JP4821048B2 - Electric motor - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an electric motor used for an air conditioner, a washing machine and the like.
[0002]
[Prior art]
A conventional technique will be described with reference to FIGS.
[0003]
FIG. 8 is a cross-sectional view of an insulator mounted on a stator core of a conventionally used electric motor.
[0004]
FIG. 9 is a perspective view of a conventional stator core of FIG. 8 in which an insulator is mounted. 41 is an upper insulator, 42 is a lower insulator, 47 is an upper insulator thick portion, and 48 is an upper insulator thin portion. , 49 is a lower insulator thick portion, and 60 is a lower insulator thin portion.
[0005]
In recent years, in a stator of an electric motor used for an air conditioner or the like, the stator core has been divided to improve the space factor of the winding as shown in FIG. 3, and then an insulator is mounted as shown in FIG. Next, winding is performed as shown in FIG. 5, and then the unit stator winding products divided as shown in FIG. 6 are connected and rounded to form a stator winding product, which is then molded with resin and then molded as shown in FIG. The stator constituting the electric motor as shown in FIG.
[0006]
In addition, in a conventional electric motor in which the stator is molded with resin, an insulator used to insulate the stator core from the winding is formed by winding the thick portion 47 so that the stator core can be easily mounted as shown in FIG. The upper insulator 41 and the thick wall portion 49 are in close contact with the core, and the lower insulator 42 is in close contact with the core. The insulator thick portions 47 and 49 have the same thickness), and the upper and lower insulator thin portions 48 and 60 overlap each other inside the slot. The upper and lower insulator thin portions 48 and 60 overlap with each other, so that the upper and lower insulator thick portions 47 and 49 have substantially the same thickness.
[0007]
8 in which an insulator is attached to a stator core of a conventionally used electric motor shown in FIG. 8, the length of the stator core 3 in the axial direction is Lc, and the upper insulator 41 is thicker in the axial direction along the slot inner wall of the upper insulator 41 and in contact with the core. The length of the portion 47 is Lua, the length of the upper insulator thin portion 48 in the axial direction of the upper insulator is Luu, and the length of the lower insulator thick portion 49 is axially along the slot inner wall of the lower insulator 42 and contacts the core. Is Lla, and the length of the lower insulator thin portion 60 in the axial direction of the lower insulator is Llu, Lc = Lua + Luu + Llu = Lua + Luu + Lla, or the upper insulator thin portion 48 and the lower insulator thin portion 60 have a dimensional tolerance. There were only gaps to absorb.
[0008]
In particular, in a brushless motor using a permanent magnet, it is necessary to change the voltage applied to the electric motor in order to change the rotation speed and torque. As a method for changing the voltage applied to the electric motor, a PWM method is generally employed in which the voltage is turned on / off at a carrier frequency of about several kHz to 20 kHz. When such a PWM inverter is used, particularly when the voltage is low, the duty ratio is low, and the excitation frequency of the carrier frequency and its sidebands is generated, which may increase the high frequency sound. This is because even when the stator core is molded, the vibration of the winding and the vibration of the stator core are transmitted to the entire stator, resonate, and become sound. In particular, when there is a minute gap between insulators, or between an insulator and a stator core, and between an insulator and a winding, the sound tends to increase.
[0009]
[Problems to be solved by the invention]
In an electric motor in which the conventional insulator as described above is used and the stator winding product is molded with resin, the resin does not enter the overlapping portions inside the slots of the two insulators. Due to the electromagnetic vibration generated from the wire, the overlapping portions vibrate and generate noise, and there is a strong demand for noise reduction.
[0010]
This invention is invented in view of such a subject, and it aims at providing the electric motor with low noise.
