WO2013070007A1 - Motor and method for manufacturing same - Google Patents

Abstract

A motor according to the present invention comprises: outer teeth on which a first coil is wound; a circular stator having a plurality of partitioned core assemblies spaced in the circumferential direction thereof, the core assemblies having inner teeth on which a second coil, which is connect to the first coil, is wound; a rotor support connected to a rotating shaft; an outer rotor, which is attached to the outside of the rotor support and positioned on the outside of the stator, and which forms a first magnetic circuit by interacting with the first coil; and a rotor, which is attached in the interior of the rotor support and arranged in the interior of the stator and provided with an inner rotor, and which forms a second magnetic circuit by interacting with the second coil. The present invention reduces the loss in magnetic force by reducing magnetic resistance, improves motor efficiency, reduces manufacturing costs, enhances ease of assembly, and minimizes noise and vibration.

Description

Motor and motor manufacturing method

The present invention relates to a motor that can improve motor efficiency while reducing manufacturing costs by applying a split core to a double rotor / double stator type motor.

In general, a double rotor / single stator type motor has an inner and outer flange in which first and second coupling protrusions are formed at the lower center of the inner and outer sides of a plurality of split stator cores, as disclosed in Korean Patent Publication No. 10-0908396. A plurality of stator core assemblies having coils wound around the bobbins, an outer rotor disposed with a predetermined gap outside the stator core, and an inner rotor disposed with a predetermined gap inside the stator core. It includes.

The motor disclosed in Korean Patent Publication No. 10-0908396 can reduce manufacturing costs, reduce weight, and improve productivity because the stator core assembly is integrally formed by insert molding in a split core manner.

However, since the motor is a single stator type, the inner magnet and the outer magnet interact with one stator coil. That is, since the inner rotor, the outer rotor, and the single stator form one magnetic circuit, the magnetic path becomes long, and accordingly, the magnetic force loss increases due to the increase of the magnetoresistance and the motor efficiency decreases.

To solve this problem, a double rotor / double stator type motor has been developed. That is, the double rotor / double stator type motor has an inner stator having an inner stator core and an inner coil wound on the inner stator core, and an outer stator having an outer coil disposed outside the inner stator and wound on the outer stator core and outer stator core. A stator, an inner rotor disposed to face each other with a predetermined gap on the inner surface of the inner stator, and an outer rotor disposed to face each other with a predetermined gap on the outer surface of the outer stator.

Such a double rotor / double stator type motor forms an internal magnetic circuit between the internal stator and the internal rotor, and an external magnetic circuit between the external stator and the external rotor to form independent magnetic circuits inside and outside, respectively. It can be shortened, thereby reducing the magnetoresistance, thereby reducing the magnetic force loss and improving the motor efficiency.

However, in the double rotor / double stator type motor, since the inner stator core and the outer stator core are integrally formed by using a cylindrical steel sheet, waste of steel sheet is increased in the manufacturing process, and thus manufacturing cost is increased and weight is increased. there is a problem.

In addition, since the inner and outer stator cores use cylindrical steel plates, the concentricity and roundness are not good, so noise and vibration are generated, and two coil winding operations are performed in which the coil is wound on the inner stator core and the coil on the outer stator core. Since it must be performed, the manufacturing time is long, the assembly performance is lowered, and the cost is increased.

Accordingly, an object of the present invention is to form a first magnetic circuit between the first coil of the double stator and the outer rotor, and to form a second magnetic circuit between the second coil of the double stator and the inner rotor, thereby reducing the magnetic resistance to reduce magnetic force. It is to provide a motor and a method of manufacturing the same that can reduce and improve motor efficiency.

Another object of the present invention is to provide a motor and a method of manufacturing the same, by forming a double stator into a split core type to reduce manufacturing costs, improve assembly, and minimize noise and vibration.

Still another object of the present invention is to arrange a plurality of split cores horizontally and then to coil the coils one after the other to facilitate the coil winding operation, reduce the coil winding operation time, and reduce the manufacturing cost of the motor manufacturing. To provide a way.

The problem to be solved by the present invention is not limited to the technical problem mentioned above, and other technical problems not mentioned will be clearly understood by those skilled in the art from the following description. .

