JP7038894B2 - Method of manufacturing a stator of a rotary electric machine, a rotary electric machine, a stator of a rotary electric machine, and a method of manufacturing a rotary electric machine. - Google Patents

Description

The present application relates to a stator of a rotary electric machine, a method of manufacturing a rotary electric machine, a stator of a rotary electric machine, and a method of manufacturing a rotary electric machine.

Conventionally, a stator used in a rotary electric machine such as an electric motor or a generator is composed of a coil mounted in a slot between a stator core and a tooth of the stator core. The coil wire forming the coil is insulated and coated, and the coil is insulated from the stator core. However, in the stator of a rotary electric machine, in order to secure sufficient insulation between the coil and the stator core, an insulating portion is further provided at a portion where the stator core and the coil are in contact with each other.

In a conventional stator, a coil is installed by winding a coil wire around a stator core via an insulating portion. The above-mentioned insulating portion has a cavity that can accommodate the pressure welding terminal. Then, in the stator, a coil wire and a pressure welding terminal are inserted, and each tooth is connected by a jumper wire (see, for example, Patent Document 1). Further, in other conventional stators, there is one in which a coil wire is wound continuously for 3 teeth in order to reduce the number of wiring portions (see, for example, Patent Document 2). Further, as another conventional stator, there is one in which a coil wire is continuously wound around two teeth separated by two teeth (see, for example, Patent Document 3, Patent Document 4, and Patent Document 5).

International Publication No. WO2016 / 51923 Japanese Unexamined Patent Publication No. 2016-127706 Japanese Unexamined Patent Publication No. 9-191588 Japanese Unexamined Patent Publication No. 2000-78789 Japanese Unexamined Patent Publication No. 2008-167604

Generally, in the manufacture of a stator for a rotary electric machine, it is important to save materials and shorten the manufacturing time in order to maintain the quality and lower the price. For example, in the stator described in Patent Document 1, a pressure welding terminal and a jumper wire connecting each tooth are used for connection. In this case, for example, a 9-teeth stator requires 18 pressure-displacement terminals and 8 jumper wires. Therefore, a large number of wiring members are required, which does not save materials and increases the price. Further, in the process of inserting the pressure welding terminal, a problem due to strength occurs in the cavity portion of the insulating portion.

Further, in the stator described in Patent Document 2, although the number of connecting members is reduced by continuously winding the coil wire, when the same phase winding is performed three times in a row in a 6-pole 9-slot rotary electric machine, Problems such as torque pulsation or vibration occur.

Further, in the stators described in Patent Documents 3 and 4, three winding nozzles are used to wind the stator cores of 6 teeth at the same time for each of the 3 teeth. Further, the winding starts continuously across the teeth separated by 2 teeth, but in order to prevent the winding start wire and the crossover wire from crossing and interfering with each other, for example, the stator is wound axially on the upper side of the winding start wire. If so, the crossover is provided via the lower insulating member. When winding this continuous winding with a 9-teeth stator, two crossovers are required, and the number of turns of the 3 teeth that is wound the third time to turn the winding start wire and winding end wire upward is half a turn. More or less winding, causing electrical problems such as pulsation or vibration.

Further, in the stator described in Patent Document 5, when crossovers are made to the teeth two teeth apart, the three-phase crossovers interfere with each other, so that the nozzles are operated in a complicated manner for each one to avoid the interference. This increases equipment costs and increases winding cycle time. Further, when the direction of the crossover is reversed from the stator core side to the tip of the insulating member and the crossover is made in the direction away from the stator core, the winding start wire can be arranged at the tip of the insulating member, so that the winding start wire is a crossover. It is placed above and can prevent interference due to cloth. However, when winding 3 teeth continuously to 9 teeth, the crossover wire and the winding end line interfere with each other when winding from the 2nd teeth to the 3rd teeth continuously, so it is possible to wind only with 2 teeth continuous winding. However, there is a problem that it is not possible to apply windings of 3 teeth or more.

The present application discloses a technique for solving the above-mentioned problems, in which interference of the crossover wire of the stator core in the winding of the coil wire at the time of coil formation can be prevented, the number of connecting members can be reduced, and the manufacturing can be performed. It is an object of the present invention to provide a rotary electric machine stator, a rotary electric machine, a method for manufacturing a rotary electric machine stator, and a method for manufacturing a rotary electric machine, which can shorten the time and improve the productivity.

The stator of the rotary electric machine disclosed in the present application is
A stator core having a plurality of teeth formed on the inner peripheral surface of the yoke portion arranged in an annular shape and the inner peripheral surface of the yoke portion in the radial direction so as to project inward in the radial direction at predetermined intervals in the circumferential direction. And a stator of a rotary electric machine provided with a coil formed by winding a coil wire around each of the plurality of teeth, and an insulating portion disposed between the stator core and the coil to insulate the stator core and the coil. And,
The insulating portion has a first protruding portion protruding from one side in the axial direction from the stator core, and has a groove portion having a plurality of steps in the axial direction on the outer peripheral surface on the outer peripheral surface in the radial direction of the first protruding portion. death,
The winding start wire, the winding end wire, and the crossover wire connecting the coils of the different teeth are all installed in the first protruding portion of the insulating portion in the same direction in the axial direction.
The winding start wire is continuous with the groove portion formed in the first protrusion of the insulation portion on the side closest to the stator core in the axial direction, and has a diameter from the outside in the radial direction of the first protrusion. An introduction that is formed so as to communicate with the inside of the direction and has an inclined surface along the axial direction in which the width in the circumferential direction gradually decreases from the side opposite to the stator core in the axial direction toward the stator core side to hold the coil wire. Placed in the groove,
The crossover is a continuous line diagonally arranged from the side opposite to the stator core in the axial direction of the insulating portion toward the stator core side in the axial direction while crossing between different teeth, and is held in the groove portion. Being done
The inclined surface is formed on the first protruding portion where the groove portion is not provided .
Further, the rotary electric machine disclosed in the present application is a rotary electric machine.
With the stator of the rotary electric machine described above,
The stator is provided with a rotor arranged so as to face each other via an air gap.
Further, the method for manufacturing a stator of a rotary electric machine disclosed in the present application is as follows.
The yoke portion of the stator core is deformed in a straight line, and the three coil wires are simultaneously wound by three winding nozzles along a trajectory along the shape of the three teeth continuous in the circumferential direction. After forming the coil on the tooth, the three coil wires are held in the groove portion of the first protrusion of the three teeth as the crossover wire, and the coil wires are separated from each other by three in the circumferential direction. When moving to the teeth and crossing the three crossovers, the crossovers are formed so that the three crossovers do not interfere with each other while rotating the three winding nozzles once .
Further, the method for manufacturing a stator of a rotary electric machine disclosed in the present application is as follows.
The yoke portion of the stator core is deformed in a reverse warp shape, and the three coil wires are simultaneously wound by three winding nozzles along a trajectory along the shape of three consecutive teeth in the circumferential direction. After forming the coil on the teeth, the three coil wires were held in the grooves of the first protrusions of the three teeth as the crossovers, respectively, and separated by three in the circumferential direction. By rotating the stator core to move to the teeth, the crossovers are formed so that the three crossovers do not interfere with each other when the three crossovers are crossed .
Further, the method for manufacturing a rotary electric machine disclosed in the present application is as follows.
A rotor is arranged to face the stator manufactured by the method for manufacturing a stator of a rotary electric machine as described above via an air gap.

According to the rotary electric machine stator, the rotary electric machine, the method for manufacturing the rotary electric machine stator, and the method for manufacturing the rotary electric machine disclosed in the present application.
Interference of the crossover of the stator core in the winding of the coil wire at the time of coil formation can be prevented, the number of wiring members can be reduced, the manufacturing time can be shortened, and the productivity can be improved.