[0011]
[Means for Solving the Problems]
In order to solve this problem, the present invention relates to a stator winding product comprising a stator core, a winding applied to the stator core, and an insulator that insulates the stator core from the winding. in the stator formed by molding, said insulator is divided into two insulators having a portion was overlapped with each other at least within the slot, the non-overlapping part with each other in the slot forms a thick portion, the overlapping mating parts two insulators Insulators that have a thin part that has the same thickness as the thick part by combining the overlapping parts of the two parts, the insulator in which the thin part is in close contact with the core is the lower insulator, and the thin part is in close contact with the winding Insulator that is The axial length of the stator core is Lc, the length of the thick portion along the axial inner wall of the slot of the upper insulator and in contact with the core is Lua, the length of the thin portion of the upper insulator in the axial direction is Luu, and the lower insulator Lc> Lua + Luu + Lla and Lc− (Lua + Luu + Lla) where Lla is the length of the thick wall portion along the axial direction of the inner wall of the slot and contacting the core, and Llu is the length of the thin wall portion in the axial direction of the lower insulator. The electric motor has a configuration in which a resin is filled in a gap generated between two insulators and a winding and a gap generated at a boundary surface between the core and the insulator .
[0012]
DETAILED DESCRIPTION OF THE INVENTION
A first invention of the present application is an electric motor including a stator and a rotor, and a stator winding product including a stator core, a winding wound around the stator core, and an insulator that insulates the stator core from the winding is molded with resin. in the stator formed by the insulator divided into two insulators having a portion was overlapped with each other at least within the slot, the non-overlapping part with each other in the slot forms a thick portion, the overlapping mating parts of the two insulators by overlapping back portion each other mate, the insulator forming a thin portion such that the same and the thick portion thickness of insulator thin portion is in close contact with the core lower insulator, the thin portion in close contact with the winding The upper insulator is used as the insulator and the stator The axial length of the upper insulator is Lc, the length of the thick portion along the axial inner wall of the slot of the upper insulator and in contact with the core is Lua, the length of the thin portion of the upper insulator in the axial direction is Lu, and the lower insulator Lc> Lua + Luu + Lla and Lc− (Lua + Luu + Lla) are 2 mm, where Lla is the length of the thick wall portion along the axial direction on the inner wall of the slot and in contact with the core, and Llu is the length of the thin wall portion in the axial direction of the lower insulator. As described above, the electric motor has a configuration in which resin is filled in a gap generated between two insulators and a winding and a gap generated in a boundary surface between the core and the insulator . Lc> Lua + Lu + Lla When the resin is molded into the gap between the insulators generated by making Lc> Lua + Luu + Lla, the resin that has entered reduces the electromagnetic vibration generated from the wires in order to firmly hold the wires in contact with the insulators In addition, since the resin that has entered firmly holds the thin wall portions of the two insulators, it has the effect of reducing the vibration of the overlapping portions of the two insulators and reducing the noise generated from the motor. In addition, when molding into the gap between the insulators, the resin can easily enter, and the inserted resin firmly holds the thin portion of the two insulators, so that the vibration of the overlapping part of the two insulators is reduced, and the electric motor It has the effect of reducing noise generated from the.
[0013]
Further, in the electric motor of the present application, the electric motor has a configuration in which resin is filled in a gap generated by Lc> Lua + Luu + Lla, and resin is provided in a gap between insulators generated by setting Lc> Lua + Luu + Lla. Filling reduces the electromagnetic vibration generated from the wires because the filled resin firmly holds the wires in contact with the insulator, and the filled resin holds the thin portions of the two insulators firmly. For this reason, it has the effect of reducing the vibration of the overlapping part of the two insulators and reducing the noise generated from the electric motor.
[0014]
Further, in the electric motor of the present application, the electric motor has a configuration in which resin is poured into a boundary surface between the core and the insulator from a gap generated by Lc> Lua + Llu + Lla, and the resin is applied to the boundary surface between the core and the insulator. By pouring, the noise generated from the electric motor is reduced and the insulation performance between the winding and the core is improved.
