JPS59191444A - Stator coil - Google Patents

Abstract

PURPOSE:To eliminate a connecting work and a connecting space by arranging coils, sensors, an electric circuit and parts on a plane sheet and continuously connecting among the parts all by pattern conductors. CONSTITUTION:Coil poles 40a-40b, 41a-41b, 42a-42b which are made of pattern conductors are formed at an interval of 60 deg. on the front and back surfaces of an insulating sheet 25, and connected between the front surface and the back surface via through hole electrodes 45a-45f. A drive electronic circuit 75 such as an IC for driving a motor and circuit parts 76, 66 are wired fixedly on the plane of the wiring units of the sheet 25. Further, a pattern conductor 80 for connecting connectors is formed at the end of the wiring unit. In this manner, the terminal connections between the coil poles, between the phases and between the sheet can be eliminated.

Description

[Detailed Description of the Invention] [Field of Application of the Invention] The present invention relates to the structure of a stator coil for a motor manufactured by machining, soching, plating, etc., and in particular to a low-cost and simple type that takes advantage of the features of this type of coil. Regarding structure.

[Behind the invention L]

Figure 1 shows an example of the structure of a conventional wire-wound coil. is a plan view of the magnetic poles of the rotor magnet of the motor.This wire-wound coil has a 6-phase 8-pole structure, and is stacked and fixed on the surface of the stator yoke 3 so as to face the magnetic pole surface of the flat rotor magnet 8. Forms the motor electromagnetic part.The coil for one phase is composed of one flat coil with 8 poles, and the terminals of each adjacent coil pole are connected in a continuous manner in a single stroke so that they are in opposite directions. The conductor wire is a self-bonding wire whose surface is coated with an adhesive that melts with heat or alcohol.A special winding machine is used to manufacture the coil.Eight coils are arranged in a ring. The wire rod is sequentially and continuously wound around the triangular winding core while being heated or immersed in alcohol, and finally both the front and back sides are heated and pressed to form a flat shape.The terminal lead 5 was 1 equivalent.

! Takes out 12 bottles of 1 liter. These three 2.

The flat coils are concentrically stacked and fixed electrically in the circumferential direction while being electrically shifted by iπ. The terminal 5 of each coil is connected by soldering to the patterned surface of a wiring board 9 fixed to the side surface. A rotor magnet and a sensor 4 for detecting the rotational position of the rotor 8 are fixed on the wiring board 9. Drive electronic circuit 7
4 is provided separately and is connected to the lead wire 93 from the wiring board 9 of the motor with a connector 82, 82'.

Furthermore, the electronic circuit 74 is connected to the power supply 73 by connectors 80, 80' and lead wires 94.

In conventional coils with this structure, the fi+ wiring board, coil, and circuit board are separate, so each terminal has to be processed a lot, and it takes a lot of man-hours to assemble it.

The more time it takes, the more expensive it becomes. Manufacturing the coil itself requires a long winding time, requires peeling off the insulation coating of the terminal, and is difficult to automate the connection to the wiring board 9.

(2) It is easy to cause poor contact at the connection part, resulting in low reliability.

(3) It is difficult to create a high-density mounting structure.

(4) The thickness of the continuous connecting wire between the coil poles becomes an ineffective thickness, reducing motor efficiency.

(5) Since it is difficult to increase the pole area of the winding, the winding coefficient (the rate at which the coil interlinks with the magnetic flux at that position) is low.

(6) It is difficult to construct a thin motor because it is difficult to reduce the coil thickness.

(7) Coil pole shape cannot be freely selected.

(8) Since the wire is wound while applying tension, thin wires are likely to break.

(9) The shape and dimensions of each coil pole tend to vary, making it difficult to maintain constant performance.

OI: Pole arrangement accuracy cannot be increased.

There are drawbacks such as.

[Purpose of the invention]

An object of the present invention is to improve the drawbacks of the prior art and provide a thin, low-cost, mass-produced motor coil.

[Summary of the invention]

In order to achieve the above object, the stator coil of the present invention has the following features: (11) The coil conductor is a sheet-like coil formed of a patterned conductor by etching, plating, etc.

(2) At least the coil poles, the connection between the coil poles, the coil phase terminal, and the wiring part of the electronic circuit or its components are provided on the front and back planes of one sheet, and wiring is conducted between them using a patterned conductor. By adopting a connected structure and improving manufacturability, we have achieved significant cost reductions.

is its main characteristic.

[Embodiments of the invention]

Hereinafter, the present invention will be explained based on examples.