It is a rear view which shows the state which the yoke part of the stator core of the stator of the rotary electric machine is deformed linearly in Embodiment 1. FIG. It is a front perspective view which shows the structure of the stator shown in FIG. It is a perspective view which shows the structure of one core plate which constitutes the stator core of the stator shown in FIG. It is a perspective view which shows the structure of the stator core which laminated the core plate shown in FIG. FIG. 4 is a plan view of the core portion including one tooth of the stator core shown in FIG. 4 as viewed from above. It is a perspective view which showed the structure of the 1st winding frame which has the 1st protrusion of the insulating part used for the stator shown in FIG. It is a perspective view which showed the structure of the 2nd winding frame which has the 2nd protrusion of the insulating part used for the stator shown in FIG. It is a perspective view which shows the structure which attached the 1st winding frame shown in FIG. 6 and the 2nd winding frame shown in FIG. 7 to the core part shown in FIG. It is a front view which shows the structure which looked at the core part shown in FIG. 8 from the direction indicated by the arrow A. It is a rear view which shows the structure which looked at the core part shown in FIG. 8 from the direction indicated by the arrow B. It is a side view which shows the structure which looked at the core part shown in FIG. 8 from the direction indicated by the arrow C. FIG. 3 is a plan view showing a configuration of the core portion shown in FIG. 8 as viewed from the direction indicated by the arrow D. It is a figure which shows the manufacturing method of the stator shown in FIG. It is a figure which shows the manufacturing method of the stator shown in FIG. It is a figure which shows the manufacturing method of the stator shown in FIG. It is a figure which shows the other manufacturing method of the stator shown in FIG. FIG. 5 is a front perspective view showing a state in which the yoke portion of the stator core of the stator of the rotary electric machine in the second embodiment is linearly deformed. It is an exploded perspective view which shows the state before attaching the insulating part to the stator core shown in FIG. It is a perspective view which shows the structure of the film part shown in FIG. It is a perspective view which shows the structure of the upper winding frame shown in FIG. It is a perspective view which shows the structure of the lower winding frame shown in FIG. It is a side sectional view which shows the structure of the rotary electric machine in Embodiment 1. FIG. It is a top sectional view showing the structure of the rotary electric machine shown in FIG. 22. It is a flowchart which shows the manufacturing method of the rotary electric machine shown in FIG. It is a flowchart which shows the manufacturing method of the rotary electric machine shown in FIG.

Embodiment 1.
FIG. 1 is a rear view showing a state in which the yoke portion of the stator core of the stator of the rotary electric machine in the first embodiment is linearly deformed. FIG. 2 is a front perspective view showing the configuration of the stator shown in FIG. FIG. 3 is a perspective view showing the configuration of one core plate constituting the stator core of the stator shown in FIG. FIG. 4 is a perspective view showing a configuration of a stator core formed by laminating a plurality of core plates shown in FIG. 3 in the axial direction. FIG. 5 is a plan view showing a configuration of a core portion including one tooth of the stator core shown in FIG. 4 as viewed from above.

FIG. 6 is a perspective view showing the configuration of the first winding frame having the first protruding portion of the insulating portion used for the stator shown in FIG. 1. FIG. 7 is a perspective view showing the configuration of the second winding frame having the second protruding portion of the insulating portion used for the stator shown in FIG. 1. FIG. 8 is a perspective view showing a configuration in which the first winding frame shown in FIG. 6 and the second winding frame shown in FIG. 7 are attached to the core portion shown in FIG.

FIG. 9 is a front view showing a configuration in which the core portion shown in FIG. 8 is viewed from the direction indicated by the arrow A. FIG. 10 is a rear view showing a configuration in which the core portion shown in FIG. 8 is viewed from the direction indicated by the arrow B. FIG. 11 is a side view showing a configuration in which the core portion shown in FIG. 8 is viewed from the direction indicated by the arrow C. FIG. 12 is a plan view showing a configuration of the core portion shown in FIG. 8 as viewed from the direction indicated by the arrow D. 13 to 15 are views showing a method of manufacturing the stator shown in FIG. 1. FIG. 16 is a diagram showing another manufacturing method of the stator shown in FIG.

In the following description, the directions of the stator 100 of the rotary electric machine are the circumferential direction Z, the axial direction Y, the radial direction X, and the radial direction X, respectively, with reference to the state when the yoke portion 11 of the stator 100 is arranged in an annular shape. It is shown as the outer side X1 of the above and the inner side X2 in the radial direction X. Therefore, even if the yoke portion 11 of the stator core 1 of the stator 100 is deformed linearly, or even when the yoke portion 11 of the stator 100 is deformed in a reverse warp shape in which the protruding direction of the teeth 12 is reversed, the yoke portion 11 of the stator 100 is deformed. Each direction will be described in each figure with reference to the direction of the state when arranged in a ring shape. In addition, in other embodiments, the direction is illustrated and described with the same reference.

As shown in FIGS. 1 and 2, the stator 100 includes a stator core 1, a coil 7, and an upper winding frame 2 and a lower winding frame 3 as insulating portions arranged to insulate the stator core 1 and the coil 7. .. The stator core 1 includes a yoke portion 11 arranged in an annular shape (however, in each figure, the yoke portion 11 is shown in a linearly deformed state as shown above) and the yoke portion 11. A plurality of teeth 12 (see FIG. 4) formed on the inner peripheral surface 112 (see FIG. 5) of the inner X2 in the radial direction so as to project to the inner X2 in the radial direction X at a predetermined interval in the circumferential direction Z. And have.

The stator core 1 is formed by laminating a plurality of core plates 6 formed by punching a thin magnetic steel plate shown in FIG. 3 in the axial direction Y as shown in FIG. Here, a portion of the yoke portion 11 where one tooth 12 is formed will be described below as a core portion 60. The stator core 1 is formed by connecting the yoke portions 11 of the plurality of core portions 60 at the connecting portion 111 in the circumferential direction Z. Here, the stator core 1 is configured by connecting nine core portions 60 with a connecting portion 111. The yoke portion 11 of the stator core 1 can be freely bent at the connecting portion 111, whereby the yoke portion 11 can be deformed into a straight line or a reverse warp shape in which the direction of protrusion in the radial direction X of the teeth 12 is reversed. Will be done.

Further, as shown in FIGS. 1, 2 and 4, the core portions 60 arranged in the circumferential direction Z are connected to the first core portion 61, the second core portion 62, and the third core from the winding start side of the coil wire 70. Section 63, fourth core section 64, fifth core section 65, sixth core section 66, seventh core section 67, eighth core section 68, and ninth core section 69. Here, it is a star connection connection structure composed of three phases, a U phase, a V phase, and a W phase, in which different phases are arranged for each adjacent core portion 60 in the circumferential direction Z. The first core portion 61 is the U phase (U1), the second core portion 62 is the V phase (V1), the third core portion 63 is the W phase (W1), and the fourth core portion 64 is the U phase (U2). The fifth core portion 65 is the V phase (V2), the sixth core portion 66 is the W phase (W2), the seventh core portion 67 is the U phase (U3), the eighth core portion 68 is the V phase (V3), and the ninth core portion 68. The core portion 69 is the W phase (W3).

When it is not necessary to explain the order, the core unit 60 will be collectively described. Further, a coil 7 and an upper winding frame 2 and a lower winding frame 3 as insulating portions are similarly installed in the core portions 61 to 69. However, each core portion 61 to 69 corresponds to the core portion 61 to 69 regardless of the state in which the coil 7, the upper winding frame 2 and the lower winding frame 3 as insulating portions are installed or not installed. Adopt the description.

