Patent Application
20240243623
The present disclosure generally relates to an electric tool and a motor, and more particularly relates to a motor including a stator core and a rotor, and an electric tool including the motor.
Patent Literature 1 discloses an electric tool including a brushless motor. The brushless motor includes a stator core, a rotor, and a plurality of coils. The stator core is divided into a plurality of teeth, around each of which a coil is wound. In one implementation, a connecting portion is provided between two protruding ends of two adjacent teeth to connect the two protruding ends, thereby fixing, and integrating, all of those teeth at their protruding ends.
Patent Literature 1: JP 2019-004601 A
It is therefore an object of the present disclosure to provide an electric tool and a motor with the ability to reduce the chances of a coil wound around a tooth coming off the tooth.
An electric tool according to an aspect of the present disclosure includes a motor. The motor includes a stator core and a rotor. The rotor has an output shaft and rotates with respect to the stator core. The stator core includes: an inner cylindrical portion having a circular cylindrical shape; and a plurality of teeth. Inside the inner cylindrical portion, the rotor is arranged. Each of the plurality of teeth includes a body portion and a tip piece. The body portion protrudes outward from the inner cylindrical portion along a radius of the inner cylindrical portion. The tip piece extends, from a tip part of the body portion, in a direction intersecting with a direction in which the body portion protrudes.
A motor according to another aspect of the present disclosure includes a stator core and a rotor. The rotor has an output shaft and rotates with respect to the stator core. The stator core includes: an inner cylindrical portion having a circular cylindrical shape; and a plurality of teeth. Inside the inner cylindrical portion, the rotor is arranged. Each of the plurality of teeth includes a body portion and a tip piece. The body portion protrudes outward from the inner cylindrical portion along a radius of the inner cylindrical portion. The tip piece extends, from a tip part of the body portion, in a direction intersecting with a direction in which the body portion protrudes.
An electric tool according to an embodiment and a motor provided for the electric tool will be described with reference to the accompanying drawings. Note that the embodiment to be described below is only an exemplary one of various embodiments of the present disclosure and should not be construed as limiting. Rather, the exemplary embodiment may be readily modified in various manners depending on a design choice or any other factor without departing from the scope of the present disclosure. Also, the drawings to be referred to in the following description of embodiments are all schematic representations. Thus, the ratio of the dimensions (including thicknesses) of respective constituent elements illustrated on the drawings does not always reflect their actual dimensional ratio.
As shown in
The motor 1 is a driving source for driving the tip tool 105. The motor 1 may be implemented as, for example, a brushless motor. The power supply 101 is a DC power supply for supplying a current to drive the motor 1. The power supply 101 includes a single or a plurality of secondary batteries. The driving force transmission unit 102 regulates the output (driving force) of the motor 1 and supplies the regulated driving force to the output unit 103. The output unit 103 is a part to be driven (in rotation, for example) with the driving force supplied from the driving force transmission unit 102. The chuck 104 is a part fixed to the output unit 103 which allows the tip tool 105 to be attached thereto removably. Examples of the tip tool 105 (also called a “bit”) include screwdrivers, sockets, and drills. One of those various types of tip tools 105 is selected depending on the intended use and attached for use to the chuck 104.
The trigger volume 106 is an operating unit for accepting a command for controlling the rotation of the motor 1. The motor 1 may be turned ON and OFF by performing the operation of pulling the trigger volume 106. In addition, adjusting the manipulative variable of the operation of pulling the trigger volume 106 allows the rotational velocity of the output unit 103, i.e., the rotational velocity of the motor 1, to be controlled. The control circuit 107 either starts or stop rotating the motor 1 in accordance with the command entered through the trigger volume 106 and also controls the rotational velocity of the motor 1. In this electric tool 10, the tip tool 105 is attached to the chuck 104. Then, the rotational velocity of the motor 1 is controlled by operating the trigger volume 106, thereby controlling the rotational velocity of the tip tool 105.
Note that the electric tool 10 according to this embodiment includes the chuck 104, thus making the tip tool 105 replaceable depending on the intended use. However, the tip tool 105 does not have to be replaceable. Alternatively, the electric tool 10 may also be designed to allow the user to use only a particular type of tip tool 105.
Next, a configuration for the motor 1 will be described with reference to
The stator core 20 includes a central core 21 and an outer cylindrical portion 22. The outer cylindrical portion 22 is mounted onto the central core 21. The central core 21 includes an inner cylindrical portion 3 having a circular cylindrical shape and a plurality of (e.g., nine in the example illustrated in
The two tip pieces 42 are provided as a stopper for reducing the chances of the coil 23 coming off the body portion 41. Specifically, having the coil 23 caught in the two tip pieces 42 while the coil 23 is moving toward a tip part of the body portion 41 reduces the chances of the coil 23 coming off.
