KR102019126B1 - A rotor for a motor and method for manufacturing the same - Google Patents

Abstract

According to the present invention, a plurality of split cores spaced apart from each other and disposed radially are disposed to be radially spaced apart from each other, and the plurality of magnets provided between the plurality of split cores, the plurality of split cores and the magnets form a radial arrangement. And a core frame for securing the core frame, wherein the core frame is formed by injection.

Description

A rotor for a motor and method for manufacturing the same

The present invention relates to a rotor and a motor including the same, and more particularly to a rotor and a motor including the improved performance and efficiency.

In addition, the rotor and the motor according to the present invention can be applied to household appliances such as washing machines, but the application is not necessarily limited thereto.

The present invention also relates to a rotor and a method for manufacturing the motor including the same.

In general, the motor transmits the rotational force of the rotor to the rotary shaft, the rotary shaft drives the load. For example, the rotating shaft may be connected to the drum of the washing machine to drive the drum, and may be connected to the fan of the refrigerator to drive the fan so that cold air is supplied to the required space.

On the other hand, in such a motor, the rotor is rotated by electromagnetic interaction with the stator. To this end, a coil is wound around the stator, and as the current is applied to the coil, the rotor rotates with respect to the stator.

The stator includes a stator core, which is made of a conductor. In addition, the stator is a configuration that is generally fixed to the object. Therefore, fixing means are required to fix the stator to an object such as a motor housing, a motor bracket, and a tub of a washing machine.

In addition, a coil is wound around the stator, and insulation means is required between the coil and the stator core. In addition, there is a need for a tab terminal structure for applying power to the coil. Therefore, the stator core needs an insulating structure from the above-mentioned fastening means, coils, and tab terminals. For this insulating structure, an insulator may be provided.

1 is a view schematically showing the structure of a motor according to the prior art, wherein the motor includes a stator 10 and a rotor 20 electromagnetically acting on the stator 10. 1 shows an inner rotor type motor in which a rotor 20 is provided inside a stator.

The stator 10 includes a tooth 11, and a coil is wound around the tooth 11. The rotor 20 is provided inside the stator 10, more specifically, adjacent to the tooth 11.

The rotor 20 includes a rotating shaft (not shown) coupled to the through hole 25, the rotor core 23, and the magnet 21. The rotating shaft rotates by an electromagnetic force acting on the coil wound around the magnet 21 and the stator 11 of the stator 10, and the rotor 20 may rotate by the rotation of the rotating shaft.

An outer rotor core 23 is provided on the outer side of the rotation shaft of the rotor 20. The rotor core 23 may be made of a material having electrical conductivity.

The magnet 21 is provided inside the rotor core 23. The magnet 210 acts electromagnetically with the coil wound around the teeth 11 of the stator.

On the other hand, according to the prior art was produced by punching the stator 10 and the rotor 20 in one iron plate. That is, the remaining portions (scraps) except for the shapes of the stator 10 and the rotor 20 were punched out and removed on the flat iron plate to produce the stator 10 and the rotor 20. At this time, the through-hole 25 of the rotor 20, the buried portion into which the magnet 21 is inserted and the space between the stator 10 and the rotor 20 was punched out and removed, respectively, the rotor 20 in the punched iron plate ) And the stator 10 were removed.

As such, when the stator 10 and the rotor 20 are punched out from one iron plate, the materials of the stator 10 and the rotor 20 may be the same. That is, there was a limitation that the materials of the stator which are highly affected by iron loss and the rotor which are relatively less affected by iron loss could be applied in the same way.

The present invention has been made to solve the above problems, and an object of the present invention is to provide a motor that can reduce the material cost by dualizing the raw materials of the stator and the rotor.

In addition, an object of the present invention is to provide a rotor of a motor that can simplify the assembling process of the split core and the magnet.

In order to achieve the above object, the present invention provides a plurality of split cores that are radially spaced apart from each other, a plurality of magnets that are radially spaced apart from each other and are provided between the plurality of split cores, the plurality of split cores, and the magnets. And a core frame for securing a radial arrangement, said core frame being formed by injection.

In addition, the end plate coupled to the top and bottom of the rotor to prevent the separation of the split core and the magnet further comprises, the end plate may be formed integrally injected with the core frame.

In addition, each of the split cores is formed by stacking a plurality of unit cores, and the split cores have coupling holes formed therein, and coupling members inserted into the coupling holes may be integrally injected with the end plate. .

The core frame may include an inner core frame provided inside the split core and the magnet and an outer core frame provided outside the magnet, and a through hole may be formed in the inner core frame to which the rotating shaft is coupled. .

