This application is based upon and claims the benefit of priority from the prior Japanese Patent Application Nos. 2005-153897 filed on May 26, 2005 and 2006-90674 filed on Mar. 29, 2006, the entire contents of which are incorporated herein by reference.
1. Field of the Invention
The present disclosure relates to an electric motor including a stator core made by joining a plurality of split cores to one another, and more particularly to such a motor in which each split core comprises a number of steel plates stamped out and stacked, and a semiconductor connecting apparatus employing the above motor, such as a bonding apparatus.
2. Description of the Related Art
JP-A-2003-134702 discloses one of conventional electric motors of the above-described type. The disclosed motor includes a stator core enclosed in a housing and made by joining a plurality of split cores. Each split core is made by stacking a number of stamped steel plates.
On the other hand, outer surfaces of the yoke section 1 and tooth section 2 both made by stacking the stamped steel plates 7 and 8 actually have minute irregularities caused by dimensional errors, slippage during stacking or the like although being deemed smooth or planar macroscopically. Furthermore, provision of the aforesaid dimensional tolerances results in occurrence of small gaps 9 in a joint between the yoke section 1 and the tooth section 2 as shown in
In the above-described motor, a magnetic circuit is established so as to start from the north pole of the permanent magnet 6 and returning via the tooth section 2, yoke section 1 and tooth section 2 to the south pole of the permanent magnet 6. When the gaps 9 occur in the middle of the magnetic circuit, magnetic resistance is increased in the part of the gap 9 in the magnetic circuit. On the other hand, the magnetic resistance is small in the part where the steel plates 7 and 8 are adhered closely to each other. As a result, the magnetic resistance in the joint of the yoke section 1 and tooth section 2 varies in the axial and circumferential directions.
Therefore, an object of the disclosure is to provide an electric motor which comprises a plurality of split cores joined together into a stator core and can provide an improved magnetic circuit and a semiconductor connecting apparatus employing the above motor, such as a bonding apparatus.
In one aspect, the disclosure provides an electric motor comprising a stator including a stator core made of a plurality of split cores joined to each other and a stator winding wound on the stator core, and an admixture interposed in a joint between the split cores and comprising a binder mixed with a granular magnetic substance.
In the above-described construction, the admixture fills one or more gaps produced in each joint when the split cores are joined to each other. Accordingly, the magnetic resistance in the joint of the split cores is reduced and the magnetic resistance in the entire joint of the split cores is substantially uniformed. Consequently, effective magnetic flux of the field permanent magnet can be increased and accordingly, motor output can be increased.
In another aspect, the disclosure also provides a semiconductor connecting apparatus which connects a lead to an electrode of a semiconductor chip, comprising a bonding head movable upward and downward, and an electric motor for swinging the bonding head upward and downward, the motor comprising a stator including a stator core made of a plurality of split cores joined to each other and a stator winding wound on the stator core, and an admixture interposed in a joint between the split cores and comprising a binder mixed with a granular magnetic substance.
In the above-described construction, a swinging mechanism for the bonding head includes a swinging motor providing for substantially uniformed magnetic resistance. Consequently, an arm can smoothly be moved upward and downward and accordingly, semiconductor chips with uniformed product quality can be manufactured.