Next, each part of the core portion 60 will be described with reference to FIG. The outer peripheral surface 113 is a surface of the yoke portion 11 along the axial direction Y of the outer side X1 of the radial direction X. A first recess 114 extending in the axial direction Y is formed on the outer peripheral surface 113 of the yoke portion 11. The first recess 114 is used for positioning when the stator core 1 is attached to the winding machine forming the coil 7. Further, the teeth 12 are provided with shoe portions 13 protruding in the circumferential direction Z at the tips of the inner X2 in the radial direction X.

The surface along the axial direction Y at both ends of the circumferential direction Z of the teeth 12 is defined as the first side surface 121, and the surface of the tip of the inner side X2 of the radial direction X of the teeth 12 along the axial direction Y is defined as the tip surface 122. The surface of the shoe portion 13 along the axial direction Y of the outer side X1 of the radial direction X is referred to as a second side surface 131. The first side surface 121, the second side surface 131, and the tip surface 122 are side surfaces along the axial direction Y of the teeth 12. The region surrounded by the inner peripheral surface 112, the first side surface 121, and the second side surface 131 becomes the slot 14 in which the coil wire 70 is wound to form the coil 7.

Next, the upper winding frame 2 and the lower winding frame 3 will be described as insulating portions with reference to FIGS. 6 to 12. As shown in FIG. 6, the upper winding frame 2 is composed of a first protruding portion 21 and a first leg portion 22. As shown in FIG. 7, the lower winding frame 3 is composed of a second protruding portion 31 and a second leg portion 32. FIG. 8 is a diagram showing a state in which the upper winding frame 2 and the lower winding frame 3 are installed on the core portion 60, and the first protruding portion 21 is formed so as to project from one side in the axial direction Y from the core portion 60. Further, the second protruding portion 31 is formed so as to protrude from the other side in the axial direction Y from the core portion 60.

As shown in FIG. 9, a groove portion 9 having a plurality of steps in the axial direction Y is formed on the outer peripheral surface 201 of the outer side X1 in the radial direction X of the first protruding portion 21 of the upper winding frame 2. Here, the groove portion 9 is formed by four stages of a first groove portion 91, a second groove portion 92, a third groove portion 93, and a fourth groove portion 94 from the side separated from the stator core 1 in the axial direction Y. Each groove 91, 92, 93, 94 is formed so as to be inclined in the axial direction Y. For example, referring to FIGS. 1 and 9, the position of the axial direction Y on the side of the second core portion 62 adjacent to the circumferential direction Z of the first groove portion 91 of the first core portion 61 and the second position of the second core portion 62. It is formed so as to be close to the position of the axial direction Y on the first core portion 61 side adjacent to the circumferential direction Z of the groove portion 92.

Further, the position of the axial direction Y on the second core portion 62 side adjacent to the circumferential direction Z of the second groove portion 92 of the first core portion 61 and the position adjacent to the circumferential direction Z of the third groove portion 93 of the second core portion 62. It is formed so as to be close to the position in the axial direction Y on the first core portion 61 side. Further, the position of the axial direction Y on the second core portion 62 side adjacent to the circumferential direction Z of the third groove portion 93 of the first core portion 61 and the position adjacent to the circumferential direction Z of the fourth groove portion 94 of the second core portion 62. It is formed so as to be close to the position in the axial direction Y on the first core portion 61 side.

Further, the first protruding portion 21 of the upper winding frame 2 is continuous with the fourth groove portion 94 on the side closest to the stator core 1 in the axial direction Y, and is radially X from the outer side X1 of the radial direction X of the first protruding portion 21. An introduction groove portion provided with an inclined surface 950 along the axial direction Y, which is formed in communication with the inner side X2 of the above and is formed in the axial direction Y from the side opposite to the stator core 1 toward the stator core 1 side, and the width of the circumferential direction Z gradually decreases. Has 95. Further, the first protruding portion 21 of the upper winding frame 2 is continuous with the first groove portion 91 on the side farthest from the stator core 1 in the axial direction Y, and is radially from the inner side X2 of the radial direction X of the first protruding portion 21. It has a lead-out groove 96 continuously formed on the outer side X1 of X. Therefore, the introduction groove portion 95 and the lead-out groove portion 96 are continuously formed from the outer peripheral surface 201 of the first protrusion 21 to the inner peripheral surface 202 of the inner X2 in the radial direction X.

Further, the first protruding portion 21 of the upper winding frame 2 is in the circumferential direction of the second groove portion 92, the third groove portion 93, and the fourth groove portion 94 other than the first groove portion 91 on the side farthest from the stator core 1 in the axial direction Y. At one end of Z, a first power supply groove portion 97, a second power supply groove portion 98, and a third power supply groove portion 99 continuous from the outer side X1 in the radial direction X of the first protrusion 21 to the inner side X2 in the radial direction X are provided. Therefore, the first power supply groove portion 97, the second power supply groove portion 98, and the third power supply groove portion 99 are formed by cutting out the inner peripheral surface 202 from the outer peripheral surface 201 of the first protruding portion 21.

The first groove portion 91, the second groove portion 92, the third groove portion 93, and the fourth groove portion 94 hold a crossover line 8 that connects the coils 7 of different teeth 12. The crossover line 8 is a continuous line between the coils 7. The introduction groove portion 95 is held for introducing the coil wire 70 from the outer side X1 in the radial direction X to the inner side X2 in the radial direction X in order to wind the coil wire 70 around the teeth 12. At this time, since the introduction groove portion 95 has an inclined surface 950, the introduction of the coil wire 70 can be easily and easily performed. The lead-out groove portion 96 holds the crossover wire 8 after winding around the teeth 12 to form the coil 7 from the inner side X2 in the radial direction X of the stator core 1 to the outer side X1 in the radial direction X to prevent loosening. conduct. The first power supply groove portion 97, the second power supply groove portion 98, and the third power supply groove portion 99 introduce the winding start portion of the coil wire 70 from the outer side X1 of the stator core 1 in the radial direction X to the inner side X2 in the radial direction X. Hold on.

The first leg portion 22 of the upper winding frame 2 and the second leg portion 32 of the lower winding frame 3 are configured to cover the inner peripheral surface 112, the first side surface 121, and the second side surface 131 of the core portion 60. That is, the legs 22 and 32 are fitted in the slot 14 to insulate the coil 7 and the stator core 1. In the first embodiment, an example is shown in which the lengths of the first leg portion 22 and the second leg portion 32 in the axial direction Y are formed to have substantially the same length, but the present invention is limited to this. It suffices that the stator core 1 and the coil 7 can be insulated from each other by the legs 22 and 32, and the length of each leg 22 and 32 in the axial direction Y can be appropriately changed.

Next, the coil wire 70 will be described with reference to FIG. The coil wire 70 is a wire for forming the coil 7. Here, three coil wires 70 of the first coil wire 71, the second coil wire 72, and the third coil wire 73 are used. In each of the coil wires 71, 72, and 73, the wires that start winding the coil 7 are the first winding start wire 711, the second winding start wire 721, and the third winding start wire 731. Further, when the first winding start wire 711, the second winding start wire 721, and the third winding start wire 731 are moved from the outer side X1 to the inner side X2 in the radial direction X of the stator core 1 and used as a power supply line, the first One power supply line 713, a second power supply line 723, and a third power supply line 733. The first power supply line 713, the second power supply line 723, and the third power supply line 733 are indicated by broken lines, and the details will be described later.

