WO2012176971A1

WO2012176971A1 - Motor and manufacturing method thereof

Info

Publication number: WO2012176971A1
Application number: PCT/KR2012/002504
Authority: WO
Inventors: Bum Re Roh
Original assignee: B M C Co Ltd
Current assignee: B M C Co Ltd
Priority date: 2011-06-21
Filing date: 2012-04-04
Publication date: 2012-12-27
Anticipated expiration: 2013-12-21

Abstract

Disclosed therein are a motor, which has a new electromagnetic field structure, a simple structure and a good driving efficiency, and a manufacturing method of the motor. The motor includes: a yoke assembly having at least two pairs of excitation poles; an amateur assembly having a plurality of pole teeth on which coils are wound and commutator thin films having the same number of the pole teeth, the coils interacting with the excitation poles; and a cover assembly arranged on the amateur assembly, wherein the coil winds at least two neighboring pole teeth out of the plural pole teeth at once.

Description

MOTOR AND MANUFACTURING METHOD THEREOF

The present invention relates to a motor and a manufacturing method of the motor, and more particularly, to a motor, which has a new electromagnetic field structure, a simple structure and a good driving efficiency, and a manufacturing method of the motor.

In general, motors are used in various machines requiring a rotary power. Such motors are classified into DC (Direct Current) motors and AC (Alternating Current) motors according to kinds of power supply, and the AC motors are divided into single-phase AC motors and three-phase AC motors.

The DC motors are used in an ABS (Anti-Lock Brake System), which is used for a brake system of a vehicle, because the DC motors can extensively control speed with a high degree of precision.

Here, the ABS can control a brake oil pressure by sensing a slip of vehicle wheels occurring at the time of quick braking or at the time of braking on the surface of a slippery road, such as a snowy road or a rainy road, so that the ABS can prevent a slip by locking the vehicle wheels and secure directional stability and controllability and reduce a braking distance at the time of braking.

The motor generally includes a yoke assembly, a cover assembly, and an amateur assembly, but, recently, in order to maximize the driving efficiency of the motor, motors with various structures have been studied and developed.

Cited References

U.S. Patent Laid-open No. 2007/0152532

International Patent Laid-open No. WO 2006/100152

Accordingly, the present invention has been made in an effort to solve the above-mentioned problems occurring in the prior arts, and it is an object of the present invention to provide a motor of an improved structure, which can reduce a size and weight under the same output, and a manufacturing method of the motor.

To achieve the above objects, the present invention provides a motor including: a yoke assembly having at least two pairs of excitation poles; an amateur assembly having a plurality of pole teeth on which coils are wound and commutator thin films having the same number of the pole teeth, the coils interacting with the excitation poles; and a cover assembly arranged on the amateur assembly, wherein the coil winds at least two neighboring pole teeth out of the plural pole teeth at once.

The number of the pole teeth is twelve, and one slot is formed between the two neighboring pole teeth out of the plural pole teeth.

The motor further includes two brushes used to supply electric power to the coil, and the two brushes are arranged at an angle of 90 degrees.

Two commutator thin films opposed to each other are directly connected to each other by means of the coil.

In the case that a left side pole tooth and a right side pole tooth based on a standard pole tooth out of the plural pole teeth are arranged at both sides of the standard pole, the coil is wound through a first winding process of winding the standard pole tooth and the left side pole tooth at once by the coil and a second winding process of winding the standard pole tooth and the right side pole tooth at once by the coil.

In another aspect of the present invention, the present invention provides a manufacturing method of the motor includes the steps of: mounting a yoke assembly having at least two pairs of excitation poles; winding coils, which interact with the excitation poles, on a plurality of pole teeth; arranging an amateur assembly, which includes a plurality of commutator thin films having the same number of the pole teeth, inside the yoke assembly; and arranging a cover assembly on the amateur assembly, wherein in the coil winding step, the coil winds at least two neighboring pole teeth of the plural pole teeth at once.

The coil winding step includes a step of directly connecting two commutator thin films, which are opposed to each other, by the coil.

In the case that a left side pole tooth and a right side pole tooth based on a standard pole tooth out of the plural pole teeth are arranged at both sides of the standard pole, the coil winding step includes: a first winding step of winding the standard pole tooth and the left side pole tooth at once by the coil; and a second winding step of winding the standard pole tooth and the right side pole tooth at once by the coil.