The rotor 5 includes a rotor core 6 having a circular cylindrical shape, a plurality of (e.g., six in the example illustrated in
The output shaft 51 is held inside the rotor core 6. The plurality of permanent magnets 7 are arranged as spokes (i.e., radially) around the center C1 of the rotor core 6 (see
In this case, when viewed along the axis of the rotor core 6, the rotor core 6 has the shape of a circle. The center C1 of the rotor core 6 corresponds to the center of the circle. Each of the permanent magnets 7 has a rectangular parallelepiped shape. When viewed along the axis of the rotor core 6, each permanent magnet 7 has a rectangular shape. If the plurality of permanent magnets 7 are arranged as spokes around the center C1 of the rotor core 6, this means that when viewed along the axis of the rotor core 6, the permanent magnets 7 are arranged along the circumference of the rotor core 6 such that the longitudinal axis of each of the permanent magnets 7 is aligned with the radius of the rotor core 6.
Arranging the plurality of permanent magnets 7 as spokes around the center C1 of the rotor core 6 facilitates shortening the diameter of the rotor 5. Particularly when the number of the permanent magnets 7 provided is relatively large, this facilitates shortening the diameter of the rotor 5 while keeping the length L1 measured along the longitudinal axis of each permanent magnet 7 (see
For example, in a rotor 5P according to a comparative example shown in
Meanwhile, even if the number of the permanent magnets 7 provided is relatively large, the rotor 5 according to this embodiment reduces the chances of the diameter of the rotor core 6 being extended, compared to the rotor core 6 according to the comparative example. Specifically, narrowing the interval between the plurality of permanent magnets 7 along the circumference of the rotor core 6 as the number of the permanent magnets 7 provided increases still allows the plurality of permanent magnets 7 to be arranged as spokes around the center C1 of the rotor core 6. Consequently, this allows the plurality of permanent magnets 7 to be arranged with the increase in the diameter of the rotor core 6 reduced.
That is to say, the rotor 5 according to this embodiment may reduce an increase in the diameter of the rotor core 6 when the torque of the motor 1 is increased by setting the number of the permanent magnets 7 provided at a relatively large number (e.g., six or more).
Next, the configuration of the stator 2 will be described in further detail. As shown in
As shown in
As shown in
The two tip pieces 42 extend from a tip part of the body portion 41 in a direction intersecting with the direction in which the body portion 41 protrudes. More specifically, the two tip pieces 42 are provided on both sides along the circumference of the inner cylindrical portion 3 at the tip part of the body portion 41. In addition, the two tip pieces 42 extend along the circumference of the inner cylindrical portion 3.
As shown in
Each tip piece 42 has a curved portion 422 as a part connected to the body portion 41. The curved portion 422 is curved such that as the distance to the outer edge of the tip piece 42 decreases along the radius of the inner cylindrical portion 3, the distance from the body portion 41 increases along the circumference of the inner cylindrical portion 3. That is to say, the curved portion 422, which is a part, located at the proximal end (i.e., closer to the body portion 41), of each tip piece 42, is chamfered to have a rounded shape.
As shown in
Alternatively, the inner cylindrical portion 3 may include a high magnetic resistance portion R1 as shown in
In the example illustrated in
Providing the inner cylindrical portion 3 with the bypass portion 301 extends the magnetic path and increases the magnetic resistance in the bypass portion 301, compared to a situation where no bypass portion 301 is provided.
In another example, the high magnetic resistance portion R1 includes a penetrating portion 302 as shown in
In still another example, the high magnetic resistance portion R1 has nine (only five of which are shown in
Yet another example will be described with reference to
Each high magnetic resistance portion R1 has a plurality of cavities 303. Each of the plurality of cavities 303 penetrates through its associated steel plate 210 along the axis. Each cavity 303 may be formed by, for example, cutting out the steel plate 210. The plurality of cavities 303 are provided for respective parts, corresponding to the coupling portions 31 of the inner cylindrical portion 3 (see
The plurality of steel plates 210 are stacked one on top of another such that the respective high magnetic resistance portions R1 (cavities 303) of two or more adjacent steel plates 210 do not overlap with each other along the thickness of the steel plates 210. In this case, the nine coupling portions 31 will be hereinafter referred to as a “first coupling portion,” a “second coupling portion,” . . . , and a “ninth coupling portion,” respectively, in the order in which the coupling portions 31 are arranged side by side along the circumference of the inner cylindrical portion 3. In addition, the plurality of steel plates 210 will be hereinafter referred to as a “first steel plate,” a “second steel plate,” . . . , and so on, respectively, in the order in which the steel plates 210 are arranged one on top of another along the thickness of the steel plates 210. For example, in the first steel plate, the cavities 303 are provided through its parts corresponding to the first, fourth, and seventh coupling portions, respectively. In the second steel plate, the cavities 303 are provided through its parts corresponding to the second, fifth, and eighth coupling portions, respectively. In the third steel plate, the cavities 303 are provided through its parts corresponding to the third, sixth, and ninth coupling portions, respectively. In the inner cylindrical portion 3, between one cavity 303 and another cavity 303, provided at such a position where the latter cavity 303 overlaps with the former cavity 303 along the thickness of the steel plates 210, arranged are respective non-cavity 303 portions of one or more (e.g., two in the example shown in
The cavities 303 may be provided through each steel plate 210, for example, before the plurality of steel plates 210 are stacked one on top of another. The plurality of steel plate 210 are formed to have the same shape when viewed in the thickness direction and are stacked one on top of another such that two adjacent ones of the steel plates 210 have mutually different orientations (angles). More specifically, the second steel plate is stacked on the first steel plate to have an orientation that forms an angle of rotation of 40 degrees with respect to the first steel plate. The third steel plate is stacked on the second steel plate to have an orientation that forms an angle of rotation of 40 degrees with respect to the second steel plate. Likewise, each of the fourth steel plate and the other steel plates is stacked to have an orientation that forms an angle of rotation of 40 degrees (which is a predetermined angle) with respect to its adjacent steel plate. Optionally, some of the plurality of steel plates 210 may have a different thickness from others of the plurality of steel plates 210.
