Armature winding, method for manufacturing armature winding, and slotless motor

• US 20060238058A1
• Filed: 03/07/2006
• Published: 10/26/2006
• Est. Priority Date: 03/07/2005
• Status: Active Grant

• Current Assignee: ASMO Company Limited (DENSO Corporation)
• Original Assignee: ASMO Company Limited (DENSO Corporation)
• Inventors: Naitou, Shinichi, Morisaki, Makoto, Nakayama, Takahiro, Takabe, Yoshiyuki, Koide, Keisuke, Nishikawa, Yoshihito
• Granted Patent: US 7,462,971 B2
• Time in Patent Office: Days
• US Class Current: 310/156.550
• CPC Class Codes: H02K 1/2783 with magnets arranged in Halbach arrays
• CPC Class Codes: H02K 15/0414 Windings consisting of separate elements, e.g. bars, hairpins, segments, half coils
• CPC Class Codes: H02K 3/28 Layout of windings or of connections between windings windings for pole-changing H02K17/06, H02K17/14, H02K19/12, H02K19/32
• CPC Class Codes: H02K 3/47 Air-gap windings, i.e. iron-free windings

Abstract

A first armature winding and a second armature winding each include a tubular member, a first conductor arranged in a radially inner side of the tubular member, and a second conductor arranged in a radially outer side of the tubular member. The first conductor includes a first coated portion, which is coated by a coating formed from an insulator, and a first wire connection portion, which is free from the insulator. The second conductor includes a second coated portion, which is coated by a coating formed from an insulator, and a second wire connection portion, which is free from the insulator. The first wire connection portion and the second wire connection portion are electrically connected to each other. A large output is obtained from a slotless motor including the first armature winding and the second armature winding.

Claims

1. An armature winding comprising:

a tubular member;

a first conductor, arranged in a radially inner side of the tubular member, for receiving current; and

a second conductor, arranged in a radially outer side of the tubular member, for receiving current;

wherein the first conductor includes a first coated portion, coated by an insulator, and a first wire connection portion, located at an end of the first coated portion and being free from the insulator, and the second conductor includes a second coated portion, coated by an insulator, and a second wire connection portion, located at an end of the second coated portion and being free from the insulator, the first wire connection portion and the second wire connection portion being electrically connected to each other.

2. The armature winding according to claim 1, wherein the first conductor and the second conductor extend in different torsional directions.

3. The armature winding according to claim 1, wherein the first conductor and the second conductor each include an inclined portion inclined with respect to an axis of the tubular member and a parallel portion extending parallel to the axis of the tubular member.

4. The armature winding according to claim 1, wherein:

the first conductor includes a plurality of first conductor strips aligned in a first direction, the first conductor strips extending in a second direction that differs from the first direction, and the first conductor having a cross-sectional shape in which its longitudinal direction coincides with the first direction; and

the second conductor includes a plurality of second conductor strips aligned in a third direction, the second conductor strips extending in a fourth direction that differs from the third direction, and the second conductor having a cross-sectional shape in which its longitudinal direction coincides with the third direction.

5. The armature winding according to claim 1, wherein the first conductor and the second conductor are each smaller in size in a radial direction of the tubular member than in a circumferential direction of the tubular member.

6. The armature winding according to claim 1, wherein the first conductor and the second conductor each have a cross-sectional shape including at least two corners.

7. The armature winding according to claim 1, wherein the first wire connection portion and the second wire connection portion are each thicker at its middle part than at its ends with respect to the circumferential direction of the tubular member.

8. The armature winding according to claim 7, wherein the first conductor and second conductor each have an elliptical cross-section.

9. The armature winding according to claim 1, wherein the first conductor and the second conductor each have a circular cross-section.

10. The armature winding according to claim 1, wherein the first wire connection portion and the second wire connection portion project from an edge of the tubular member so that the first wire connection portion and the second wire connection portion do not overlap the tubular member in the radial direction of the tubular member.

11. A method for manufacturing an armature winding, the armature winding including a tubular member, a first conductor, arranged in a radially inner side of the tubular member, for receiving current, and a second conductor, arranged in a radially outer side of the tubular member, for receiving current, wherein the first conductor includes a first coated portion, coated by an insulator, and a first wire connection portion, located at an end of the first coated portion and being free from the insulator, and the second conductor includes a second coated portion, coated by an insulator, and a second wire connection portion, located at an end of the second coated portion and being free from the insulator, the first wire connection portion and the second wire connection portion being electrically connected to each other, the method comprising the steps of:

forming the first conductor and the second conductor;

forming the tubular member;

fixing the first conductor to an inner surface of the tubular member and fixing the second conductor to an outer surface of the tubular member; and

electrically connecting the first wire connection portion of the first conductor and the second wire connection portion of the second conductor, which are fixed to the tubular member, to each other.

12. A method for manufacturing an armature winding, the armature winding including a tubular member, a first conductor, arranged in a radially inner side of the tubular member, for receiving current, and a second conductor, arranged in a radially outer side of the tubular member, for receiving current, wherein the first conductor includes a first coated portion, coated by an insulator, and a first wire connection portion, located at an end of the first coated portion and being free from the insulator, and the second conductor includes a second coated portion, coated by an insulator, and a second wire connection portion, located at an end of the second coated portion and being free from the insulator, the first wire connection portion and the second wire connection portion being electrically connected to each other, the method comprising the steps of:

forming the first conductor and the second conductor;

fixing the first conductor and the second conductor to a plate member having a first surface and a second surface, the first conductor being fixed to the first surface, and the second conductor being fixed to the second surface;

forming a tubular shape with the plate member to which the first conductor and the second conductor are fixed so that the first conductor is arranged at the radially inner side of the tubular member and the second conductor is arranged at the radially outer side of the tubular member; and

electrically connecting the first wire connection portion of the first conductor and the second wire connection portion of the second conductor to each other.

13. The method according to claim 12, wherein the electrical connection between the first wire connection portion and the second wire connection portion is performed after forming a tubular shape with the plate member to which the first conductor and the second conductor are fixed.

14. A slotless motor comprising:

an armature winding including;

a tubular member;

a first conductor, arranged in a radially inner side of the tubular member, for receiving current; and

a second conductor, arranged in a radially outer side of the tubular member, for receiving current, wherein the first conductor includes a first coated portion, coated by an insulator, and a first wire connection portion, located at an end of the first coated portion and being free from the insulator, and the second conductor includes a second coated portion, coated by an insulator, and a second wire connection portion, located at an end of the second coated portion and being free from the insulator, the first wire connection portion and the second wire connection portion being electrically connected to each other.

15. The slotless motor according to claim 14, further comprising a rotor including a plurality of magnets arranged in a halbach arrangement.

16. The slotless motor according to claim 15, wherein the magnet is larger in size in a radial direction of the rotor than in a circumferential direction of the rotor.

17. The slotless motor according to claim 15, wherein the rotor includes a magnet fixing plate made of a non-magnetic body or a slightly magnetic body, the magnet fixing plate contacting one end of the magnet in an axial direction of the rotor.

18. The slotless motor according to claim 14, wherein the first conductor and the second conductor are connected via an external inductance to a drive circuit for supplying drive current to the first conductor and the second conductor.