Further, in each of the coil wires 71, 72, and 73, the wires at which the coil 7 has been wound are referred to as the first winding ending wire 712, the second winding ending wire 722, and the third winding ending wire 732. The first volume ending line 712, the second volume ending line 722, and the third volume ending line 732 are connected to form a neutral point 700. As shown above, when it is not necessary to explain using each part of the coil wire 70, the coil wire 70 will be generically described.

Next, the crossover line 8 will be described with reference to FIG. The crossover wire 8 is formed of a coil wire 70. The crossover 8 includes a first crossover 81, a second crossover 82, a third crossover 83, a fourth crossover 84, a fifth crossover 85, and a sixth crossover 86. The first crossover 81 connects the coil 7 of the first core portion 61 and the coil 7 of the fourth core portion 64 separated by three in the circumferential direction Z. The second crossover 82 connects the coil 7 of the second core portion 62 and the coil 7 of the fifth core portion 65 separated by three in the circumferential direction Z. The third crossover line 83 connects the coil 7 of the third core portion 63 and the coil 7 of the sixth core portion 66 separated by three in the circumferential direction Z.

The fourth crossover 84 connects the coil 7 of the fourth core portion 64 and the coil 7 of the seventh core portion 67. The fifth crossover 85 connects the coil 7 of the fifth core portion 65 and the coil 7 of the eighth core portion 68 separated by three in the circumferential direction Z. The sixth crossover 86 connects the coil 7 of the sixth core portion 66 and the coil 7 of the ninth core portion 69 separated by three in the circumferential direction Z. As shown above, when it is not necessary to explain each part of the crossover line 8, the crossover line 8 will be generically described.

As shown in FIGS. 22 and 23, the rotary electric machine 10 is a rotor arranged so as to face the stator 100 shown above with a predetermined air gap (gap) 107 provided on the inner side X2 of the stator 100 in the radial direction X. It includes a 102 and a housing 101 for fixing the rotor 102 and the stator 100. The rotor 102 is rotatably held by fitting the shaft 104 to the inner rings of the bearings 103 provided at both ends of the housing 101 in the axial direction Y. Further, a permanent magnet 105 is embedded in a V shape in the rotor core 106 fixed to the outer periphery of the shaft 104.

Although the permanent magnet 105 is shown in an example of being arranged in a V shape, the present invention is not limited to this, and the permanent magnet 105 may be arranged in a straight line or in another shape. Further, the permanent magnet 105 is shown as an example of being embedded and formed, but the present invention is not limited to this, and the permanent magnet 105 is attached to the outer peripheral surface of the outer surface X1 of the radial direction X of the rotor core 106 and arranged so as to face the stator 100. You may. The number of magnetic poles generated by the permanent magnet 105 is not limited to 6 poles as shown in FIG. 22, and may be appropriately set according to the number of teeth 12 of the stator 100.

Next, regarding the method of manufacturing the stator of the rotary electric machine of the first embodiment and the method of manufacturing the rotary electric machine configured as described above, the flowchart of the method of manufacturing the rotary electric machine of the first embodiment shown in FIG. 24 is used. explain. First, the pre-process of the coil forming process will be described. The magnetic steel plate is punched out to form the core plate 6 as shown in FIG. Then, a plurality of the formed core plates 6 are laminated in the axial direction Y and connected by the connecting portion 111 of the yoke portion 11 to form the stator core 1 (step ST1 in FIG. 24). Next, the upper winding frame 2 and the lower winding frame 3 are formed by, for example, injection molding of an insulating resin. Next, the first leg portion 22 of the upper winding frame 2 and the second leg portion 32 of the lower winding frame 3 are inserted and fitted into the slots 14 from both ends of the stator core 1 in the axial direction Y, and the upper winding frame 2 and the lower winding frame 3 are fitted. It is attached to the stator core 1 (step ST2 in FIG. 24).

Next, the step of forming the coil 7 (step ST3 in FIG. 24) will be described with reference to the flowchart of the manufacturing method of the rotary electric machine of FIG. First, as shown in FIGS. 1, 15, and 9, the first coil wire 71 is introduced from the outer side X1 to the inner side X2 in the radial direction X by using the introduction groove portion 95 of the first core portion 61. At this time, since the introduction groove portion 95 has an inclined surface 950, the introduction of the coil wire 70 can be easily and easily performed. Since this is the same in the case of introduction using the introduction groove portion 95 of the coil wire 70 in another place, the description thereof will be omitted as appropriate.

Similarly, the second coil wire 72 and the third coil wire 73 are also introduced from the outer side X1 to the inner side X2 in the radial direction X by using the introduction groove portions 95 of the second core portion 62 and the third core portion 63, respectively. do. Then, as shown in FIG. 13, three winding nozzles 51, 52, and 53 are used to first attach the first to each tooth 12 of the first core portion 61, the second core portion 62, and the third core portion 63. The coil wire 71, the second coil wire 72, and the third coil wire 73 are simultaneously wound in the same manner as the arrows 511, 521, and 513 (however, FIG. 11 shows the seventh core portion 67, the eighth core portion 68, and the ninth core portion. An example of winding around the core portion 69 is illustrated).

Then, after forming the coil 7 in the teeth 12 of the first core portion 61, the second core portion 62, and the third core portion 63, the first coil wire 71, the second coil wire 72, and the third coil wire 73 are formed. Each of the lead-out groove portions 96 of the first core portion 61, the second core portion 62, and the third core portion 63 is held so as to prevent loosening, and is led out from the inner side X2 in the radial direction X to the outer side X1 (FIG. 14, FIG. Step ST31 in FIG. 25). Next, it is determined whether or not the coil wire 70 is wound around all the core portions 60 (step ST32 in FIG. 25). Then, here, it becomes NO and the process proceeds to the next process. Next, in order to move the winding nozzles 51, 52, 53 in the direction of arrow E and perform the next winding step, the first coil wire 71 is connected to the fourth core portion 64, and the second coil wire 72 is connected to the fourth core portion 64. The third coil wire 73 is moved to the five core portions 65 to the respective positions of the sixth core portion 66 (step ST33 in FIG. 25).

When moving in the direction of arrow E, the nozzle unit having the winding nozzles 51, 52, and 53 makes one rotation in the direction of arrow F shown in FIG. 14, and crossovers so that the crossovers do not interfere with each other between different phases. Form a line. That is, the winding nozzle 51 operates on the track G, the winding nozzle 52 operates on the track H, and the winding nozzle 53 operates on the track I. When moving the winding nozzle 51, the entire winding nozzle 51 is outside the first protruding portion 21 in the radial direction X so that the winding nozzle 51 does not interfere with all of the first core portion 61 to the ninth core portion 69. It is located at X1.

As a result, the winding nozzle 51 can be arranged on the core portion 60 side of the crossover wire coming out of the winding nozzle 52 and the winding nozzle 53, and the winding nozzle 52 can be arranged on the core portion 60 side of the crossover wire coming out of the winding nozzle 53. Can be placed in. Therefore, it is possible to prevent the winding nozzle 51 from interfering (crossing) with the crossover wire coming out of the winding nozzle 52 and the winding nozzle 53 and the winding nozzle 52 with the crossover wire coming out of the winding nozzle 53.

At this time, the first crossover 81 connecting the coil 7 of the first core portion 61 and the coil 7 of the fourth core portion 64 is held from the lead-out groove portion 96 to the first groove portion 91 of the first core portion 61, and is held in the circumferential direction. A fourth core portion held by the second groove portion 92 of the second core portion 62 connected to Z, further held by the third groove portion 93 of the third core portion 63 connected to the circumferential direction Z, and further connected to the circumferential direction Z. From the introduction groove portion 95 held by the fourth groove portion 94 of 64 and connected to the fourth groove portion 94, the fourth core portion 64 is introduced from the outer side X1 to the inner side X2 in the radial direction X (step ST31 in FIG. 25).