The motor of the present invention includes a stator, a rotor disposed on outer and inner surfaces of the stator, and the stator includes an outer tooth to which the first coil is wound, and an inner tooth to which the second coil connected to the first coil is wound. A plurality of split core assemblies having a plurality of divided core assemblies are arranged at intervals in the circumferential direction, the rotor is connected to the rotating shaft, and the rotor support is mounted to the outside of the rotor support and disposed outside the stator to interact with the first coil An outer rotor forming a first magnetic circuit, and an inner rotor mounted inside the rotor support and disposed inside the stator to interact with the second coil to form a second magnetic circuit. .

The split core assembly may include a split core having an outer tooth formed at an outer side thereof and an inner tooth formed at an inner side thereof, a bobbin as an insulator surrounding the outer surface of the split core, a first coil wound around the outer tooth, and the inner tooth. It characterized in that it comprises a second coil wound on.

The splitting core may include: an outer tooth on which the first coil is wound; an inner tooth formed on an opposite side of the outer tooth; and a partition extending between the outer tooth and the inner tooth and extending laterally; And a connection part formed at both ends of the partition part to connect the split cores.

The motor manufacturing method of the present invention includes the steps of manufacturing a split core having an outer tooth and an inner tooth, forming a bobbin on an outer surface of the split core, winding the coil continuously to the outer tooth and the inner tooth, Winding coils continuously between the split cores to produce three sets of split core assemblies corresponding to each of U, V, and W phases; and three sets of split core assemblies alternately arranged to form an annular stator. And manufacturing the stator between the outer rotor and the inner rotor.

The coil winding step includes the steps of aligning the split cores in a line, winding the coil in succession to the outer teeth and the inner teeth of the split core, and split cores disposed adjacent to each other when the coil winding is completed on the split core. Subsequent to winding the coil.

The split cores are aligned such that the outer tooth and the inner tooth are horizontally aligned using a core alignment jig, and the core alignment jig is a magnet jig for aligning the split cores using magnetic force.

As described above, the motor of the present invention implements a double rotor / double stator type to form a first magnetic circuit between the first coil and the outer rotor of the stator, and a second magnetic circuit between the second coil and the inner rotor of the stator. By forming the magnetoresistance, the magnetic force loss can be reduced and the motor efficiency can be improved.

In addition, the motor of the present invention has the advantage of forming a double stator in a split core type to reduce the manufacturing cost, improve assembly and minimize noise and vibration.

In addition, the motor manufacturing method of the present invention has the advantage of reducing the work time, the manufacturing cost according to the coil winding by winding the coil in succession to a plurality of split cores.

1 is a cross-sectional view of a motor according to an embodiment of the present invention.

2 is a plan view of a motor according to an embodiment of the present invention.

3 is a partial cross-sectional view of the stator according to an embodiment of the present invention.

4 is a cross-sectional view of a split core assembly in accordance with one embodiment of the present invention.

5 is a plan view of a split core according to an embodiment of the present invention.

6 is a perspective view of a split core connector according to a second exemplary embodiment of the present invention.

7 is a perspective view of a split core connector according to a third exemplary embodiment of the present invention.

8 is a plan view of the upper fixing plate according to an embodiment of the present invention.

9 is a plan view of the lower fixing plate according to an embodiment of the present invention.

10 is a plan view of a coiled stator according to an embodiment of the present invention.

11 is a side view illustrating a process of winding a coil on a split core according to an exemplary embodiment of the present invention.

Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings. In this process, the size or shape of the components shown in the drawings may be exaggerated for clarity and convenience of description. In addition, terms that are specifically defined in consideration of the configuration and operation of the present invention may vary depending on the intention or custom of the user or operator. Definitions of these terms should be made based on the contents throughout the specification.

1 is a cross-sectional view of a motor according to an embodiment of the present invention, Figure 2 is a plan view of the motor according to an embodiment of the present invention.

1 and 2, the double rotor / double stator type motor includes a stator 10 and a rotor 20.

The motor according to the present embodiment may be mainly used in a washing machine, and may be used in other equipment requiring a driving force in addition to the washing machine.