Here, the split core may have a fan shape having an outer end, an inner end, a first side surface, and a second side surface, and at least one protrusion may be formed on the first side surface and the second side surface of the split core.

The split core is provided in a radially outward direction, and has outer protrusions formed on the first and second side surfaces, respectively, and an upper end of the magnet is mounted on the outer protrusion.

In addition, the split core is provided in the radially inward direction, and has an inner projection formed on the first side and the second side, respectively, it is preferable that the lower end of the magnet is seated on the inner projection.

The outer core frame may have a recessed shape corresponding to the outer protrusion, and the inner core frame may have a recessed shape corresponding to the inner protrusion.

In addition, the present invention, the step of radially arranging a plurality of split cores and magnets, the injection of the injection molding to the inside of the split core and the magnet to form an inner core frame and the injection of the injection to the outside of the magnet It provides a method of manufacturing a rotor of a motor comprising the step of forming an outer core frame.

Here, the step of alternately arranging the plurality of split cores and magnets, the step of seating the upper end of the magnet in the outer projection formed on the side of the split core in the outer direction and formed on the side of the inner side of the split core It may include the step of seating the bottom of the magnet to the inner projection.

The present invention has the advantage of reducing the material cost by dualizing the raw material of the stator and the rotor.

In addition, the present invention has the advantage of simplifying the assembly process of the split core and the magnet by forming the core frame and the end plate by injection.

In addition, there is an advantage that the assembly process can be simplified by forming the coupling member inserted into the coupling hole of the split core by injection.

1 is a plan view schematically showing the structure of a motor according to the prior art.
Figure 2 is a perspective view showing a rotor of the motor according to an embodiment of the present invention.
3 is a cross-sectional view taken along line AA ′ of FIG. 2;
4 is a cross-sectional view taken along line BB ′ of FIG. 2.
5 is a cross-sectional view taken along line C-C 'of FIG.
6 is a perspective view illustrating a split core in which unit cores are stacked;
Figure 7 is a perspective view showing the coupling of the split core and the magnet.

Hereinafter, exemplary embodiments of the present invention will be described with reference to the accompanying drawings.

First, a motor according to an embodiment of the present invention includes a rotor and a stator.

The stator 10 has a tooth 11 on which a coil is wound (see FIG. 1). In addition, the rotor rotates by electromagnetic action with the coil wound on the tooth 11. Since the stator 10 is a known stator structure, detailed description thereof will be omitted.

The rotor described below and a motor including the same will be described based on an inner rotor type in which the rotor is provided inside the stator.

Hereinafter, referring to Figures 2 and 3, the rotor 1 of the motor according to an embodiment of the present invention will be described in detail.

The rotor 1 according to an embodiment of the present invention includes a plurality of split cores 230 disposed radially apart from each other. In addition, the plurality of magnets 210 may be provided between the plurality of split cores 230.

In addition, the plurality of split cores 230 and the magnets 210 may include core frames 270 and 280 to fix the arrangement. In this case, the core frames 270 and 280 may be formed by injection.

It is preferable that end plates 110 and 130 are provided at the top and bottom of the split core 230 and the magnet 210. The end plates 110 and 130 may include an upper end plate 110 coupled to the upper end of the split core 230 and the magnet 210 and a lower end plate 130 coupled to the lower end.

The plurality of split cores 230 are disposed radially. The plurality of split cores 230 are preferably spaced apart from each other at a predetermined interval. The magnet 210 is provided between two adjacent split cores 230 in the plurality of split cores 230. Therefore, a plurality of magnets 210 may be provided, and the magnets 210 may be provided between two split cores 230 adjacent to each other. In addition, the split core 230 may be provided between two magnets 210 adjacent to each other. That is, the magnet 210 and the split core 230 are alternately arranged along the circumferential direction.

The split core 230 has a fan shape as a whole, and the magnet 210 may be a rectangular permanent magnet. The structure and shape of the split core 230 will be described later.

Meanwhile, the split core 230 and the magnet 210 are disposed along the circumferential direction, and a member for fixing the split core 230 and the magnet 210 is required.

In the present invention, the core frames 270 and 280 are provided such that the plurality of split cores 230 and the magnets 210 form a radial arrangement.

The core frames 270 and 280 may include an inner core frame 270 provided inside the rotor and an outer core frame 280 provided outside the rotor.

The inner core frame 270 is provided inside the split core 230 and the magnet 210, and is coupled to the inner surfaces of the split core 230 and the magnet 210. In addition, the inner core frame 270 preferably has a through hole 250 to which a rotating shaft is coupled at the center thereof. The inner core frame 270 is coupled to the inner surfaces of the split core 230 and the magnet 210 to fix the radial arrangement of the split core 230 and the magnet 210.