Similarly, the second crossover wire 82 connecting the coil 7 of the second core portion 62 and the coil 7 of the fifth core portion 65 is held from the lead-out groove portion 96 to the first groove portion 91 of the second core portion 62. A fifth that is held by the second groove 92 of the third core portion 63 that is connected to the circumferential direction Z, is further held by the third groove portion 93 of the fourth core portion 64 that is connected to the circumferential direction Z, and is further connected to the circumferential direction Z. From the introduction groove portion 95 held by the fourth groove portion 94 of the core portion 65 and connected to the fourth groove portion 94, the fifth core portion 65 is introduced from the outer side X1 to the inner side X2 in the radial direction X.

Further, the third crossover wire 83 connecting the coil 7 of the third core portion 63 and the coil 7 of the sixth core portion 66 is held from the lead-out groove portion 96 to the first groove portion 91 of the third core portion 63, and is connected to the circumference. The sixth core is held by the second groove 92 of the fourth core 64 connected to the direction Z, further held by the third groove 93 of the fifth core 65 connected to the circumferential Z, and further connected to the circumferential Z. From the introduction groove portion 95 held by the fourth groove portion 94 of the portion 66 and connected to the fourth groove portion 94, the sixth core portion 66 is introduced from the outer side X1 to the inner side X2 in the radial direction X.

Then, similarly to the above, as shown in FIG. 13, using the three winding nozzles 51, 52, 53, each of the fourth core portion 64, the fifth core portion 65, and the sixth core portion 66, respectively. The first coil wire 71, the second coil wire 72, and the third coil wire 73 are simultaneously wound around the teeth 12 as shown by arrows 511, 521, and 513.

Then, after forming the coil 7 in the teeth 12 of the fourth core portion 64, the fifth core portion 65, and the sixth core portion 66, the first coil wire 71, the second coil wire 72, and the third coil wire 73 are formed. Each of the lead-out groove portions 96 of the fourth core portion 64, the fifth core portion 65, and the sixth core portion 66 is held so as to prevent loosening, and is led out from the inner side X2 in the radial direction X to the outer side X1. Then, in order to move the winding nozzles 51, 52, 53 in the direction of arrow E and perform the next winding step, the first coil wire 71 is connected to the seventh core portion 67, and the second coil wire 72 is connected to the eighth core portion 67. The third coil wire 73 is moved to the core portion 68 to each position of the ninth core portion 69. When moving in the direction of arrow E, the nozzle unit having the winding nozzles 51, 52, and 53 has one rotation in the direction of arrow F shown in FIG. 14, as in the first crossover processing shown above. Perform crossover processing while letting it.

At this time, the fourth crossover wire 84 connecting the coil 7 of the fourth core portion 64 and the coil 7 of the seventh core portion 67 is held from the lead-out groove portion 96 to the first groove portion 91 of the fourth core portion 64, and is held in the circumferential direction. A seventh core portion held by the second groove portion 92 of the fifth core portion 65 connected to Z, further held by the third groove portion 93 of the sixth core portion 66 connected to the circumferential direction Z, and further connected to the circumferential direction Z. From the introduction groove portion 95 held by the fourth groove portion 94 of 67 and connected to the fourth groove portion 94, the seventh core portion 67 is introduced from the outer side X1 to the inner side X2 in the radial direction X.

Similarly, the fifth crossover wire 85 connecting the coil 7 of the fifth core portion 65 and the coil 7 of the eighth core portion 68 is held from the lead-out groove portion 96 to the first groove portion 91 of the fifth core portion 65. The eighth core portion 66 connected to the circumferential direction Z is held by the second groove portion 92 of the sixth core portion 66, further held by the third groove portion 93 of the seventh core portion 67 connected to the circumferential direction Z, and further connected to the circumferential direction Z. It is introduced from the introduction groove portion 95 held in the fourth groove portion 94 of the core portion 68 and connected to the fourth groove portion 94 from the outer side X1 to the inner side X2 of the eighth core portion 68 in the radial direction X.

Further, the sixth crossing wire 86 connecting the coil 7 of the sixth core portion 66 and the coil 7 of the ninth core portion 69 is held from the lead-out groove portion 96 to the first groove portion 91 of the sixth core portion 66, and is peripheral. The ninth core is held by the second groove 92 of the seventh core 67 connected to the direction Z, further held by the third groove 93 of the eighth core 68 connected to the circumferential Z, and further connected to the circumferential Z. It is introduced from the introduction groove portion 95 held in the fourth groove portion 94 of the portion 69 and connected to the fourth groove portion 94 from the outer side X1 to the inner side X2 of the ninth core portion 69 in the radial direction X.

Then, similarly to the above, as shown in FIG. 13, using the three winding nozzles 51, 52, 53, each of the seventh core portion 67, the eighth core portion 68, and the ninth core portion 69, respectively. The first coil wire 71, the second coil wire 72, and the third coil wire 73 are simultaneously wound around the teeth 12 as in the arrows 511, 521, and 513.

Then, after forming the coil 7 on each tooth 12 of the seventh core portion 67, the eighth core portion 68, and the ninth core portion 69 (the determination in step ST32 in FIG. 25 is YES), the first coil wire 71 and the second coil wire 71. The two-coil wire 72 and the third coil wire 73 are cut to form the first volume end line 712, the second volume end line 722, and the third volume end line 732 (step ST34 in FIGS. 15 and 25). Then, the end lines 712, 722, and 732 of each volume are crimped together to form the neutral point 700 of the star connection (FIG. 1). As a method of putting together, a wiring process such as brazing or soldering may be used.

The first coil wire 71 is formed in this way as a continuous wire without cutting, and is the coil of the first winding start wire 711, the coil 7 of the first core portion 61, the first crossover wire 81, and the coil of the fourth core portion 64. 7, the fourth crossover wire 84, the coil 7 of the seventh core portion 67, and the first volume final wire 712. The second coil wire 72 is a continuous wire without being cut, and is the second winding start wire 721, the coil 7 of the second core portion 62, the second crossover wire 82, the coil 7 of the fifth core portion 65, and the fifth crossover wire. 85, the coil 7 of the eighth core portion 68, and the second volume final line 722. The third coil wire 73 is a continuous wire without being cut, and the third winding start wire 731, the coil 7 of the third core portion 63, the third crossover wire 83, the coil 7 of the sixth core portion 66, and the sixth crossover wire. 86, the coil 7 of the ninth core portion 69, and the third volume final line 732.

Next, processing is performed when the power line is used as the power supply line for the first volume start line 711, the second volume start line 721, and the third volume start line 731. The three first winding start wires 711, the second winding start wire 721, and the third winding start wire 731 need to be arranged inside X2 in the radial direction X of the stator 100 when the stator 100 is made into an annular shape. .. When the coil 7 is formed as described above, the second groove portion 92, the third groove portion 93, and the fourth groove portion 94 of the first core portion 61, the third groove portion 93, the fourth groove portion 94, and the third of the second core portion 62 are formed. The fourth groove portion 94 of the core portion 63 is not used for holding the crossover line 8.

Therefore, utilizing these, the first winding start line 711 of the first core portion 61 is held by the fourth groove portion 94 of the first core portion 61, and the third power supply groove portion 99 communicating with the fourth groove portion 94 is used. , Introduces from the outer side X1 to the inner side X2 in the radial direction X. Further, the second winding start line 721 of the second core portion 62 is held by the fourth groove portion 94 of the second core portion 62 and held by the third groove portion 93 of the first core portion 61 adjacent to the circumferential direction Z. Using the second power supply groove portion 98 communicating with the third groove portion 93, the second power supply groove portion 98 is introduced from the outer side X1 to the inner side X2 in the radial direction X.