The stator 10 includes a plurality of split core assemblies 50 on which the first coil 12 and the second coil 14 are wound, as shown in FIG. 3.

The rotor 20 is attached to the rotor support 40 fixed to the rotation shaft 48 and the rotor support 40 and disposed at a predetermined gap on the outer surface of the stator 10 to interact with the first coil 12. An outer rotor 26 and an inner rotor 30 mounted to the rotor support 40 and disposed with a predetermined gap on the inner surface of the stator 10 to interact with the second coil 14 are included.

As shown in FIG. 4, the plurality of split core assemblies 50 include a split core 60, a bobbin 70, which is a nonmagnetic material wrapped around an outer circumferential surface of the split core 60, and one side of the split core 60. And a first coil 12 wound around the second coil 14 and a second coil 14 wound around the other side of the split core 60.

As shown in FIG. 5, the split core 60 is formed on the outer tooth 62 on which the first coil 12 is wound, and the inner coil on the opposite side of the outer tooth 62, and the second coil 14 is wound. A partition 66 partitioning between the tooth 64, the outer tooth 62 and the inner tooth 64, and formed at both ends of the partition 66 to interconnect the split cores 60. It includes a connecting portion (82, 84).

The first extension part 67 is formed at the end of the outer tooth 62 to face the outer rotor 26, and the end tooth is disposed to face the inner rotor 30 at the end of the inner tooth 64. The two extension parts 68 are formed.

In addition, a through hole 80 for bolting between the split core 60 and the upper fixing plate 54 and the lower fixing plate 52 which are stacked in plural is formed at the center of the split core 60.

The first extension part 67 and the second extension part 68 are inwardly cured to correspond to the first magnet 22 of the outer rotor 26 and the second magnet 32 of the inner rotor 30, respectively. And outwardly curved surfaces. Therefore, since the roundness of the inner circumferential portion and the outer circumferential portion of the split core 60 is increased, a constant magnetic gap is achieved while the inner circumferential portion and the outer circumferential portion of the stator 10 are close to each other while being close to the first magnet 22 and the second magnet 32. gap).

Between the split cores 60 should have a structure directly connected to each other to form a magnetic circuit. Therefore, the connecting portions 82 and 84 have a structure directly connected to allow the division cores 60 to be energized with each other.

The connection portions 82 and 84 are, for example, coupling protrusions 84 formed on one side of the partition 66 to protrude, and coupling grooves 84 to which the coupling protrusion 84 is fitted to the other side of the partition 66. 82) is formed. The engaging projection 84 is formed to narrow the neck portion 86 is caught by the inlet 88 of the coupling groove (82).

And, in addition to such a structure, as shown in FIG. 6, as shown in FIG. 6, the pin member 90 is formed at both ends of the partition 64 of the split core, and the pin members are formed in contact with each other. It is also possible to apply a structure in which 92 is inserted between the pin holes 90 of the two split cores to connect the split cores 60, and as shown in FIG. 7, between the split cores 60. A method of caulking using the caulking member 94 in contact with each other is also applicable.

The bobbin 70 has a first extension portion such that the first extension portion 67 and the second extension portion 68 of the split core 60 are exposed to interact with the first magnet 22 and the second magnet 24. It is formed to be wrapped around the outer circumferential surface of the remaining divided core 60 except for the 67 and the second extension portion (68). That is, the bobbin 70 is formed on the outer circumferential surface of the split core 60 by insert molding and insulates the split core 60 from the first coil 12 and the second coil 14.

The lower surface of the bobbin 70 is coupled to the lower fixing plate 52, and the upper surface of the bobbin 70 is coupled to the upper fixing plate 54. Therefore, a first coupling groove 72 is formed on the bottom surface of the bobbin 70 and fitted to the first coupling protrusion 56 formed on the lower fixing plate 52. In addition, a second coupling groove 74 is formed on the upper surface of the bobbin 70 to be fitted to the second coupling protrusion 58 formed on the upper fixing plate 54.

The stator 10 includes a lower fixing plate 52 on which lower surfaces of the plurality of split core assemblies 50 are fixed at equal intervals in the circumferential direction, and upper surfaces of the plurality of split core assemblies 50 at equal intervals in the circumferential direction. And an upper fixing plate 54 to be fixed.