The motor and the manufacturing method of the motor according to the present invention have following effects.

First, twelve pole teeth and twelve commutator thin films are mounted, and a coil winds two neighboring pole teeth of the plural pole teeth at once, so that the motor has a new electromagnetic field structure and a simple structure.

Second, the two neighboring pole teeth are wound at once by the coil and two commutator thin films, which are opposed to each other, are directly connected to each other, so that the motor has a new electromagnetic field structure and has enhanced driving efficiency. In detail, the motor manufactured by the coil winding methods according to the present invention has 20% to 30% less size and weight in the same output than conventional motors.

FIG. 1 is a perspective view of a motor according to a preferred embodiment of the present invention.

FIG. 2 is an exploded perspective view of the motor of FIG. 1.

FIG. 3 is a plan view of the motor of FIG. 1.

FIG. 4 is a view showing a state where a coil is wound on pole teeth of the motor according to the present invention.

FIG. 5 is a view showing a coil winding method for manufacturing a motor according to a first preferred embodiment of the present invention.

FIG. 6 is a view showing a coil winding method for manufacturing a motor according to a second preferred embodiment of the present invention.

FIG. 7 is a view showing a coil winding method for manufacturing a motor according to a third preferred embodiment of the present invention.

FIG. 8 is a view showing pole teeth and commentator thin films according to another preferred embodiment of the present invention.

FIG. 9 is a view showing a coil winding method of the motor of FIG. 8.

Reference will be now made in detail to a motor and a manufacturing method of the motor according to the present invention with reference to the attached drawings.

Referring to FIGS. 1 to 5, a motor and a manufacturing method of the motor according to a first preferred embodiment of the present invention will be described.

The motor according to the first preferred embodiment of the present invention includes: a yoke assembly 300 having two pairs of excitation poles 310; an amateur assembly 200 mounted inside the yoke assembly 300; and a cover assembly 100 arranged on the amateur assembly 200.

The excitation poles 310 includes a first N pole P1, a first S pole P2, a second N pole P3, and a second S pole P4 arranged in order. Of course, the present invention is not limited to the above embodiment, and the number of the excitation poles 310 may be at least three pairs.

The cover assembly 100 includes: an upper cover 110 joined with the yoke assembly 300; and a bearing 120 arranged on the upper cover 110 for supporting a rotary shaft 210 of the amateur assembly 200.

The amateur assembly 200 is arranged inside the yoke assembly 300 and the cover assembly 100 is arranged on the amateur assembly 200 and joined with the yoke assembly 300, so that the amateur assembly 200 is supported in stability.

The amateur assembly 200 includes: a plurality of pole teeth 230 on which coils 250 are wound, the coils 250 interacting with the excitation poles 310; commutator thin films 220 having the same number of the pole teeth 230; and a rotary shaft 210 rotating due to interaction between the coils 250 and the excitation poles 310.

Moreover, the motor includes a brush 260 for supplying electric power to the coils 250. The motor further includes two

brushes

261 and 263 for supplying electric power to the coils 250, and the two

brushes

261 and 263 may be arranged at an angle of 90 degrees.

In the meantime, the rotary shaft 210 is located at the center of the amateur assembly 200, and the commutator thin films 220 are arranged in such a way as to form a concentric circle near the rotary shaft 210.

Furthermore, the pole teeth 230 are protrudingly formed in a radial form around the rotary shaft 210, and slots are formed between the pole teeth 230.

In detail, the number of the pole teeth 230 are twelve, namely, the pole teeth 230 include: a first pole tooth T1; a second pole tooth T2, a third pole tooth T3, a fourth pole tooth T4, a fifth pole tooth T5, a sixth pole tooth T6, a seventh pole tooth T7, an eighth pole tooth T8, a ninth pole tooth T9, a tenth pole tooth T10, an eleventh pole tooth T11, and a twelfth pole tooth T12.

Additionally, the number of the commutator thin films 220 are also twelve, namely, the commutator thin films 220 include: a first thin film C1; a second thin film C2, a third thin film C3, a fourth thin film C4, a fifth thin film C5, a sixth thin film C6, a seventh thin film C7, an eighth thin film C8, a ninth thin film C9, a tenth thin film C10, an eleventh thin film C11, and a twelfth thin film C12.