[0015]
Further, in the electric motor of the present application, the electric motor is configured to have a configuration in which Lc− (Lua + Luu + Lla) is 2 mm or more. This makes it easier for the resin to enter when molding into the gap between the insulators. By securing 2 mm or more, the resin can sufficiently enter when molding into the gap between the insulators to sufficiently reduce the noise generated from the motor. Has the effect of being able to.
[0016]
In the above electric motor, which has a motor having a thin configuration towards the thin portion of the lower insulator than the thin portion of the upper insulator is thinning towards the thin portion of the lower insulator than the thin portion of the upper insulator Thus, the gap generated by Lc> Lua + Luu + Lla is further increased, and the resin can easily enter when molding into the gap.
[0017]
In the above electric motor, which has a motor towards the thin portion of the lower insulator than the thin portion of the upper insulator is provided with a thick structure, increasing the thickness towards the thin portion of the lower insulator than the thin portion of the upper insulator Thus, the gap generated by Lc> Lua + Llu + Lla is further increased, and the resin can easily enter when molding into the gap.
[0018]
In the above electric motor, which has a motor having a structure in which direct winding is applied to the teeth, an increase and a decrease in noise insulation which has been generated by applying a direct winding on the teeth It has the effect of reducing defects.
[0019]
In the above electric motor, a resin material for molding the stator, from the start of injecting resin into the mold die, is until it has obtained by an electric motor having a thermosetting resin does not start curing, the stator By using a thermosetting resin that does not start until the resin material to be molded is injected into the mold, the resin is in the gap generated by Lc> Lua + Luu + Lla or Lc> Lua + Llu + Lla. The resin is completely filled, and the resin flows into the interface between the insulator and the core, so that the noise can be reduced and the insulation performance between the electric wire and the core can be improved.
[0020]
【Example】
Hereinafter, embodiments of the present invention will be described with reference to FIGS. 1, 2, 3, 4, 5, 6, and 7.
[0021]
FIG. 1 is a cross-sectional view taken along a line AB of an insulator mounted on a stator core of an electric motor according to the present invention.
[0022]
FIG. 2 is a perspective view of an insulator mounted on the stator core of the electric motor of the present invention.
[0023]
FIG. 3 is a perspective view of one piece of the stator core.
[0024]
FIG. 4 is an exploded perspective view of the stator core and the insulator of the electric motor of the present invention.
[0025]
FIG. 5 is a perspective view of a part of a stator winding product in which an insulator is mounted on the stator core of the electric motor of the present invention and the winding is applied.
[0026]
FIG. 6 is a perspective view of a stator winding product configured by connecting a part of the stator winding product of FIG. 5.
[0027]
FIG. 7 is a sectional view of the electric motor after the stator winding product of FIG. 6 is molded with resin and the rotor is assembled.
[0028]
In the figure, 1 is an upper insulator, 2 is a lower insulator, 3 is a stator core, 4 is an upper insulator thick portion, 5 is an upper insulator thin portion, 6 is a lower insulator thick portion, 7 is a lower insulator thin portion, and 8 is a winding. Line 9, stator 10, rotor 11, resin 11, bearing 12, shaft 13, bracket 14, and stator winding 15.
[0029]
Next, examples of the present motor will be described.
[0030]
First, in the insulator as shown in FIG. 1, Lc− (Lua + Luu + Lla) = 2 mm in the upper insulator 1, Lc− (Lua + Llu + Lla) = 2 mm in the lower insulator 2, and the upper and lower insulators 1 are arranged in the stator core 3 as shown in FIG. 4. 2 and winding 8 as shown in FIG. 5 to form a stator winding product 15 as shown in FIG. 6, and resin 11 is molded with an unsaturated polyester resin molding material as shown in FIG. The rotor 10, the bearing 12, the shaft 13, and the bracket 14 are attached to form an electric motor. Moreover, the unsaturated polyester molding material used in this case is a liquid resin comprising an unsaturated polyester resin with a styrene monomer, a thermoplastic resin, a curing agent, an aluminum hydroxide, calcium carbonate, glass fiber, a release agent, a colorant, etc. It was a thermosetting resin mixed with the above filler, and by selecting the type and amount of peroxide used as the curing agent, curing was started at 150 ° C. in 50 seconds. The mold temperature at the time of molding was 150 ° C., the time from the start of pouring the resin 11 into the mold mold to the end of the mold was 20 seconds, and the curing time in the mold mold was 350 seconds.
