CN109478813B

CN109478813B - Axial gap type rotating electric machine

Info

Publication number: CN109478813B
Application number: CN201780045652.9A
Authority: CN
Inventors: 山崎克之; 仓井大辅
Original assignee: Hitachi Industrial Equipment Systems Co Ltd
Current assignee: Hitachi Industrial Equipment Systems Co Ltd
Priority date: 2017-01-27
Filing date: 2017-01-27
Publication date: 2021-04-06
Anticipated expiration: 2037-01-27
Also published as: TW201828573A; CN109478813A; JPWO2018138859A1; WO2018138859A1; TWI673937B; JP7025355B2

Abstract

The present invention provides an axial gap type rotating electrical machine, comprising: a stator formed by arranging a plurality of iron core units in a ring shape along an inner peripheral surface of a casing with a rotating shaft as a center, wherein the iron core units have a substantially cylindrical shape. an iron core composed of a body, a coil wound on the iron core, and a bobbin disposed between the iron core and the coil; and facing the end face of the iron core with a predetermined air gap in the direction of the rotation axis at least one rotor, the bobbin has a cylindrical portion into which the iron core is inserted, and a bobbin extending a predetermined length in a direction perpendicular to the outer circumference of the cylindrical portion in the vicinity of at least one of the two open ends of the cylindrical portion The flange portion, the coil is wound around the outer circumference of the barrel portion of the bobbin in a regular winding manner, and the coil is composed of a plurality of consecutive layers, which are wound compared to the layer wound in contact with the flange portion The number of turns of each layer in the outer layer is the number of turns that decreases by at least one turn layer by layer compared with the number of adjacent inner turns, from the innermost peripheral layer of the first core unit to the adjacent second layer. The coils of the first layer of the core unit are provided with jumper wires.

Description

Axial gap type rotating electric machine

Technical Field

The present invention relates to an axial gap type rotating electrical machine, and more particularly to an axial gap type rotating electrical machine in which coils arranged adjacent to each other are in phase and wires wound around the coils are connected to each other.

Background

In the gap (gap between the stator and the rotor) of the motor, 1 pair of N · S or N times thereof magnetic poles are formed. The magnetic poles are not necessarily equal to the number of stator windings (number of slots), and are designed to have various values of 12 slots, 10 poles, or 48 slots, 8 poles. The number of poles and the frequency of the current flowing through the winding determine the synchronous speed of the motor, at which the rotor rotates. In order to realize these magnetic poles, a winding method of the stator winding is studied.

For example, in a motor in which a coil is formed by winding a stator winding around a bobbin, an arbitrary number of magnetic poles is realized by using various winding methods such as winding 1 stator winding around 1 bobbin, winding 1 stator winding around 2 bobbins (hereinafter, referred to as continuous winding), and winding 2 stator windings around 1 bobbin.

In general, the motor includes 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 the direction perpendicular to the output shaft. In this axial gap motor, as a method of manufacturing a continuously wound bobbin, for example, patent document 1 is known. Patent document 1 discloses a configuration including a stator in which a plurality of core units are arranged on a disk, and 1 pair of rotors facing both side surfaces of the stator with a gap therebetween, and each rotor is coaxially fixed to an output shaft that outputs a rotational driving force. The core unit constituting the stator is provided with a connecting member, and the core unit is connected in a straight line, so that one winding is simultaneously wound on two bobbins to manufacture a continuously wound coil.

Documents of the prior art

Patent document

Patent document 1: japanese patent laid-open publication No. 2006-230179

Disclosure of Invention

Technical problem to be solved by the invention

When the coils are wound in a continuous manner as in patent document 1, if the layer connection from the core unit that started to be wound to the adjacent core unit is completed from the outermost layer, there is a possibility that the coils will be loosened when the coils are arranged after the winding operation is completed. The core unit in which the winding deformation occurs due to the slack crossover wires has a problem that the space factor is also lowered, and the performance is lowered. In the case of a motor having a structure in which a stator is molded in a case, there are problems in that when core units are arranged in parallel in the case, a jumper wire interferes with the operation, a jumper pad is damaged under the core unit, or the case and the jumper wire are too close to each other to ensure insulation performance.

Techniques for ensuring the productivity of electric motors while improving performance and reliability are desired.