FIG. 2 is a side view of the basic structure of a sheet-like coil constituting the stator coil of the present invention, in which (α) is a plan view and (hl is a cross-sectional view). By forming a spiral pattern conductor 28 and forming a coil pole, if the zero pattern conductor 28 is formed on both the front and back sides of the insulating sheet 25, the coil efficiency can be improved because the number of turns can be increased with low resistance and the coil pole area can be widened. The resulting high-efficiency motor can be constructed easily. Also, the coil pole shape is uniform, increasing the accuracy of pole arrangement and making the motor output completely stable. The surface of the patterned conductor 28, 28' is covered with an insulating coating material 26. This structure In this example, the patterned conductors 28 and 28' are formed on the surface of the thin insulating film 25, but in addition, the patterned conductors 28 and 28' may be formed separately in advance and then fixed on a thin insulating material, or the patterned conductors 28 and 28' There is also an example of a structure in which 28' and 28' are bonded via an insulating layer.The basic structure and effect of the finished form are the same in either case.

Examples of the stator coil of the present invention are shown below.

Both have a coil structure that rotates once (8-pole magnetized rotor magnet) as in the conventional example.

FIG. 3 is a diagram showing a first embodiment of the stator coil of the present invention, (c
1 is a front plan view, (b) is a back plan view, and cl is a wiring diagram. This example is also an example of a flat coil in which an 8-pole flat magnet is rotationally driven by three phases.

Six coil poles made of patterned conductors are formed at 60" intervals on each of the front and back surfaces of the insulating sheet. The coil poles on the front and back of the sheet are arranged so that the coil poles of the same phase are overlapped with each other. Then coil fi, 40(Z, 40b
is the U phase, 41z, 41A are the V phase, 424°42h is the W phase, on the back of the sheet 25, the coil pole 40C140d is the U phase, 41c, 41d are the V phase, 42C, 42ct
is the W phase. The coil pole 40α is 40C, 40/l is 40d, 41a (d41c, 41b is 41d, 4
2α overlaps with 42c, and 42h overlaps with 42d on the front and back of the insulating sheet 250. The connection between the front and back is through-hole electrodes 45a, 45d, 45C, 4 provided inside the poles of each coil.
5f, 45h, and 45g, and the whole wire is connected in a star shape. On the sheet surface of the inner circumference of the coil pole is a wiring pattern 60α for a rotational position detection sensor of the rotor magnet.
60h and 60t2f are provided to fix the arrangement of sensors such as Ashihole elements. Further, a pattern conductor (pattern conductor for FG) 46 of a frequency generator is formed on the outer periphery of the coil pole to generate electricity by changes in magnetic field due to rotation of the rotor magnet. The insulating sheet 25 has a circular part provided with the coil poles of each phase extended in the radial direction to form a wiring part. A drive electronic circuit 75 such as an IC for driving the motor and circuit components 76 and 77 are wired and fixed on the plane of the wiring section. For this reason, each terminal end of the coil pole, the FG pattern conductor terminal, and the output terminal of the sensor are continuously drawn in here using a pattern conductor. 65 and 71 are connection lead pattern conductors of the coil, 6
Reference numerals 6 and 67 are connection IJ-dot pattern conductors at the end of the sensor, and 69 is an FG terminal connection lead pattern conductor. 68
is a connection lead pattern conductor for electronic circuits and component quantity wiring. Furthermore, a patterned conductor 80 for connecting a connector is provided at the tip of the wiring portion, and is connected to the two components of the drive electronic circuit. Connect a connector here and supply current, signals, etc. from the outside. In addition to the coil terminals, through holes are also used to connect the sensor terminals, etc., and all pattern conductors on the front and back of the sheet are connected.

In stator coils with this structure, the coils, sensors, electronic circuits, and components are all arranged on a single sheet plane, and all parts are connected continuously with patterned conductors, so there is no need for terminal processing due to the morph structure. At the same time, an inexpensive insulating sheet that does not require heat resistance can be used, resulting in a significant cost reduction. Furthermore, since the coil conductor, FG, each wiring pattern conductor, etc. can be manufactured using the same pattern manufacturing process, the productivity of the coil can be increased from this point of view as well, and further cost reduction can be achieved. In addition, electronic circuits can be used as sensors,
Since it is arranged close to the FG and the coil, the connecting lead portion can be completely shortened, and the S/IVf of the signal can be improved without the effects of induction noise, etc., and the entire motor can be configured with high control accuracy. Furthermore, in the 6-wire structure that allows the outer diameter of the motor, including the electronic circuit, to be made smaller and more compact, resulting in a high-density mounting type motor, is there a reinforcing plate on the sheet surface of the electronic circuit/component wiring section? If you take reinforcement measures such as attaching the parts, it will be easier to assemble and increase the reliability.