Further, the third winding start line 731 of the third core portion 63 is held by the fourth groove portion 94 of the third core portion 63 and held by the third groove portion 93 of the second core portion 62 adjacent to the circumferential direction Z. Further, it is introduced from the outer side X1 to the inner side X2 in the radial direction X by using the first power supply groove portion 97 which is held in the second groove portion 92 of the first core portion 61 adjacent to the circumferential direction Z and communicates with the second groove portion 92. do. Each power line 713, 723, 733 is covered with an insulating tube on the inner side X2 in the radial direction X to maintain insulation and perform wiring processing.

Next, the stator core 1 is formed into an annular shape, and the ends of the stator core 1 are fixed to each other by welding or the like. The stator 100 is formed by these steps (step ST4 in FIG. 24). Next, the outer peripheral surface of the outer side X1 of the stator 100 in the radial direction X is fixed to the inner peripheral surface of the inner peripheral surface X2 in the radial direction X of the housing 101 (step ST5 in FIG. 24). Next, the rotor 102 is rotatably supported on the housing 101 by the bearing 103, and the rotor 102 is arranged to face the stator 100 via the air gap 107 (step ST6 in FIG. 24). The rotary electric machine 10 is formed by these steps.

In the first embodiment, the number of magnetic poles generated by the permanent magnet 105 is limited to the number of teeth 12 of the stator 100, although the example of 6 poles is shown as shown in FIG. It may be the corresponding number. For example, in this proposal (UVWUVW ...), which requires a crossover to the teeth 12 that are two teeth apart in the circumferential direction Z, when the number of teeth 12 is 3.N (N is an integer of 2 or more), the magnetic poles The number may be ((3 ± 1) · N). Further, in a method (UU'UVV'VWW'W ...) in which 3 teeth are continuously wound in the circumferential direction Z to the teeth 12 adjacent to the circumferential direction Z, 1 tooth and 3 are used when winding the second tooth. It is required for windings that rotate in the opposite direction to the teeth, and if the number of teeth 12 is 9.N (N is an integer of 1 or more), the number of magnetic poles may be ((9 ± 1) / N). .. Further, in the method of continuously winding two teeth 12 adjacent teeth 12 in the circumferential direction (UU'VV'WW'...), the number of teeth 12 is 6.N (N is an integer of 1 or more). If so, the number of magnetic poles may be ((6 ± 1) · N).

When the number of magnetic poles is ((9 ± 1) · N) and N is 2 or more, after winding 3 teeth continuously in the circumferential direction Z, the next teeth separated by 6 teeth in the circumferential direction Z. Since it is necessary to wind the wire to 12, it is necessary to process the crossover at a distance of 6 teeth. When the number of magnetic poles is ((6 ± 1) · N), it is necessary to wind two teeth continuously in the circumferential direction Z and then wind the next teeth 12 four teeth apart in the circumferential direction Z. Therefore, it is necessary to process the crossover line 4 teeth apart in the circumferential direction Z. Since this is the same in the following embodiments, the description thereof will be omitted as appropriate.

In the first embodiment, a method of linearly deforming the yoke portion 11 of the stator core 1 and winding the coil wire 70 around the teeth 12 to form the coil 7 is shown, but the present invention is not limited to this. As a method of the above, a case will be described in which the yoke portion 11 of the stator core 1 is deformed into a reverse warp shape in which the direction of protrusion in the radial direction X of the teeth is reversed by using the connecting portion 111.

FIG. 16 shows that the stator 100 of the first embodiment is the same as the stator 100 of the first embodiment except that the winding method is different. The winding machine 400 has a hexagonal chuck mechanism 40. The chuck mechanism 40 has chucks 41, 42, 43, 44, 45, 46. Winding nozzles 54, 55, 56 for winding the coil wire 70 are installed at positions of the chuck mechanism 40 facing the chucks 41, 42, and 43. Each winding nozzle 54, 55, 56 is rotated by a rotation shaft T, a rotation shaft M, and a rotation shaft N, and the coil wire 70 is wound around each tooth 12. However, unlike the case of FIG. 1, FIG. 16 shows the axial direction Y reversed. That is, FIG. 16 is a diagram showing a state in which the lower winding frame 3 of the core portion 60 is visible.

First, as shown in FIG. 16, the stator core 1 fixes the first core portion 61, the second core portion 62, and the third core portion 63 to the chuck 41, the chuck 42, and the chuck 43, respectively. Then, the winding nozzles 54, 55, and 56 are rotated by the rotation shafts T, M, and N, and the coil wire 70 is wound around each tooth 12 to form the coil 7. Then, after the first winding is completed, the winding nozzles 54, 55, 56 are moved back and forth, and the chuck mechanism 40 is rotated, so that the crossover wire 8 is formed into a predetermined core in the same manner as shown above. Let it pass to part 60. At this time, the chuck mechanism 40 rotates at a pitch of 60 °. That is, the fourth core portion 64 moves by repeating the rotation of 60 ° pitch three times to the position of the chuck 41 to which the first core portion 61 is fixed in the first winding. The other core portion 60 also moves at the same time. Since the material is discharged from the position of the chuck 46, the stator core 1 is not fixed at the position of the chuck 45.

According to this method, the coil wire 70 can be wound around the teeth 12 to form the coil 7 by ensuring a wide space between the teeth 12 adjacent to each other in the circumferential direction Z. That is, as shown in FIG. 16, the rotation shafts T, M, and N of the winding nozzles 54, 55, and 56 can always be wound toward the teeth 12. Therefore, the coil wire 70 can be wound around the teeth 12 at high speed, and the winding cycle time can be shortened. Since the method for manufacturing the stator of the rotary electric machine shown in the first embodiment can be similarly performed in the following embodiments, the description thereof will be omitted as appropriate.

According to the stator of the rotary electric machine of the first embodiment configured as described above,
A stator core having a plurality of teeth formed on the inner peripheral surface of the yoke portion arranged in an annular shape and the inner peripheral surface of the yoke portion in the radial direction so as to project inward in the radial direction at predetermined intervals in the circumferential direction. And a stator of a rotary electric machine provided with a coil formed by winding a coil wire around each of the plurality of teeth, and an insulating portion disposed between the stator core and the coil to insulate the stator core and the coil. And,
The insulating portion has a first protruding portion protruding from one side in the axial direction from the stator core, and has a groove portion having a plurality of steps in the axial direction on the outer peripheral surface on the outer peripheral surface in the radial direction of the first protruding portion. death,
The winding start wire, the winding end wire, and the crossover wire connecting the coils of the different teeth are all installed in the first protruding portion of the insulating portion in the same direction in the axial direction.
The winding start wire is continuous with the groove portion formed in the first protrusion of the insulation portion on the side closest to the stator core in the axial direction, and has a diameter from the outside in the radial direction of the first protrusion. An introduction that is formed so as to communicate with the inside of the direction and has an inclined surface along the axial direction in which the width in the circumferential direction gradually decreases from the side opposite to the stator core in the axial direction toward the stator core side to hold the coil wire. Placed in the groove,
The crossover is a continuous line diagonally arranged from the side opposite to the stator core in the axial direction of the insulating portion toward the stator core side in the axial direction while crossing between different teeth, and is held in the groove portion. Because it will be done
Also, according to the rotary electric machine,
Since the stator is provided with a rotor arranged so as to face each other via an air gap,
In addition, according to the manufacturing method of the rotary electric machine,
Since the rotor was placed facing the stator manufactured by the method for manufacturing a stator of a rotary electric machine described above via an air gap,
Interference of crossovers can be prevented, wiring members can be reduced, manufacturing time can be shortened, and productivity can be improved.