As shown in FIG. 8, the lower fixing plate 52 is in the form of a disc with an open center, and a plurality of first coupling protrusions 56 protrude at equal intervals in the circumferential direction of the outer edge thereof, thereby forming the bobbin 70. 1 coupling groove 72 is fitted. In addition, a plurality of first fastening holes 112 are formed at inner edges of the lower fixing plate 52 in which bolts are fastened to fix the stator 10 to the structure in the circumferential direction, and between the first fastening holes 112. When assembling the lower fixing plate 52 to the structure, the alignment pin 114 for aligning the assembly position is formed to protrude.

As shown in FIG. 9, the upper fixing plate 54 is formed in a disc shape having an open center, and the second coupling protrusion 58 is fitted into the second coupling groove 74 formed on the upper surface of the bobbin 70. Are formed at equal intervals in the circumferential direction.

The lower fixing plate 52 and the upper fixing plate 54 are fastened to the split core 60 and the bolt 120. Therefore, the through hole 80 through which the bolt 120 passes is formed in the split core 60, and the first insert into which the nut 116 fastened to the bolt 120 or the bolt head is inserted into the lower fixing plate 52. The groove 110 is formed, and the second fixing groove 122 into which the other of the bolt head or the nut 116 is inserted is formed in the upper fixing plate 54.

As described above, the stator 10 is divided in addition to a structure in which the lower fixing plate 52 is coupled to the lower surfaces of the split cores 60 and the upper fixing plate 54 is assembled to the upper surfaces of the split cores 60. It is also possible to apply a structure in which the cores 60 are integrally formed by insert molding after arranging the cores 60 in a mold.

In addition, between the split cores 60, the upper fixing plate 54, and the lower fixing plate 52, as described above, in addition to the structure in which the bolts 120 are fastened, the upper fixing plate 54 may be press-fitted on the upper surfaces of the split cores. It is also possible to fix by heat fusion, and a press-fit method for pressing or thermally fusion fixing the lower fixing plate 52 on the lower surface of the split cores.

In addition, the method of fastening by the bolt without the coupling protrusion or the coupling groove described above may be applied between the split cores 60 and the upper fixing plate 54 and between the split cores and the lower fixing plate 52.

The rotor support 40 is generally in the form of a disc, and is formed in the center to be coupled to the rotation shaft coupling portion 42 coupled to the outer circumferential surface of the rotation shaft 48 and the outer rotor 26 to be installed at right angles. The first rotor support 44 and the second rotor support portion 46 are provided at intervals inside the first rotor support portion 44 and the inner rotor 30 is installed.

Here, the rotor support 40 is formed integrally with the outer rotor 26 and the inner rotor 30 by insert molding.

The outer rotor 26 is mounted on the outer first surface of the first back yoke 24 and the annular first yoke 24 fixed to the inner surface of the first rotor support 44 of the rotor support 40 and the stator ( And a plurality of first magnets 22 disposed to face each other with a predetermined gap on the outer circumferential surface of 10) and alternately arranged with the N pole and the S pole.

The inner rotor 30 is mounted to an annular second back yoke 34 and an outer circumferential surface of the second back yoke 34 fixed to an outer surface of the second rotor support 46 of the rotor support 40. It includes a plurality of second magnets 32 arranged to face each other with a predetermined gap on the inner peripheral surface of the stator 10 and the N pole and the S pole are alternately arranged.

Such a motor forms a first magnetic circuit L1 between one side of the stator 10 on which the outer rotor 26 and the first coil 12 are wound, and the inner rotor 30 and the second coil 14 Since the second magnetic circuit L2 is formed between the other sides of the wound stator 10 to form a pair of magnetic circuits that are independent of each other, the magnetic path is shortened, thereby reducing the magnetic resistance to reduce magnetic force loss and motor efficiency. Can improve.

In detail, the first magnetic circuit L1 faces the first magnet 22 of the N pole, the outer tooth 62 on which the first coil 12 is wound, and the partition portion ( 66, via the first magnet 22 and the first back yoke 24 of the S pole adjacent to the first magnet 22 of the N pole.

