Detailed Description
The manner in which the objects of the present disclosure are implemented will be described with reference to the accompanying drawings. In the drawings, the same or corresponding portions are denoted by the same reference numerals, and repetitive description thereof will be appropriately simplified or omitted. The object of the present disclosure is not limited to the following embodiments, and modifications of any of the components of the embodiments or omission of any of the components of the embodiments may be made without departing from the scope of the present disclosure.
Embodiment 1.
Fig. 1 is a partial cross-sectional view showing a rotary electric machine according to embodiment 1. The rotary electric machine 1 as an electric device has a housing 2, a main shaft 3, a rotor 4, and an armature 5.
The housing 2 has a cylindrical portion 21 and a plate-like portion 22. The cylindrical portion 21 has a cylindrical shape having an axis. The plate-like portion 22 is fixed to an end portion of the cylindrical portion 21 in the axial direction of the cylindrical portion 21. The plate-like portion 22 closes one opening of the cylindrical portion 21.
The spindle 3 is fixed to the plate-like portion 22 of the housing 2. The spindle 3 is disposed coaxially with the cylindrical portion 21 inside the cylindrical portion 21. Thereby, the spindle 3 is disposed on the axis of the cylindrical portion 21.
The rotor 4 is supported by the main shaft 3 as a movable member. The rotor 4 is rotatably mounted to the main shaft 3 via a bearing 6. Thereby, the rotor 4 rotates inside the cylindrical portion 21 with respect to the housing 2 and the spindle 3 centering on the axis of the spindle 3.
The rotor 4 has a rotor core 41 and a plurality of permanent magnets 42. The rotor core 41 is made of a magnetic material. The rotor core 41 has a cylindrical shape. A through hole 43 through which the spindle 3 passes is provided in the center of the rotor core 41. The bearing 6 is interposed between the inner peripheral surface of the through hole 43 and the outer peripheral surface of the spindle 3. The rotor core 41 is disposed coaxially with the main shaft 3.
A plurality of permanent magnets 42 are provided in the rotor core 41. The plurality of permanent magnets 42 are arranged at intervals in the circumferential direction of the rotor 4, and thereby a plurality of magnetic poles are formed on the outer circumferential portion of the rotor 4.
In addition, a cage type rotor, a wound rotor, or the like may be used as the rotor 4. The cage rotor is a rotor in which a plurality of uninsulated rotor conductors are provided in the rotor core 41, and a pair of short-circuit rings disposed at both end portions of the rotor core 41 are short-circuited by the respective rotor conductors. The wound rotor is a rotor in which rotor windings electrically insulated from the rotor core 41 are provided in the rotor core 41.
The armature 5 is fixed to the housing 2 in a state of being fitted into the inner peripheral surface of the cylindrical portion 21. The armature 5 is annular in shape. The armature 5 surrounds the outer peripheral portion of the rotor 4. Thus, the inner peripheral portion of the armature 5 faces the outer peripheral portion of the rotor 4 with a gap therebetween. The armature 5 is arranged coaxially with the main shaft 3.
Fig. 2 is a cross-sectional view showing the armature 5 of fig. 1. The armature 5 has an armature core 51, an armature winding 52, a plurality of holding members 53, a plurality of first insulating films 54, and a plurality of second insulating films 55.
The armature core 51 has a yoke 56 and a plurality of teeth 57. The yoke 56 is annular in shape along the circumferential direction of the armature 5. The circumferential direction of the armature 5 is a direction along the circumference of a circle centered on the axis of the armature 5. The outer peripheral surface of the yoke 56 is fitted into the inner peripheral surface of the cylindrical portion 21 of the housing 2.
The plurality of teeth 57 are provided to the yoke 56 at intervals. The plurality of teeth 57 are arranged at equal intervals in the circumferential direction of the armature 5. Thus, spaces are formed between the plurality of teeth 57 as grooves 58, respectively. Each tooth 57 protrudes radially inward of the armature 5 from the yoke 56. The radial direction of the armature 5 is a direction along the radius of a circle centered on the axis of the armature 5.
As shown in fig. 1, the armature core 51 is configured by laminating a plurality of magnetic plates 511. Each magnetic plate 511 is made of a magnetic material. In the present embodiment, an electromagnetic steel plate is used as the magnetic plate 511. The plurality of magnetic plates 511 are laminated along the axial direction of the armature 5. Therefore, the lamination direction of the plurality of magnetic plates 511 is a direction perpendicular to both the circumferential direction of the armature 5 and the radial direction of the armature 5. The plurality of magnetic plates 511 are stacked so as not to be bonded to each other.
Here, fig. 3 is an enlarged view showing the tooth 57 of the armature core 51 of fig. 2. Fig. 4 is a front view showing a state when the tooth 57 of fig. 3 is viewed from the inside in the radial direction of the armature 5. As shown in fig. 4, each magnetic plate 511 has a yoke-constituting plate portion 511a and a plurality of tooth-constituting plate portions 511b.