Other objects, features and advantages of the present disclosure on will become clear upon reviewing the following description of the embodiment with reference to the accompanying drawings, in which:
A first embodiment of the present invention will be described with reference to FIGS. 1 to 4. Referring to
The rotor 16 comprises a rotor core 20 having a rotating shaft 19 supported on the bearings 17 and 18 and, for example, six field permanent magnets 21 disposed on an outer circumferential surface of the rotor core 20, as shown in
The yoke section 22 and the tooth section 23 are each made by stacking a plurality of stamped steel plates 26 and 27 (shown only in
A method of manufacturing the stator 15 will now be described. Firstly, the stator winding 25 is wound on the teeth 24 of the tooth section 23 and thereafter, the admixture 30 is applied to or sprayed onto at least one of the concave portions 28 and outer circumferential end faces of the teeth 24, thereby being formed into a thin film. Successively, the outer peripheral ends of the teeth 24 are force fitted into the concave portions 28 respectively using a forming jig (not shown). Thus, the teeth 24 are pressed against the concave portions 28 respectively such that the yoke section 22 and the tooth section 23 are joined to each other. In this case, as shown in
In the motor 11 as described above, a magnetic circuit is established so that magnetic flux extends from the north pole of the permanent magnet 21 of the rotor 16 and returns through the tooth section 23 (teeth 24), yoke section 22 and tooth section 23 (teeth 24) to the south pole of the permanent magnet 21. In this case, the gaps 29 in the joints between the tooth section 23 and yoke section 23 are filled with the admixture 30 containing iron powder. This can suppress increase in the magnetic resistance in both axial and radial directions in the gaps 29. The axial direction refers to a direction in which the stamped steel plates 26 and 27 are stacked. Consequently, variations can be reduced in the magnetic resistance in the joint between the tooth section 23 and the yoke section 22.
Furthermore, the gaps in the joints between the tooth section 23 and the yoke section 22 are filled with the admixture 30. Consequently, variations can be reduced in the magnetic flux in the joint. This allows obtainment of induced voltage waveform with smaller amount of harmonic component and accordingly can render torque ripple smaller. Yet furthermore, since the magnetic resistance is reduced in the joint without dependence upon accuracy of the yoke section 23 and tooth section 22, the efficiency in the assembly of the yoke section 23 and tooth section 22 can be improved.
The stator core 31 is manufactured as follows. Firstly, the admixture 30 is applied or sprayed onto the outer peripheral end of the tooth section 23 thereby to be formed into a thin film. The thin film is solidified by warm compaction. In this case, the thin film is solidified while the obliquely-stacked state of the steel plates is corrected. Successively, the stator winding 25 is wound on the tooth section 23 and thereafter, the tooth section 23 is force fitted into the concave portions 28. As a result, the admixture 30 can fill the gap 29 caused in the joint between the tooth section 23 and the yoke section 22 by obliquely stacking the steel plates 27. Thus, in the embodiment, too, the motor output and motor efficiency can be improved, whereupon the power consumption and the motor size can be reduced.
Furthermore, since the admixture 30 is solidified in the embodiment, the teeth 23 can easily be force fitted into the concave portions 28 respectively.
FIGS. 6 to 9 illustrate a third embodiment of the invention. Only the difference of the third embodiment from the first embodiment will be described. In the third embodiment, the stator core 31 comprises nine split cores 41 and the admixture 30, as shown in
A method of manufacturing the stator 15 will be described with reference to
According to the third embodiment, the gap in the joint between the adjacent split cores 41 is filled with the admixture 30, no axial or circumferential gaps are formed. Consequently, an increase in the magnetic resistance can be suppressed. Furthermore, the circularity of the stator 15 can be improved as the result of use of the assembling jig 44.
The semiconductor device connecting apparatus is provided for connecting a lead 53 to an electrode 52a of a semiconductor chip 52 using a bonding wire 51.
A swing motor 60 is provided for vertically moving the swing arm 56. The swing motor 60 employs the stator 15 as shown in the third embodiment. The direction of energization to the stator winding 25 is reversed so that the swing arm 56 is vertically moved in a predetermined angular range. A rotational position of the swing motor 60 is detected by a position sensor 61. The swing arm 56 includes a holder 56a to which an arm 56b is fixed. The arm 56b has a distal end on which a bonding tool 56c is provided. The arm 56b and the bonding tool 56c have through holes (not shown) respectively. A bonding wire 51 is inserted through the holes of the arm 56b and the bonding tool 56c. The bonding wire 51 is joined to the electrode 52a of the semiconductor chip 52 and the lead 53 by the bonding tool 56c.