Still another example will be described with reference to
Although some examples of the high magnetic resistance portion R1 have been described one by one, two or more of these examples may be adopted in combination as appropriate.
As shown in
The motor 1 further includes a coil bobbin 8. The coil bobbin 8 may be made of a synthetic resin, for example. The coil bobbin 8 has electrical insulation properties. The coil bobbin 8 at least partially covers at least one (e.g., all, in this embodiment) of the plurality of teeth 4.
As shown in
As shown in
The two members 81 are out of contact with each other along the axis of the inner cylindrical portion 3. Thus, in a region around the middle of the thickness of the central core 21, each tooth 4 is exposed in a direction perpendicular to the thickness of the central core 21. If the number of the steel plates 210 that form the central core 21 is changed to modify the design of the motor 1, for example, the thickness of the central core 21 changes. Then, as the thickness of the central core 21 changes, the gap distance between the two members 81 also changes.
As shown in
As shown in
The outer cylindrical portion 22 includes a plurality of (e.g., nine) fitting portions 221. In other words, the outer cylindrical portion 22 includes as many fitting portions 221 as the teeth 4. Each of the plurality of fitting portions 221 is a recess provided on the inner peripheral surface of the outer cylindrical portion 22. The plurality of fitting portions 221 correspond one to one to the plurality of teeth 4. Each of the plurality of fitting portions 221 and one tooth 4, corresponding to the fitting portion 221, out of the plurality of teeth 4 are fitted into each other by causing at least one of the fitting portion 221 or the tooth 4 to move along the radius of the inner cylindrical portion 3. This allows the outer cylindrical portion 22 to be mounted onto the plurality of teeth 4.
To each fitting portion 221, a portion, including the two tip pieces 42, of an associated tooth 4 is fitted. Thus, the length, measured along the circumference of the outer cylindrical portion 22, of each fitting portion 221 is equal to the length as measured from the protruding tip of one of the two tip pieces 42 protruding from the body portion 41 through the protruding tip of the other tip piece 42. Note that as used herein, if some value is “equal to” another, these two values do not have to be exactly equal to each other but may also be different from each other within a tolerance range. The tolerance range may be defined by an error of within 3%, within 5%, or within 10%, for example.
With the coil bobbin 8 attached onto the central core 21 and the coils 23 wound around the coil bobbin 8, the outer cylindrical portion 22 may be mounted onto the plurality of teeth 4 by shrink-fitting, for example. Specifically, with the outer cylindrical portion 22 heated and expanded radially, the central core 21 is put inside the outer cylindrical portion 22. This makes the inner surface of the outer cylindrical portion 22 face the respective tips of the plurality of teeth 4 along the radius of the inner cylindrical portion 3 with a narrow gap left between the inner surface of the outer cylindrical portion 22 and the plurality of teeth 4. Thereafter, as the temperature of the outer cylindrical portion 22 falls to cause the outer cylindrical portion 22 to shrink, the inner surface of the outer cylindrical portion 22 comes into contact with the respective tips of the plurality of teeth 4. That is to say, when the plurality of fitting portions 221 move inward along the radius of the outer cylindrical portion 22 as the outer cylindrical portion 22 shrinks, the plurality of fitting portions 221 and the plurality of teeth 4 are fitted into each other. The outer cylindrical portion 22 applies, to the plurality of teeth 4, contact pressure produced inward along the radius of the outer cylindrical portion 22.
Next, the configuration of the rotor 5 will be described in detail. As shown in
The rotor core 6 is formed in the shape of a circular cylinder, which is concentric with the inner cylindrical portion 3 of the stator core 20. Along the axis of the rotor core 6, both ends of the rotor core 6 are aligned with both ends of the stator core 20. That is to say, a first end (e.g., the upper end on the paper on which
Inside the rotor core 6, the output shaft 51 is held. As shown in
The rotor body 62 includes a plurality of (e.g., six in the example illustrated in
The plurality of magnet housings 621 are provided at regular intervals along the circumference of the rotor core 6. This allows the plurality of permanent magnets 7 to be arranged at regular intervals along the circumference of the rotor core 6. In addition, the longitudinal axis of each of the plurality of permanent magnets 7 is aligned with the radius of the rotor core 6.
