JPH0373224B2 - - Google Patents

Description

[Detailed Description of the Invention] [Field of Application of the Invention] The present invention relates to the structure of a motor stator coil manufactured by etching, plating, etc., and particularly to a small, thin, low-cost, and simple structure that takes advantage of the features of this type of coil. Concerning type structure.

[Background of the invention]

Figure 1 shows a conventional wire-wound coil and an example of its structure; a is a plan view of one phase, b is a cross-sectional view of the laminated layers, c is an example of the structure of a flat brushless motor using this coil, and d
is a plan view of the magnetic poles of the rotating magnet of the motor. This wire-wound coil has a 3-phase 8-pole structure, and forms a motor electromagnetic section that is stacked and fixed on the surface of the stator yoke 3, facing the magnetic pole surface of the flat rotor magnet 8. The coil for one phase is composed of one eight-pole flat coil, and the terminals of each adjacent coil pole are connected in a continuous manner in a single stroke, and the coils are wound in opposite directions. The conductor used is a self-bonding wire whose surface is coated with an adhesive that melts with heat or alcohol. A special winding machine is used to manufacture the coil. The wire is sequentially and continuously wound around eight triangular winding cores arranged in an annular manner while being heated or dipped in alcohol, and finally both the front and back sides are heated and pressed to form a flat shape. Two terminal leads 5 are taken out per one phase. These three flat coils are concentrically stacked and fixed with electrical angles of 2/3π shifted from each other in the circumferential direction. The terminals 5 of each coil are soldered and tangential to the pattern surface of the wiring board 9 fixed to the side surface.
A sensor 4 for detecting the rotational position of the rotor magnet 8 is fixed on the wiring board 9. The drive electronic circuit 74 is provided separately and is connected to the wiring board 9 of the motor.
The lead wire 93 and the connectors 82, 82' are connected to this. Furthermore, the electronic circuit 74 is connected to the connector 8
0,80' and a lead wire 94 to connect to the power source 73.

Conventional coils with this structure: (1) Because the wiring board, coil, and circuit board are separate, the number of terminals required for each terminal is large, and the number of man-hours required for integration is
It is time consuming and costly. Manufacturing the coil itself requires a long winding time, requires peeling off the insulation coating of the terminal, and is difficult to automate the connection to the wiring board 9.

(2) It is easy to cause poor contact at the connection part, resulting in low reliability.

(3) It is difficult to create a high-density mounting structure.

(4) The thickness of the continuous connecting wire between the coil poles becomes an ineffective thickness within the motor electromagnetic section, reducing motor efficiency.

(5) Since it is difficult to increase the pole area of the winding, the winding coefficient (the rate at which the coil interlinks with the magnetic flux at that position)
is low.

(6) It is difficult to construct a thin motor because it is difficult to reduce the coil thickness.

(7) The coil pole shape cannot be freely selected.

(8) Since the wire is wound under tension, thin wires tend to break.

(9) The shape and dimensions of each coil pole tend to vary, making it difficult to maintain consistent performance.

(10) Pole alignment accuracy cannot be increased.

There are drawbacks such as.

[Purpose of the invention]

SUMMARY OF THE INVENTION An object of the present invention is to improve the drawbacks of the prior art and to provide a stator coil for a motor that is compact and thin, including a drive circuit, and has a structure that can be manufactured at low cost and in mass production.

[Summary of the invention]

In order to achieve the above object, the stator coil of the present invention includes coil poles made of patterned conductors, rotational speed detection means, a drive circuit, and rotational position detection means on one substrate, A stator coil for an axial gap type motor combined with a flat stator yoke having holes or recesses and disposed facing a rotor magnet, comprising a flexible substrate (corresponding example code 25). , a first surface portion (corresponding example code 2) having a coil pole (corresponding example code 40, 41, or 42)
0), a second surface part (corresponding example code 22) to which a drive circuit (corresponding example code 75) is wired, a third surface part (corresponding example code 23) having a rotational speed detection means, and a rotation The fourth surface (corresponding example code 24) to which the position detection means (corresponding example code 46) is wired, and the coil pole located at least between the first, third and second surface parts. It has a bent part (corresponding example code 100) in which a connection pattern conductor for connecting to the drive circuit is formed and has a longer dimension than the stator yoke side surface thickness, and the stator yoke (corresponding example code 100) is formed at the bent part. Example code 3) is folded back, and the first and third surfaces are arranged concentrically with each other on the opposing surface side of the rotor magnet (corresponding example code 8) of the stator yoke, and the second surface section is placed on the opposite surface side. A substrate (corresponding embodiment numeral 25) is provided in which the drive circuit is disposed within the planar outer area of the stator yoke, and the rotational position detection means is disposed within the hole or recess of the stator yoke.

[Embodiments of the invention]

The present invention will be explained below based on examples.