In describing the effects of the fourth embodiment, the swing motor 60 employing the stator 15 described in the third embodiment has a small and substantially uniform magnetic resistance and can accordingly reduce the cogging torque. Thus, since the swing motor 60 vertically moves the arm 56b smoothly, a bonding operation with high accuracy can be performed. Consequently, joint can be uniformed between the electrode 52a of the semiconductor chip 52 and the bonding wire 51 and between the lead 53 and the bonding wire 51, whereupon the quality of the semiconductor chips 52 can be uniformed.
The stator core 31 of the fifth embodiment has a plurality of small sawtooth irregularities 71 which are formed in both end faces 43a of each split core 41 so as to be brought into mesh engagement with the irregularities of each split core 41 to be joined to each other.
In the fifth embodiment, too, the stator 15 is manufactured using the assembling jig 44 as in the third embodiment. More specifically, the stator winding 25 is wound on each tooth 42, and the admixture 30 is applied or sprayed to both end faces 43a of each split core 41. Thereafter, the inner peripheral ends of nine teeth 42 are pressed against the outer circumferential face 44a of the assembling jig 44. As a result, the irregularities 71 of the adjacent split cores 41 are brought into mesh engagement with each other. In this state, pressure is applied to the split cores 41 at outer peripheral surface 43b, whereby the irregularities 71 are crushed such that joined portions of the split cores 41 are adhered closely to each other. Consequently, since the gaps between the split cores 41 are rendered as small as possible, the cogging torque can further be reduced.
In describing the effects of the sixth embodiment, when the split cores 41 are joined to each other, the convex portion 81 of each split core 41 is fitted with the concave portion 82 of the adjacent split core 41. Consequently, the stator core with a high degree of circularity can easily be obtained.
In the seventh embodiment, too, the stator core 31 with a high degree of circularity can easily be obtained as in the sixth embodiment.
The admixture 30 flows into gaps in each joint of the split cores 41. Accordingly, the magnetic resistance in each joint can be rendered smaller in the embodiment.
The invention should not be limited to the above-described embodiments but may be modified or expanded as follows. The stator core 31 is circumferentially divided into nine split cores 41 in each of the third to fifth and eighth embodiments. The number of split cores 41 should not be limited to nine. Two or more split cores may be used, instead.
In the fifth embodiment, the nine split cores 41 are pressed against the outer circumferential face 44a of the assembling jig 44 and thereafter, pressure is applied to the split cores 41 at the outer peripheral surfaces 43b. However, when the irregularities 71 of the adjacent split cores 41 are engaged with each other and a sufficiently adherent state is obtained from the engagement of the irregularities 71, the pressure applying step may be eliminated.
In the sixth and seventh embodiments, each end face 43a of each split core 41 is formed with one convex portion and one concave portion. However, each end face 43a may have two or more convex portions and two or more concave portions, instead.
The tooth section 23 and the yoke section 22 in each of the sixth and seventh embodiments may have sawtooth-like convex and concave portions 71, the step-like convex portion 81 and concave portion 82 or the semicircular convex portion 91 and concave portion 92.
The stator 15 in each of the sixth and seventh embodiments may be manufactured using the assembling jig 44 and the forming die 101 as shown in the third or eighth embodiment.
The motor 11 described in the first embodiment may be applied to the swing motor 60 of the semiconductor device connecting apparatus. Furthermore, the motor of each embodiment may be applied to each of the X-axis and Y-axis motors 58 and 59 of the semiconductor device connecting apparatus. According to this construction, the bonding head frame 55 can be moved with a high degree of accuracy.
The invention may be applied to outer rotor type motors, instead of the inner rotor type motor
The foregoing description and drawings are merely illustrative of the principles of the present invention and are not to be construed in a limiting sense. Various changes and modifications will become apparent to those of ordinary skill in the art. All such changes and modifications are seen to fall within the scope of the invention as defined by the appended claims.
Number | Date | Country | Kind |
---|---|---|---|
2005-153897 | May 2005 | JP | national |
2006-090674 | Mar 2006 | JP | national |