The yoke structural plate portion 511a is an annular plate. The tooth forming plate portion 511b protrudes from the yoke forming plate portion 511a to the inside in the radial direction of the yoke forming plate portion 511a on the same plane as the yoke forming plate portion 511 a. The yoke 56 is formed by stacking yoke structural plate portions 511 a. The tooth portion 57 is formed by stacking tooth constituent plate portions 511 b.
As shown in fig. 3, each tooth 57 has a tooth main body 571 and a tooth tip 572. The tooth main body 571 protrudes from the yoke 56 to the inside of the yoke 56 in the radial direction of the armature 5. In each of the tooth portions 57, when the direction in which the tooth main body portion 571 protrudes from the yoke portion 56 is the tooth protruding direction, the cross-sectional shape of each of the tooth main body portion 571 and the tooth distal end portion 572 in a plane perpendicular to the tooth protruding direction is rectangular. In the present embodiment, the cross-sectional area of the tooth body portion 571 in the plane perpendicular to the tooth projecting direction is the same at any position in the tooth projecting direction.
The tooth distal end portion 572 is provided at a protruding end portion of the tooth main body portion 571. The protruding end portion of the tooth main body portion 571 is an end portion located on a side away from the yoke 56, of both end portions of the tooth main body portion 571 in the tooth protruding direction.
A part of the tooth tip portion 572 protrudes outward from the tooth body portion 571 in the circumferential direction of the armature 5. Thus, the cross-sectional area of the tooth tip portion 572 in a plane perpendicular to the tooth projecting direction is larger than the cross-sectional area of the tooth main body portion 571 in a plane perpendicular to the tooth projecting direction. The tooth tip 572 of each tooth 57 faces the outer peripheral portion of the rotor 4 with a gap therebetween.
As shown in fig. 2, the armature winding 52 is provided to the armature core 51. The armature winding 52 is wound around each tooth 57. A portion of the armature winding 52 is disposed in each slot 58. A rotating magnetic field is generated in the armature 5 by energizing the armature winding 52. The rotor 4 rotates about the axis of the spindle 3 with respect to the armature 5 and the housing 2 by the generation of the rotating magnetic field.
The plurality of holding members 53 are provided to the armature core 51. The holding members 53 are attached to the respective tooth portions 57.
Each holding member 53 is formed in a ring shape from an elastic material having electrical insulation. As the holding member 53, for example, a rubber endless belt is used. Each holding member 53 is elastically stretchable. When each holding member 53 is stretched, each holding member 53 generates an elastic restoring force in a contracting direction.
Each holding member 53 is attached to the tooth 57 in a state where the tooth 57 is inserted into the inside of the holding member 53. A tooth body 571 is inserted inside each holding member 53. Thus, the holding member 53 is attached to the tooth body portion 571 at each tooth portion 57.
Each holding member 53 is elastically stretched by being expanded from the inside of the holding member 53 by the tooth body portion 571. Accordingly, each holding member 53 generates an elastic restoring force of the fastening tooth portion 57 in a state where the tooth portion 57 is inserted into the inside of the holding member 53. Thus, each holding member 53 integrates the plurality of magnetic plates 511. Accordingly, the stacked state of the plurality of magnetic plates 511 is held by each holding member 53.
Each holding member 53 is interposed between the tooth body 571 and the armature winding 52. The electrically insulating state between each tooth body 571 and the armature winding 52 is ensured by each holding member 53.
Each of the first insulating films 54 and each of the second insulating films 55 is an insulating member made of a material having electrical insulation properties. A pair of first insulating films 54 and a pair of second insulating films 55 are mounted on each holding member 53. In the present embodiment, the first insulating film 54 and the second insulating film 55 are attached to the respective holding members 53 by welding or the like. In the armature core 51, the first insulating film 54 and the second insulating film 55 are respectively opposed to portions adjacent to the holding members 53.
A pair of first insulating films 54 are attached as yoke-side insulating members to the yoke-56-side end portions of the both end portions of the holding member 53 in the tooth projecting direction. The pair of first insulating films 54 attached to the holding member 53 are disposed on both sides of the teeth 57 in the circumferential direction of the armature 5. Thus, each first insulating film 54 is interposed between the yoke 56 and the armature winding 52. The electrically insulating state between the yoke 56 and the armature winding 52 is ensured by each first insulating film 54.
A pair of second insulating films 55 are attached as tooth tip side insulating members to the end portions on the tooth tip end portion 572 side of the both end portions of the holding member 53 in the tooth projecting direction. The pair of second insulating films 55 attached to the holding member 53 are disposed on both sides of the teeth 57 in the circumferential direction of the armature 5. Thus, each second insulating film 55 is interposed between the tooth end portion 572 and the armature winding 52. The electrically insulating state between the tooth tip portion 572 and the armature winding 52 is ensured by each second insulating film 55.
Accordingly, the electrical insulation state between the armature core 51 and the armature winding 52 is ensured by the respective holding members 53, the respective first insulating films 54, and the respective second insulating films 55.