FIG. 2 shows an example of the basic structure of a sheet-like coil constituting the stator coil of the present invention, in which a is a plan view and b is a cross-sectional view. A spiral pattern conductor 28 is formed on the surface of a thin insulating substrate (sheet) 25 by etching, plating, etc. to form a coil pole. This pattern conductor 28 is a flexible insulating substrate (sheet) 25
By forming the coil on both the front and back sides, it is possible to obtain a large number of turns with low resistance and to increase the coil pole area, thereby improving coil efficiency and easily constructing a high-efficiency motor. In addition, the coil pole shape is uniform, allowing for high pole arrangement accuracy and stable motor output. pattern conductor 28,2
The surface of 8' is covered with an insulating coating material 26. This structure example is an example in which pattern conductors 28, 28' are formed on the surface of a thin insulating substrate 25, but in addition, pattern conductors 28 may be formed separately in advance and then fixed on a thin insulating material, or patterned conductors 28 and 2
There is also an example of a structure in which the electrode 8' is bonded to the electrode 8' via an insulating layer.
The basic structure and effects of the finished form are the same in either case.

Examples of the stator coil of the present invention are shown below.
Both have a coil structure that rotates an eight-pole magnetized rotor magnet, similar to the conventional example.

Figure 3 shows a first embodiment of the stator coil of the present invention, in which a is a plan view of the coil, b is a structural example of this coil incorporated into the motor electromagnetic section, and c is a plan view of the stator yoke and sensor incorporated. It is. One board 25
Coil poles 40a, 4 are formed on the surface of the patterned conductor.
0b, 41a, 41b, 42a, 42b are formed on the first surface section 20, 20', 20'', the second surface section 22 on which the drive circuit 75 and circuit components 76, 77 are wired, and the rotational speed detection means. The third FG (frequency signal generator) pattern 46 is formed.
and a fourth surface portion 2 to which position sensors 4a, 4b, and 4c as rotational position detection means are wired.
4 is provided. Coil poles 40a, 40
b, 41a, 41b, 42a, 42b are the substrates 25
They are also formed in positions that overlap with each other on the back side of the . The same coil poles as the surface portion 20 are formed on the surface portions 20', 20''.The coil poles 40a,
40b constitutes a U-phase coil, 41a and 41b constitute a V-phase coil, and 42a and 42b constitute a W-phase coil. A through-hole electrode 45 is provided inside each coil pole.
is provided to connect the coil poles of the same phase that overlap on the front and back of the board. The coil poles between the plane parts 20, 20', and 20'' are connected by a connection pattern conductor 72. Also, the second plane part of the terminal of these coil poles and the terminal of the FG (frequency signal generator) pattern 46 The connection pattern conductor 71 is used to lead out to the 22 side. 68 is a drive circuit 75 and circuit components 76, 77.
67 is a pattern conductor for connection between the position sensor 4a,
4b and 4c are terminal connection pattern conductors. Furthermore, a pattern conductor 80 for connector connection is formed at the tip of the wiring portion of the second surface portion 22 and is connected to the connection pattern conductor 68 and the like. In the configuration of this embodiment, the first surface section 20 and the third surface section 23 are formed on the same sheet section, and the second surface section 22 and the fourth surface section 24 are formed on the same sheet section. A first bent portion 100 is provided at an intermediate portion between the first surface portion 20, the third surface portion 23, and the second surface portion 22, and the fourth surface portion 24;
Second bent portions 101 and 102 (not shown) are provided between 0' and between 20' and 20'', as shown in FIG.
As shown, the bending lines A-A′,
Folded back 180 degrees at B-B' and C-C', the surface parts 20, 2
0', 20'', 22, 23, and 24 are stacked concentrically. The first surface portion 20, the third surface portion 23, and the second surface portion
The surface portion 22 and the fourth surface portion 24 sandwich the stator yoke 3 and are disposed on the front and back sides thereof. That is, the first
The surface portion 20 and the third surface portion 23 are located on the side facing the magnetic poles of the rotor magnet 8 like 20' and 20'', and the second surface portion 22 and the fourth surface portion 24 are located on the side opposite to the rotor magnet 8. For this reason, the bent portion 100 has a dimension longer than the side thickness of the stator yoke 3.Furthermore, the position sensor 4
a, 4b, and 4c are inserted into holes in the center of the stator yoke 3 so that the magnetic field of the rotor magnet 8 can be detected to detect the rotational position of the rotor magnet 8. Drive circuit 75, circuit components 76, 7
7 is located within the second surface portion 22 of the substrate 25 and is fixed by wiring within the planar outline area of the stator yoke 3. With this configuration, in this embodiment, the external dimensions of the motor including the drive circuit portion can be reduced to a configuration suitable for compact high-density packaging.

Further, since the wiring sheet portion is fixed to the back surface of the stator yoke 3, there is no need to take measures to reinforce this portion, and costs can be reduced. It is also possible to provide the stator yoke 3 with a heat radiation effect. Furthermore, since the sensor wiring pattern is provided outside the stator yoke 3, induction by the rotating magnetic field of the rotor magnet 8 can be eliminated, and the S/N of the sensor output can be improved, allowing highly accurate rotation control. .

