CN111033953A - Stator, motor provided with the stator, compressor provided with the motor, and air conditioner provided with the compressor - Google Patents

Stator, motor provided with the stator, compressor provided with the motor, and air conditioner provided with the compressor Download PDF

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Publication number
CN111033953A
CN111033953A CN201880050812.3A CN201880050812A CN111033953A CN 111033953 A CN111033953 A CN 111033953A CN 201880050812 A CN201880050812 A CN 201880050812A CN 111033953 A CN111033953 A CN 111033953A
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China
Prior art keywords
insulating sheet
stator
insulating
sheet
tooth
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CN201880050812.3A
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CN111033953B (en
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石嵜明宣
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Daikin Industries Ltd
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Daikin Industries Ltd
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    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K3/00Details of windings
    • H02K3/32Windings characterised by the shape, form or construction of the insulation
    • H02K3/34Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Insulation, Fastening Of Motor, Generator Windings (AREA)

Abstract

An insulating member arranged between a plurality of teeth (53) of a stator core (51) of a stator (50) and a coil (55) includes a first insulating sheet (60B) and a second insulating sheet (60C) that cover a slot portion (56). The number of bends of the second insulating sheet (60C) is smaller than the number of bends of the first insulating sheet (60B), and the second insulating sheet (60C) is bent into a shape such that, when the stator (50) is viewed in plan: the shape of the portion of the slot portion (56) closer to the back yoke (52) than the tip of the tooth portion (53).

Description

Stator, motor provided with the stator, compressor provided with the motor, and air conditioner provided with the compressor
Technical Field
The present invention relates to a stator, a motor provided with the stator, a compressor provided with the motor, and an air conditioner provided with the compressor.
Background
In a compressor motor provided in an outdoor unit of an air conditioner, an insulating member for insulating a stator core made of an electromagnetic steel sheet from a coil is disposed between the stator core and the coil. The insulating member has an insulating sheet that is inserted into the slot portions of the stator core and covers side surfaces of the tooth portions of the stator core. In such an insulating sheet, in order to extend the insulation distance between the teeth and the coil, a plurality of insulating sheets may be inserted into the slot portions in a stacked state (see, for example, patent documents 1 and 2).
Documents of the prior art
Patent document
Patent document 1: japanese patent laid-open publication No. 2014-50290
Patent document 2: japanese patent laid-open publication No. 2010-115040
Disclosure of Invention
Problems to be solved by the invention
However, when the insulating sheet is inserted into the slot portion, the insulating sheet needs to be bent in advance into the same shape as the slot portion in order to ensure ease of insertion. However, if the shape of the insulating sheet becomes complicated, the number of times of bending the insulating sheet increases, and the production facility for manufacturing the insulating sheet becomes complicated.
The present invention has been made in view of the above circumstances, and an object thereof is to provide a stator that facilitates simplification of production facilities, a motor provided with the stator, a compressor provided with the motor, and an air conditioner provided with the compressor.
Means for solving the problems
The stator for solving the problem is a stator comprising: a stator core having an annular back yoke and a plurality of teeth extending in a radial direction from the back yoke; a coil formed by winding a wire around the plurality of teeth; and an insulating member disposed between the plurality of tooth portions and the coil and electrically insulating the stator core from the coil, wherein the insulating member includes a plurality of insulating sheets, a side surface of a portion of the stator core constituting a slot portion is covered with the plurality of insulating sheets, the slot portion is formed by the tooth portions adjacent in a circumferential direction and the back yoke connecting the tooth portions, the plurality of insulating sheets are inserted into the slot portion in a state of being bent and overlapping each other, and the plurality of insulating sheets include: a first insulating sheet of a first number of bends; and a second insulating sheet having a smaller number of bends than the first number of bends, the second insulating sheet being bent in a shape such that, when the stator is viewed from above: a shape along a portion of the slot portion closer to the back yoke side than a tip of the tooth portion.
