JPWO2018142465A1 - Axial gap type electric rotating machine - Google Patents

Abstract

In an axial gap type rotating electric machine, a plurality of core units formed by a core, a coil and a bobbin are provided in a stator in which a plurality of core units are annularly arranged along the inner circumferential surface of the housing about the rotation axis, An axial gap type electric rotating machine having an end face of a core and a rotor facing through a gap, wherein the housing has an outlet for drawing out the wiring to the rotor, and the outlet of the housing is An inclined surface was provided on the lower side so that the inner peripheral side was down. Alternatively, the housing has a recess below the outlet so that the inclined surface and the recess are integrated. As a result, when molding the stator, the resin mold can be made to flow easily and breakage of the bobbin of the core unit can be avoided.

Description

  The present invention relates to an axial gap type rotating electrical machine, and more particularly to an axial gap type rotating electrical machine for molding a stator.

  An axial gap type rotary electric machine is one in which a cylindrical stator and a disk-like rotor are disposed face to face in the rotation axis direction via a predetermined air gap. The stator includes a plurality of iron cores disposed in a curved manner in the inner circumferential direction of the housing portion, and a coil wound around the cores. The axial gap type rotating electrical machine has a high efficiency and thin shape compared with the radial gap type of the mechanism having a gap in the radial direction, since the gap surface that generates torque increases approximately in proportion to the square of the diameter. It is considered to be a suitable rotating electrical machine.

  In particular, a double rotor type axial gap type rotating electrical machine in which one stator is sandwiched by two rotors can secure a gap area twice as high, so that it is possible to obtain better characteristics. It is noted as a structure. In this double rotor type axial gap type rotating electrical machine, since the iron core and the coil are disposed independently, they are often supported and fixed to the housing by a molding resin.

  For example, in Patent Document 1, the housing has a hole communicating with the outside on the surface facing the stator, and the stator has a plurality of core units facing the side surface facing the housing inner circumferential surface and the hole An axial air gap type rotary electric machine is disclosed in which the resin is filled in the part and molded integrally (FIG. 4, paragraph number 0024).

International Publication No. 2015/162819

  The patent document 1 provides a hole for fixing the resin mold in the housing, thereby causing a tensile force acting on the tip of the resin filled in the hole with the force acting in the rotation axis direction and the rotation axis radial direction. Can be released, and damage to the housing can be prevented.

  In general, a thermosetting resin is often used when molding by resin molding. When such a resin is used, in the latter half of the resin encapsulation process, it is necessary to perform resin encapsulation at high pressure in order to start curing of the previously injected resin and to fill the resin to every corner.

  When molding a stator by molding, an axial gap type rotary electric machine which can be easily manufactured by making the resin mold flow easily is desired.

  In the axial gap type rotating electrical machine according to the present invention, preferably, a plurality of core units formed by the core, the coil and the bobbin are arranged in a ring along the inner circumferential surface of the housing around the rotation axis, It is an axial gap type rotary electric machine having a rotor axially opposed to an end face of the core via a predetermined gap in an axial radial direction, and the housing has an outlet for drawing out the wiring to the rotor to the outside. Further, an inclined surface is formed on the lower side of the outlet of the housing so that the inner peripheral side is downward.

  Also preferably, the housing has a recess below the outlet so that the inclined surface and the recess are integrated.

  According to the present invention, it is possible to provide an axial gap type rotary electric machine capable of facilitating flow of a resin mold when molding a stator and avoiding breakage of a bobbin of a core unit.

FIG. 1 is a schematic configuration view of an axial gap type rotary electric machine according to Embodiment 1 (part 1). FIG. 6 is a schematic configuration diagram of an axial gap type rotating electric machine according to Embodiment 1 (part 2). It is a perspective view of a core unit. It is a figure which shows the mode of resin mold formation of a stator. It is sectional drawing which drew the stator part of the axial gap type rotary electric machine of prior art in detail. It is BB sectional drawing of the stator part of the axial gap type rotary electric machine of FIG. 4 when satisfy | filling resin mold. FIG. 5 is an enlarged cross-sectional view of an essential part around a core unit and a housing of the axial gap type rotary electric machine of FIG. 4 when a resin mold is filled. It is a principal part enlarged view of the core unit of an axial gap type rotary electric machine, and a housing periphery concerning Embodiment 1, (the 1). It is a principal part enlarged view of the core unit of an axial gap type rotary electric machine, and a housing periphery concerning Embodiment 1, (the 2). FIG. 6 is a perspective view of the vicinity of the outlet of the housing of the axial gap type rotary electric machine according to the first embodiment; FIG. 6 is an enlarged sectional view of an essential part around a core unit and a housing of an axial gap type rotary electric machine according to Embodiment 1 when a resin mold is filled (part 1). It is sectional drawing to which the principal part peripheral part of the core unit of an axial gap type rotary electric machine and the housing periphery which concern on Embodiment 1 when resin mold is filled (the 2). It is a principal part enlarged view of the core unit of an axial gap type rotary electric machine, and a housing periphery concerning Embodiment 1, (the 1). It is a principal part enlarged view of the core unit of an axial gap type rotary electric machine, and a housing periphery concerning Embodiment 1, (the 2). FIG. 6 is a perspective view of the vicinity of the outlet of the housing of the axial gap type rotary electric machine according to the first embodiment; FIG. 6 is an enlarged sectional view of an essential part around a core unit and a housing of an axial gap type rotary electric machine according to Embodiment 1 when a resin mold is filled (part 1). It is sectional drawing to which the principal part peripheral part of the core unit of an axial gap type rotary electric machine and the housing periphery which concern on Embodiment 1 when resin mold is filled (the 2).