The outer core frame 280 may be provided outside the split core 230 and the magnet 210 and may be coupled to the outer surfaces of the split core 230 and the magnet 210.

Referring to FIG. 3, according to an embodiment of the present disclosure, the outer core frame 280 may be coupled to an outer surface of the magnet 210 and may not be provided on an outer surface of the split core 230. . However, a portion of the outer core frame 280 may be combined with a portion of the side of the outer end of the split core 230. That is, the inner surface of the outer core frame 280 is coupled to the outer surface of the magnet 210, the outer surface of the outer core frame 280 forms a part of the outer end of the rotor 1 to the outside Exposed. In addition, both side surfaces of the outer core frame 280 may be combined with a portion of the side surface of the split core 230. At this time, the outer surface of the outer core frame 280 and the split core 230 preferably extends smoothly. That is, it is preferable that a step is not formed at the boundary between the outer core frame 280 and the outer surface of the split core 230.

Meanwhile, according to one embodiment of the present invention, the core frames 270 and 280 may be formed by injection. In this case, the core frame 270, 280 may be made of a non-magnetic material, preferably formed of a plastic injection molding. In addition, the end plates 110 and 130 may be formed by injection. In this case, the end plates 110 and 130 may be integrally formed with the core frames 270 and 280 by injection. Likewise, the end plates 110 and 130 may be made of a nonmagnetic material, and preferably, may be formed of a plastic injection molding.

Specifically, the upper end plate 110 and the lower end plate 130 may be integrally formed with the inner core frame 270 and the outer core frame 280 by injection. The end plates 110 and 130 and the core frames 270 and 280 may be formed of plastic injection moldings, but are not necessarily limited thereto.

The lower surface of the upper end plate 110 may be combined with the upper ends of the outer core frame 280 and the inner core frame 270, and may be integrally formed. In addition, the upper surface of the lower end plate 130 may be combined with the lower ends of the outer core frame 280 and the inner core frame 270, and may be integrally formed. Therefore, according to an embodiment of the present invention, the upper surface of the upper end plate 110, the lower surface of the lower end plate 130 and the outer surface of the outer core frame 280 is exposed to the outside.

Hereinafter, the shape and coupling of the split core 230 and the magnet 210 will be described with reference to FIGS. 6 and 7.

Split core 230 according to an embodiment of the present invention is composed of a plurality of unit cores are stacked. The unit core may be provided by punching an iron plate. A plurality of unit cores may be provided by punching out an iron plate, and the plurality of unit cores may be aligned and stacked to form one split core 230.

Each of the unit cores may have a coupling hole 231 inside, and the coupling member 150 may be inserted into the coupling hole 231 to configure a plurality of unit cores as one split core 230.

Therefore, coupling holes 231 may be formed in each of the split cores 230, and coupling members 150 may be inserted into the coupling holes 231. The coupling member 150 may be a rivet.

On the other hand, referring to Figures 3 and 4, in accordance with an embodiment of the present invention the coupling member 150 may be formed by injection. That is, the coupling member 150 may be integrally formed with the end plates 110 and 130.

As described above, when the end plates 110 and 130 are formed by injection, the coupling member 150 may be integrally formed with the end plates 110 and 130. That is, when the end plates 110 and 130 are formed by injection, the injection plate may be injected into the coupling hole 231 to integrally form the end plate and the coupling member 150.

In addition to the end plates 110 and 130 being integrally formed with the coupling member 150, the coupling member 150 may be integrally formed with the core frames 270 and 280. As described above, the end plates 110 and 130 and the core frames 270 and 280 may be integrally formed by injection. At this time, as the end plates 110 and 130 are integrally formed with the coupling member 150 by injection, the end plates 110 and 130, the coupling member 150 and the core frame 270 and 280 are It can be formed integrally.

6 and 7, the split core 230 has an outer end 230a, an inner end 230b, and both side surfaces 230c and 230d. The split core 230 may have a fan shape as a whole, and the outer edge of the fan shape may form the outer end 230a and the inner surface of the split end 230b. In addition, it has both side surfaces (230c, 230d) connecting the outer end (230a) in the inner end (230b). Both side surfaces 230c and 230d may include a first side surface 230c and a second side surface 230d. The first side surface 230c and the second side surface 230d are disposed to face each other, and form a symmetrical shape with respect to the centerline of the split core 230. The first side surface 230c and the second side surface 230d form a fan-shaped both side surfaces of the split core 230, and are thus disposed in a radial direction.