Each permanent magnet 7 may be a neodymium magnet, for example. The two magnetic poles of each permanent magnet 7 are arranged along the circumference of the rotor core 6. Two permanent magnets 7, which are adjacent to each other along the circumference of the rotor core 6, are arranged with their magnetic poles with the same polarity facing each other. Part of the magnetic flux generated between two permanent magnets 7 which are adjacent to each other along the circumference of the rotor core 6 is directed from a region 622, located between the two permanent magnets 7, of the rotor body 62 toward the stator 2 (see
The rotor core 6 has a high magnetic resistance portion R2. The high magnetic resistance portion R2 has higher magnetic resistance than parts, surrounding the high magnetic resistance portion R2, of the rotor core 6. The high magnetic resistance portion R2 is provided on the magnetic path of the magnetic flux generated by the plurality of permanent magnets 7. The magnetic path of the magnetic flux generated by the plurality of permanent magnets 7 includes: a region facing any of the two magnetic poles of a particular one of the permanent magnets 7; and a region located adjacent to the particular permanent magnet 7 and on a curve connecting the two magnetic poles of the particular permanent magnet 7. Providing the high magnetic resistance portion R2 may reduce the magnetic flux generated by, and leaking from, the permanent magnets 7. In other words, the magnetic flux directed from the region 622 located between two permanent magnets 7 adjacent to each other along the circumference of the rotor core 6 toward the stator 2 (see
The high magnetic resistance portion R2 may include, for example, the plurality of penetrating portions 63 described above. Each of the plurality of penetrating portions 63 penetrates through the rotor core 6 along its axis. In addition, the high magnetic resistance portion R2 further includes a plurality of (e.g., twelve in the example illustrated in
In this embodiment, the rotor core 6 includes first parts 601 and second parts 602. A plurality of (e.g., six) first parts 601 and a plurality of (e.g., six) second parts 602 are provided one to one for the plurality of permanent magnets 7. The following description will be focused on one permanent magnet 7 and the first part 601 and second part 602 provided for the permanent magnet 7.
The first part 601 and the second part 602 are adjacent to the permanent magnet 7 along the radius of the rotor core 6. The first part 601 includes a part of the shaft holder 61. The first part 601 is one end portion, located closer to the center C1 of the rotor core 6, out of two end portions (along the radius of the rotor core 6) of the permanent magnet 7. More specifically, the first part 601 is a part located between the permanent magnet 7 and the shaft hole 611.
The first part 601 is provided with at least respective parts of the two penetrating portions 63. The two penetrating portions 63 are arranged side by side along the circumference of the rotor core 6. Each of the two penetrating portions 63 includes a part extending along the circumference of the rotor core 6 and a part extending along the radius of the rotor core 6. In addition, a projection 66 protruding from the shaft holder 61 is further provided between the two penetrating portions 63. That is to say, the rotor core 6 includes the projection 66. The projection 66 is in contact with the permanent magnet 7 along the radius of the rotor core 6.
The second part 602 includes a part of the rotor body 62. The second part 602 is one end portion, located closer to the outer periphery of the rotor core 6, out of the two end portions (along the radius of the rotor core 6) of the permanent magnet 7. More specifically, the second part 602 is a part located between the permanent magnet 7 and the outer edge of the rotor core 6.
The second part 602 is provided with two penetrating portions 65. The two penetrating portions 65 are arranged side by side along the circumference of the rotor core 6. The longitudinal axis of each of the two penetrating portions 65 extends along the circumference of the rotor core 6. In addition, a projection 67 in contact with the permanent magnet 7 along the radius of the rotor core 6 is further provided between the two penetrating portions 65. That is to say, the rotor core 6 includes the projection 67. Interposing the permanent magnet 7 between the projections 66, 67 regulates the movement of the permanent magnet 7 along the radius of the rotor core 6.
That is to say, at least parts (namely, the penetrating portions 63, 65) of the high magnetic resistance portion R2 are provided for at least one of the first part 601 or the second part 602.
The length L3 in the first part 601 of the high magnetic resistance portion R2 (i.e., the length measured along the radius of the rotor core 6) is different from the length L4 in the second part 602 of the high magnetic resistance portion R2 (i.e., the length measured along the radius of the rotor core 6). Specifically, the length L3 is greater than the length L4. The length L3 in the first part 601 is the length, measured along the radius of the rotor core 6, of the penetrating portions 63. The length L4 in the second part 602 is the length, measured along the radius of the rotor core 6, of the penetrating portions 65.
A bridge portion 64 is provided between a penetrating portion 63 provided adjacent to an arbitrary one of the plurality of permanent magnets 7 and another penetrating portion 63 provided adjacent to another permanent magnet 7 that is adjacent to the arbitrary permanent magnet 7. Thus, a plurality of (e.g., six) bridge portions 64 are provided at regular intervals along the circumference of the rotor core 6. In addition, a penetrating portion 68 is also provided for a region, facing the bridge portion 64 along the radius of the rotor core 6, of the rotor body 62. The penetrating portion 68 is included in the high magnetic resistance portion R2. The penetrating portion 68 penetrates through the rotor core 6 along its axis. When viewed along the axis of the rotor core 6, the penetrating portion 63 has a circular shape. A plurality of (e.g., six in the example illustrated in
The rotor core 6 has a plurality of (e.g., six in the example illustrated in
Optionally, the respective voids 69 may be included in the high magnetic resistance portion R2. That is to say, the respective voids 69 may be provided for the magnetic path of the magnetic flux generated by the plurality of permanent magnets 7.