In addition, the slots are respectively formed between two neighboring pole teeth of the plural pole teeth 230. In other words, a first slot S1 is formed between the first pole tooth T1 and the second pole tooth T2. Likewise, a third slot S3, a fourth slot S4, a fifth slot S5, a sixth slot S6, a seventh slot S7, an eighth slot S8, a ninth slot S9, a tenth slot S10, an eleventh slot S11, and a twelfth slot S12 are respectively formed between the two pole teeth 230.

Here, the coil 250 winds the two neighboring pole teeth of the plural pole teeth 230 at once. For instance, assuming that the first pole tooth T1 is a standard tooth out of the plural pole teeth 230, a left side pole tooth which is located at the left of the standard pole tooth is the twelfth pole tooth T12 and a right side pole tooth which is located at the right of the standard pole tooth is the second pole tooth T2, and hence, the coil 250 may be wound on the first and second pole teeth T1 and T2 through a first winding process of winding the coil 250 on the first pole tooth T1 and the twelfth pole tooth T12 at once and a second winding process of winding the coil 250 on the first pole tooth T1 and the second pole tooth T2 at once.

Moreover, two commutator thin films, which are opposed to each other, are directly connected to each other by means of the coil 250.

A manufacturing method of the motor will be described as follows.

First, the yoke assembly 300 having at least two pairs of excitation poles 310 is mounted.

Next, the coils 250 interacting with the excitation poles 310 are respectively wound on the plural pole teeth 230. Of course, a coil winding step for winding the coils 250 from the amateur assembly 200 is carried out separately from the step of mounting the yoke assembly 300.

Next, the amateur assembly 200, which has the plural commutator thin films 220 having the same number of the plural pole teeth 230, is arranged inside the yoke assembly 300.

Next, the cover assembly 100 is arranged on the amateur assembly 200, so that the cover assembly 100 and the yoke assembly 300 are joined to each other.

Here, in the coil winding step, the coil 250 winds the two neighboring pole teeth of the plural pole teeth 230 at once. For instance, in the case that the left side pole tooth and the right side pole tooth are arranged at both sides of the standard pole tooth, the coil winding step includes: a first winding step of winding the standard pole tooth and the left side pole tooth at once; and a second winding step of winding the standard pole tooth and the right side pole tooth at once.

Furthermore, the coil winding step includes a commutator thin film connecting step of directly connecting the two commutator thin films, which are opposed to each other, with each other by means of the coil 250.

Hereinafter, referring to FIGS. 4 and 5, a process of winding the coil 250 on the plural pole teeth 230 and a process of connecting the commutator thin films 220 by the coil 250 will be described in detail.

First, the coil 250 starts from the first thin film C1 and is connected to the seventh thin film C7.

Next, the coil 250, which passed the seventh thin film C7, surrounds the twelfth pole tooth T12 and the first pole tooth T1 at once. Next, the coil 250 surrounds the sixth pole tooth T6 and the seventh pole tooth T7 at once.

After that, the coil 250 is connected to the twelfth thin film C12, and then, is connected to the sixth thin film C6.

Next, the coil 250 surrounds the twelfth pole tooth T12 and the eleventh pole tooth T11 at once. Next, the coil 250 surrounds the sixth pole tooth T6 and the fifth pole tooth T5 at once.

After that, the coil 250 is connected to the eleventh thin film C11, and then, is connected to the fifth thin film C5.

Next, the coil 250 surrounds the eleventh pole tooth T11 and the tenth pole tooth T10 at once. Next, the coil 250 surrounds the fifth pole tooth T5 and the fourth pole tooth T4 at once.

After that, the coil 250 is connected to the tenth thin film C10, and then, is connected to the fourth thin film C4.

Next, the coil 250 surrounds the tenth pole tooth T10 and the ninth pole tooth T9 at once. Next, the coil 250 surrounds the fourth pole tooth T4 and the third pole tooth T3 at once.

After that, the coil 250 is connected to the ninth thin film C19, and then, is connected to the third thin film C5.

Next, the coil 250 surrounds the ninth pole tooth T9 and the eighth pole tooth T8 at once. Next, the coil 250 surrounds the third pole tooth T3 and the second pole tooth T2 at once.

After that, the coil 250 is connected to the eighth thin film C8, and then, is connected to the second thin film C2.