Means for solving the problems

To solve the above problems, the structure described in the claims is applied. As an example, an axial gap type rotating electrical machine includes:

a stator configured by arranging a plurality of core units in a ring shape along an inner circumferential surface of a housing with a rotation shaft as a center, wherein the core units have a core formed of a substantially cylindrical body, a coil wound around the core, and a bobbin provided between the core and the coil; and at least one rotor facing the end face of the core with a predetermined air gap in the direction of the rotation axis, wherein the bobbin has a cylinder portion into which the core is inserted and a flange portion extending a predetermined length in the vicinity of at least one of the two open ends of the cylinder portion in the direction perpendicular to the outer periphery of the cylinder portion, the coil is wound around the outer periphery of the cylinder portion of the bobbin in a regular winding manner, the coil is composed of a plurality of connected layers, the number of turns of each of the layers wound outside the layer wound in contact with the flange portion is decreased by at least 1 turn from one layer to the next inside, and a jumper wire is arranged from the innermost peripheral layer of the first core unit to the coil of the first layer of the second core unit adjacent thereto.

Effects of the invention

According to one aspect of the present invention, it is possible to reduce the slack of the jumper wire between the core units that are wound adjacently, and to improve the reliability and productivity of the rotating electric machine.

Drawings

Fig. 1 is a sectional view of a general axial gap type rotating electric machine.

Fig. 2 is an external view of a coil to which embodiment 1 of the present invention is applied.

Fig. 3 is a perspective view of a process of winding a coil according to embodiment 1.

Fig. 4 is a perspective view of a core unit formed by continuous winding according to example 1.

Detailed Description

Hereinafter, embodiments for carrying out the present invention will be described with reference to the drawings. Fig. 1 is an axial longitudinal cross-sectional view illustrating a schematic structure of a double rotor type axial gap permanent magnet synchronous motor 100 (hereinafter, may be simply referred to as "motor 100") to which embodiment 1 of the present invention is applied.

The motor 100 is arranged such that 2 disc-shaped rotors 30 face each other across an air gap so as to sandwich a stator 10 arranged in a ring shape along an inner peripheral surface of a housing 50. The center of the disk of the rotor 30 is fixed to the rotating shaft 40, the rotating shaft 40 is disposed to penetrate the center portion of the stator 10, and both end portions are rotatably fixed to the support 60 via bearings 70. The end supports 60 are fixed near both open ends of the housing 50, which is formed in an approximately cylindrical shape. The present invention is not limited to this, and can be applied to various forms such as a single-rotor type, a form including a plurality of stators and a plurality of rotors, and the like.

The rotor 30 has a permanent magnet 31 on a circular base 33 via a yoke 32. The permanent magnet is composed of a plurality of flat plate-like magnets having a substantially fan-shaped inner circumference with a rotation axis as a center, and magnets having different polarities are arranged in a rotation direction. In the present embodiment, a ferrite magnet is generally used as the permanent magnet 31, but the present invention is not limited thereto. For example, the yoke 32 may be omitted.

The stator 10 is constituted by 12 core units 20 arranged along the inner circumference of the housing 30 with the rotation axis a as the center direction. 1 core element 20 constitutes 1 slot. In addition, the core units 20 and the inner circumferential surface of the housing 50 are integrally molded with each other by resin molding and fixed to the stator.

The structure of the core unit will be described with reference to fig. 2. Fig. 2 (a) is a perspective view and (b) is a sectional view of the core unit. The core unit 20 has a core 21, a bobbin 22, and a coil 23. The core 21 is a laminated core formed of a cylindrical body having a substantially trapezoidal shape (including a fan shape and a shape similar thereto) at an end surface facing the rotor 30. The laminated core is obtained by laminating plate-like (or including elongated strip-like, belt-like) sheets containing a magnetic material, the width of which gradually increases from the rotation axis center a toward the inner peripheral surface of the case. The core 21 is not limited to this, and may be a dust core or a cut core, and may have a cross section in the rotation axis direction in the shape of T, H or I. Further, as the magnetic material, an amorphous metal is generally used, but is not limited to this material.

The bobbin 22 is an insulating member made of resin or the like, and has a cylindrical portion having an inner diameter approximately matching the outer shape of the core 21 and flange portions extending a predetermined length from the vicinity of both open ends of the cylindrical portion over the entire circumference in the vertical direction. The predetermined length does not have to be the same throughout the flange, and may be set as appropriate according to the specification. In the present embodiment, the portions located on the left and right sides in the rotation axis direction (the portions facing the oblique sides of the trapezoid) and the portions located on the inner peripheral side of the housing 50 (the portions facing the lower bottom of the trapezoid) are slightly longer than the layer thickness margin of the wound coil 23, and the coil 23 of the adjacent core unit and the inner peripheral surface of the housing 50 are insulated. Further, the portion extending in the direction of the rotation axis is slightly longer than the portion. The flange may have a structure equal to or less than the coil layer thickness.