Each high magnetic resistance portion R3 has a plurality of cavities 603. Each of the plurality of cavities 603 penetrates through an associated steel plate 600 along its axis. The plurality of cavities 603 are provided for regions, corresponding to the bridge portions 64, of the steel plates 600. That is to say, each of the plurality of cavities 603 is provided to cut off a region corresponding to the bridge portion 64 into two parts. In this embodiment, one cavity 603 is provided for each steel plate 600. Note that illustration of the plurality of cavities 603 is omitted from all drawings but
The plurality of steel plates 600 are stacked one on top of another such that the respective high magnetic resistance portions R3 (cavities 603) of adjacent steel plates 600 do not overlap with each other along the thickness of the steel plates 600. In this case, the six bridge portions 64 will be hereinafter referred to as a “first bridge portion,” a “second bridge portion,” . . . , and a “sixth bridge portion,” respectively, in the order in which the bridge portions 64 are arranged side by side in the circumferential direction. In addition, the plurality of steel plates 600 will be hereinafter referred to as a “first steel plate,” a “second steel plate,” . . . , and so on, respectively, in the order in which the steel plates 600 are arranged one on top of another along the thickness of the steel plates 600. For example, in the first, seventh, thirteenth, and other steel plates, the cavity 603 is provided for a region corresponding to the first bridge portion. In the second, eighth, fourteenth, and other steel plates, the cavity 603 is provided for a region corresponding to the second bridge portion. In the third, ninth, fifteenth, and other steel plates, the cavity 603 is provided for a region corresponding to the third bridge portion. In the rotor core 6, parts, other than the cavities 603, of one or more (e.g., five in the example illustrated in
The cavities 603 may be provided through the respective steel plates 600, for example, before the plurality of steel plates 600 are stacked one on top of another. The plurality of steel plates 600 are formed to have the same shape when viewed in the thickness direction and are stacked one on top of another such that two adjacent ones of the steel plates 600 have mutually different orientations (angles). More specifically, the second steel plate is stacked on the first steel plate to have an orientation that forms an angle of rotation of 60 degrees with respect to the first steel plate. The third steel plate is stacked on the second steel plate to have an orientation that forms an angle of rotation of 60 degrees with respect to the second steel plate. Likewise, each of the fourth steel plate and the other steel plates is stacked to have an orientation that forms an angle of rotation of 60 degrees (which is a predetermined angle) with respect to its adjacent steel plate. Optionally, a plurality of cavities 603 may be provided for each steel plate 600. For example, the plurality of cavities 603 may be provided at regular intervals along the circumference of the steel plate 600. Optionally, some of the plurality of steel plates 600 may have a different thickness from others of the plurality of steel plates 600.
In still another example, the high magnetic resistance portion R3 of each steel plate 600 may have a thinned portion 604 instead of the cavity 603 as shown in
Note that the cavities 603 and thinned portions 604 do not have to be provided for regions, corresponding to the bridge portions 64, of the rotor core 6. Alternatively, the cavities 603 and the thinned portions 604 may be provided for a region, corresponding to the first part 601, of the rotor core 6 and/or a region, corresponding to the second part 602, of the rotor core 6.
As shown in
In a manufacturing process of the motor 1, with the central core 21 and outer cylindrical portion 22 of the stator 2 separated from each other, the coils 23 are wound around the body portions 41 of the plurality of teeth 4 of the central core 21 via the coil bobbin 8. Thereafter, the outer cylindrical portion 22 is mounted onto the plurality of teeth 4.
The coils 23 are wound around the teeth 4 using a tool arranged beside the tip part of the respective teeth 4, for example. The plurality of teeth 4 protrude radially outward from the inner cylindrical portion 3. This allows the space left at the tip of each tooth 4 to be broadened, compared to a situation where the plurality of teeth 4 protrude inward. This facilitates winding the coils 23 around the respective teeth 4, and in some cases, allows the space factor of the coils 23 to be increased.
In addition, each tooth 4 includes two tip pieces 42 that reduce the chances of the coil 23 coming off the body portion 41, thus allowing the coil 23 to be wound more easily around each tooth 4. Furthermore, the stress applied to each tooth 4 may be distributed in the two tip pieces 42, thus reducing the chances of the tooth 4 being deformed. Furthermore, each tip piece 42 includes the curvilinear surface 421, which is in contact with the outer cylindrical portion 22. This allows, when the outer cylindrical portion 22 is mounted onto the plurality of teeth 4, the stress applied from the outer cylindrical portion 22 to the respective teeth 4 to be distributed more easily along the curvilinear surface 421, compared to a situation where the surface of the tip pieces 42 is formed as a flat surface.
