Single rotor type motor and manufacturng method thereof

A single rotor type motor includes: a stator including a plurality of stator cores that are split and radially arranged, a bobbin made of an insulating material and wrapped on an outer surface of each of the stator cores, coils wound on an outer surface of the bobbin, an upper fixing plate disposed on the upper surfaces of the stator cores and on which the stator cores are radially arranged, and a lower fixing plate that is disposed on the lower surfaces of the stator cores and is coupled with the upper fixing plate; and a single rotor disposed with a certain gap from any one surface of an inner surface of the stator and an outer surface thereof. The plurality of wiring units for electrically connecting between the coils wound around each of the stator cores are formed integrally on the upper surface of the upper fixing plate.

TECHNICAL FIELD

The present invention relates to a single rotor type motor, and more particularly to a single rotor type motor and a manufacturing method thereof, in which wiring units for electrically connecting between stator coils are placed on a plate for fixing the stator cores, to thus enable easy assembly and solve a problem of coil disconnection.

BACKGROUND ART

Typically, a single rotor type motor includes a stator that receives power from an external power source and a rotor that is disposed with a certain gap on the outer circumferential surface or the inner circumferential surface of the stator and to which a rotating shaft is fixed.

The stator includes a stator core on which a plurality of iron pieces are stacked and formed and are arranged radially at regular intervals, a bobbin that is formed to be surrounded on the outer circumferential surface of the stator core and made of an insulating material, and coils that are wound around the outer circumferential surface of the bobbin.

The rotor includes a rotor support that is fixed to a rotating shaft, and a magnet that is mounted on the rotor support and that is arranged with a certain gap on the inner surface or the outer surface of the stator.

Here, the stator core is formed of individually divided split cores, and thus includes coil connection terminals for electrically connecting between coils wound around the cores.

A device for fixing terminals in bobbins for a conventional motor is disclosed in Korean Utility Model Registration 20-0159355. Each of the bobbins includes a coil winding portion on which coil wires for a circuit are wound. Each of the bobbins includes a plurality of slot grooves at one side thereof so that terminals are tight fitted with the slot grooves. Each of the terminals includes: a support surface that is inserted into the inner side of one slot groove; a first wiring unit that is bent and formed at one side end of the support surface so as to be inserted into one side of the slot groove and simultaneously to be protruded on the upper surface of the bobbin; and a second wiring unit that is bent and formed at the other side end of the support surface so as to be in contact with the side edge of the bobbin.

However, a structure of terminals for connecting coils of such a conventional motor has no structure of peeling off insulating outer sheaths of the coils and thus workers should strip out the insulating outer sheaths of the coils, to accordingly cause a complicated process.

Furthermore, the terminal fixing device of the conventional motor may cause the terminals to be seceded from the slot grooves, to accordingly cause a problem such as disconnection of the coils.

SUMMARY OF THE INVENTION

To solve the above problems or defects, it is an object of the present invention to provide a single rotor type motor in which wiring units for connecting between coils wound on respective stator cores are provided on a fixing plate on which the split stator cores are fixed in a radial form, to thus simplify wiring of the coils and to thus prevent occurrence of disconnection of the coils.

It is another object of the present invention to provide a single rotor type motor in which a coil terminal is formed integrally with a blade and thus when the coil terminal is inserted into a terminal pocket, insulating outer sheaths of coils are peeled off by the blade and fixed to the coil terminal, to thereby make a separate process of peeling off the insulating outer sheaths of the coils unnecessary, and simplify a manufacturing process of the single rotor type motor.

The objects of the present invention are not limited to the above-described objects, and other objects and advantages of the present invention can be appreciated by the following description and will be understood more clearly by embodiments of the present invention.