Next, a method of manufacturing the armature will be described. Fig. 5 is a flowchart showing a method for manufacturing an armature according to embodiment 1. The armature manufacturing method includes a lamination step S1, a holding member mounting step S2, an insulation processing step S3, and a winding step S4. In manufacturing the armature 5, the lamination step S1, the holding member mounting step S2, the insulation processing step S3, and the winding step S4 are performed in this order.
< Lamination Process S1>
In manufacturing the armature 5, the lamination step S1 is performed. In the lamination step S1, the armature core 51 is produced by laminating a plurality of magnetic plates 511.
Each magnetic plate 511 is manufactured in advance by punching out from a raw material plate made of a magnetic material. In the lamination step S1, as shown in fig. 3 and 4, the yoke structure plate portions 511a of the magnetic plates 511 are overlapped with each other, and the tooth structure plate portions 511b of the magnetic plates 511 are overlapped with each other, thereby laminating the plurality of magnetic plates 511.
When the plurality of magnetic plates 511 are laminated in the lamination step S1, the portion where the yoke constituent plate portions 511a are laminated becomes the yoke portion 56, and the portion where the tooth constituent plate portions 511b are laminated becomes the tooth portion 57. Thereby, the armature core 51 is manufactured. In the lamination step S1, the plurality of magnetic plates 511 are laminated so as not to join the magnetic plates 511 to each other.
< Holding Member mounting Process S2>
After the lamination step S1, a holding member mounting step S2 is performed. In the holding member mounting step S2, the holding members 53 are mounted on the respective tooth portions 57.
Fig. 6 is an enlarged view showing a state in which the holding member 53 is separated from the tooth 57 and the holding member 53 is contracted before the holding member mounting step S2 in fig. 5. Fig. 7 is a front view showing a state in which the holding member 53 and the tooth 57 of fig. 6 are seen from the inside in the radial direction of the armature core 51. In a state where the holding member 53 is separated from the tooth portion 57 and the holding member 53 is contracted, the area of the region surrounded by the annular holding member 53 is smaller than the sectional area of the tooth main body portion 571 in a plane perpendicular to the tooth projecting direction. Accordingly, in the holding member mounting step S2, the holding member 53 is stretched and the holding member 53 is mounted to the tooth 57.
Fig. 8 is an enlarged view showing a state in which the holding member 53 of fig. 6 is stretched in the holding member mounting step S2. Fig. 9 is a front view showing a state in which the holding member 53 and the tooth 57 of fig. 8 are seen from the inside in the radial direction of the armature core 51. In the holding member mounting step S2, when the tooth portion 57 is viewed in the tooth projecting direction, the holding member 53 is pulled against the elastic restoring force of the holding member 53 until the area surrounded by the holding member 53 is larger than the outer shape of the tooth portion 57. Thereafter, in the holding member mounting step S2, the holding member 53 is stretched, and the tooth 57 is inserted into the inside of the holding member 53.
Fig. 10 is an enlarged view showing a state in which the tooth 57 is inserted inside the holding member 53 in fig. 8. In the holding member mounting step S2, the tooth 57 is inserted inside the holding member 53 until the position of the holding member 53 reaches the position of the tooth main body 571. Thereafter, in the holding member mounting step S2, the force to stretch the holding member 53 is removed from the holding member 53, and the holding member 53 is contracted by the elastic restoring force of the holding member 53, whereby the holding member 53 is mounted on the tooth 57.
Fig. 11 is an enlarged view showing a state in which the holding member 53 of fig. 10 is attached to the tooth 57. Fig. 12 is a front view showing a state in which the holding member 53 and the tooth 57 of fig. 11 are seen from the inside in the radial direction of the armature core 51. In a state where the holding member 53 is attached to the tooth 57, the holding member 53 generates an elastic restoring force to tighten the tooth 57 from the periphery of the tooth main body portion 571. In this way, in the holding member mounting step S2, after the holding member 53 is pulled and the tooth portion 57 is inserted into the inside of the holding member 53, the holding member 53 is caused to generate an elastic restoring force for fastening the tooth portion 57. Thereby, the plurality of magnetic plates 511 are integrated.
< Insulating treatment Process S3>
After the holding member mounting step S2, an insulation processing step S3 is performed. In the insulating process step S3, the first insulating film 54 and the second insulating film 55 are mounted as insulating members on the respective holding members 53.
In the insulation processing step S3, a pair of first insulation films 54 are attached to the yoke 56-side end portions of the holding member 53. Thus, the first insulating film 54 faces the inner peripheral surface of the yoke 56 on both sides of the tooth 57 in the circumferential direction of the armature core 51.
In the insulation processing step S3, a pair of second insulation films 55 are attached to the end portions of the holding member 53 on the tooth tip portion 572 side. Thus, the second insulating film 55 faces the side surfaces of the tooth end portions 572 on both sides of the tooth portion 57 in the circumferential direction of the armature core 51. Therefore, the first insulating film 54 and the second insulating film 55 are respectively opposed to portions of the armature core 51 adjacent to the respective holding members 53.