According to this configuration, direct contact between the coil and the tooth portion can be suppressed between the entire tooth portion and the coil by the first insulating sheet. Further, since the number of bends of the second insulation sheet is smaller than the number of bends of the first insulation sheet, and the second insulation sheet is bent into such a shape: along the shape of the portion on the back yoke side than the tip of the tooth portion, therefore, the structure of the portion where the second insulating sheet is manufactured can be simplified in the production apparatus for manufacturing the first insulating sheet and the second insulating sheet.
In the stator, it is preferable that the teeth have a wide width portion enlarged in the circumferential direction at the tip thereof, and the first insulating sheet covers the wide width portion and extends toward the teeth adjacent in the circumferential direction.
According to the above configuration, since the first insulating sheet covers the wide width portion and extends toward the teeth adjacent in the circumferential direction, the insulating distance between the coil and the teeth can be extended. Therefore, the insulation durability can be improved.
In the stator, it is preferable that the insulating member has cover members that cover both end surfaces of the tooth portion in the axial direction, the cover members include tip cover portions that cover tip ends of the tooth portion and at least a part of a wide portion, the tip cover portions protrude from the wide portion toward the back yoke, and the coil is in contact with the tip cover portions in the radial direction.
According to this structure, the shortest distance between the coil at the tip of the tooth and the wide portion of the tooth is longer than the shortest distance between the coil at the other portion of the tooth and the tooth. Therefore, leakage current between the coil and the stator coil can be reduced.
In the stator, it is preferable that the first insulating sheet is disposed on the coil side, the second insulating sheet is disposed on the tooth portion side, and a thickness of the second insulating sheet is thinner than a thickness of the first insulating sheet.
According to this configuration, the second insulating sheet on the tooth portion side having a small thickness can be pressed against the side surfaces of the tooth portion by the first insulating sheet on the coil side having a large thickness, and therefore, the first insulating sheet and the second insulating sheet can be arranged along the side surfaces of the tooth portion. Therefore, when the wire is wound around the teeth by the winding machine, the nozzle of the winding machine can be prevented from contacting the first insulating sheet.
In the stator, it is preferable that the insulating member includes cover members that cover both end surfaces of the tooth portion in the axial direction, and an axial length of an insulating sheet disposed closest to the tooth portion among the plurality of insulating sheets is shorter than axial lengths of the other insulating sheets.
When the cover members are attached to both end surfaces in the axial direction of the tooth portions after the plurality of insulating sheets are inserted into the slot portions, the insulating sheet closest to the tooth portion among the plurality of insulating sheets is highly likely to contact the cover members. Since the insulating sheet closest to the teeth portion side is in contact with the cover member, the insulating sheet is bent and may be sandwiched between the cover member and the end face of the teeth portion in the axial direction.
In this regard, according to the above configuration, since the axial length of the insulating sheet closest to the tooth portion among the plurality of insulating sheets is shorter than the axial lengths of the other insulating sheets, when the cover members are attached to both end surfaces in the axial direction of the tooth portion, the insulating sheet closest to the tooth portion comes into contact with the cover members, and the insulating sheet is bent and sandwiched between the cover members and the end surfaces in the axial direction of the tooth portion.
In the stator, it is preferable that the second insulation sheet is disposed closest to the tooth portion side, an axial length of the first insulation sheet is longer than an axial length of the tooth portion, and the axial length of the second insulation sheet is shorter than the axial length of the first insulation sheet.
According to this configuration, the length of the second insulation sheet protruding in the axial direction from the end surface of the tooth portion in the axial direction is shorter than in the case where the axial length of the first insulation sheet and the axial length of the second insulation sheet are equal to each other. Therefore, the second insulating sheet is not easily sandwiched between the end face of the tooth portion in the axial direction and the cover member.
In the stator, it is preferable that an axial length of the second insulation sheet is equal to an axial length of the tooth portion.
According to this configuration, the length of the second insulating sheet protruding from the end surface in the axial direction of the tooth portion in the axial direction becomes shorter or the second insulating sheet does not protrude from the end surface in the axial direction of the tooth portion, as compared with the case where the axial length of the first insulating sheet and the axial length of the second insulating sheet are equal to each other. Therefore, the second insulating sheet is less likely to be sandwiched between the end surfaces of the teeth in the axial direction and the cover member.