To accomplish the above and other objects of the present invention, according to an aspect of the present invention, there is provided a single rotor type motor comprising: a stator including a plurality of stator cores that are split and radially arranged, a bobbin made of an insulating material and wrapped on an outer surface of each of the stator cores, coils wound on an outer surface of the bobbin, an upper fixing plate that is disposed on the upper surfaces of the stator cores and on which the stator cores are radially arranged, and a lower fixing plate that is disposed on the lower surfaces of the stator cores and is coupled with the upper fixing plate; and a single rotor disposed with a certain gap from any one surface of an inner surface of the stator and an outer surface thereof, wherein a plurality of wiring units for electrically connecting between the coils wound around each of the stator cores are formed integrally on the upper surface of the upper fixing plate, and each of the wiring units comprises: a terminal pocket that is integrally formed on the upper surface of the upper fixing plate and into which the coils are inserted; and a coil terminal that is made of a metallic material that can be electrified and is inserted into the terminal pocket for electrically connecting between the coils.

The stator core according to the present invention comprises: a rod portion of a plate shape and around which the coils are wound; a tooth portion that is extensibly formed in a lateral direction on one end of both ends of the rod portion and that is disposed facing a magnet of the rotor; and a flange portion that is formed at the other side end of the rod portion, in which the flange portion comprises: a connecting portion for mutually connecting between the stator cores; and a bolt fastening hole for coupling the stator core, the upper fixing plate, and the lower fixing plate with a bolt.

As described above, a single rotor type motor according to the present invention is configured to include wiring units for electrically connecting between coils wound around stator cores are formed on the upper surface of an upper fixing plate on which the split stator cores are radially fixed, in which a terminal pocket into which coils of each of the wiring units are inserted is integrally formed on the upper surface of the upper fixing plate, to thus enable easy manufacturing, simplify coil wirings, and prevent occurrence of disconnection of the coils.

Further, the single rotor type motor according to the present invention is configured to form a coil terminal integrally with a blade, to thus peel off insulating outer sheaths of coils by the blade and fixed to the coil terminal, when the coil terminal is inserted into a terminal pocket, to thereby make a separate process of peeling off the insulating outer sheaths of the coils unnecessary, and simplify a manufacturing process of the single rotor type motor.

DETAILED DESCRIPTION OF THE INVENTION

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. In the process, the size and shape of the components illustrated in the drawings may be shown exaggerated for convenience and clarity of explanation. Further, by considering the configuration and operation of the present invention the specifically defined terms can be changed according to user or operator's intention, or the custom. Definitions of these terms herein need to be made based on the contents across the whole application.

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

Referring toFIG. 1, a single rotor type motor includes a stator10and a rotor20.

The motor according to the present embodiment may be mainly used in washing machines. In addition to the washing machines, the motor according to the present embodiment may be also used in other devices requiring a rotational drive force.

The rotor20is configured in the form of an outer rotor type disposed on the outer circumferential surface of the stator10, and includes: a magnet22disposed with a certain gap from the inner surface of the stator10; and a rotor support26to which the magnet22is fixed and at the center of which a rotating shaft30is mounted.

The stator10includes: a plurality of stator cores12that are divided in a plural number and radially arranged; a bobbin14made of an insulating material and wrapped on an outer surface of each of the stator cores12; coils16wound on an outer surface of the bobbin14; an upper fixing plate40on which the upper surfaces of the stator cores are radially fixed; and a lower fixing plate50on which the lower surfaces of the stator cores are radially fixed.

FIG. 2is a plan view of a motor according to an embodiment of the present invention, andFIG. 3is a partially enlarged view of an example of the stator according to the embodiment of the present invention.

In the embodiment of the present invention, when the stator10is driven by using a three-phase drive method, coil windings for a plurality of split-type stator cores12are successively executed for respective phases U, V, and W. When a magnetic circuit of the motor is made of, for example, a 27-slot-24-pole structure, or a 27-slot-36-pole structure, coil windings corresponding to the respective three phases U, V, and W are performed in the nine split-type stator cores for the respective phases U, V, and W.

As shown inFIG. 4, the stator core12includes: a rod portion60of a plate shape having a certain width and around which coils16are wound; an outer tooth portion62that is extensibly formed in a bilateral direction on the outer end of the rod portion60and that is disposed facing a magnet22of the rotor; and a flange portion64that is extensibly formed in a bilateral direction on the inner end of the rod portion60.