[0031]
The upper insulator 1 may be Lc> Lua + Luu + Lla.
[0032]
Further, the lower insulator 2 may be Lc> Lua + Llu + Lla.
[0033]
Further, when the resin 11 enters between the two upper and lower insulators 1, 2 and the winding 8, the effect is further improved.
[0034]
Further, when the resin enters the boundary surface between the stator core 3 and the upper insulator 1, the effect is further improved.
[0035]
When the upper insulator satisfies Lc> Lua + Luu + Lla, the lower insulator thin portion 7 is thinner than the upper insulator thin portion 5 because the gap 16a formed by the two upper and lower insulators 1 and 2 is larger.
[0036]
When the lower insulator 2 is Lc> Lua + Llu + Lla, the lower insulator thin portion 7 is thicker than the upper insulator thin portion 5 because the gap 16b formed by the two upper and lower insulators 1, 2 and the stator core 3 is larger. .
[0037]
Further, as conventional examples, in upper and lower insulators 41 and 42 as shown in FIG. 8, Lc− (Lua + Luu + Lla) = 0, Lc− (Lua + Llu + Lla) = 0, and the thickness of the upper insulator thin portion 48 and the lower insulator thin portion 60 are set. Is the same as the thickness of the two upper insulator thick portions 47 or the lower insulator thick portions 49, and the stator winding product 15 shown in FIG. 6 is used in the above embodiment. The same unsaturated polyester resin molding material was molded under the same conditions to obtain an electric motor as shown in FIG.
[0038]
As a result of attaching the electric motor of the example and the conventional example as an indoor fan motor of the air conditioner and measuring the noise in the rated operation, the air conditioner incorporating the electric motor of the example is compared with the air conditioner incorporating the electric motor of the conventional example, Noise was reduced by 2 dB. Further, it was confirmed that the resin entered the gap between the insulators generated by disassembling the stator 9 of the electric motor of the example and setting Lc− (Lua + Llu + Lla) and Lc− (Lua + Lu + Lla) to 2 mm or more. Further, when the stator of the conventional electric motor was disassembled, no resin entered the portion where the two upper and lower insulator thin portions 48 and 60 overlapped. As a result, the resin 11 entering the gaps 16a and 16b formed by the upper insulator 1 and the lower insulator 2 or the upper insulator 1, the lower insulator 2, and the stator core 3 firmly holds the winding 8 in contact with the insulator. In order to reduce the electromagnetic vibration generated from the winding 8 and to firmly hold the two upper and lower insulator thin portions 5 and 7 by the resin 11 entering, the two overlapping upper and lower insulator thin portions 5 and 7 Vibration can be reduced and noise generated from the electric motor can be reduced.
[0039]
In addition, although the divided | segmented core was used in the Example, the same effect is acquired even if it is not a core by division | segmentation. Further, even if the core is divided, the insulator is not divided for each divided core, and the same effect can be obtained even with an arbitrary number of divisions.
[0040]
In addition, when the washing tub with a large inertia is directly connected to the electric motor or connected through a mechanism, the noise reduction effect is particularly effective. In addition, when used for a pump that is splashed with water, or when used for an outdoor fan motor of an air conditioner, the insulation between the winding and the core can be improved, so that the water resistance can be improved.
