WO2018138859A1 - Axial gap-type rotary electric machine - Google Patents

Abstract

An axial gap-type rotary electric machine is provided with: a stator in which a plurality of core units comprising a core made from an approximately cylindrical body, a coil wound around the core, and a bobbin arranged between the core and the coil are arranged annularly along the inner circumferential surface of a housing with a rotational axis at the center thereof; and at least one rotor facing the end surfaces of the cores with a predetermined air gap therebetween in the direction of the rotational axis. The bobbin comprises a cylinder section for inserting the cores and a flange section that extends to a predetermined length in a direction perpendicular to the outer circumference of the cylinder section in the vicinity of at least one of the two open ends of the cylinder section. The coil is wound around the outer circumference of the cylinder section of the bobbin in an aligned manner, and layers are configured continuously such that the number of turns in layers that are further outward than a layer wound so as to be in contact with the flange section decrease by at least one turn per layer relative to the number of turns of the layer adjacent thereto on the inner side. A crossover wire is arranged as the first layer of the coil of a second core unit adjacent to the innermost circumferential layer of a first core unit.

Description

Axial gap type rotating electrical machine

The present invention relates to an axial gap type rotating electrical machine, and particularly relates to a coil in which adjacent coils are in phase and electric wires wound around the coil are connected.

In the motor gap (the gap between the stator and the rotor), a pair of N · S or n times as many magnetic poles as N · S is formed. This magnetic pole does not necessarily correspond to the number of stator windings (the number of slots), and is designed to have various values such as 10 slots in 12 slots and 8 poles in 48 slots. . The number of poles and the frequency of the current flowing through the winding determine the synchronous speed of the motor, and the rotor rotates at this synchronous speed. In order to realize these magnetic poles, it is necessary to devise how to wind the stator winding.

For example, in an electric motor in which a stator winding is wound around a bobbin to form a coil, one stator winding is wound around one bobbin, and one stator winding is wound around two bobbins (Hereinafter referred to as “continuous winding”) An arbitrary number of magnetic poles is realized by using various winding methods such as one in which two stator windings are wound around one bobbin.

Generally, there are a radial gap type motor having a gap in the same direction as the output shaft and an axial gap type motor having a gap in a direction perpendicular to the output shaft. In this axial gap type electric motor, there is, for example, Patent Document 1 as means for creating a continuous bobbin. Patent Document 1 includes a stator in which a plurality of core units are arranged on a disk, and a pair of rotors opposed to each other on both sides of the stator via a gap, and each rotor is coaxial with an output shaft that outputs a rotational driving force. A structure is disclosed which is fixed to the. The core unit constituting this stator is provided with a connecting means, and by connecting the core unit in a straight line, one winding is wound around two bobbins at a time to produce a continuous coil. It is.

JP 2006-230179 A

When the coil is wound continuously as in Patent Document 1, if the connecting wire passing from the core unit at the start of winding to the adjacent core unit is passed from the outermost layer, there is a slack when the winding operation is finished and the coils are arranged. There is a risk that it will occur. There is a problem that the core unit that has collapsed due to the slack crossover also has a reduced space factor and performance. In addition, in the case of an electric motor having a structure in which the stator is molded in the housing, the crossover wires get in the way when the core units are arranged and arranged in the housing, or the crossover wires are damaged under the core unit. There is also a problem that insulation performance cannot be ensured when the housing and the crossover wire are too close to each other.

Technology that improves performance and reliability while securing the productivity of electric motors is desired.

In order to solve the above-mentioned problems, the configuration described in the claims is applied. As an example, a plurality of core units each having a substantially cylindrical core, a coil wound around the core, a core, and a bobbin disposed between the coils are arranged around the inner periphery of the housing. An axial gap type rotating electrical machine comprising: a stator arranged in an annular shape along a plane; and at least one rotor facing a face of an end face of a core via a predetermined air gap in a rotation axis direction. Has a cylindrical portion into which the core is inserted, and an outer periphery of the cylindrical portion and a flange portion extending in a vertical direction in the vicinity of at least one of both opening end portions of the cylindrical portion, and the coil , Wound around the outer periphery of the cylindrical part of the bobbin by the aligned winding, and the number of turns per layer of the layer wound outside the layer wound in contact with the collar portion is adjacent to the inner side At least one less than the number of turns Layer serving as the number of turns are those becomes continuously, it is to place the connecting wire as the first layer of the coil of the second core unit adjacent the innermost layer of the first core units.