Next, the coil 250 surrounds the eighth pole tooth T8 and the seventh pole tooth T7 at once. Next, the coil 250 surrounds the second pole tooth T2 and the first pole tooth T1 at once.

After that, the coil 250 is connected to the seventh thin film C7. The coil 250 is wound on the plural pole teeth 230, and the process of connecting the plural commutator thin films 220 is repeated as described above.

In this embodiment, the coil 250 surrounds two pole teeth at once, but the present invention is not limited by the above embodiment, but the coil 250 may surround at least three pole teeth at once so as to be wound thereon.

Referring to FIGS. 4 and 6, a manufacturing method of the motor according to a second preferred embodiment of the present invention will be described.

The manufacturing method of the motor according to the second preferred embodiment is different from the first preferred embodiment in the process of winding the coil 250 on the plural pole teeth 230 while the coil 250 connects the plural commutator thin films 220.

In the first preferred embodiment, the coil 250 starting from the first thin film C1 is connected to the seventh thin film C7, and then, surrounds the first pole tooth T1 and the twelfth pole tooth T12 at once.

However, in the second preferred embodiment, the coil 250 starting from the first thin film C1 is connected to the seventh thin film C7, and then, surrounds the seventh pole tooth T7 and the sixth pole tooth T6 at once.

In other words, the coil winding method according to the second preferred embodiment surrounds the two pole teeth at once like the first preferred embodiment, but is different from the first preferred embodiment in the order of winding the plural pole teeth 230 by the coil 250.

Here, the seventh pole tooth T7 and the sixth pole tooth T6 are respectively arranged in positions opposed to the first pole tooth T1 and the twelfth pole tooth T12.

Meanwhile, according to this embodiment, the coil 250 surrounds the seventh pole tooth T7 and the sixth pole tooth T6, and then, surrounds the first pole tooth T1 and the twelfth pole tooth T12 at once.

Next, the coil 250 surrounds the sixth pole tooth T6 and the fifth pole tooth T5 at once. Next, the coil 250 surrounds the twelfth pole tooth T12 and the eleventh pole tooth T11 at once.

Next, the coil 250 surrounds the fifth pole tooth T5 and the fourth pole tooth T4 at once. Next, the coil 250 surrounds the eleventh pole tooth T11 and the tenth pole tooth T10 at once.

Next, the coil 250 surrounds the fourth pole tooth T4 and the third pole tooth T3 at once. Next, the coil 250 surrounds the tenth pole tooth T10 and the ninth pole tooth T9 at once.

Next, the coil 250 surrounds the third pole tooth T3 and the second pole tooth T2 at once. Next, the coil 250 surrounds the ninth pole tooth T9 and the eighth pole tooth T8 at once.

Next, the coil 250 surrounds the second pole tooth T2 and the first pole tooth T1 at once. Next, the coil 250 surrounds the eighth pole tooth T8 and the seventh pole tooth T7 at once.

Referring to FIGS. 4 and 7, a manufacturing method of the motor according to a third preferred embodiment of the present invention will be described.

The manufacturing method of the motor according to the third preferred embodiment is different from the first preferred embodiment in the process of winding the coil 250 on the plural pole teeth 230 while the coil 250 connects the plural commutator thin films 220.

In the first preferred embodiment, the coil 250 starting from the first thin film C1 is connected to the seventh thin film C7, and then, surrounds the first pole tooth T1 and the twelfth pole tooth T12 at once. In this instance, the coil 250 is introduced into the first slot S1 located between the first pole tooth T1 and the second pole tooth T2, and then, goes to the eleventh slot S11 located between the twelfth pole tooth T12 and the eleventh pole tooth T11.

However, in the third preferred embodiment, the coil 250 starting from the first thin film C1 is connected to the seventh thin film C7, and then, surrounds the first pole tooth T1 and the twelfth pole tooth T12 at once, but the coil is introduced into the eleventh slot S11 and goes to the first slot S1.

That is, in the third preferred embodiment and the first preferred embodiment, the commutator thin films are connected to the pole teeth by the coil 250 in the same order, but the third preferred embodiment is different from the first preferred embodiment in the winding direction of the coil 250.

The motor manufactured by one of the coil winding methods according to the embodiments of the present invention has 20% to 30% less size and weight in the same output than conventional motors. The reason is that the coil winding method according to the present invention efficiently generates an electromagnetic interaction in the four excitation poles, the twelve commutator thin films, and the twelve pole teeth.