No. 4V is a diagram showing a second embodiment of the stator coil of the present invention, (α
) is the top plan view, (b) is the sensor/FG wiring section? Side plan view, (schematic diagram explaining how to fold the C1 sheet, (d)
(e) is a wiring diagram of the coil section, and (e) is an example of the structure for incorporating it into the motor lightning magnetic section. This example is an example in which the number of coil sheet portions in the first embodiment is increased to three, and the sensor wiring portion and the FG pattern portion are provided on a separate sheet portion from the coil pole sheet. The basic configuration is the same as in the first embodiment. In this example, the first
The coil sheet portion 20, the second coil sheet portion 20', and the third coil sheet portion 20# are connected to the sensor wiring portion sheet 2.
A-A', B-B', C4 respectively on the surface of 1
The stator coil is formed by bending and stacking the ``'' part.

At this time, the first. Second. 3rd coil sea) 20.20'
, 20'' coil poles and the sensor positions of the sensor wiring sheet 21 are arranged in a predetermined positional relationship. That is, in the U phase, the coil poles 40 (Z,
40b, doe, 40f, 40i, AO)' and the coil poles on the back side 40c, 40d, 40. q, A
Oh, 4 [Between IJC and AOl, the coil poles 41α, 41b, and 41g on the surface side in the V phase.

41f, 41i, 41j and the coil pole 41c on the back side
, 41d, 41y.

41A, 41&, 411, and in the W phase, the front side coil poles 42a, 42h, 42g, 42f
, 42i, 427 and the coil pole on the back side 42c, 4
2d, 42y, 42A, 42, and 421 so that the coil poles between the sheets completely overlap each other. Further, the sensors are stacked and fixed so that the sensor position is at a predetermined angular position with respect to the coil pole position.

An FG pattern conductor 4 is provided on the back side of the sensor wiring sheet 21.
There are 6 items. The driving electronic circuit 752, the circuit component 77, and the connector wiring section are wired and fixed to the continuous sheet section 22 adjacent to the sensor wiring section sheet 21.

The arrangement of the connection lead pattern conductors is the same as in the first embodiment, as long as they are continuous between the sheet parts. As a structure for incorporating this coil into the motor electromagnetic part, ρ)
There is an example of the structure. This coil is fixed on the surface of the stator yoke 3 and is opposed to the magnetic poles of the rotor magnetide 8. Since a protruding element such as a Hall element is used as the sensor, a concentric step is provided at the periphery of the center hole of the stator yoke 3 and the sensor 4 is fitted therein. A reinforcing plate 90 is provided on the back side of the electronic circuit/component wiring section 22. When the reinforcing plate 90 is made of a material with high heat transfer properties such as aluminum or ceramic, all of the heat generated in the driving electronic circuits and components can be dissipated, and the heat resistance of the circuits and components can be improved.

By adopting such a laminated structure, the outer diameter of the coil can be increased and the number of coil conductors can be increased, so that the amount of linkage with the rotor magnetic flux can be increased, and a high-efficiency motor can be constructed. Furthermore, since the length of the F'G pattern conductor can be increased, the FG small output can be increased. Furthermore, since the outer diameter of the coil can be easily reduced, a small motor can be constructed. Other effects similar to those of the first embodiment can be obtained.

FIG. 5 is a diagram showing a third embodiment of the stator coil of the present invention, (C
1 is a plan view of the coil, (BL is a side view of the structure in which this coil is assembled into the motor electromagnetic part, and (C1 is a plan view of the assembly of the stator yoke and sensor. This example shows the sensor wiring part and the electronic circuit.
This is an example in which the component wiring section is the same sheet section, and basically has the same foldable laminated structure as the second embodiment. In this structure, when incorporated into the motor electromagnetic section, the sensor wiring section txt child circuit e component wiring section is located outside the stator yoke 3 and fixed within its plane. Therefore, sensors 4α, 4h
, 4c pass completely through the center hole of the stator yoke 3 and face the magnetic pole surface of the magnet 8 in the electromagnetic section from the outside surface side.

By adopting such a structure, the outer diameter of the motor can be reduced and a high-density mounting structure can be achieved. Further, since the wiring sheet portion is fixed to the back surface of the stator yoke 3, there is no need to take measures to reinforce this portion, and costs can be reduced. It is also possible to provide the stator yoke 6 with a heat radiation effect.

Furthermore, since the sensor wiring pattern is all provided outside the stator yoke 3, induction by the rotating magnetic field of the rotor magnet 8 can be eliminated, and the S/7vf of the sensor output can be improved to achieve high-precision rotation division. be able to.

FIG. 6 is a diagram showing a fourth embodiment of the stator coil of the present invention.