According to one embodiment of the present invention, at least one protrusion 233, 235 may be formed on the first side surface 230c and the second side surface 230d of the split core 230.

Preferably, the outer protrusion 233 and the inner protrusion 235 are formed on the first side surface 230c and the second side surface 230d, respectively. That is, the outer protrusion 233 is formed in the outer direction of the first side surface 230c, and the inner protrusion 235 is formed in the inner direction. In addition, an outer protrusion 233 is formed in an outer direction of the second side surface 230d, and an inner protrusion 235 is formed in an inner direction.

Here, the inner direction means a direction toward the center in the radial direction relative to the center of the rotor, the outer direction means a direction away from the center in the radial direction relative to the center of the rotor. In other words, the outward direction means a direction from the center of the rotor toward the outside in the radial direction.

The outer protrusion 233 formed on the first side surface 230c and the outer protrusion 233 formed on the second side surface 230d preferably have a symmetrical shape, and the two outer protrusions 233 are provided to face each other.

In addition, the inner protrusion 235 formed on the first side surface 230c and the inner protrusion 235 formed on the second side surface 230d may have a symmetrical shape, and the two inner protrusions 235 may face each other. do.

At this time, the inner protrusion 235 and the outer protrusion 233 is disposed along the circumferential direction of the rotor.

Specifically, the outer protrusions 233 and the inner protrusions 235 may be formed to extend in the circumferential direction of the rotor from the first side surface 230c and the second side surface 230d.

The outer protrusions 233 formed on the first side surface 230c and the second side surface 230d are provided to contact the upper end of the magnet 210. That is, the upper end of the magnet 210 is in close contact with the outer protrusion 233 is seated. The upper end of the magnet 210 means the end which is located in the radially outward direction.

In addition, the inner protrusion 235 formed on the first side surface 230c and the second side surface 230d is provided to contact the lower end of the magnet 210. That is, the lower end of the magnet 210 is in close contact with the inner protrusion 235. The lower end of the magnet 210 means the end which is located in the radially inward direction.

The inner protrusion 235 may be formed at the lower end (the inner direction of the radial direction) of the split core 230. In addition, the outer protrusion 233 may be formed at a position spaced a predetermined distance in the inward direction from the upper end (outer direction of the radial direction) of the split core 230.

The inner protrusion 235 and the outer protrusion 233 prevent the separation of the magnet 210. More specifically, the inner protrusions 235 and the outer protrusions 233 limit the movement of the magnet 210 in the radial direction.

The inner protrusion 235 contacts the lower end of the magnet 210 to prevent the magnet 210 from moving away from the rotor in a radially inward direction.

In addition, the outer protrusion 233 is in contact with the upper end of the magnet 210, to prevent the magnet 210 is moved outward from the rotor in the radial direction.

Meanwhile, recesses are formed in the inner core frame 270 and the outer core frame 280 to correspond to the shapes of the outer protrusions 233 and the inner protrusions 235.

Specifically, an outer concave portion is formed in the outer core frame 280 so as to correspond to the shape of the outer protrusion 233, and an inner concave portion is formed in the inner core frame 270 so as to correspond to the shape of the inner protrusion 235. Can be.

Hereinafter, a method of manufacturing a motor and a rotor according to an embodiment of the present invention will be described.

First, an iron plate is provided to form the split core 230 and the stator 10 (see FIG. 1), and the stator and unit core are formed by punching the provided iron plate. In this case, materials of the iron plate for forming the stator and the unit core may be different from each other. That is, the material of the stator and the material of the split core 230 may be different from each other.

Relatively, the stator is affected by iron loss, and the rotor is affected by iron loss. Accordingly, the iron plate for forming the stator may use a high-grade iron plate, and the iron plate for forming the split core 230 (that is, the unit core) may use an iron plate of a relatively inexpensive material.

After preparing a plurality of unit cores by punching, the plurality of unit cores are stacked to provide a split core 230. In this case, a plurality of split cores 230 may be provided.

The plurality of split cores 230 are provided, and the plurality of split cores 230 and the plurality of magnets 210 are alternately disposed.

In this case, the magnet 210 is disposed between two split cores 230 adjacent to each other, and similarly, the split core 230 is disposed between two magnets 210 adjacent to each other.

The plurality of split cores 230 and the magnets 210 are disposed radially.

In this case, the outer protrusion 233 of the split core 230 is coupled to be in contact with the upper end of the magnet 210 (close contact), the inner protrusion 235 of the split core 230 is the magnet 210 It is coupled to be in contact with the bottom of (close). That is, an upper end of the magnet 210 is seated on the outer protrusion 233, and a lower end of the magnet 210 is seated on the inner protrusion 235. Therefore, the upper and lower ends of the magnet 210 may be restricted in the radial direction by the outer protrusion 233 and the inner protrusion 235.