Furthermore, each tip piece 42 has the curved portion 422 in a part connected to its associated body portion 41. Thus, part of the magnetic flux passing through each tooth 4 passes through the body portion 41 and the curved portion 422 and then passes through the curved portion 422 and body portion 41 of an adjacent tooth 4 (as indicated by the arrow A2 shown in
Furthermore, the plurality of teeth 4 are connected together at one end thereof via the inner cylindrical portion 3 and are in contact with the outer cylindrical portion 22 at the other end thereof. In other words, the inner cylindrical portion 3 is provided at one end of the plurality of teeth 4 and the outer cylindrical portion 22 is provided at the other end of the plurality of teeth 4. This contributes to increasing the mechanical strength of the stator core 20, compared to a situation where only either the inner cylindrical portion 3 or the outer cylindrical portion 22 is provided. In addition, this may increase the robustness of the dimensional tolerance of the stator core 20 and contributes to reducing cogging of the motor 1.
Furthermore, the plurality of permanent magnets 7 are arranged as spokes around the center C1 of the rotor core 6, thus facilitating shortening the diameter of the rotor 5.
Next, variations of the exemplary embodiment described above will be enumerated one after another. Note that the variations to be described below may be adopted in combination as appropriate.
The configuration of the rotor 5 may be changed arbitrarily. For example, the plurality of permanent magnets 7 do not have to be arranged as spokes but may also be arranged to form a polygonal pattern. Also, the rotor core 6 does not have to include the high magnetic resistance portions R2, R3.
When viewed along its axis, the rotor core 6 does not have to have a perfectly circular shape. Alternatively, the rotor core 6 may also have a generally circular or elliptical shape with some projections or recesses provided along its circumference.
Into each of the penetrating portions 302 of the stator core 20 and the penetrating portions 63, 65, 68 of the rotor core 6, a spacer made of a non-magnetic material may be inserted. That is to say, the high magnetic resistance portion R2 may include not only the penetrating portions 63, 65, 68 but also spacers.
The number of the permanent magnets 7 provided does not have to be six but may also be two or more.
The motor 1 does not have to be provided for the electric tool 10. Alternatively, the motor 1 may also be provided for an electric bicycle or an electric assist bicycle, for example.
Optionally, the motor 1 may further include a weight adjuster attached to the rotor 5. The weight adjuster may be configured as, for example, a cylindrical weight and may be attached to the output shaft 51 of the rotor 5. The weight balance of the rotor 5 may be adjusted by partially cutting off the weight adjuster and thereby changing the weight and center of gravity of the weight adjuster. This allows compensating for a shift caused, by providing the penetrating portions 63, 65, 68 and the cavities 603 for the rotor core 6, in the weight balance of the rotor 5. Still alternatively, the weight balance of the rotor 5 may also be adjusted by partially cutting off the rotor core 6 itself. Yet alternatively, the weight balance of the rotor 5 may also be adjusted by adjusting the positions and amount of the adhesive applied to the rotor 5.
Optionally, in the plurality of steel plates 210 (or 600), the arrangement of the cavities 303 (or 603) may be changed. To ensure sufficient mechanical strength for the plurality of steel plates 210 (or 600), it is recommended that two or more cavities 303 (or 603) not be adjacent to each other along the thickness of the plurality of steel plates 210 (or 600).
Optionally, the cavities 303 (or 603) may also be provided periodically along the thickness of the plurality of steel plates 210 (or 600). For example, between an arbitrary cavity 303 (or 603) and another cavity 303 (or 603) overlapping with the former cavity 303 (or 603) along the thickness of the plurality of steel plates 210 (or 600), a certain number of steel plates 210 (or 600) may be arranged. Alternatively, the distance between an arbitrary cavity 303 (or 603) and another cavity 303 (or 603) overlapping with the former cavity 303 (or 603) along the thickness of the plurality of steel plates 210 (or 600) may also be a constant distance.
Furthermore, the arrangement of the thinned portions 304 (or 604) in the plurality of steel plates 210 (or 600) may also be changed in the same way as the arrangement of the cavities 303 (or 603). Optionally, the plurality of steel plates 210 (or 600) may be provided with both the cavities 303 (or 603) and the thinned portions 304 (or 604).
Alternatively, the cavities 303 and/or the thinned portions 304 may be provided for only some of the plurality of steel plates 210. Likewise, the cavities 303 and/or the thinned portions 304 may be provided for only some of the plurality of steel plates 600.
Furthermore, each of the plurality of steel plates 210 and the plurality of steel plates 600 is suitably a single member, of which the respective parts are connected together. This may reduce the number of parts of the motor 1, compared to a situation where each steel plate 210 (or 600) is made up of a plurality of members.
Optionally, the voids 69 may also be provided for parts other than the shaft holder 61. Alternatively, each void 69 may also be a recess depressed along the axis of the rotor core 6.
Optionally, each of the plurality of fitting portions 221 of the outer cylindrical portion 22 may also be a projection. In that case, each of the plurality of teeth 4 may have a recess to which an associated fitting portion 221 is fitted.
The embodiment and its variations described above may be specific implementations of the following aspects of the present disclosure.
An electric tool 10 according to a first aspect includes a motor 1. The motor 1 includes a stator core 20 and a rotor 5. The rotor 5 has an output shaft 51 and rotates with respect to the stator core 20. The stator core 20 includes: an inner cylindrical portion 3 having a circular cylindrical shape; and a plurality of teeth 4. Inside the inner cylindrical portion 3, the rotor 5 is arranged. Each of the plurality of teeth 4 includes a body portion 41 and a tip piece 42. The body portion 41 protrudes outward from the inner cylindrical portion 3 along a radius of the inner cylindrical portion 3. The tip piece 42 extends, from a tip part of the body portion 41, in a direction intersecting with a direction in which the body portion 41 protrudes.
