Method of making a rotary motor

• US 6,167,610 B1
• Filed: 01/03/1996
• Issued: 01/02/2001
• Est. Priority Date: 11/08/1993
• Status: Expired due to Term

• Current Assignee: Mitsubishi Denki Kabushiki Kaisha (Mitsubishi Electric Corporation)
• Original Assignee: Mitsubishi Denki Kabushiki Kaisha (Mitsubishi Electric Corporation)
• Inventors: Azuma, Ken-ichi, Matsumoto, Masaru, Akutsu, Satoru, Hashimoto, Akira, Miyazaki, Hiroshi, Fujita, Youichi, Hasegawa, Tadashi, Nakahara, Yuji, Kawada, Junji, Takai, Yasunori
• Primary Examiner(s): Hall, Carl E.
• Application Number:
  US08/582,595
• Time in Patent Office: 1,826 Days
• Field of Search: 295/96, 295/98, 296/09, 296/06, 310/42, 310/43, 310/259
• US Class Current: 29/596
• CPC Class Codes: H02K 1/14 Stator cores with salient poles
• CPC Class Codes: H02K 1/146 consisting of a generally annular yoke with salient poles
• CPC Class Codes: H02K 1/148 Sectional cores H02K1/141 takes precedence
• CPC Class Codes: H02K 1/185 to outer stators
• CPC Class Codes: H02K 11/40 Structural association with grounding devices
• CPC Class Codes: H02K 15/022 with salient poles or claw-shaped poles
• CPC Class Codes: H02K 15/095 by laying conductors around salient poles
• CPC Class Codes: H02K 21/14 with magnets rotating within the armatures
• CPC Class Codes: H02K 21/22 with magnets rotating around the armatures, e.g. flywheel magnetos
• CPC Class Codes: H02K 2201/06 Magnetic cores, or permanent magnets characterised by their skew
• CPC Class Codes: H02K 2201/09 Magnetic cores comprising laminations characterised by being fastened by caulking
• CPC Class Codes: H02K 2201/15 Sectional machines
• CPC Class Codes: H02K 2203/03 Machines characterised by the wiring boards, i.e. printed circuit boards or similar structures for connecting the winding terminations
• CPC Class Codes: H02K 2203/06 Machines characterised by the wiring leads, i.e. conducting wires for connecting the winding terminations
• CPC Class Codes: H02K 2203/12 Machines characterised by the bobbins for supporting the windings
• CPC Class Codes: H02K 2211/03 Machines characterised by circuit boards, e.g. pcb
• CPC Class Codes: H02K 29/03 with a magnetic circuit specially adapted for avoiding torque ripples or self-starting problems
• CPC Class Codes: H02K 3/18 Windings for salient poles
• 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 3/522 for generally annular cores with salient poles
• CPC Class Codes: H02K 3/524 : for U-shaped, E-shaped or similarly shaped cores
• CPC Class Codes: H02K 5/225 : Terminal boxes or connection arrangements specially adapted for submersible motors H02K5/132
• CPC Class Codes: H02K 7/14 : Structural association with mechanical loads, e.g. with hand-held machine tools or fans with fan or impeller for cooling the machine H02K9/06
• CPC Class Codes: Y10T 29/49009 : Dynamoelectric machine
• CPC Class Codes: Y10T 29/49073 : by assembling coil and core
• CPC Class Codes: Y10T 29/49078 : Laminated

Abstract

Magnetic materials which are divided into a plurality of blocks or divided corresponding to respective magnetic pole teeth are connected by means of thin portions. The respective magnetic pole teeth are wound continuously with wire without cutting the wire at the positions in which the thin portions are connected. When a stator is assembled, a plurality of blocks or magnetic pole teeth are disposed on a substrate by separating or bending the thin portions.

Claims

1. A method of producing a rotary motor, the method comprising steps of:

forming a plurality of sheets of magnetic material, each sheet including a plurality of blocks and a plurality of bendable coupling portions, each block having a plurality of magnetic pole teeth and being free of the bendable coupling portions between the magnetic pole teeth, the plurality of blocks being connected with the plurality of bendable coupling portions in series in a direction perpendicular to the direction of magnetic flux flow of the magnetic pole teeth of each block;

laminating the plurality of sheets of magnetic material;

winding the magnetic pole teeth of the laminated sheets with a continuous length of wire to form coils thereon, respectively, at least one coil on a block being connected to at least one coil on an adjacent block with a crossover wire that is a portion of the continuous length of wire; and

bending the laminated sheets at the bendable coupling portions to arrange the blocks in a circular configuration after the winding step.

2. The method according to claim 1, wherein the rotary motor has n phases, the number of magnetic pole teeth of each block being n and one of the n magnetic pole teeth corresponding to each of the n phases.

3. The method according to claim 1, wherein the step of winding the magnetic pole teeth includes simultaneously winding wire on each of the magnetic pole teeth of one of the blocks.

4. The method according to claim 1, wherein the step of forming the plurality of sheets includes forming the plurality of coupling portions as thin portions.

5. The method according to claim 4, further comprising a step of:

mounting the bent sheets on a molded resin product or a substrate.

6. The method according to claim 5, wherein the step of mounting the bent sheets includes removing the coupling portions from the bent sheets.

7. A method of producing a rotary motor, the method comprising steps of:

forming a plurality of sheets of magnetic material, each sheet including a plurality of blocks and a plurality of thin portions, each block having at least one magnetic pole tooth and at least one hole, the plurality of blocks being connected with the plurality of thin portions in series in a direction perpendicular to the direction of magnetic flux flow of the magnetic pole tooth of each block;

laminating the plurality of sheets of magnetic material;

forming an integrated resin molded member having a plurality of pins fixed to the blocks of the laminated sheets, the pins of the integrated resin molded member being fitted into the holes of the blocks;

winding the plurality of the magnetic pole teeth of the blocks with wire to form coils thereon;

cutting the plurality of thin portions of the laminated sheets; and

bending the laminated sheets at the pins of the integrated molded member after the winding and cutting steps.

8. A method of producing a rotary motor, the method comprising steps of:

producing a linear core that includes a plurality of block portions and a plurality of bendable coupling portions, the plurality of block portions being connected with the plurality of bendable coupling portions in series, each block portion including a plurality of magnetic pole teeth and being free of the bendable coupling portions between the magnetic pole teeth;

winding the magnetic pole teeth with a continuous length of wire to form coils thereon, respectively; and

bending the core at the bendable coupling portions to arrange the block portions in a nonlinear configuration after the winding step.

9. The method according to claim 8, wherein the rotary motor has n phases, the number of magnetic pole teeth of each block being n and one of the n magnetic pole teeth corresponding to each of the n phases.

10. The method according to claim 9, wherein the n magnetic pole teeth of each block portion are parallel to each other.

11. The method according to claim 10, wherein the step of winding includes simultaneously winding each of the n magnetic pole teeth of one of the block portions.

12. The method according to claim 8, wherein the step of winding includes connecting at least one coil on a block to at least one coil on an adjacent block with a crossover wire that is a portion of the continuous length of wire and positioning at least one portion of the crossover wire on a side of the core opposite the magnetic pole teeth.