Meanwhile, the plurality of magnets 210 and the split core 230 may be disposed in the injection mold. That is, the plurality of magnets 210 and the split cores 230 may be alternately arranged radially in the injection mold. Alternatively, the plurality of magnets 210 and the split cores 230 may be alternately arranged radially and then placed in the injection mold.

After the arrangement of the plurality of magnets 210 and the split core 230 is completed in the injection mold, the core frames 270 and 280, the end plates 110 and 130, and the coupling member 150 are formed. .

Specifically, an injection of a nonmagnetic material is injected into the injection mold. The injected injection is injected into the coupling hole 231 of the split core 230 to form the coupling member 150. In addition, the injection molding is injected into the split core 230 and the magnet 210 to form an inner core frame 270. In addition, it is injected into the outer surface of the magnet 210 to form an outer core frame 280. In addition, the upper and lower ends of the split core 230 and the magnet 210 are injected to form the upper end plate 110 and the lower end plate 130.

After injection of the injection is completed, the injection mold is removed to manufacture the rotor.

The present invention described above is capable of various substitutions, modifications, and changes without departing from the technical spirit of the present invention for those skilled in the art to which the present invention pertains. It is not limited by the drawings.

1 rotor 10 stator
11 tooth 110 upper end plate
130 Lower end plate 150 Coupling member
210 Magnet 230 Split Core
231 Coupling Hole 233 Outer Projection
235 Inner protrusion 250 Gutol hole
270 inner core frame 280 outer core frame

Claims (10)

A plurality of split cores disposed to be spaced apart from each other along a circumferential direction, and having a plurality of unit cores stacked on each other and having a perforated coupling hole formed therein;
A plurality of magnets disposed to be spaced apart from each other along a circumferential direction and provided in close contact with the plurality of split cores between the plurality of split cores;
An inner core frame provided inside the plurality of split cores and the plurality of magnets and coupled to inner surfaces of the plurality of split cores and the plurality of magnets;
An outer core frame provided at an outer side of the plurality of split cores and the plurality of magnets and coupled to outer surfaces of the plurality of split cores and the plurality of magnets;
An upper end plate coupled to an upper end of the inner core frame and the outer core frame to prevent separation of the split core and the magnet to an upper side thereof;
A lower end plate coupled to a lower end of the inner core frame and the outer core frame to prevent separation of the split core and the magnet to the lower side; And
And a coupling member inserted into the coupling hole to connect the upper end plate and the lower end plate.
The plurality of split cores,
An outer protrusion fixed to the magnet in a radially outer side and protruding in a circumferential direction; And
Fixing the magnet in a radially inward, and includes an inner projection formed protruding in the circumferential direction,
The inner core frame is formed with a through hole coupled to the rotation shaft,
The inner core frame and the outer core frame, the upper end plate and the lower end plate and the coupling member are integrally formed by injection molding,
The radial length of the magnet is formed so as to correspond to the radial length between the outer projection and the inner projection, to fix the radial movement of the magnet, the rotor of the motor.
delete delete delete delete delete delete The method of claim 1,
The outer core frame has a concave portion having a shape corresponding to the outer protrusion, and the inner core frame has a concave portion having a shape corresponding to the inner protrusion.
Arranging the plurality of split cores and the plurality of magnets alternately along the circumferential direction and disposing them in the injection mold;
Injecting an injection material of a nonmagnetic material into the injection mold; And
The injection is injected into the coupling holes of the plurality of split cores to form a coupling member, and are injected into the plurality of split cores and the plurality of magnets to form an inner core frame, and are injected to the outside of the plurality of magnets. Forming an outer core frame, injected into upper ends of the plurality of split cores and the plurality of magnets to form an upper end plate, and injected into lower ends of the split cores and the plurality of magnets to form a lower end plate; Including,
Arranging the plurality of split cores and the plurality of magnets alternately along the circumferential direction,
A step of seating the magnet between the outer protrusions protruding in the circumferential direction and fixing the magnet radially outwardly and the inner protrusions protruding in the circumferential direction and fixing the magnet radially inward in the plurality of split cores; Include,
The inner core frame and the outer core frame, the upper end plate and the lower end plate and the coupling member are integrally formed by injection molding,
The radial length of the magnet is formed to correspond to the radial length between the outer projection and the inner projection, to fix the radial movement of the magnet, a method for manufacturing a rotor of the motor. delete

Images