FIG. 4 is a diagram showing a second embodiment of the stator coil of the present invention. This example also has a folded laminated structure. This embodiment differs from the first embodiment in that each side of the coil sheet is constructed with coil poles of the same phase. Both parts 20 have 8 poles on the front and back, all of which are U-phase coil poles,
Similarly, for the surface part 20, all the coil poles are connected to V
All the coil poles of the surface portion 20''''', each having 8 poles, are W-phase coil poles. The eight coil poles on the front and back sides of each coil sheet portion are arranged in a conductor winding direction such that adjacent poles have opposite polarities. In this embodiment, the sensor wiring section and the FG pattern conductor 46 are provided on the same sheet section. Sensor wiring patterns include 96 in addition to 60a, 60b, and 60c.
has been added. Sensors for detecting the rotational position of the rotor magnet are fixed to 60a, 60b, and 60c, and a sensor (for example, a phase control sensor) for detecting a specific position of the rotating body is fixed to 96. coil,
Each terminal of the sensor and FG is connected to an electronic circuit continuously using each connection lead pattern conductor as in the previous embodiment.
It is led to the component wiring sheet section 22. The bending points for lamination are A-A', B-B', C-C' and D.
-D', the surface portion 22 is placed at the bottom with the stator yoke 3 in between, as in the first embodiment. In this structure, since the number of coil poles is large, the effective conductor length can be longer than that of the coil of the first embodiment, and the motor efficiency can be increased. Other effects are similar to those of the first embodiment. In this structure as well, the number of coil sheet portions for each phase may be further increased continuously, and it is also possible to add a reinforcing plate or a heat sink to the sheet portion 22 of the circuit/component wiring portion.

In the above embodiment, the stator coil structure for a motor that drives an 8-pole magnet in 3 phases was described.
Stator coils for motors of other drive systems are also substantially similar, and these are also within the scope of the present invention. In addition, the sheet surface does not include sensor wiring patterns, FG patterns, etc., but coil conductor patterns and their connection lead patterns, drive electronic circuits, etc.
The structure may include only a component wiring pattern and its connection lead pattern. Furthermore, the sensor is manufactured using patterning technology, and the wiring patterns 60a, 60
It may also be formed in the portions b and 60c from the beginning.

〔Effect of the invention〕

According to the present invention, the stator coil is made to: (1) eliminate the need for terminal connections between coil poles, between phases, and between sheets, reducing the number of steps during coil manufacturing, simplifying the work, and lowering costs; can.

(2) Since it is incorporated into the coil sheet with the wiring board containing the electronic circuit, connection work and connection space with the circuit section are unnecessary. Therefore, it is possible to realize cost reduction and downsizing of the motor, especially the external dimensions including the circuit. Furthermore, the signal S/
N can be improved.

(3) The terminal wiring pattern of the position detection sensor, the speed generator, the terminal wiring pattern of the phase detection sensor, etc. can be easily installed together with a low-cost structure.

(4) Since it is manufactured by etching or meshing and is in sheet form, it is highly workable in manufacturing and assembling.

(5) The motor output can be stabilized because the coil pole arrangement accuracy and pole shape uniformity can be improved.

(6) Motor efficiency can be improved because the conductor space factor and winding coefficient can be increased.

Effects such as this can be obtained.

[Brief explanation of drawings]

Fig. 1 is a structural diagram of a conventional stator coil, Fig. 2 is a basic configuration diagram of a stator coil of the present invention, Fig. 3 is a diagram showing a first embodiment of the stator coil of the present invention, Fig. 4 FIG. 2 is a diagram showing a second embodiment of the stator coil of the present invention. 25... Board, 40, 41, 42... Coil pole, 67, 68, 71, 72... Connection pattern conductor, 75... Drive circuit, 80... Connector connection pattern conductor, 100, 101, 102... ...Bending portion, 3...Stator yoke, 46...FG pattern (rotational speed detection means).

Claims (1)

[Claims] 1. A plate-like fixing device having a coil pole made of a patterned conductor, a rotational speed detection means, a drive circuit, and a rotational position detection means on a single substrate, and having holes or recesses. In a stator coil for an axial gap type motor, which is combined with a child yoke and arranged opposite to a rotor magnet, the stator coil is composed of a flexible substrate and has a first surface portion having coil poles, and a drive circuit is wired thereto. a third surface having a rotational speed detection means, a fourth surface to which a rotational position detection means is wired, and at least an intermediate between the first and third surfaces and the second surface. In this case, a connecting pattern conductor is formed to connect the coil poles and the drive circuit, and has a bent part that is longer than the side thickness of the stator yoke, and is folded back with the stator yoke at the bent part. The first and third surfaces are arranged concentrically on the side of the stator yoke facing the rotor magnet, and the second surface is on the opposite side, and a drive circuit is arranged within the planar outline area of the stator yoke to detect the rotational position. A stator coil characterized in that the means comprises a substrate configured to be disposed within the hole or recess of the stator yoke.