< Winding Process S4>
After the insulation processing step S3, a winding step S4 is performed. In the winding step S4, the armature winding 52 is provided to the armature core 51 so that the holding member 53 is interposed between the armature winding 52 and the tooth 57. In the present embodiment, the armature winding 52 is provided to the armature core 51 by winding a wire around each tooth 57. Thus, as shown in fig. 2, the armature winding 52 is provided to each tooth 57 via the holding member 53. In each slot 58, the first insulating film 54 is interposed between the yoke 56 and the armature winding 52, and the second insulating film 55 is interposed between the tooth end portion 572 and the armature winding 52. The armature 5 is manufactured in this way.
In the armature 5, the holding member 53 is attached to each tooth 57. Each holding member 53 is formed in a ring shape from an elastic material having electrical insulation. Each holding member 53 generates an elastic restoring force of the fastening tooth portion 57 in a state where the tooth portion 57 is inserted into the inside of the holding member 53, thereby integrating the plurality of magnetic plates 511. Therefore, the plurality of magnetic plates 511 can be easily integrated by merely attaching the holding members 53 to the respective tooth portions 57 and generating elastic restoring force to the respective holding members 53. Thus, the plurality of magnetic plates 511 can be integrated without using an adhesive, a heat shrinkable material, or the like, and the time required to cure the adhesive, the time required to heat shrink the heat shrinkable material, or the like can be eliminated. Therefore, improvement in productivity of the armature core 51 can be achieved. Further, since each holding member 53 is an insulator having electrical insulation, the plurality of magnetic plates 511 can be prevented from being electrically connected to each other, and an increase in eddy current generated in the armature core 51 can be prevented. This also suppresses an increase in core loss of the armature core 51.
In addition, the cross-sectional area of the tooth tip portion 572 in a plane perpendicular to the tooth projecting direction is larger than the cross-sectional area of the tooth main body portion 571 in a plane perpendicular to the tooth projecting direction. The holding member 53 is attached to the tooth body 571. In a state where the holding member 53 is detached from the tooth portion 57 and the holding member 53 is contracted, the area of the region surrounded by the holding member 53 is smaller than the sectional area of the tooth main body portion 571 in a plane perpendicular to the tooth projecting direction. Accordingly, the holding member 53 attached to the tooth body 571 can be prevented from being detached from the tooth 57 by the tooth tip 572. In addition, the tooth body 571 can more reliably expand the holding member 53 from the inside of the holding member 53, and can more reliably generate the elastic restoring force of the holding member 53. Therefore, the stacked state of the plurality of magnetic plates 511 can be more reliably maintained.
The holding member 53 is interposed between the tooth body 571 and the armature winding 52. Accordingly, the electrically insulating state between the tooth body portion 571 and the armature winding 52 can be ensured by the holding member 53. That is, the holding member 53 can have both a function of securing an electrically insulated state between the tooth body portion 571 and the armature winding 52 and a function of integrating the plurality of magnetic plates 511. Accordingly, it is not necessary to dispose a dedicated insulating member for ensuring an electrically insulating state between the tooth body portion 571 and the armature winding 52, in addition to the holding member 53, between the tooth body portion 571 and the armature winding 52. Therefore, the insulating member can be reduced, and the cost of the insulating member can be reduced. In addition, by reducing the number of dedicated insulating members disposed in each slot 58, the space factor of the armature winding 52 in the slot 58 can be improved. This can increase the torque generated by energizing the armature 5.
In the method of manufacturing the armature, in the holding member mounting step S2, after the holding member 53 is pulled and the tooth portion 57 is inserted into the holding member 53, the holding member 53 is caused to generate an elastic restoring force for fastening the tooth portion 57. Therefore, the plurality of magnetic plates 511 can be easily integrated by merely stretching the holding member 53 and inserting the tooth 57 into the inside of the holding member 53. Thus, the plurality of magnetic plates 511 can be integrated without using an adhesive, a heat shrinkable material, or the like, and the time required to cure the adhesive, the time required to heat shrink the heat shrinkable material, or the like can be eliminated. Therefore, improvement in productivity of the armature core 51 can be achieved. Further, since each holding member 53 is an insulator having electrical insulation, the plurality of magnetic plates 511 can be prevented from being electrically connected to each other, and an increase in eddy current generated in the armature core 51 can be prevented. This also suppresses an increase in core loss of the armature core 51.
In the winding step S4, the armature winding 52 is provided to the armature core 51 so that the holding member 53 is interposed between the armature core 51 and the armature winding 52. Therefore, the insulating member can be reduced, and the cost of the insulating member can be reduced. In addition, the duty ratio of the armature winding 52 in the slot 58 can be increased, and the torque generated by energizing the armature 5 can be increased.