  Hereinafter, embodiments to which the present invention is applied will be described with reference to FIGS. 1A to 12B.

Embodiment 1

  Hereinafter, Embodiment 1 according to the present invention will be described with reference to FIGS. 1A to 9B.

  First, the entire configuration of the axial gap type rotating electrical machine according to the first embodiment will be described using FIGS. 1A and 1B.

  The cross-sectional view of FIG. 1A represents a schematic configuration of a double rotor type axial gap permanent magnet synchronous motor 1 (hereinafter sometimes simply referred to as “motor 1”) according to the first embodiment.

  As shown in FIG. 1A, the motor 1 has a doughnut-shaped stator 19 disposed along the inner peripheral surface of the housing 50, and two disk-shaped rotors 30 each having a predetermined air diameter in the rotational axis direction. They are arranged face to face so as to sandwich the gap. Here, the housing 50 is formed by, for example, aluminum die casting.

  The rotor 30 is fixed to the rotation shaft 40 at the center of the disk. The rotating shaft 40 is disposed so as to penetrate the central portion of the stator 19, and both ends thereof are rotatably fixed to the end bracket 60 via the bearings 70. Further, the end bracket 60 is fixed in the vicinity of both open ends of the substantially cylindrical housing 50.

  Further, the rotor 30 is provided with a permanent magnet 31 via a rotor base 32 in a circular yoke 33. The yoke 33 may be omitted, and the rotor base 32 may be made of a material that plays the role of a yoke. The permanent magnet is composed of a plurality of flat magnets having a generally fan-like shape centered on the direction of the rotational axis 40, and magnets of different polarities are arranged in the rotational direction. In addition, although the permanent magnet 31 shall apply a ferrite, it does not restrict to this.

  The armature configuration of the motor 1 is as shown in the perspective view of FIG. 1B. The stator 19 is composed of twelve core units 20 disposed along the inner periphery of the housing 50 with the rotational axis A as a center direction. One core unit 20 is configured to constitute one slot. Further, the core units 20 and the inner circumferential surfaces of the housing 50 are integrally molded with each other by resin molding and fixed to the stator (described later).

  Next, the configuration of the core unit will be described using FIG.

  The core unit 20 comprises a bobbin 22, a core 21 and a coil 23, as shown in FIG. The core 21 is an iron-based amorphous metal having a substantially trapezoidal or triangular prism shape in which metal plates shaped so as to gradually increase in width are sequentially stacked in the radial direction. The cross-sectional shape of the core 21 may be a cross-section having two oblique sides having intersections in the extension direction, in addition to the substantially trapezoidal shape and the triangular shape. The metal plate to be stacked may be iron or the like, but in the present embodiment, the metal containing amorphous is thinned in a tape shape, and the core 21 is obtained by sequentially increasing the width in the rotational direction. It has become.

  Next, the state of the resin molding process integrally molded with core units 20 comrades and the housing 50 inner periphery is demonstrated using FIG.

  When resin molding is performed integrally with the core units 20 and the inner periphery of the housing 50, as shown in FIG. 3, the housing 50 is inserted into the lower mold 62 whose inner diameter substantially matches, and From the opposite side opening, a cylindrical middle mold 61 is formed at the center of the lower mold 62 for forming an axial center space for the rotation shaft to pass through later. The core units 20 are arranged in a ring around the middle mold 61. At this time, the flange portion 22b of the bobbin is adapted to perform positioning in the radial direction and positioning in the rotational axis direction with the adjacent core unit 20.