According to this configuration, a tip part of the body portion 41 is provided with a tip piece 42, thus reducing, compared to a situation where no tip piece 42 is provided, the chances of a coil 23 wound around the body portion 41 moving toward the tip part of the body portion 41 to come off the body portion 41.
In an electric tool 10 according to a second aspect, which may be implemented in conjunction with the first aspect, the stator core 20 further includes an outer cylindrical portion 22 having a circular cylindrical shape. The outer cylindrical portion 22 is mounted on the plurality of teeth 4 to surround the plurality of teeth 4.
This configuration allows the outer cylindrical portion 22 to be used as a part of a magnetic path through which a magnetic flux passes.
In an electric tool 10 according to a third aspect, which may be implemented in conjunction with the second aspect, the outer cylindrical portion 22 includes a plurality of fitting portions 221. The plurality of fitting portions 221 correspond one to one to the plurality of teeth 4. Each of the plurality of fitting portions 221 and one tooth 4, corresponding to the fitting portion 221, out of the plurality of teeth 4 are fitted into each other when at least one of the fitting portion 221 or the tooth 4 is caused to move along the radius.
This configuration more easily reduces, compared to a situation where the plurality of fitting portions 221 and the plurality of teeth 4 are fitted to each other by moving along the axis of the inner cylindrical portion 3, misalignment between the outer cylindrical portion 22 and the plurality of teeth 4 along the axis.
An electric tool 10 according to a fourth aspect, which may be implemented in conjunction with any one of the first to third aspects, further includes a coil bobbin 8. The coil bobbin 8 has electrical insulation properties. The coil bobbin 8 at least partially covers at least one of the plurality of teeth 4.
This configuration allows electrical insulation between the plurality of teeth 4 and the coils 23 to be increased by winding the coils 23 around the coil bobbin 8.
In an electric tool 10 according to a fifth aspect, which may be implemented in conjunction with the fourth aspect, the coil bobbin 8 includes two members 81. The two members 81 are arranged along an axis of the inner cylindrical portion 3. The two members 81 are formed separately from each other.
This configuration allows the coil bobbin 8 to be mounted onto the plurality of teeth 4 more easily than in a situation where the coil bobbin 8 is a single member.
In an electric tool 10 according to a sixth aspect, which may be implemented in conjunction with the fifth aspect, the two members 81 are out of contact with each other along the axis of the inner cylindrical portion 3.
This configuration allows the coil bobbin 8 to be attached to respective stator cores 20, of which the plurality of teeth 4 have mutually different dimensions as measured along the axis of the stator cores 20, to have the same configuration in common. That is to say, the same coil bobbin 8 may be attached to any of those stator cores 20 by varying the distance between the two members 81 of the coil bobbin 8 from one stator core 20 to another.
In an electric tool 10 according to a seventh aspect, which may be implemented in conjunction with any one of the first to sixth aspects, the tip piece 42 of each of the plurality of teeth 4 includes two tip pieces 42. The two tip pieces 42 are provided, in the tip part of the body portion 41, on both sides along a circumference of the inner cylindrical portion 3.
This configuration further reduces, compared to a situation where a single tip piece 42 is provided, the chances of the coil 23 wound around the body portion 41 moving toward the tip part of the body portion 41 to come off the body portion 41.
In an electric tool 10 according to an eighth aspect, which may be implemented in conjunction with any one of the first to seventh aspects, a surface, located at an outer end along the radius of the inner cylindrical portion 3, of the tip piece 42 includes a curvilinear surface 421.
This configuration allows, compared to a situation where the surface, located at an outer end along the radius of the inner cylindrical portion 3, of the tip piece 42 is a flat surface, the pressure applied to that surface to be distributed more easily.
In an electric tool 10 according to a ninth aspect, which may be implemented in conjunction with any one of the first to eighth aspects, the tip piece 42 includes, in its part connected to the body portion 41, a curved portion 422. The curved portion 422 is curved such that as a distance to an outer edge of the tip piece 42 decreases along the radius of the inner cylindrical portion 3, a distance from the body portion 41 increases along a circumference of the inner cylindrical portion 3.
According to this configuration, a magnetic path passing through the respective body portions 41 and curved portions 422 of two adjacent teeth 4 is formed as a part of a magnetic path connecting the two adjacent teeth 4 (as indicated by the arrow A2 in
In an electric tool 10 according to a tenth aspect, which may be implemented in conjunction with any one of the first to ninth aspects, the inner cylindrical portion 3 includes a high magnetic resistance portion R1. The high magnetic resistance portion R1 has higher magnetic resistance than parts, surrounding the high magnetic resistance portion R1, of the inner cylindrical portion 3.
This configuration may reduce the magnetic flux leaking from the inner cylindrical portion 3.
In an electric tool 10 according to an eleventh aspect, which may be implemented in conjunction with the tenth aspect, the high magnetic resistance portion R1 includes a penetrating portion 302. The penetrating portion 302 penetrates through the inner cylindrical portion 3 along an axis thereof to divide the inner cylindrical portion 3 into multiple pieces along a circumference thereof.