The flange portion64is configured to include: connecting portions65and66that electrically connect between the stator cores12that are radially arranged to thus form a magnetic circuit, and that mutually connect between the stator cores12so that the stator cores12are radially arranged, and a bolt fastening hole67for mutually coupling the stator core12, the upper fixing plate40, and the lower fixing plate50.

Here, the connecting portions65and66are configured to include: a coupling protrusion65that is formed at one end of the flange portion64; and a coupling groove66that is formed at the other end of the flange portion64, and into which a coupling protrusion65of another stator core that is disposed adjacently to the stator core12is inserted and coupled.

Further, in addition to such a structure, the connecting portions65and66are also configured to have another structure that pin holes that are formed at both sides of the flange portion64in which pin members are fitted between the pin holes of two adjacent stator cores12at a state where the two adjacent stator cores12are in contact with each other, to thereby connect between the two adjacent stator cores12. Meanwhile, as shown inFIG. 5, the connecting portions65and66are also configured to have another structure that recess portions that are formed at both sides of the flange portion in which the recess portions of two adjacent stator cores12are caulked by using a caulking member32at a state where the two adjacent stator cores12are in contact with each other, to thereby connect between the two adjacent stator cores12.

The bolt fastening hole67is a throughhole formed on the front surface of the flange portion64. After having stacked the stator cores12, the upper fixing plate40is disposed on the front surfaces of the stator cores12and the lower fixing plate50is disposed on the rear surfaces of the stator cores12. Then, a fastening bolt34is inserted into the bolt fastening hole67, and then a nut36is coupled at the end of the fastening bolt34, to thereby complete an assembly of the stator cores12by tightening the fastening bolt34and the nut36.

As described above, since the motor according to this embodiment is a single rotor type motor in which only a single rotor20is disposed on one surface of the stator10, an outer tooth portion62facing the magnet22of the rotor20is formed on one surface of the stator core12and no magnets are disposed on the other surface of the stator core12. Accordingly, the connecting portions65and66and the bolt fastening hole67can be formed on the other surface of the stator core12, to thus enable an easy and simplified assembly.

Further, in the case of the motor according to this embodiment, the bolt fastening hole67is formed in the stator core12, and thus the upper fixing plate40, the lower fixing plate50, and the stator core12can be fastened with the fastening bolt34. Accordingly, no insert molding work is required after the stator cores12are arranged into a mold, to thereby simplify the manufacturing process, eliminate tolerances at the time of performing insert molding, and solve a problem of coil disconnection when the stator cores are inserted into the mold.

The bobbin14includes: a coil winding portion70that is formed to be wrapped around the outer circumferential surface of a plurality of rod portions50in a state where the rod portions60are stacked and around which coils16are wound; a first extension portion72that is formed on the outer end of the coil winding portion70and surrounds a part of the outer tooth portion62; and a second extension portion74that is formed on the inner end of the coil winding portion70and surrounds a part of the flange portion64.

As shown inFIG. 6, the upper fixing plate40is configured in the form of a disc whose central portion is opened, in which first fastening bolt holes42that are coupled with the stator cores12by a fastening bolt are formed at predetermined intervals on the outer circumferential surface of the upper fixing plate40and first fixing holes44that are coupled with the lower fixing plate50and further fixes a drive motor to an apparatus such as a washing machine are formed at predetermined intervals on the inner circumferential surface of the upper fixing plate40.

The lower fixing plate50is configured in the form of a disc whose central portion is opened, in which second fastening bolt holes52that are disposed on the lower surface of the stator cores12and are communicated from the bolt fastening holes67of the stator cores12are formed at predetermined intervals in the circumferential direction of the lower fixing plate50and second fixing holes54that are in contact with the lower surface of the upper fixing plate40and are communicated from the first fastening holes44are formed at predetermined intervals in the circumferential direction of the lower fixing plate50. Further, the lower fixing plate50is integrally formed with a cover portion56extending from the outer surface of the stator10and covering the lower surfaces of the stator cores12.

A plurality of wiring units80that connect between coils for electrically connecting between the coils16wound on the respective stator cores12are mounted on the upper fixing plate40.