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 with a high space factor with a large winding tension. In the present embodiment, a round wire is applied to the coil 23, but the present invention can be applied to a case where a diagonal line of a square wire is used perpendicular to the extending direction of the core 21.

Fig. 2 (b) shows a radial cross-sectional view of the core unit. The coil 23 is wound by regular winding with a root end portion of the cylindrical portion side surface of the flange portion as a winding start. The winding of the coil 23 is performed such that the first regions 231 are formed on both flange portions and wound on the outside of the bobbin 22, and the number of turns per 1 layer is reduced by 1 turn.

First, the coil 23 of the first layer is wound (23a) from the root end portion of the flange portion (upper in the figure), and then wound to the root end portion of the other flange portion. The second layer is folded and wound so as to be disposed between the coils 23 of the second layer as much as possible.

The coil 23 of the second layer folded back to the flange portion side (upper side in the figure) is folded back to the winding of the third layer with the turn between the coil 23b and the coil 23c wound in the subsequent turn of the coil 23a of the first layer being the last winding. Then, the fourth layer, the fifth layer and the sixth layer are respectively wound by reducing the number of turns of the adjacent layers by 1 turn. As a result, as shown in fig. 2 (b), the coil 23 forms a trapezoidal winding having an angle θ with the flange portion. The coil 23 wound to the final layer is wound directly around the root of the adjacent bobbin flange portion.

Fig. 3 is a perspective view showing two bobbins 22, around which a coil 23 is continuously wound (continuously wound). The two bobbins 22 are fixed to a jig during winding, but not shown. At this time, the two bobbins are arranged obliquely with the center of gravity as the center so that the notch 22a of the first bobbin and the notch 22b of the second bobbin in the notch portion are close to each other. After the bobbins were fixed by a jig, the two bobbins were rotated in the winding direction. At the same time, the bobbin opening supporting the coil is moved in the horizontal direction, thereby winding the coil around the bobbin.

In this example, after the bobbin opening is reciprocated a plurality of times on the cylindrical portion of the first bobbin to form the trapezoidal winding, the coil 23 is passed through the notch 22a to the notch 22b of the opposing second bobbin. The second bobbin is also rotated to form a trapezoidal winding. After winding, the coil 22 between the bobbins is removed from the notch portion as shown in fig. 4, and both the bobbins are rotated so that the jumper wire 231 passes through the first region of the winding of the second bobbin. Whereby successive coils with different winding directions D are completed.

By connecting the jumper wires 231 from the innermost circumference side to the adjacent core unit (second bobbin) in this way, the slack of the connection wires can be reduced, and the possibility of winding deformation and the possibility of failure to ensure the insulation performance can be reduced.

The direction of winding is opposite on the first bobbin and the second bobbin. For example, if the coil 23 is wound on the first bobbin counterclockwise as viewed from directly above the bobbins, the coil 23 is wound on the coil of the second bobbin continuously wound clockwise. Of course, the relationship of the first and second bobbins is not the same, but opposite.

The embodiments for carrying out the present invention have been described above, but the present invention is not limited thereto. For example, in the present embodiment, a double rotor type axial gap motor is taken as an example, but a single rotor type is also possible. In addition, a generator may be used instead of the motor.

Description of the reference numerals

1 … electric motor

10 … stator

20 … iron core unit

21 … iron core

23 … coil

22 … reel

24 … resin

30 … rotor

31 … permanent magnet

32 … … base

40 … … rotating shaft

50 … … casing

60 … … support

70 … … bearing.

Claims

1. An axial gap type rotating electrical machine, comprising:

a stator configured by arranging a plurality of core units in a ring shape along an inner circumferential surface of a housing with a rotation shaft as a center, wherein the core units have a core formed of a substantially cylindrical body, a coil wound around the core, and a bobbin provided between the core and the coil; and

at least one rotor facing the end face of the core with a predetermined air gap in the direction of the rotation axis,

the bobbin has a cylindrical portion into which the core is inserted and a flange portion extending a predetermined length in a direction perpendicular to an outer periphery of the cylindrical portion in the vicinity of at least one of two opening ends of the cylindrical portion,

the coil is wound around an outer periphery of the cylindrical portion of the bobbin in a regular winding manner,

the coil is composed of a plurality of connected layers, wherein the number of turns of each layer of the layers wound outside the layer wound in contact with the flange portion is at least 1 turn in a stepwise decreasing manner compared with the number of turns of the adjacent inner side, a first region is formed on the flange portion side, and a jumper wire is arranged from the first layer of the innermost circumference of the first core unit to the coil of the first layer of the adjacent second core unit.

2. The axial gap type rotary electric machine according to claim 1, characterized in that:

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.