Further, since the groove portion is formed so as to be inclined in the axial direction,
The inclination of the groove can reliably prevent the interference of the crossover of the stator core.

Further, the groove portion of the first protruding portion of the insulating portion is formed by four stages of a first groove portion, a second groove portion, a third groove portion, and a fourth groove portion from a side away from the stator core in the axial direction.
The crossover connects the coils of the teeth separated by three in the circumferential direction, and the first protrusions sequentially adjacent to the first groove portion in the circumferential direction up to the teeth separated by three in the circumferential direction. Since it is continuously held in the second groove portion, the third groove portion, and the fourth groove portion of the portion,
Since the coil wire is wound between three teeth separated in the circumferential direction to form a coil, the crossover wire of another phase and the winding start wire of the coil wire do not interfere with each other. It is possible to obtain a stator in which pulsation and vibration can be prevented and the electrical characteristics are stable, while suppressing the above.

Further, the first protruding portion of the insulating portion is continuous with the groove portion on the side closest to the stator core in the axial direction, and communicates from the radial outer side to the radial inner side of the first protruding portion. Since it is formed and has an introduction groove for holding the coil wire,
The coil wire can be easily guided to the teeth side.

Further, the first protruding portion of the insulating portion is continuous with the groove portion on the side farthest from the stator core in the axial direction, and is continuous from the radial inside to the radial outside of the first protruding portion. And has a lead-out groove that holds the crossover.
The crossover can be easily guided to the place where the groove of the first protrusion is formed.

Further, the first protruding portion of the insulating portion has a diameter at one end in the circumferential direction of the groove portion other than the groove portion on the side farthest from the stator core in the axial direction from the outside in the radial direction of the first protruding portion. Since it is continuously formed inside the direction and has a power supply groove for holding the coil wire,
The coil wire can be easily guided inward in the radial direction of the stator core.

Further, since the yoke portion is formed so as to be deformable in a linear shape or in a reverse warp shape in which the direction in which the teeth project in the radial direction is reversed.
The coil wire can be easily wound around the teeth of the stator core.

Further, according to the manufacturing method of the stator of the rotary electric machine,
The yoke portion of the stator core is deformed in a straight line, and the three coil wires are simultaneously wound by three winding nozzles along a trajectory along the shape of the three teeth continuous in the circumferential direction. After forming the coil on the tooth, the three coil wires are held in the groove portion of the first protrusion of the three teeth as the crossover wire, and the coil wires are separated from each other by three in the circumferential direction. I will move to Teeth, so
A coil can be formed by winding a continuous coil wire around three consecutive teeth in the circumferential direction. As a result, the number of wiring members can be reduced, and the product cost can be suppressed.
The number of teeth, which is the number of core portions, may be 3.N (N is an integer of 2 or more).

Further, according to the manufacturing method of the stator of the rotary electric machine,
The yoke portion of the stator core is deformed in a reverse warp shape, and the three coil wires are simultaneously wound by three winding nozzles along a trajectory along the shape of three consecutive teeth in the circumferential direction. After forming the coil on the teeth, the three coil wires were held in the grooves of the first protrusions of the three teeth as the crossovers, respectively, and separated by three in the circumferential direction. As it moves to the teeth,
A coil can be formed by winding a continuous coil wire for three consecutive teeth in the circumferential direction at high speed. As a result, the number of wiring members can be reduced, and the product cost can be suppressed.

Embodiment 2.
FIG. 17 is a perspective view showing a state in which the yoke portion 11 of the stator core 1 is linearly deformed in the stator of the rotary electric machine according to the second embodiment, and the upper winding frame 20, the lower winding frame 30, and the film portion 230 are attached as insulating portions. be. FIG. 18 is an exploded perspective view showing a state before the upper winding frame 20, the lower winding frame 30, and the film portion 230 are mounted on the stator core 1 on the stator shown in FIG. FIG. 19 is a perspective view showing the configuration of the film portion 230 shown in FIG. FIG. 20 is a perspective view showing the configuration of the upper winding frame 20 shown in FIG. FIG. 21 is a perspective view showing the configuration of the lower winding frame 30 shown in FIG.

In the figure, the same parts as those in the first embodiment are designated by the same reference numerals and the description thereof will be omitted. As shown in the figure, the stator 100 of the second embodiment has a different configuration of the upper winding frame 2 and the lower winding frame 3 as an insulating portion for insulating the stator core 1 and the coil 7 shown in the first embodiment. In the second embodiment, in order to insulate the stator core 1 and the coil 7, the insulating portion is composed of an upper winding frame 20, a lower winding frame 30, and a film portion 230.

The upper winding frame 20 and the lower winding frame 30 have a first protruding portion 21 of the upper winding frame 2 and a second protruding portion 31 of the lower winding frame 3 in the first embodiment, and the first leg portion 22 and the second leg portion 32 are provided. It is a configuration that does not have. Further, the first protruding portion 21 includes claw portions 211, 212, 213, and 214 for fixing the film portion 230, which will be described later. Further, the second protruding portion 31 includes a claw portion 311, 312, 313, 314 for fixing the film portion 230. Further, the lower winding frame 30 includes a convex portion 315. The stator core 1 includes a second recess 115 formed in the tooth 12 in the axial direction Y. The convex portion 315 of the lower winding frame 30 is fitted and installed in the second concave portion 115 of the stator core 1.

The film portion 230 is formed of a thin-walled insulating film material, and it is conceivable to use, for example, a film material having a thickness of 0.125 mm. Then, the film material is formed by making creases in the shape as shown in FIG. Due to this crease, the film portion 230 is a side surface of the first side surface 231 covering the inner peripheral surface 112 which is the side surface of the inner X2 of the yoke portion 11 in the radial direction X in the axial direction Y, and the side surface of the teeth 12 in the axial direction Y. It includes one side surface 121, a second side surface 232 covering the second side surface 131, and a third side surface 233 covering the tip surface 122, which is the side surface of the teeth 12 in the axial direction Y. Further, when the film portion 230 is attached to the stator core 1, it is connected to the first protruding portion 21 and the second protruding portion 31 in the axial direction Y. Further, the film portion 230 is continuously formed corresponding to all of the core portions 61 to 69 of the stator core 1.

The connection of the film portion 230 with respect to the first protruding portion 21 of the upper winding frame 20 and the second protruding portion 31 of the lower winding frame 30 in the axial direction is specifically such that the stator core 1 is connected at both ends of the axial direction Y of the film portion 230. It is formed longer than the length in the axial direction Y and corresponds to it. A portion formed longer than both ends of the stator core 1 of the film portion 230 in the axial direction is formed on the claw portions 212, 212, 213, 214 of the upper winding frame 20 and the claw portions 311, 312, 313, 314 of the lower winding frame 30. Each is fixed. The other configurations and the method for manufacturing the stator of the rotary electric machine are the same as those in the first embodiment.

The stator of the rotary electric machine of the second embodiment configured as described above is
The insulating portion includes a second protruding portion protruding from the other side in the axial direction from the stator core, and a second protruding portion.
Since it is provided with a film portion that is axially connected to the first protrusion and the second protrusion and that covers the axial side surface of the tooth and the radial inner axial side surface of the yoke portion. The insulating portion can be formed of a thin film portion, and the same effect as that of the first embodiment can be obtained.

The present disclosure describes various exemplary embodiments and examples, although the various features, embodiments, and functions described in one or more embodiments are those of a particular embodiment. It is not limited to application, but can be applied to embodiments alone or in various combinations.
Therefore, innumerable variations not illustrated are envisioned within the scope of the techniques disclosed herein. For example, it is assumed that at least one component is modified, added or omitted, and further, at least one component is extracted and combined with the components of other embodiments.