In embodiment 1, the first insulating film 54 and the second insulating film 55 are attached to the holding members 53. However, the present invention is not limited to this, and the first insulating film 54 and the second insulating film 55 may be directly attached to the armature core 51. In this case, the first insulating film 54 and the second insulating film 55 are attached to the armature core 51 by welding or the like. In this case, the first insulating film 54 and the second insulating film 55 are attached to the armature core 51 so as to face portions of the armature core 51 adjacent to the holding member 53. That is, in this case, the first insulating film 54 is attached to the armature core 51 so as to face the inner peripheral surface of the yoke 56, and the second insulating film 55 is attached to the armature core 51 so as to face the side surface of the tooth end portion 572.
Embodiment 2.
Fig. 13 is an enlarged cross-sectional view showing a main part of the armature of embodiment 2. Fig. 14 is a cross-sectional view taken along line XIV-XIV of fig. 13. In fig. 13 and 14, the armature winding 52 is not shown. The armature 5 has a plurality of bobbins 7 as insulating members. In the present embodiment, the armature 5 does not include the first insulating film 54 and the second insulating film 55 of embodiment 1. Each bobbin 7 is provided to the armature core 51.
The bobbins 7 are respectively attached to the tooth portions 57 via the holding members 53. Each coil bobbin 7 is made of an electrically insulating material. As a material constituting the bobbin 7, plastic, resin, or the like is used.
The bobbins 7 are interposed between the teeth 57 and the armature winding 52, and between the inner peripheral surface of the yoke 56 and the armature winding 52. Thereby, each bobbin 7 is interposed between the armature core 51 and the armature winding 52.
In each tooth 57, the holding member 53 is interposed between the tooth body 571 and the coil bobbin 7. Accordingly, the electrically insulating state between the armature core 51 and the armature winding 52 is ensured by the respective bobbins 7 and the respective holding members 53.
Each bobbin 7 has a pair of bobbin constituting members 71. The pair of coil frame members 71 is disposed so as to sandwich the tooth 57 in the stacking direction of the plurality of magnetic plates 511. The bobbin 7 is attached to the tooth 57 in a state where the pair of bobbin constituting members 71 are fitted into the tooth 57 via the holding member 53. The other configuration is the same as that of embodiment 1.
Next, a method of manufacturing the armature will be described. In manufacturing the armature 5, the steps are performed in the order of the lamination step S1 and the holding member mounting step S2, as in embodiment 1.
Thereafter, an insulation process step S3 is performed. In the insulation processing step S3, the coil bobbin 7 is mounted to each tooth 57 via the holding member 53.
Fig. 15 is an enlarged cross-sectional view showing a state when the coil bobbin 7 is mounted to the tooth 57 of fig. 13. In the insulation processing step S3, when the coil bobbin 7 is attached to the tooth portion 57, the pair of coil bobbin constituent members 71 are fitted into the tooth portion 57 from both sides of the tooth portion 57 in the stacking direction of the plurality of magnetic plates 511. Thereby, the bobbin 7 is attached to the tooth 57 via the holding member 53.
After the insulation processing step S3, a winding step S4 is performed. In the winding step S4, the armature winding 52 is provided to the armature core 51. At this time, the armature winding 52 is provided to the armature core 51 so that the bobbin 7 is interposed between the armature winding 52 and the armature core 51. Thereby, the holding member 53 is interposed between the armature winding 52 and the tooth 57. In the present embodiment, as in embodiment 1, the armature winding 52 is provided to the armature core 51 by winding a wire around each tooth 57. Thus, the armature winding 52 is provided to the armature core 51 through the bobbins 7 and the holding members 53. The armature 5 is manufactured in this way.
In the armature 5, the bobbin 7 as an insulating member is attached to each tooth 57 via the holding member 53. Each bobbin 7 is interposed between the armature core 51 and the armature winding 52. Therefore, the electrically insulating state between the armature core 51 and the armature winding 52 can be ensured not only by the respective holding members 53 but also by the respective bobbins 7. This can ensure the electrically insulated state between the armature core 51 and the armature winding 52 more reliably. The armature winding 52 can be provided to the tooth 57 through the bobbin 7. This makes it possible to easily hold the armature winding 52 to the armature core 51. Therefore, the operation of providing the armature winding 52 to the armature core 51 can be easily performed, and the productivity of the armature 5 can be further improved. Further, an increase in core loss of the armature core 51 can be suppressed.
Embodiment 3.
Fig. 16 is an enlarged cross-sectional view showing a main part of the armature of embodiment 3. In fig. 16, the armature winding 52 is not shown. The armature core 51 is provided with a plurality of bobbins 7 as insulating members. The bobbins 7 are attached to the teeth 57. The bobbins 7 are interposed between the teeth 57 and the armature winding 52, and between the inner peripheral surface of the yoke 56 and the armature winding 52. Thereby, each bobbin 7 is interposed between the armature core 51 and the armature winding 52.
The structure of each bobbin 7 is the same as that of embodiment 2. In each bobbin 7, a pair of bobbin constituent members 71 is arranged with the tooth 57 interposed therebetween in the lamination direction of the plurality of magnetic plates 511. Each bobbin 7 is attached to the tooth 57 in a state where the pair of bobbin constituent members 71 are directly fitted into the tooth 57.