This example also has a folded laminated structure.

This embodiment differs from the first to third embodiments in that each side of the coil sheet is constructed with coil poles of the same phase. 1st
The coil sheet part 2o has 8 poles on the front and back, all yU-phase coil poles, and the second coil sheet part 20'' has 8 poles on the front and back, all 2W-phase coil poles. The eight coil poles on the front and back sides of each coil sheet are arranged in the conductor winding direction so that adjacent poles have opposite polarities. In this example, as in the second embodiment, the sensor wiring section and the FG pattern conductor 46 are provided on the same sheet section. The sensor wiring pattern is 96 in addition to 60a, 60b, and 60c. The sensor for detecting the rotational position of the rotor magnet is fully fixed on 60α+ 60h and 60C.
A sensor (for example, a phase control sensor) for detecting a specific position of the rotating body is fixed to 96. Coil, sensor, FG
Each terminal is continuously led to the electronic circuit/component wiring sheet section 22 using each connection lead pattern conductor as in the previous embodiment. The bending points for lamination are A-A', B-
D', C-C' and I-)-D', the seat portion 22 is disposed at the bottom with the stator yoke in between, as in the third embodiment. In such a structure, since the number of coil poles is large, the first to
The effective conductor length of the coil in the third embodiment can be lengthened (as a result, the motor efficiency can be increased.Other effects are the same as those of the first to third embodiments.In this structure, the coil sheet portions of each phase are further continuous. It is also possible to add a reinforcing plate or a heat sink to the sheet part 22 of the circuit/component wiring part.

In the above embodiments, the structure of a stator coil for a motor that drives an 8-pole magnet in three phases has been described, but stator coils for motors using other drive methods are almost the same, and these are also within the scope of the present invention. It is. Further, the sensor wiring pattern, FG pattern, etc. on the sheet surface may have a structure consisting only of LTF, a coil conductor pattern and its connecting lead pattern, a drive electronic circuit/component wiring pattern, and its connecting lead pattern. Furthermore, the sensor was manufactured using patterning technology, with wiring patterns 60α, 60b, 6
It may be formed in the 0C portion from the beginning.

〔Effect of the invention〕

Stator coil according to the invention? +11 Since terminal connections between coil poles, between phases, and between sheets can be eliminated, the number of steps during coil manufacturing can be reduced, the work can be simplified, and costs can be reduced.

(2) Since the wiring board containing the electronic circuit is also incorporated into the coil sheet, connection work and connection space to the circuit section are unnecessary. This makes it possible to reduce costs and make the motor more compact.

Furthermore, the S/IV6 of the signal can be improved.

(3) An unwired pattern at the end of the position detection sensor, an unwired pattern at the end of the speed generator 9 phase detection sensor, etc. can be easily installed together with a low-cost structure.

(4) Since it is manufactured by etching or plating and is in sheet form, it is highly workable in manufacturing and assembling.

(5) Coil pole arrangement accuracy, uniformity of capital punishment, etc.? Since it can be made higher, the motor output can be stabilized.

(6) Since the conductor space factor and winding coefficient can be increased, the motor efficiency can be completely improved.

Effects such as this can be obtained.

[Brief explanation of drawings]

Fig. 1 is a structural diagram of a conventional stator coil, Fig. 2 is a basic configuration diagram of a stator coil of the present invention, and Fig. 3 is a plan view and circuit diagram showing a first embodiment of the stator coil of the present invention. , FIG. 4 shows a second embodiment of the stator coil, FIG. 5 shows a third embodiment of the stator coil, and FIG. 6 shows a fourth embodiment of the stator coil. . 25...Insulating material 40σ~1.41α~1.42α~l...Pattern conductor coil poles 65, 66, 67α~b, 6B, 69.
71... Connection lead pattern conductor A5a-r, 47
．． 4B, 49.50.55a-, f, 70-Through hole 74, 75.76, 77... Drive electronic circuit/component 80... Patterning technology for connector connection 1 Figure (Q-) (d,) Figure 2 (Q-) Figure 3 (α) Figure 3 (b) Figure 3 (2) (C) S 417] Figure 4 (d-)

Claims (1)

[Claims] 1. In a stator coil for a brushless motor that obtains rotational driving force by controlling and supplying current corresponding to the magnetic poles of the rotor magnet to the stator coil using a drive electronic circuit, at least a pattern formed by etching, plating, etc. It is characterized by a structure in which a spiral coil pole made of a conductor, a connection part between the coil poles, an interphase terminal part/connection part, and a wiring part for the drive electronic circuit or its peripheral parts are provided on the front and back planes of one sheet. stator coil,