As shown inFIGS. 7 and 8, each of the wiring units80includes: a terminal pocket82that is integrally formed with the upper surface of the upper fixing plate40so that the ends of two or three strands of coils16are inserted into the terminal pocket82; and a coil terminal84that is inserted into the terminal pocket82for electrically connecting between the coils16.

One of a plurality of the wiring units80is used to form the neutral point NP at which three-phase coils of U, V, and W phases are mutually wired.

Here, the terminal pocket82is integrally formed with the upper fixing plate40on the upper surface of the upper fixing plate40, and includes: a plurality of seating grooves86that are formed at equal intervals in the circumferential direction of the upper fixing plate40and into the side surface of which the ends of two or three strands of coils16are inserted; and insertion grooves90whose upper surfaces are opened and into which a coil terminal84is inserted.

The coil terminal84is fitted into the insertion grooves90of the terminal pocket82and is formed of a metallic material that can be electrically energized to electrically connect between the coils16. A plurality of slots92into which coils are press-fitted are formed at the lower side of the coil terminal84. A blade94is formed on both side ends of each of the slots92, and thus plays a peel-off role of peeling off an insulating outer sheath surrounding the outer surface of the coil16when the coil16is press-fitted into the slot92.

Further, a coil fixing groove96with which the coil16is fitted and fixed is formed on the inside of the slot92.

A locking projection102is formed on the side of the coil terminal84and a locking recess104with which the locking projection102is locked is formed on the inner surface of the terminal pocket82. Thus, when the coil terminal84is inserted into the terminal pocket82, the locking projection102is in engagement with the locking recess104, to thus prevent the coil terminal84from being seceded from the terminal pocket82.

An assembly process of assembling the stator cores according to the embodiment of the present invention that is configured as described above will follow.

First, after the split stator cores12are laminated, the bobbin14is formed on the outer surfaces of the split stator cores12by insert molding. Then, the coils16are wound on the outer circumferential surface of the bobbin14.

Then, the stator cores12are radially arranged the upper surface of the lower fixing plate50, and the upper fixing plate40is seated on the upper surface of the radially arranged stator cores12. Then, the fastening bolt34is made to pass through the first fastening hole42of the upper fitting plate40, the bolt fastening holes67formed in the stator cores12, and the second fastening holes52of the lower fixing plate50, the nut36is coupled with the fastening bolt34to thereby tighten and couple the upper fixing plate40, the stator cores12and the lower fixing plate50.

Then, the ends of the coils16wound on the respective stator cores12are connected with the wiring units80formed on the upper fixing plate40, to thus connect between the coils16.

That is, the ends of the coils16are seated on the respective seating grooves86of the terminal pocket82. Then, the coil terminal84is inserted into the insertion grooves90of the terminal pocket82, and thus the coils16are fitted into the slots92. Here, since the slots92are narrow, the insulating outer sheaths of the coils16are peeled off by the blade94formed at the ends of the slots92, and only the coils16whose insulating outer sheaths have been peeled off are press-fitted into the slots92. Further, the coils16are respectively fixed in the coil fixing grooves96formed in the slots92.

As described above, the single rotor type motor according to the embodiment of the present invention is configured so that the terminal pocket is arranged on the outer surface of the upper fixing plate, to thus secure a sufficient space in which the terminal pocket can be placed and to thereby solve the coil disconnection problem.

Further, the single rotor type motor according to the embodiment of the present invention is configured so that the blade is formed on the coil terminal. Thus, when the coil terminal is inserted into the terminal pocket, the insulating outer sheaths of the coils are peeled off by the blade, and thus no further action of peeling off the insulating outer sheaths of the coils is required to improve the assembly of the motor.

As described above, the present invention has been described with respect to particularly preferred embodiments. However, the present invention is not limited to the above embodiments, and it is possible for one of ordinary skill in the art to make various modifications and variations, without departing off the spirit of the present invention. Thus, the protective scope of the present invention is not defined within the detailed description thereof but is defined by the claims to be described later and the technical spirit of the present invention.

The present invention may be applied to a single rotor type motor in which wiring units for electrically connecting between stator coils are placed on fixing plates on which stator cores are fixed, to thus make it easy to assemble the motor and solve a coil disconnection problem.