Each holding member 53 is attached to each tooth 57 through a part of the coil bobbin 7 at the position of the tooth body 571. That is, in each tooth 57, a part of the bobbin 7 is interposed between the tooth body 571 and the holding member 53. Further, each holding member 53 is interposed between the bobbin 7 and the armature winding 52. Accordingly, the electrically insulating state between the armature core 51 and the armature winding 52 is ensured by the respective bobbins 7 and the respective holding members 53.
In a state where the holding member 53 is attached to the tooth portion 57 through a part of the coil bobbin 7, the tooth body portion 571 is inserted inside the holding member 53 through a part of the coil bobbin 7. Each holding member 53 is elastically stretched by being expanded by the tooth body 571 from the inside of the holding member 53 through a part of the bobbin 7. Accordingly, each holding member 53 generates an elastic restoring force for tightening the tooth 57 from the periphery of the tooth body 571 via a part of the coil bobbin 7. Thus, the plurality of magnetic plates 511 are integrated with the bobbin 7 by the holding members 53. That is, each holding member 53 generates an elastic restoring force for fastening the tooth 57 through a part of the bobbin 7 in a state where the bobbin 7 is interposed between the holding member 53 and the tooth 57, thereby integrating the plurality of magnetic plates 511 with the bobbin 7. The other structure is the same as that of embodiment 2.
Next, a method of manufacturing the armature will be described. In the present embodiment, when manufacturing the armature 5, the lamination step S1, the insulation processing step S3, the holding member mounting step S2, and the winding step S4 are performed in this order. Therefore, in the case of manufacturing the armature 5 in this embodiment, the lamination step S1 is performed similarly to embodiment 1, and then the insulation processing step S3 is performed before the holding member mounting step S2 is performed.
In the insulation processing step S3, the bobbins 7 are disposed on the armature core 51. The bobbins 7 are disposed on the armature core 51 by being directly attached to the tooth portions 57. When the bobbin 7 is attached to the tooth 57, the pair of bobbin constituting members 71 are fitted into the tooth 57 from both sides of the tooth 57 in the stacking direction of the plurality of magnetic plates 511. Thereby, the bobbin 7 is mounted to the tooth 57.
After the insulation processing step S3, a holding member mounting step S2 is performed. In the holding member mounting step S2, the holding members 53 are mounted on the teeth 57 through a part of the coil bobbin 7.
Fig. 17 is an enlarged cross-sectional view showing a state in which the holding member 53 of fig. 16 is attached to the tooth 57 in the holding member attaching step S2. In the holding member mounting step S2, the holding member 53 is pulled and the tooth 57 is inserted into the holding member 53 until the position of the holding member 53 reaches the position of the tooth main body 571, as in embodiment 1. Thereafter, in the holding member mounting step S2, the holding member 53 is contracted by the elastic restoring force of the holding member 53, whereby the holding member 53 is mounted on the tooth 57. Thereby, the holding member 53 is attached to the tooth 57 through a part of the bobbin 7.
When the holding member 53 is attached to the tooth 57, an elastic restoring force of the holding member 53 is applied to the tooth 57 via a part of the bobbin 7. Thereby, the holding member 53 generates an elastic restoring force for tightening the tooth 57 from the periphery of the tooth body 571 through a part of the coil bobbin 7. Therefore, the plurality of magnetic plates 511 are integrated with the bobbin 7. That is, in the holding member mounting step S2, the plurality of magnetic plates 511 are integrated with the bobbin 7 by generating an elastic restoring force for fastening the tooth 57 through a part of the bobbin 7 by the holding member 53.
After the holding member mounting step S2, a winding step S4 is performed. In the winding step S4, the armature winding 52 is provided to the armature core 51. At this time, the armature winding 52 is provided to the armature core 51 such that each bobbin 7 is interposed between the armature winding 52 and the armature core 51. The holding member 53 is interposed between the armature winding 52 and the tooth 57. In the present embodiment, as in embodiment 1, the armature winding 52 is provided to the armature core 51 by winding a wire around each tooth 57. Thus, the armature winding 52 is provided to the armature core 51 through the bobbins 7 and the holding members 53. The armature 5 is manufactured in this way.
In the armature 5, a bobbin 7 as an insulating member is attached to each tooth 57. Each holding member 53 generates an elastic restoring force for fastening the tooth 57 through a part of the bobbin 7 in a state where a part of the bobbin 7 is interposed between the holding member 53 and the tooth 57, thereby integrating the plurality of magnetic plates 511 with the bobbin 7. Therefore, the effects of embodiment 2 can be obtained, and the coil frames 7 can be attached to the armature core 51 by the elastic restoring force of the holding members 53. This can further improve the productivity of the armature 5.
In the method of manufacturing the armature, in the holding member mounting step S2, the holding member 53 is caused to generate an elastic restoring force for fastening the tooth 57 through a part of the bobbin 7. Therefore, each coil bobbin 7 can be attached to the armature core 51 by the elastic restoring force of each holding member 53. This can further improve the productivity of the armature 5.