The second magnetic circuit L2 is opposed to the first magnet 32 of the N pole, the inner magnet 64 of which the second coil 14 is wound, and the partition portion ( 66, via the second magnet 32 and the second back yoke 34 of the S pole.

Thus, the stator manufacturing process according to an embodiment of the present invention is configured as follows.

FIG. 10 is a side view illustrating a process of winding a coil on split cores according to an exemplary embodiment, and FIG. 11 is a plan view of a motor in which split core assemblies are arranged, according to an exemplary embodiment.

First, after the plurality of split cores 60 are stacked, insert molding is performed to form a bobbin 70 wrapped on an outer circumferential surface of the split core.

Thereafter, a coil winding process is performed in which the first coil 12 is wound around the outer tooth 62 of the split core 60 and the second coil 14 is wound around the inner tooth 64.

Looking at the coil winding process, the split cores 60 are aligned. That is, the outer teeth 62 and the inner teeth 64 are aligned horizontally in a line and are fixed to be horizontally aligned between the split cores 60 using the core alignment jig 112. Here, the jig for connecting the core 112 is preferably a magnet jig to which the split core 60 is attached to both sides to fix the split cores 60 by magnetic force.

As such, when the alignment of the split cores 60 is completed, the first coil 12 is wound around the outer circumferential surface of the outer tooth 12 using a continuous winding device, and subsequently passes through the partition 66 to receive an inner tooth ( The second coil 14 is wound around the outer circumferential surface of 64. In this case, since only the partition 66 passes between the first coil 12 and the second coil 14, the first coil 12 and the second coil 14 are connected to the first jump line 110 having a short length.

When the winding of one split core is completed, the coil winding is successively performed in succession to the split cores arranged adjacently. That is, the first coil 12 is wound around the outer circumferential surface of the outer tooth 62 of the split core 60 disposed adjacent to each other, and then the second coil 14 is wound around the outer circumferential surface of the inner tooth 64. . In this case, the split core and the split core are connected to each other by the second jump line 114 having a long length since the split core assembly needs to have some margin when assembling the split core assembly.

By repeating this process, the coil is continuously wound on the plurality of split cores 60, and in the case of three phases, three sets of split core assemblies 50 corresponding to each of the U, V, and W phases are manufactured.

As described above, in the coil winding method according to the present embodiment, the first coil 12 is wound around the outer circumferential surface of the outer tooth 62, and the second coil 14 is wound around the outer circumferential surface of the inner tooth 64. Since the coil 12 and the second coil 14 are wound at the same time, productivity can be improved and manufacturing time can be shortened.

That is, if the process of winding the first coil 12 on the outer circumferential surface of the outer tooth 62 and the process of winding the second coil 14 on the outer circumferential surface of the inner tooth 64 are separated separately, the coil winding is Although two processes must be performed, in the present embodiment, since the first coil 12 and the second coil 14 are wound in one process, the coil winding time can be saved and productivity can be improved.

When the manufacturing of the split core assembly is completed in such a manufacturing process, as shown in FIG. 11, the split cores of the U, V, and W phases are alternately arranged in turns for each phase. At this time, the interval between the split core assembly 50 is widened when the three phase split core assembly 50 is alternately arranged because the length of each split core 60 is connected by a long second jump line 114. Even if it can respond enough.

Looking at the assembling process of the split core assembly 50, the lower fixing plate 52 and the upper fixing plate 54, first, the split core assembly 50 is aligned on the upper surface of the lower fixing plate 52 in the circumferential direction. That is, the first coupling grooves 72 formed on the lower surface of the bobbin 70 are assembled to the first coupling protrusions 56 formed on the lower fixing plate 52.

Then, the upper fixing plate 54 is assembled to the upper surface of the split core assembly 50. That is, the second coupling protrusion 58 formed on the upper fixing plate 54 is assembled by inserting the second coupling groove 74 formed on the upper surface of the bobbin 70.

Then, the assembly is completed by fastening the bolt 120 between the upper fixing plate 54, the split core assembly 50 and the lower fixing plate 52.

In addition to the above bolt assembly structure as a method of fixing the split core assembly 50, a method of integrally forming a stator support by aligning the split core assembly circumferentially in a mold and then insert molding is also applicable.