In the stator, it is preferable that a length of the first insulation sheet is longer than a length of the second insulation sheet in a circumferential direction of the slot portion.
In the stator, it is preferable that the first insulating sheet has a distal end portion which is arranged on a distal end side of the tooth portion and turns back to the back yoke side.
The motor to solve the above problem includes the stator and a rotor that faces the stator in the radial direction and rotates by a magnetic field formed by the stator.
With this configuration, the same effect as that of the stator can be obtained.
The compressor for solving the above problems includes the motor and a compression mechanism driven by the motor.
With this configuration, the same effect as that of the motor can be obtained.
An air conditioner that solves the problem is provided with the compressor.
With this configuration, the same effect as that of the compressor can be obtained.
Effects of the invention
According to the stator, the motor with the stator, the compressor with the motor and the air conditioner with the compressor, the production equipment can be simplified.
Drawings
Fig. 1 is a schematic diagram showing an air conditioner according to the present embodiment.
Fig. 2 is a longitudinal sectional view of a compressor of an air conditioner.
Fig. 3 is a cross-sectional view taken along line 3-3 of fig. 2.
Fig. 4 is an exploded perspective view of a stator core and first and second insulation sheets in a stator of a motor of a compressor.
Fig. 5 is a top sectional view of the stator.
Fig. 6 is a plan view of the first insulating sheet.
Fig. 7 is a plan view of the second insulation sheet.
Fig. 8 is a longitudinal sectional view of the tooth portion and the periphery thereof in a state where the insulating member is attached to the stator core.
Fig. 9(a) is a plan view of the stator, and (b) is an enlarged view of a one-dot chain line circle of (a).
Fig. 10 is a schematic view of a production apparatus for manufacturing the first insulating sheet and the second insulating sheet.
Fig. 11 is a top sectional view of a stator according to a modification.
Fig. 12 is a top cross-sectional view of a stator according to another modification.
Detailed Description
As shown in fig. 1, the air conditioner 1 is a heat pump type air conditioner including: the refrigerant is reversibly circulated by connecting the compressor 10, the four-way switching valve 2, the outdoor heat exchanger 3, the expansion valve 4, and the indoor heat exchanger 5 in a ring shape by the pipe 6 and switching the four-way switching valve 2.
That is, the air conditioner 1 forms a refrigeration cycle in which the refrigerant circulates through the compressor 10, the four-way switching valve 2, the outdoor heat exchanger 3, the expansion valve 4, the indoor heat exchanger 5, the four-way switching valve 2, and the compressor 10 in this order by switching the four-way switching valve 2 to the cooling mode connection state (the state shown by the solid line). Thus, the air conditioner 1 performs a cooling operation in which the outdoor heat exchanger 3 functions as a condenser and the indoor heat exchanger 5 functions as an evaporator. The air conditioner 1 forms a heating cycle in which the refrigerant circulates through the compressor 10, the four-way switching valve 2, the indoor-side heat exchanger 5, the expansion valve 4, the outdoor-side heat exchanger 3, the four-way switching valve 2, and the compressor 10 in this order by switching the four-way switching valve 2 to the heating mode connection state (the state indicated by the broken line). Thus, the air conditioner 1 performs a heating operation in which the indoor-side heat exchanger 5 functions as a condenser and the outdoor-side heat exchanger 3 functions as an evaporator.
As shown in fig. 2 and 3, the compressor 10 is an oscillating piston type compressor, and includes: a compression mechanism 20; a motor 30; a crankshaft 11 for transmitting the driving force of the motor 30 to the compression mechanism 20; a casing 12 accommodating the compression mechanism 20, the motor 30, and the crankshaft 11; and a gas-liquid separator 13 for performing gas-liquid separation of the refrigerant. The gas-liquid separator 13 is disposed on the side of the housing 12 and is connected to the housing 12 via a suction pipe 14. The motor 30 is disposed above the housing 12 and the compression mechanism 20 is disposed below the housing 12 in a direction in which the crankshaft 11 extends (hereinafter, simply referred to as "axial direction"). A reservoir 16 for storing lubricating oil is formed in the lower portion of the housing 12 than the compression mechanism 20. A discharge pipe 15 for discharging the refrigerant is provided at an upper end portion of the casing 12. The discharge pipe 15 is connected to the pipe 6 (see fig. 1).