[0041]
【The invention's effect】
As described above, according to the present invention, the resin that has entered the gap between the insulators reduces the electromagnetic vibration generated from the wires in order to firmly hold the wires in contact with the insulators. In order to firmly hold the thin-walled portions of the two insulators, an advantageous effect of reducing the vibration of the overlapping portions of the two insulators and reducing the noise generated from the electric motor can be obtained.
[0042]
In addition, when molding into the gap between the insulators, the resin can easily enter, and the inserted resin firmly holds the thin portion of the two insulators, so that the vibration of the overlapping part of the two insulators is reduced, and the electric motor The advantageous effect of reducing the noise generated from the is obtained.
[0043]
In addition , according to the present invention, the resin between the insulators is filled with resin, so that the filled resin firmly holds the electric wire in contact with the insulator, thereby reducing electromagnetic vibration generated from the electric wire, and further filling. Since the formed resin firmly holds the thin wall portions of the two insulators, an advantageous effect of reducing the vibration of the overlapping portion of the two insulators and reducing the noise generated from the electric motor can be obtained.
[0044]
In addition , according to the present invention, the resin is poured into the interface between the core and the insulator, thereby reducing the noise generated from the electric motor and improving the insulation performance between the winding and the core. .
[0045]
Further, according to the present invention, Lc− (Lua + Luu + Lla) is set to 2 mm or more, so that the resin can easily enter when molding into the gap between the insulators, and it is advantageous in that noise generated from the electric motor is reduced. An effect is obtained.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view of a state where an insulator is mounted on a stator core of an electric motor of the present invention. FIG. 2 is a perspective view of a state where an insulator is mounted on a stator core of the electric motor of the present invention. FIG. 5 is an exploded perspective view of a stator core and an insulator of the electric motor of the present invention. FIG. 5 is a partial perspective view of a stator winding product in which the insulator is mounted on the stator core of the electric motor of the present invention. FIG. 7 is a perspective view of a stator winding product formed by connecting a part of a wire product. FIG. 7 is a sectional view of an electric motor after the stator winding product of FIG. 6 is molded with resin and a rotor is assembled. FIG. 9 is a cross-sectional view of a conventional stator core mounted with an insulator. FIG. 9 is a conventional motor stator core mounted with an insulator. Perspective view DESCRIPTION OF SYMBOLS
DESCRIPTION OF SYMBOLS 1 Upper insulator 2 Lower insulator 3 Stator core 4 Upper insulator thick part 5 Upper insulator thin part 6 Lower insulator thick part 7 Lower insulator thin part 8 Winding 9 Stator 10 Rotor 11 Resin 12 Bearing 13 Shaft 14 Bracket 15 Stator winding product 16a, 16b gap

Claims (1)

A motor comprising a stator and a rotor, a stator core, a winding applied to the stator core, the stator windings article comprising a stator core and windings from an insulator for insulating the stator formed by molding a resin, the insulator Is divided into at least two insulators having overlapping portions inside the slot, the portions that do not overlap each other in the slot of the insulator form a thick portion, and the overlapping portions are the overlapping portions of the two insulators. it allows the insulator forming a thin portion such that the substantially the same as the thick portion thickness, top to bottom insulator the insulator thin portion is in close contact with the core, the insulator thin portion is in close contact with the winding Insulator and stator core Lc is the axial length of the upper insulator, Lua is the length of the thick wall portion that is axially in contact with the inner wall of the slot of the upper insulator and contacts the core, Lu is the length of the thin wall portion of the upper insulator in the axial direction, and Luo is the slot of the lower insulator Lc> Lua + Luu + Lla and Lc− (Lua + Luu + Lla) are 2 mm or more, where Lla is the length of the thick wall portion along the inner wall along the axial direction and in contact with the core, and Llu is the length of the thin wall portion in the axial direction of the lower insulator. An electric motor having a configuration in which a gap formed between two insulators and a winding and a gap formed at a boundary surface between the core and the insulator are filled with resin .

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