In the above, the present invention has been illustrated and described with reference to specific preferred embodiments, but the present invention is not limited to the above-described embodiments, and the present invention is not limited to the spirit of the present invention. Various changes and modifications will be possible by those who have the same.

The present invention is a motor for generating a rotational drive force, a double rotor / double stator type, and two magnetic circuits in one motor to improve the efficiency of the motor, so the rotational drive force of the washing machine or various home appliances and electronics It can be applied as a motor for generating

Claims (15)

A stator, and a rotor disposed on the outer and inner surfaces of the stator, The stator includes a plurality of split core assemblies having an outer tooth wound around a first coil and an inner tooth wound around a second coil connected to the first coil, and spaced in the circumferential direction. The rotor may include a rotor support connected to a rotating shaft, an outer rotor mounted outside the rotor support and disposed outside the stator to interact with the first coil to form a first magnetic circuit, and an inner side of the rotor support. And an inner rotor mounted to the inner side of the stator to interact with the second coil to form a second magnetic circuit. The method of claim 1, The split core assembly may include: a split core having an outer tooth formed at an outer side thereof and an inner tooth formed at an inner side thereof; Bobbin which is an insulator surrounding the outer surface of the split core, A first coil wound around the outer tooth, And a second coil wound around the inner tooth. The method of claim 2, The split core may include: an outer tooth to which the first coil is wound; An inner tooth formed on the opposite side of the outer tooth and wound with a second coil; A partition that partitions between the outer tooth and the inner tooth and extends laterally; And a connection part formed at both ends of the partition part to connect the split cores. The method of claim 3, The connection unit includes a coupling protrusion formed on one side of the partition portion, and the coupling groove formed on the other side of the partition portion to which the coupling projection is fitted. The method of claim 3, The connection unit includes a pin member formed at both ends of the partition portion and a pin member that is fitted between the pin groove of the two divided cores arranged adjacently. The method of claim 3, The connection unit is a motor, characterized in that by connecting the two compartments of the divided core which is disposed adjacent to each other by caulking using a caulking member. The method of claim 1, The stator includes a lower fixing plate to which lower surfaces of the plurality of split core assemblies are fastened, and an upper fixing plate to which upper surfaces of the plurality of split core assemblies are fastened, And the split core assembly and the upper fixing plate and the lower fixing plate are fastened by any one of press-fitting, heat welding, and bolt fastening. The method of claim 1, And the plurality of split core assemblies are integrally molded by insert molding after the plurality of divided core assemblies are arranged at intervals in the circumferential direction. The method of claim 2, And the first coil and the second coil are successively wound in one process, and the first coil and the second coil are connected to each other by a first jump line. The method of claim 2, And the split cores are successively wound, and the coils of the split cores are connected by a second long jump line. Manufacturing a split core having an outer tooth and an inner tooth; Forming a bobbin on an outer surface of the split core; A coil winding step of winding a coil in succession to the outer tooth and the inner tooth and winding the coil continuously between the split cores to manufacture three sets of split core assemblies corresponding to each of U, V, and W phases; Alternately arranging three sets of split core assemblies to produce an annular stator; And A motor manufacturing method comprising the step of assembling the stator between the outer rotor and the inner rotor. The method of claim 11, The coil winding step includes aligning the split cores in a line; Winding a coil subsequent to an outer tooth and an inner tooth of the split core; And And winding the coil subsequent to the divided cores arranged adjacently when the coil winding is completed on the one divided core. The method of claim 12, The split cores are aligned so that the outer tooth and the inner tooth are horizontal using a core alignment jig, The core alignment jig is a motor manufacturing method, characterized in that the magnet jig for aligning the split cores using a magnetic force is used. The method of claim 11, The step of manufacturing the stator includes connecting between a plurality of split core assemblies; Aligning a plurality of split core assemblies with the lower fixing plate; Assembling an upper fixing plate to an upper surface of the split core assembly; And And coupling the upper fixing plate, the split core assembly, and the lower fixing plate. The method of claim 11, The step of manufacturing the stator includes connecting between a plurality of split core assemblies; And Inserting the plurality of split core assemblies into a mold and insert molding the motor.

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