According to one aspect of the present invention, the sag of the crossover between the core units wound adjacently is reduced, and the reliability and productivity of the rotating electrical machine are improved.

It is sectional drawing of a general axial gap type rotary electric machine. It is an external view of the coil of Example 1 to which this invention is applied. It is a perspective view of the process in which the coil of Example 1 is wound. It is a perspective view of the core unit by which the continuous winding of Example 1 was carried out.

Hereinafter, an embodiment for carrying out the present invention will be described with reference to the drawings. FIG. 1 is an axial longitudinal sectional view showing a schematic configuration of a double rotor type axial gap type permanent magnet synchronous motor 100 (hereinafter, simply referred to as “motor 100”) according to a first embodiment to which the present invention is applied. .

The motor 100 is configured such that two disk-shaped rotors 30 sandwich a stator 10 arranged in a donut shape along the inner peripheral surface of the housing 50 via a predetermined air gap in the rotational axis radial direction. They are arranged so as to face each other. The center of the disk of the rotor 30 is fixed to the rotating shaft 40. The rotating shaft 40 is disposed through the central portion of the stator 10, and both end portions thereof are rotatably fixed to the bracket 60 via bearings 70. The end bracket 60 is fixed in the vicinity of both opening ends of the housing 50 having a substantially cylindrical shape. The present invention is not limited to this, and can be applied to various types such as a single rotor type and a type including a plurality of stators and a plurality of rotors.

The rotor 30 includes a permanent magnet 31 on a circular base 33 via a yoke 32. The permanent magnet is composed of a plurality of plate-like magnets having a substantially fan-shaped inner periphery centered on the rotation axis, and magnets having different polarities are arranged in the rotation direction. In this embodiment, a ferrite magnet is applied as the permanent magnet 31, but the present invention is not limited to this. For example, the yoke 32 may be omitted.

The stator 10 is composed of twelve core units 20 arranged along the inner periphery of the housing 30 with the rotation axis A as the central direction. One core unit 20 constitutes one slot. Further, the core units 20 and the inner peripheral surface of the housing 50 are integrally formed with each other by a resin mold and are fixed to the stator.

The configuration of the core unit will be described with reference to FIG. 2A is a perspective view of the core unit, and FIG. 2B is a cross-sectional view. The core unit 20 includes an iron core (core) 21, a bobbin 22, and a coil 23. The iron core 21 is a laminated iron core made of a columnar body whose end surface facing the rotor 30 has a substantially trapezoidal shape (including a fan shape and a shape equivalent thereto). The laminated iron core is formed by laminating plate-like plates (or belt-like or tape-like shapes) containing a magnetic material, which are gradually increased in width from the rotation axis A toward the housing inner peripheral surface. obtain. Further, the iron core 21 is not limited to this, and may be a dust core or a machined one, and may have a T, H, or I-shaped cross section in the rotation axis direction. In addition, although an amorphous metal shall be applied as a magnetic material, it is not restricted to this.

The bobbin 22 is an insulating member made of resin or the like, and has a cylindrical portion having an inner diameter that approximately matches the outer shape of the iron core 21, and a flange portion that extends a predetermined length from the vicinity of both opening ends of the cylindrical portion over the entire circumference in the vertical direction. Have The predetermined length does not need to be uniform over the entire buttock, and can be set as appropriate according to the specifications. In the present embodiment, the part located on the left and right of the rotation axis rotation direction (the part facing the oblique side of the trapezoid) and the part located on the inner peripheral side of the housing 50 (the part facing the lower bottom of the trapezoid) are wound. The thickness of the coil 23 is slightly longer than that of the coil 23 so as to insulate the coil 23 of the adjacent core unit and the inner peripheral surface of the housing 50. Moreover, the part extended | stretched in a rotating shaft core direction is a little longer than these. In addition, the structure which makes a collar part below coil thickness is also possible.

The coil 23 is wound around the outer peripheral side surface of the cylindrical portion and between the two flange portions. The coil 23 is wound at a high space factor by increasing the winding tension. In this embodiment, a round wire is applied to the coil 23. However, the present invention can also be applied to the case where the diagonal of the square wire is perpendicular to the extending direction of the iron core 21.

