Nidec Corporation

Yasuaki Nakahara

Takayuki Migita

Takeshi Honda

Hisashi Fujihara

Hiroshi Kitagaki

Yosuke Yamada

Hirofumi Muto

Osamu Fujimoto

Ryusuke Sato

Tsuyoshi Nakamura

Hidehiro Haga

Keisuke Saito

Takao Atarashi

Takashi Shiraishi

Tatsuro Kawamoto

Junichi Uno

Yusuke Makino

A method of manufacturing a rotor includes forming plates each including a scrap portion that has a center hole and core plate portions that are disposed continuously with the scrap portion on an inner side of the center hole and that each defines a portion of a corresponding one of the outer cores forming a multilayer body including the outer cores by stacking the plates, setting at least a portion of the multilayer body and a portion of the inner core in a mold with a gap therebetween in the radial direction, forming a molded body by pouring a molten filling material into a gap in the mold and forming the filling section, at least a portion of the filling section being positioned between the outer cores, and separating the scrap portion and the core plate portions from each other.

Method of manufacturing rotor, rotor, and motor

A method of manufacturing a rotor core, the method including laminating first laminated steel plates in an axial direction. The first laminated steel plates each include a plurality of flake portions arranged in a circumferential direction with gaps between each other and a plurality of protrusions protruding radially outward from an outer side surface of a base portion and each having at least a portion located in the gap between the flake portions. The method further includes fixing the base portions to each other and fixing the flake portions to each other. The method further includes removing the protrusions of the laminated steel plates radially outward.

Rotor core with concave portions between flake portions and base portions with dimensions

A rotor includes magnets, and magnet holes each of which includes an opening extending in a radial direction in plan view, penetrates a rotor core in the axial direction, and includes the magnet located therein. A magnetic pole surface of the magnet opposes a circumferential direction. The rotor core includes first thin plate cores and second thin plate cores. The first thin plate cores include an annular first inner plate, first outer plates on a radially outer side of the first inner plate and arrayed side by side in the circumferential direction, first inner connecting portions connecting the first inner plate and the first outer plate, and a first outer connecting portion that is on a radially outer side of the first outer plate and connects the adjacent first outer plates in the circumferential direction.

Rotor and motor

A rotor includes a rotor core in which laminate steel plates extending in a radial direction with respect to a central axis are laminated in an axial direction, and magnets are inserted into the rotor core. Each of the laminate steel plates includes a base portion positioned on a radially outer side of the central axis, and pieces separately disposed on a radially outer side of the base portion with penetrating portions therebetween, and arranged side by side at predetermined intervals in a circumferential direction. The magnets are inserted into the penetrating portions and arranged side by side at predetermined intervals in the circumferential direction. Space portions are provided between the magnets adjacent to each other in the circumferential direction. A circumferential length of the pieces is shorter than a circumferential length of the magnets.

A rotor includes a rotor core including laminated thin plate cores. A single thin plate core includes an inner plate portion defining a portion of an inner core portion and outer plate portions defining a portion of an outer core portion. At least some of the laminated thin plate cores include a connecting portion. A number of connecting portion is one or a plurality, and, when the number of connecting portions is a plurality, the connecting portions at positions other than both left and right sides of each other in a circumferential direction, and, in plan view, the thin plate core includes the connecting portion at a position different from that of a connecting portion in another thin plate core adjacent in an axial direction.

Rotor, motor, and rotor manufacturing method

A rotor core includes first and second laminate steel plates extending in a radial direction with respect to a central axis. The first laminate steel plate includes a first base portion positioned on a radially outer side of the central axis, and pieces separately positioned on a radially outer side of the first base portion with penetrating portions therebetween, and disposed at predetermined intervals in a circumferential direction. The second laminated steel sheet includes a second base portion positioned on a radially outer side of the central axis, and annular portions separately disposed on a radially outer side of the second base portion with penetrating portions therebetween, and extending in a circumferential direction. The rotor core is defined by the first laminate steel plates and at least one of the second laminate steel plates laminated in an axial direction.

Rotor core, rotor and motor

A rotor core includes laminate steel plates extending in a radial direction with respect to a central axis. The laminate steel plates each include a base portion on a radially outer side of the central axis, and pieces separately disposed on a radially outer side of the base portion with penetrating portions therebetween, and arranged side by side at predetermined intervals in a circumferential direction. The laminate steel plates are laminated in an axial direction. The laminated steel plate at an upper end in the axial direction includes at least one of an outward projection extending radially outward from an outer edge portion of the base portion and an inward projection extending radially inward from an inner edge portion of the piece, and the laminated steel plate at a lower end in the axial direction includes an intervening portion between the base portion and the piece portion.

