomotive force generator for magnetizing the rotor portion in the direction of the rotation axis;
    A U-shaped coil that is attached to each tooth of the stator core and generates a rotational force of the rotor portion;
    The magnetomotive force generator is sandwiched between the stator cores provided on both sides, and is formed of a resin member integrally formed by arranging the coils on the teeth, and the magnetomotive force generator, the stator core, and a mold part for holding the coils And an electric motor.
  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. 　コイルは、Ｕ字形に折り曲げた板部材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 coil is a plate member bent into a U-shape.
  4. 　モールド部に保持された各コイルは、Ｕ字形に折り曲げた先端部の高さ位置が同じであることを特徴とする請求項３記載の電動機。 4. The electric motor according to claim 3, wherein each coil held in the mold part has the same height position of a tip part bent in a U-shape.
  5. 　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、
    　環状の起磁力発生部と、
    　前記ステータコアの各ティースに装着されるＵ字形のコイルと、
    　前記起磁力発生部、前記ステータコアおよび前記コイルを一体に保持するモールド部とを備える電動機の製造方法であって、
    　金型の所定位置に、前記起磁力発生部を両側に設けた前記ステータコアで挟み込んだ状態に配置すると共に、板部材をＵ字形に折り曲げて成るコイルを、当該折り曲げた先端部を前記金型の底面内壁に当てた状態で、前記各ティースの周囲に配置する工程と、
    　前記金型に樹脂部材を注入してステータ部を一体成形し、前記モールド部を形成する工程とを有することを特徴とする電動機の製造方法。     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 magnetomotive force generator,
    A U-shaped coil attached to each tooth of the stator core;
    A method of manufacturing an electric motor comprising the magnetomotive force generating part, the stator core, and a mold part that integrally holds the coil,
    A coil formed by bending the plate member into a U-shape is arranged at a predetermined position of the mold in a state where the magnetomotive force generating part is sandwiched between the stator cores provided on both sides, and the bent tip is attached to the mold. A step of placing the teeth around the inner wall in the state of being applied to the bottom inner wall;
    And a step of injecting a resin member into the mold and integrally forming a stator portion to form the mold portion.
PCT/JP2011/001917 2011-03-30 2011-03-30 Electric motor and method for producing electric motor WO2012131776A1 (en)

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US20180366996A1 (en) * 2017-06-20 2018-12-20 Dyson Technology Limited Brushless motor and stator therefor
JP2020509727A (en) * 2017-02-17 2020-03-26 サントル ナシオナル ドゥ ラ ルシェルシェ シアンティフィクＣｅｎｔｒｅ Ｎａｔｉｏｎａｌ Ｄｅ Ｌａ Ｒｅｃｈｅｒｃｈｅ Ｓｃｉｅｎｔｉｆｉｑｕｅ Low voltage powered electric machines and associated multi-cell powertrains

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JPH05227683A (en) * 1992-02-12 1993-09-03 Jeco Co Ltd Securing method of motor magnet
JPH08214519A (en) * 1995-02-06 1996-08-20 Akira Chiba Both-saliency motor-generator using permanent magnet
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JP2005176470A (en) * 2003-12-10 2005-06-30 Toyota Motor Corp Method for manufacture of stator
WO2009136574A1 (en) * 2008-05-08 2009-11-12 三菱電機株式会社 Rotary electric motor and air blower using same
WO2009139278A1 (en) * 2008-05-14 2009-11-19 三菱電機株式会社 Magnetic inductor type rotary machine, and fluid transfer device using the rotary machine

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JP2020509727A (en) * 2017-02-17 2020-03-26 サントル ナシオナル ドゥ ラ ルシェルシェ シアンティフィクＣｅｎｔｒｅ Ｎａｔｉｏｎａｌ Ｄｅ Ｌａ Ｒｅｃｈｅｒｃｈｅ Ｓｃｉｅｎｔｉｆｉｑｕｅ Low voltage powered electric machines and associated multi-cell powertrains
US20180366996A1 (en) * 2017-06-20 2018-12-20 Dyson Technology Limited Brushless motor and stator therefor
US11588360B2 (en) * 2017-06-20 2023-02-21 Dyson Technology Limited Brushless motor and stator therefor

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