FIG. 2 (b) shows a radial cross-sectional view of the core unit. The coil 23 is wound by aligned winding, starting from the base portion of the surface of the collar portion on the tube portion side. In addition, the coil 23 is wound so that the number of turns per layer is reduced by one turn as the coil is wound around the outside of the bobbin 22 so that the first regions 231 are formed on both sides. It has become.

First, the coil 23 of the first layer is started to be wound from the base of the buttock (upper in the drawing) (23a), and then wound to the base of the other buttock. The second layer is folded and wound so as to be arranged as much as possible between the coils 23 of the second layer.

In addition, the second-layer coil 23 that is wound back to the buttocks side (upper in the drawing) is a coil 23b and a coil 23c that are wound on the next turn of the first-layer coil 23a. Finally, the intermediate winding is turned back to the third layer winding. Thereafter, the fourth layer, the fifth layer, and the sixth layer are each wound by subtracting one turn from the number of turns of the adjacent layers. As a result, as shown in FIG. 2 (b), the coil 23 forms a step winding having an angle θ between the coil 23 and the coil portion. The coil 23 wound to the final layer is wound as it is on the root of the adjacent bobbin collar.

FIG. 3 is a perspective view in which the coil 23 is continuously wound around the two bobbins 22 (continuous winding). Although not shown, at the time of winding, the two bobbins 22 are fixed to a jig. At this time, the two bobbins are inclined with respect to each other about the center of gravity so that the notch 22a of the first bobbin and the notch 22b of the second bobbin approach each other. After fixing the bobbin with a jig, the two bobbins are wound and rotated. At the same time, the nozzle that supports the coil is moved in the horizontal direction so that the coil is wound around the cylindrical portion.

In this example, the nozzle is reciprocated a plurality of times through the cylindrical portion of the first bobbin to form a stepped winding, and then the coil 23 is passed through the notch 22a and the notch 22b of the second bobbin facing thereto. The bobbin is also rotated with respect to the second bobbin to form a corrugated winding. After winding, as shown in FIG. 4, the coil 22 between the bobbins is removed from the notch, and both bobbins are rotated so that the crossover wire 231 passes through the first region of the winding of the second bobbin. As a result, continuous coils having different winding directions D are completed.

In this way, by passing the crossover wire 231 from the innermost peripheral side to the adjacent core unit (second bobbin), the crossover slack is reduced, and the possibility that the wire may collapse or insulation performance may not be ensured is reduced. Can do.

The winding direction is reversed between the first bobbin and the second bobbin. For example, if the coil 23 is wound counterclockwise around the first bobbin when viewed from directly above the bobbin, the coil 23 is wound clockwise around the second bobbin to be wound continuously. It will be. Of course, the relationship between the first bobbin and the second bobbin may be reversed.

As mentioned above, although the Example for implementing this invention was described, this invention is not limited to this. For example, in this embodiment, a double rotor type axial gap type motor is taken as an example, but a single rotor type may be used. Moreover, a generator may be used instead of the motor.

DESCRIPTION OF SYMBOLS 1 ... Electric motor 10 ... Stator 20 ... Core unit 21 ... Core 23 ... Coil 22 ... Bobbin 24 ... Resin 30 ... Rotor 31 ... Permanent magnet 32 ... Base 40 ... Rotating shaft 50 ... Housing 60 ... Bracket 70 ... Bearing.

Claims (2)

A plurality of core units each having a substantially columnar core, a coil wound around the core, and the core and a bobbin disposed between the coils are annular along the inner peripheral surface of the housing around the rotation axis An axial gap type rotating electrical machine comprising: a stator arranged in an axis; and at least one rotor facing the end surface of the core via a predetermined air gap in a rotation axis direction,
The bobbin
A cylindrical portion into which the core is inserted, and an outer periphery of the cylindrical portion in the vicinity of at least one of both opening end portions of the cylindrical portion and a flange portion extending a predetermined length in the vertical direction,
The coil is
The bobbin is wound around the outer periphery of the cylindrical portion with aligned winding,
A layer in which the number of turns per layer of the layer wound outside the layer wound in contact with the collar portion is reduced by at least one turn from the number of adjacent inner turns; It is a series of
An axial gap type rotating electrical machine in which a crossover is arranged as a first layer coil of a second core unit adjacent to the innermost peripheral layer of the first core unit. The axial gap type rotating electrical machine according to claim 1,
An axial gap type rotating electrical machine in which the winding direction of the coil of the first core unit is different from the winding direction of the coil of the second core unit.

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