  Thereafter, an upper mold having an outer diameter substantially matching the inner diameter of the housing 50 and having a cylindrical space in the center to penetrate the middle mold 61 is inserted from the housing opening opposite to the lower mold 62, Hold and support the unit 20. Thereafter, the mold resin 80 is sealed from the opposing surface of the upper mold and the lower mold 62. The mold resin is filled between the core units 20, the inner peripheral surface of the housing 50, the direction of the middle mold 61, and the surface of the flange portion 22b of the bobbin facing the rotor 30 without any gap. As this mold resin 80, a thermosetting unsaturated polyester resin (for example, BMC (Bulk Molding Compound)) having a low molding shrinkage and high dimensional stability is generally used.

  Next, the structure of the housing of the present embodiment will be described using FIGS. 4 to 9B.

  When the stator portion of the axial gap type rotary electric machine is viewed in cross section, it becomes as shown in FIG. 4 and as shown in FIG. 5 when the B-B cross sectional view of FIG. 4 is shown. Recesses 51 for fixing the mold resin 80 and the stator 19 at intervals of 90 degrees are provided on the inner periphery of the housing 50.

  A recessed portion-shaped outlet 52 is provided at one position on the inner peripheral side of the housing 50, for example, above the recessed portion 51, and a wiring hole 53 is provided from the outlet 52 for wiring from outside to the coil 23 of the stator. It can be connected.

  When the stator is fixed to the mold resin 80 by the resin molding process shown by FIG. 3, the mold resin 80 up to the line M-M in FIG. 4 and FIG. Is filled. At this time, in particular, at the final stage of filling, the viscosity of the resin is increased by the fact that the previously injected resin begins to cure, and the pressure applied to the surrounding structure is increased. There is a possibility that the portion 22B may be easily damaged by the influence of high temperature and high pressure.

  Therefore, in the present embodiment, the lower side is expanded at the outlet 52, and the inclined surface 54 is formed at the lower side of the outlet 52 as shown in FIGS. 7A and 8. As a result, as shown in FIG. 9A, at the final stage of the filling, the mold resin 80 flows into this portion, the sealing pressure is reduced, and breakage of the bobbin 22 of the core unit 20 can be prevented.

  The inclined surface provided on the lower side of the outlet 52 is not limited to a flat surface, as shown in FIGS. 7B and 9B, and may be an upwardly convex R (round) surface 55. Further, the shape of the slope formed in the outlet 52 is not limited to the flat slope or the R-shaped surface, and may be a step-like shape or a flat slope, and may have an inclined shape different in inclination angle.

Embodiment 2

  Embodiment 2 to which the present invention is applied will be described below with reference to FIGS. 10A to 12B.

  In the first embodiment, at the final stage of the filling of the mold resin 80, an inclined surface for releasing the mold resin 80 is formed on the lower side of the outlet 52.

  Similarly, in the second embodiment, the lower surface of the outlet 52 is formed with an inclined surface for releasing the mold resin 80, but the shapes of the outlet 52 and the recess 51 are different.

  In the present embodiment, as shown in FIGS. 10A, 11 and 12A, the inclined surface 54a of the outlet 52 and the recess 51a are integrally connected. In addition to the effect of preventing damage to the bobbin 22 of the core unit 20 due to the flow of the mold resin 80, this shape has an advantage of easy molding.

  Further, as shown in FIGS. 10B and 12B, the inclined surface provided on the lower side of the outlet 52 is not limited to a flat surface, and may be an upwardly convex R surface 55. It may be a step-like shape or a flat slope, and it may be an inclined shape whose inclination angle is gradually different.

  DESCRIPTION OF SYMBOLS 1 ... motor, 19 ... stator, 20 ... core unit, 21 ... core, 22 ... bobbin, 23 ... coil, 30 ... rotor, 31 ... permanent magnet, 32 ... rotor base, 33 ... yoke, 40 ... rotating shaft, DESCRIPTION OF SYMBOLS 50 ... Housing, 51, 51a ... Recess, 52 ... Outlet, 53 ... Wiring hole, 54, 54a ... Slope surface, 55 ... R surface, 60 ... End bracket, 70 ... Bearing, 80 ... Mold resin

Claims (3)

A plurality of core units formed of a core, a coil and a bobbin, a stator arranged annularly along the inner circumferential surface of the housing centering on the rotation axis, and the core of the core via a predetermined gap in the rotation axis radial direction An axial gap type rotating electric machine having an end face and a rotor facing in a face,
The housing has an outlet for drawing the wiring to the rotor to the outside,
An axial gap type electric rotating machine characterized in that an inclined surface is formed on the lower side of the outlet of the housing so that the inner peripheral side is down.   The axial gap type electric rotating machine according to claim 1, wherein the housing has a recess below the outlet, and the inclined surface and the recess are integrated.   The axial gap type rotating electrical machine according to claim 1, wherein the inclined surface is an R surface.

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