Embodiment 4.
Fig. 18 is an enlarged cross-sectional view showing a main part of the armature of embodiment 4. In fig. 18, the armature winding 52 is not shown. The armature 5 has a plurality of insulating films 8 as insulating members. In the present embodiment, the armature 5 does not include the first insulating film 54 and the second insulating film 55 of embodiment 1. Each insulating film 8 is provided on the armature core 51. Each insulating film 8 is made of an electrically insulating material.
A pair of insulating films 8 are attached to each of the teeth 57. Each insulating film 8 overlaps the outer peripheral surface of the tooth 57 and the inner peripheral surface of the yoke 56. Accordingly, each insulating film 8 is interposed between the tooth 57 and the armature winding 52, and between the inner peripheral surface of the yoke 56 and the armature winding 52. Thus, each insulating film 8 is interposed between the armature core 51 and the armature winding 52.
Each holding member 53 is attached to each tooth portion 57 with a pair of insulating films 8 interposed therebetween at the position of the tooth main body portion 571. That is, in each tooth 57, a part of the insulating film 8 is interposed between the tooth body 571 and the holding member 53. Further, each holding member 53 is interposed between the insulating film 8 and the armature winding 52. Accordingly, the electrical insulation state between the armature core 51 and the armature winding 52 is ensured by the insulating films 8 and the holding members 53.
In a state where the holding member 53 is attached to the tooth portion 57 through a part of the insulating film 8, the tooth body portion 571 is inserted inside the holding member 53 through a part of the insulating film 8. Each holding member 53 is elastically stretched by being expanded by the tooth body portion 571 from the inside of the holding member 53 through a part of the insulating film 8. Accordingly, each holding member 53 generates an elastic restoring force for tightening the tooth 57 from the periphery of the tooth body 571 via a part of the insulating film 8. Thus, the plurality of magnetic plates 511 are integrated with the insulating films 8 by the holding members 53. That is, each holding member 53 generates an elastic restoring force for fastening the tooth 57 through a portion of the insulating film 8 in a state where a portion of the insulating film 8 is interposed between the holding member 53 and the tooth 57, thereby integrating the plurality of magnetic plates 511 together with each insulating film 8. The other structure is the same as that of embodiment 3.
Next, a method of manufacturing the armature will be described. In the present embodiment, when manufacturing the armature 5, the steps are performed in the order of the lamination step S1, the insulation processing step S3, the holding member mounting step S2, and the winding step S4, as in embodiment 3.
In the insulation processing step S3, a plurality of insulation films 8 are disposed on the armature core 51. The insulating films 8 are directly attached to the teeth 57, and are disposed on the armature core 51. At this time, the pair of insulating films 8 attached to the tooth 57 are temporarily held by the tooth 57 by a holder or the like.
After the insulation processing step S3, a holding member mounting step S2 is performed. In the holding member mounting step S2, the holding members 53 are mounted on the tooth portions 57 through a part of the insulating film 8.
Fig. 19 is an enlarged cross-sectional view showing a state in which the holding member 53 of fig. 18 is attached to the tooth 57 in the holding member attaching step S2. In the holding member mounting step S2, the holding member 53 is pulled and the tooth 57 is inserted into the holding member 53, and then the holding member 53 is contracted by the elastic restoring force of the holding member 53, as in embodiment 3. Thereby, the holding member 53 is attached to the tooth 57 through a part of the insulating film 8.
When the holding member 53 is attached to the tooth 57, an elastic restoring force of the holding member 53 is applied to the tooth 57 via a part of the insulating film 8. Thereby, the holding member 53 generates an elastic restoring force for tightening the tooth 57 from the periphery of the tooth body 571 via a part of the insulating film 8. Therefore, the plurality of magnetic plates 511 are integrated with the respective insulating films 8. That is, in the holding member mounting step S2, the plurality of magnetic plates 511 are integrated with the respective insulating films 8 by generating an elastic restoring force of the holding member 53 to fasten the tooth portions 57 via a part of the insulating films 8. The holders or the like for holding the insulating films 8 to the tooth portions 57 are removed from the armature core 51 after the plurality of magnetic plates 511 are integrated with the insulating films 8 by the holding members 53. The subsequent steps are the same as those of embodiment 3.
In this way, even if a plurality of insulating films 8 are used as insulating members without using a plurality of bobbins 7, the insulating state between the armature core 51 and the armature winding 52 can be ensured more reliably. Further, since it is not necessary to attach each insulating film 8 to the armature core 51 by welding or the like, the productivity of the armature 5 can be further improved.
In each of the above embodiments, the holding member 53 is attached to only the tooth body portion 571 of the tooth portions 57. However, the present invention is not limited thereto. For example, the holding member 53 may be attached to not only the tooth body 571 but also the tooth tip 572. In this case, each holding member 53 is interposed between the entire tooth 57 and the armature winding 52. In this way, the plurality of magnetic plates 511 can be more reliably held in an integrated state. That is, each holding member 53 may be interposed between at least a part of the tooth 57 and the armature winding 52.