This configuration may reduce the magnetic flux leaking from the inner cylindrical portion 3.
In an electric tool 10 according to a twelfth aspect, which may be implemented in conjunction with the eleventh aspect, the penetrating portion 302 of the high magnetic resistance portion R1 includes a plurality of penetrating portions 302. The plurality of penetrating portions 302 separate the plurality of teeth 4 from each other.
This configuration further reduces the magnetic flux leaking from the inner cylindrical portion 3 compared to a situation where some of the plurality of teeth 4 is connected to another tooth 4.
In an electric tool 10 according to a thirteenth aspect, which may be implemented in conjunction with the tenth aspect, the inner cylindrical portion 3 is continuous along a circumference thereof.
This configuration allows the motor 1 to be assembled more easily than in a situation where the inner cylindrical portion 3 is divided into multiple pieces along the circumference thereof.
In an electric tool 10 according to a fourteenth aspect, which may be implemented in conjunction with any one of the tenth to thirteenth aspects, the high magnetic resistance portion R1 includes a thinned portion 304. The thinned portion 304 has a shorter dimension as measured along the axis of the inner cylindrical portion 3 than parts, surrounding the thinned portion 304, of the inner cylindrical portion 3.
This configuration may reduce the magnetic flux leaking from the inner cylindrical portion 3.
In an electric tool 10 according to a fifteenth aspect, which may be implemented in conjunction with any one of the tenth to fourteenth aspects, the stator core 20 is formed by stacking a plurality of steel plates 210 one on top of another in a thickness direction. The high magnetic resistance portion R1 is provided for each of two or more steel plates 210 selected from the plurality of steel plates 210. The two or more steel plates 210 are stacked one on top of another such that the respective high magnetic resistance portions R1 of mutually adjacent steel plates 210 do not overlap with each other in the thickness direction.
This configuration may increase the mechanical strength of the stator core 20 compared to a situation where the respective high magnetic resistance portions R1 of adjacent steel plates 210 overlap with each other in the thickness direction.
Note that the constituent elements according to all aspects but the first aspect are not essential constituent elements for the electric tool 10 but may be omitted as appropriate.
A motor 1 according to a sixteenth aspect includes a stator core 20 and a rotor 5. The rotor 5 has an output shaft 51 and rotates with respect to the stator core 20. The stator core 20 includes: an inner cylindrical portion 3 having a circular cylindrical shape; and a plurality of teeth 4. Inside the inner cylindrical portion 3, the rotor 5 is arranged. Each of the plurality of teeth 4 includes a body portion 41 and a tip piece 42. The body portion 41 protrudes outward from the inner cylindrical portion 3 along a radius of the inner cylindrical portion 3. The tip piece 42 extends, from a tip part of the body portion 41, in a direction intersecting with a direction in which the body portion 41 protrudes.
According to this configuration, a tip part of the body portion 41 is provided with a tip piece 42, thus reducing, compared to a situation where no tip piece 42 is provided, the chances of a coil 23 wound around the body portion 41 moving toward the tip part of the body portion 41 to come off the body portion 41.
Optionally, a configuration according to the following seventeenth aspect may be implemented without being based on the configuration according to the first aspect as an essential one. Specifically, an electric tool 10 according to the seventeenth aspect includes a motor 1. The motor 1 includes a stator core 20 and a rotor 5. The rotor 5 has an output shaft 51 and rotates with respect to the stator core 20. The stator core 20 includes: an inner cylindrical portion 3 having a circular cylindrical shape; a plurality of teeth 4; and an outer cylindrical portion 22 having a circular cylindrical shape. Inside the inner cylindrical portion 3, the rotor 5 is arranged. Each of the plurality of teeth 4 includes a body portion 41. The body portion 41 protrudes outward from the inner cylindrical portion 3 along a radius of the inner cylindrical portion 3. The outer cylindrical portion 22 are mounted on the plurality of teeth 4 to surround the plurality of teeth 4. The outer cylindrical portion 22 includes a plurality of fitting portions 221. The plurality of fitting portions 221 correspond one to one to the plurality of teeth 4. Each of the plurality of fitting portions 221 and one tooth 4, corresponding to the fitting portion 221, out of the plurality of teeth 4 are fitted into each other by causing at least one of the fitting portion 221 or the tooth 4 to move along the radius of the inner cylindrical portion 3.
This configuration more easily reduces, compared to a situation where the plurality of fitting portions 221 and the plurality of teeth 4 are fitted into each other by moving along the axis of the inner cylindrical portion 3, misalignment between the outer cylindrical portion 22 and the plurality of teeth 4 along the axis.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2019-021091 | Feb 2019 | JP | national |
The present is continuation of U.S. patent application Ser. No. 17/428,198 filed on Aug. 3, 2021, which is a PCT National Entry of PCT/JP2019/045650 filed on Nov. 21, 2019, which claims priority to JP 2019-021091 filed on Feb. 7, 2019, each of which is hereby incorporated by reference in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 17428198 | Aug 2021 | US |
| Child | 18434702 | US |