Rotor core, rotor, motor, manufacturing method of rotor core, and manufacturing method of rotor

A motor may include a rotor including a shaft; a stator; and a bearing supporting the shaft. The rotor may include a plurality of core pieces on an outer side of the shaft, a plurality of permanent magnets, a mold resin part between the core pieces, and an interposed part in contact with a surface on one side in a circumferential direction of each of the core pieces. The neighboring core pieces may include a magnet insertion hole provided therebetween. The permanent magnet may include two poles, with poles of neighboring magnets facing each other having identical polarity. Each of the permanent magnets is in indirect contact with the core piece positioned on the other side in the circumferential direction of the magnet insertion hole via the interposed part.

Motor

A stator includes core pieces in which at least first and second laminate members are laminated, the first laminate member includes a first tooth portion and a first core back portion, the second laminate member includes a second tooth portion and a second core back portion, the first core back portion includes a first protrusion on one side thereof in a circumferential direction and a first recess on the other side thereof in the circumferential direction, the second core back portion includes a second recess on one side thereof in a circumferential direction and a second protrusion on the other side thereof in the circumferential direction, and an area of a region in which the first and second core back portions of the core piece adjacent thereto overlap in a lamination direction is greater than a circumferential cross-sectional area of the first core back portion circumferentially inward from the first protrusion.

Stator, stator manufacturing method and motor

A motor includes a bus bar assembly including a bus bar, a wiring member, and a bus bar holder. The bus bar holder includes a main body portion, a bottom portion, and a first circuit board support portion. The wiring member includes a circuit board connection terminal electrically connected to the circuit board. The circuit board connection terminal includes a contact portion connected to the circuit board, and applies force to the circuit board through the contact portion. The first circuit board support portion is disposed at a region of the bottom portion to define a side at which the circuit board connection terminal is located when viewed from one direction. The first circuit board support portion and the contact portion are located at different positions when viewed from the one direction.

A manufacturing method comprising: a process Sof forming a plate member which has a substantially annular scrap portion having a center hole through an axial direction and a core plate portion defining a portion of the core pieces arranged continuously with the scrap portion on a radially inner side of the scrap portion; a process Sof forming a laminated body, which has the core pieces, by laminating the plate member; a process Sof providing the laminated body and the shaft in a mold; a process Sof forming a molding body by inserting a molten resin or a nonmagnetic material in the mold and forming the filling portion of which at least a portion is located between the core pieces; and a process Sof separating the scrap portion and the core plate portion.

Manufacturing method of rotor core, manufacturing method of rotor, rotor and motor

A stator includes core pieces in which at least first and second laminate members are laminated, the first laminate member includes a first tooth portion and a first core back portion, the second laminate member includes a second tooth portion and a second core back portion, the first core back portion includes a first protrusion on one side thereof in a circumferential direction and a first recess on another side thereof in the circumferential direction, the second core back portion includes a second recess on one side thereof in a circumferential direction and a second protrusion on the other side thereof in the circumferential direction, and an area of a region in which the first core back portion and the second core back portion of the core piece adjacent thereto overlap in a lamination direction is greater than a circumferential cross-sectional area of the first core back portion circumferentially inward from the first protrusion.

A stator includes conductive wires wound around teeth, and slots between adjacent teeth in a circumferential direction. The conductive wires include conductive wires of three phases corresponding to a U-phase, a V-phase, and a W-phase, and the conductive wires are delta connected. Coils, in which any one of the conductive wires is wound around the teeth, are repeatedly disposed in order of the U-phase, the V-phase, and the W-phase in the circumferential direction. In each of the U-phase, the V-phase, and the W-phase, at least two coils are connected in series and adjacent in the circumferential direction. A direction in which the U-phase and W-phase conductive wires are wound around the teeth and a direction in which the V-phase conductive wire is wound around the tooth are opposite.

A case includes a cylindrical housing arranged to hold a stator, and having an opening portion at a top thereof; and a motor cover fitted to an upper side of the housing, and arranged to cover an upper side of the stator. A busbar unit includes a sensor busbar electrically connected to a rotation sensor, and a busbar holder arranged at the opening portion to hold the sensor busbar. The case includes a case through hole arranged to open into a space outside of the case. The busbar holder includes a cylindrical holder body portion having at least a portion thereof arranged radially inside of the opening portion; and a protruding portion arranged to protrude out of the case, and having at least a portion thereof arranged in the case through hole. A gap is defined circumferentially between the protruding portion and an edge of the case through hole.

Growing community of inventors

Kyoto, Japan

Yasuaki Nakahara