1 Stator core, 10 rotary electric machine, 11 yoke part, 12 teeth, 13 shoe part, 100 stator, 101 housing, 102 rotor, 103 bearing, 104 shaft, 105 permanent magnet, 106 rotor core, 107 air gap, 111 connection part, 112 inside Peripheral surface, 113 outer peripheral surface, 114 first concave portion, 115 second concave portion, 121 first side surface, 122 tip surface, 131 second side surface, 14 slots, 2 upper winding frame, 20 upper winding frame, 201 outer peripheral surface, 202 inner peripheral surface , 21 1st protruding part, 211 claw part, 212 claw part, 213 claw part, 214 claw part, 22 1st leg part, 230 film part, 3 lower winding frame, 30 lower winding frame, 31 second protruding part, 311 claw part 312 claws, 313 claws, 314 claws, 315 convex parts, 32 second legs, 40 chuck mechanism, 400 winding machines, 41 chucks, 42 chucks, 43 chucks, 44 chucks, 45 chucks, 46 chucks, 51 winding nozzle, 52 winding nozzle, 53 winding nozzle, 54 winding nozzle, 55 winding nozzle, 56 winding nozzle, 6 core plate, 60 core part, 61 first core part, 62 second core part, 63 3rd core part, 64 4th core part, 65 5th core part, 66 6th core part, 67 7th core part, 68 8th core part, 69 9th core part, 7 coils, 70 coil wires, 700 Neutral point, 71 1st coil line, 711 1st volume start line, 712 1st volume end line, 713 1st power supply line, 72 2nd coil line, 721 2nd volume start line, 722 2nd volume end line, 723 2nd power supply line, 73 3rd coil line, 731 3rd volume start line, 732 3rd volume end line, 733 3rd power supply line, 8 crossover line, 81 1st crossover line, 82 2nd crossover line, 83rd Three crossovers, 84 fourth crossovers, 85 fifth crossovers, 86 sixth crossovers, 9 grooves, 91 first grooves, 92 second grooves, 93 third grooves, 94 fourth grooves, 95 introduction grooves, 950. Inclined surface, 96 Outlet groove, 97 1st power groove, 98 2nd power groove, 99 3rd power groove, T rotation axis, M rotation axis, N rotation axis, X radial direction, X1 outside, X2 inside, Y axis direction , Z circumference Mukai.

Claims (12)

A stator core having a plurality of teeth formed on the inner peripheral surface of the yoke portion arranged in an annular shape and the inner peripheral surface of the yoke portion in the radial direction so as to project inward in the radial direction at predetermined intervals in the circumferential direction. And a stator of a rotary electric machine provided with a coil formed by winding a coil wire around each of the plurality of teeth, and an insulating portion disposed between the stator core and the coil to insulate the stator core and the coil. And,
The insulating portion has a first protruding portion protruding from one side in the axial direction from the stator core, and has a groove portion having a plurality of steps in the axial direction on the outer peripheral surface on the outer peripheral surface in the radial direction of the first protruding portion. death,
The winding start wire, the winding end wire, and the crossover wire connecting the coils of the different teeth are all installed in the first protruding portion of the insulating portion in the same direction in the axial direction.
The winding start wire is continuous with the groove portion formed in the first protrusion of the insulation portion on the side closest to the stator core in the axial direction, and has a diameter from the outside in the radial direction of the first protrusion. An introduction that is formed so as to communicate with the inside of the direction and has an inclined surface along the axial direction in which the width in the circumferential direction gradually decreases from the side opposite to the stator core in the axial direction toward the stator core side to hold the coil wire. Placed in the groove,
The crossover is a continuous line diagonally arranged from the side opposite to the stator core in the axial direction of the insulating portion toward the stator core side in the axial direction while crossing between different teeth, and is held in the groove portion. Being done
The inclined surface is a stator of a rotary electric machine formed in the first protruding portion where the groove portion is not provided . The stator of a rotary electric machine according to claim 1, wherein the groove portion is formed so as to be inclined in the axial direction. The groove portion of the first protruding portion of the insulating portion is formed by four stages of a first groove portion, a second groove portion, a third groove portion, and a fourth groove portion from a side away from the stator core in the axial direction.
The crossover connects the coils of the teeth separated by three in the circumferential direction, and the first protrusions sequentially adjacent to the first groove portion in the circumferential direction up to the teeth separated by three in the circumferential direction. The stator of the rotary electric machine according to claim 1 or 2, which is continuously held in the second groove portion, the third groove portion, and the fourth groove portion. The crossover connects the coil of one tooth and the coils of the other teeth three apart in the circumferential direction, and further, the coil of the other teeth and the coil of the other teeth in the circumferential direction. The stator of the rotary electric machine according to any one of claims 1 to 3, wherein the coils of the other teeth, which are further separated by three, are connected to each other. The first protruding portion of the insulating portion is continuously formed in the groove portion on the side farthest from the stator core in the axial direction, and is continuously formed from the radial inside to the radial outside of the first protruding portion. The stator of the rotary electric machine according to any one of claims 1 to 4 , further comprising a lead-out groove portion for holding the crossover. The first protruding portion of the insulating portion is radially located at one end in the circumferential direction of the groove portion other than the groove portion on the side farthest from the stator core in the axial direction from the radial outside of the first protruding portion. The stator of a rotary electric machine according to any one of claims 1 to 5 , which is continuously formed inside and has a power supply groove portion for holding the coil wire. The insulating portion includes a second protruding portion protruding from the other side in the axial direction from the stator core, and a second protruding portion.
A claim comprising a film portion that is axially connected to the first protrusion and the second protrusion and that covers the axial side surface of the tooth and the radial inner axial side surface of the yoke portion. The stator of the rotary electric machine according to any one of claims 1 to 6 . The rotary electric machine according to any one of claims 1 to 7 , wherein the yoke portion is deformably formed in a linear shape or in a reverse warp shape in which the direction in which the teeth protrude in the radial direction is reversed. Stator. The stator of the rotary electric machine according to any one of claims 1 to 8 ,
A rotary electric machine provided with a rotor arranged opposite to the stator via an air gap. In the method for manufacturing a stator of a rotary electric machine according to claim 8 .
The yoke portion of the stator core is deformed in a straight line, and the three coil wires are simultaneously wound by three winding nozzles along a trajectory along the shape of the three teeth continuous in the circumferential direction. After forming the coil on the tooth, the three coil wires are held in the groove of the first protrusion of the three teeth as the crossover, and the coil wires are separated by three in the circumferential direction. When moving to the teeth and crossing the three crossovers, the stator of the rotary electric machine forms the crossover so that the three crossovers do not interfere with each other while rotating the three winding nozzles once. Manufacturing method. In the method for manufacturing a stator of a rotary electric machine according to claim 8 ,
The yoke portion of the stator core is deformed in a reverse warp shape, and the three coil wires are simultaneously wound by three winding nozzles along a track along the shape of three consecutive teeth in the circumferential direction. After forming the coil on the teeth, the three coil wires were held in the grooves of the first protrusions of the three teeth as the crossovers, respectively, and separated by three in the circumferential direction. A method for manufacturing a stator of a rotary electric machine, which forms a crossover so that the three crossovers do not interfere with each other when the three crossovers are crossed by rotating the stator core to move to the teeth. A method for manufacturing a rotary electric machine in which a rotor is arranged so as to face the stator manufactured by the method for manufacturing a stator for a rotary electric machine according to claim 10 or 11 .

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