Referring to FIGS. 8 and 9, another motor according to another preferred embodiment of the present invention and a manufacturing method of the motor will be described as follows.

The motor according to this embodiment includes two pairs of excitation poles (not shown), thirteen pole teeth 1300, and thirteen commutator thin films 1200. Moreover, one slot is formed between two neighboring pole teeth.

Hereinafter, a process that the coil 250 surrounds the thirteen pole teeth 1300 and connects the thirteen commutator thin films 1200 in the motor according to this embodiment will be described in detail.

First, the coil 250 starts from the first thin film C1, and surrounds the twelfth pole tooth T12, the eleventh pole tooth T11 and the tenth pole tooth T10 at once.

Next, the coil 250 is connected to the eighth thin film C8, and then, surrounds the sixth pole tooth T6, the fifth pole tooth T5, and the fourth pole tooth T4 at once.

After that, the coil is connected to the second thin film C2, and then, surrounds the thirteenth pole tooth T13, the twelfth pole tooth T12, and the eleventh pole tooth T11 at once.

Next, the coil 250 is connected to the ninth thin film C9, and then, surrounds the seventh pole tooth T7, the sixth pole tooth T6 and the fifth pole tooth T5 at once.

In the same way as the above process, the coil 250 surrounds the thirteen pole teeth 1300, and connects the thirteen commutator thin films 1200. Concretely, the coil, which passed one commutator thin film, surrounds three pole teeth at once, and then, the coil repeats the process that the coil is connected with other commutator thin films spaced apart from each other at a predetermined interval.

Here, the coil 250 passes the thirteen thin films 1200 in order of the first thin film C1, the eighth thin film C8, the second thin film C2, the ninth thin film C9, the third thin film C3, the tenth thin film C10, the fourth thin film C4, the eleventh thin film C11, the fifth thin film C5, the twelfth thin film C12, the sixth thin film C6, the thirteenth thin film C13, and the seventh thin film C7.

While the present invention has been described with reference to the particular illustrative embodiments, it is not to be restricted by the embodiments but only by the appended claims. It is to be appreciated that those skilled in the art can change or modify the embodiments without departing from the scope and spirit of the present invention.

Claims

A motor comprising:

a yoke assembly having at least two pairs of excitation poles;

an amateur assembly having a plurality of pole teeth on which coils are wound and commutator thin films having the same number of the pole teeth, the coils interacting with the excitation poles; and

a cover assembly arranged on the amateur assembly,

wherein the coil winds at least two neighboring pole teeth out of the plural pole teeth at once.
The motor according to claim 1, wherein the number of the pole teeth is twelve, and one slot is formed between the two neighboring pole teeth out of the plural pole teeth.
The motor according to claim 1, further comprising:

two brushes used to supply electric power to the coil, and the two brushes are arranged at an angle of 90 degrees.
The motor according to one of claims 1 to 3, wherein two commutator thin films opposed to each other are directly connected to each other by means of the coil.
The motor according to one of claims 1 to 3, wherein in the case that a left side pole tooth and a right side pole tooth based on a standard pole tooth out of the plural pole teeth are arranged at both sides of the standard pole, the coil is wound through a first winding process of winding the standard pole tooth and the left side pole tooth at once by the coil and a second winding process of winding the standard pole tooth and the right side pole tooth at once by the coil.
A manufacturing method of a motor comprising the steps of:

mounting a yoke assembly having at least two pairs of excitation poles;

winding coils, which interact with the excitation poles, on a plurality of pole teeth;

arranging an amateur assembly, which includes a plurality of commutator thin films having the same number of the pole teeth, inside the yoke assembly; and

arranging a cover assembly on the amateur assembly,

wherein in the coil winding step, the coil winds at least two neighboring pole teeth of the plural pole teeth at once.
The manufacturing method of the motor according to claim 6, wherein the coil winding step comprises a step of directly connecting two commutator thin films, which are opposed to each other, by the coil.
The manufacturing method of the motor according to claim 6 or 7, wherein in the case that a left side pole tooth and a right side pole tooth based on a standard pole tooth out of the plural pole teeth are arranged at both sides of the standard pole, the coil winding step comprises:

a first winding step of winding the standard pole tooth and the left side pole tooth at once by the coil; and

a second winding step of winding the standard pole tooth and the right side pole tooth at once by the coil.