In addition, in each of the above-described embodiments, the cross-sectional area of the tooth tip portion 572 in the plane perpendicular to the tooth projecting direction is larger than the cross-sectional area of the tooth main body portion 571 in the plane perpendicular to the tooth projecting direction. However, the present invention is not limited thereto. For example, the cross-sectional area of the tooth tip portion 572 in a plane perpendicular to the tooth projecting direction may be the same as the cross-sectional area of the tooth body portion 571 in a plane perpendicular to the tooth projecting direction. In addition, the cross-sectional area of the tooth tip portion 572 in a plane perpendicular to the tooth projecting direction may be smaller than the cross-sectional area of the tooth main body portion 571 in a plane perpendicular to the tooth projecting direction.
In each of the above embodiments, the armature winding 52 is wound around each tooth 57. However, the present invention is not limited thereto. For example, the armature winding 52 may be constituted by a wire that is disposed in each slot 58 so as not to be wound around each tooth 57.
In each of the above embodiments, the annular armature 5 is used as an armature of the rotating electrical machine 1 as an electrical device. However, the present invention is not limited to this, and for example, the linear armature 5 may be used as an armature of a linear motor as an electric device. In this case, the movable element moves along the armature 5 by the movement of the magnetic field generated by energizing the armature winding of the armature 5.
The configuration described in the above embodiment represents an example of the present disclosure. The embodiments can be combined with other known techniques. A part of the structure of the embodiment can be omitted or changed within a range not departing from the gist of the present disclosure.
Examples of modes that can be included in the present disclosure are explicitly described as additional notes below.
(Additionally, 1)
An armature, comprising:
An armature core configured by laminating a plurality of magnetic plates;
A plurality of holding members provided to the armature core to integrate the plurality of magnetic plates, and
An armature winding provided to the armature core,
The armature core has a yoke portion, and a plurality of teeth portions provided to the yoke portion at intervals,
Each of the holding members is formed in a ring shape from an elastic material having electrical insulation,
The holding members are respectively mounted to the teeth,
Each of the holding members generates an elastic restoring force for fastening the tooth portion in a state where the tooth portion is inserted into the inside of the holding member, thereby integrating the plurality of magnetic plates.
(Additionally remembered 2)
The armature of appendix 1, wherein,
Each of the tooth portions has a tooth main body portion protruding from the yoke portion, and a tooth tip portion provided at a protruding end portion of the tooth main body portion,
The holding member is mounted to the tooth body portion,
When the direction in which the tooth main body portion protrudes from the yoke portion is set as a tooth protruding direction, a sectional area of the tooth tip portion in a plane perpendicular to the tooth protruding direction is larger than a sectional area of the tooth main body portion in a plane perpendicular to the tooth protruding direction,
In a state where the holding member is separated from the tooth portion and the holding member is contracted, an area of a region surrounded by the holding member is smaller than a sectional area of the tooth main body portion in a plane perpendicular to the tooth protruding direction.
(Additionally, the recording 3)
The armature according to supplementary note 1 or 2, wherein,
Each of the holding members is interposed between at least a portion of the tooth portion and the armature winding.
(Additionally remembered 4)
The armature according to any one of supplementary notes 1 to 3, wherein,
The armature includes an insulating member made of an electrically insulating material,
The insulating member is interposed between the armature core and the armature winding,
Each of the holding members generates an elastic restoring force for fastening the tooth portion through a portion of the insulating member in a state where a portion of the insulating member is interposed between the holding member and the tooth portion, thereby integrating the plurality of magnetic plates with the insulating member.
(Additionally noted 5)
A method of manufacturing an armature, comprising:
a lamination step of laminating a plurality of magnetic plates to produce an armature core having a yoke portion and a plurality of teeth portions provided to the yoke portion with a gap therebetween;
a holding member mounting step of mounting a holding member formed in a ring shape from an electrically insulating elastic material to each of the tooth portions after the lamination step, and
A winding step of disposing an armature winding on the armature core after the holding member mounting step,
In the holding member mounting step, after the holding member is stretched and the tooth portion is inserted into the inside of the holding member, the holding member is caused to generate an elastic restoring force that fastens the tooth portion, thereby integrating the plurality of magnetic plates.
(Additionally described 6)
The method of manufacturing an armature according to supplementary note 5, wherein,
In the winding step, the armature winding is provided to the armature core so that the holding member is interposed between the armature winding and the tooth portion.
(Additionally noted 7)
The method for manufacturing an armature according to supplementary note 5 or 6, wherein,
The method for manufacturing the armature includes an insulation processing step of disposing an insulating member made of an electrically insulating material on the armature core after the lamination step and before the holding member mounting step,
In the holding member mounting step, the plurality of magnetic plates are integrated with the insulating member by generating an elastic restoring force for fastening the tooth portion through a part of the insulating member,
In the winding step, the armature winding is provided to the armature core such that the insulating member is interposed between the armature core and the armature winding.