The compression mechanism 20 includes: a cylinder 21 attached to the housing 12; a roller piston 22 housed in a cylinder chamber 21a of the cylinder 21; a front end plate 23 and a rear end plate 24 that axially cover both sides of the cylinder chamber 21 a; and a muffler 25 for reducing the sound of the refrigerant flowing therethrough. The muffler 25 is attached to the front end plate 23.
As shown in fig. 3, the cylinder 21 further includes: a blade housing chamber 21b having a shape in which two circles are arranged in a plan view; a suction port 21c that communicates the suction pipe 14 with the cylinder chamber 21 a; and a discharge port 21d formed in the vicinity of the cylinder chamber 21a and the blade housing chamber 21 b. The cylinder chamber 21a has a circular shape in plan view. The cylinder chamber 21a communicates with the vane housing chamber 21 b. The swing bush 26 is slidably attached to a portion of the vane housing chamber 21b on the cylinder chamber 21a side. A discharge valve 27 (see fig. 2) is attached to the discharge port 21 d. One example of the discharge valve 27 is a reed valve.
The roller piston 22 is formed such that a substantially cylindrical roller portion 22a and a rod-shaped vane portion 22b are formed integrally and inseparably. The eccentric portion 11a of the crankshaft 11 is slidably fitted to the roller portion 22 a. The blade 22b is slidably fitted to the swing bush 26. The cylinder chamber 21a is divided by the roller piston 22 into a compression chamber HR on the discharge port 21d side and a suction chamber LR on the suction port 21c side. The center CA of the roller portion 22a is located at the same position as the center CB of the eccentric portion 11a, and is different from the center CC of the cylinder chamber 21 a. The center CC of the cylinder chamber 21a is the same position as the rotation center of the crankshaft 11. As the crankshaft 11 is rotated by the motor 30, the vane portions 22b oscillate, and the roller portions 22a revolve orbitally, so that the refrigerant is drawn from the suction port 21c into the suction chamber LR and compressed in the compression chamber HR. The compressed high-pressure refrigerant is discharged into the muffler 25 through the discharge port 21 d. Since the space in the muffler 25 is sufficiently larger than the opening of the discharge port 21d, noise of the refrigerant discharged into the muffler 25 is reduced.
As shown in fig. 2, the motor 30 is an inner rotor type three-phase brushless motor, and includes a rotor 40 and a stator 50.
The rotor 40 is a magnet embedded type rotor having a rotor core 41 fixed to the crankshaft 11 and a plurality of plate-shaped permanent magnets 42. The rotor core 41 is formed by laminating thin electromagnetic steel plates in the axial direction. The permanent magnets 42 are embedded in the rotor core 41. The shape of the permanent magnet 42 can be set arbitrarily. In one example, the permanent magnet 42 is a flat plate.
As shown in fig. 2 and 4, the stator 50 includes a stator core 51, and the stator core 51 is formed by laminating thin electromagnetic steel plates in the axial direction. The stator core 51 is fixed to the housing 12 by, for example, shrink fitting. The stator core 51 includes an annular back yoke 52 and a plurality of teeth 53 extending radially inward from the back yoke 52. Further, the stator core 51 has a slot portion 56, and the slot portion 56 is a portion surrounded by the circumferentially adjacent teeth 53 and the back yoke 52 connecting these teeth 53. A wide portion 53a extending in the circumferential direction is formed at the tip of the tooth portion 53. The wide portion 53a has a shape that tapers toward the circumferential end in plan view.
The stator 50 further includes: a coil 55 formed of a so-called concentrated winding formed by winding a conductive wire 54 around each tooth portion 53; and an insulating member 60 disposed between the stator core 51 and the coil 55.
The insulating member 60 includes: a pair of cover members 60A (see fig. 2) that cover both end surfaces of the stator core 51 in the axial direction; and a first insulating sheet 60B and a second insulating sheet 60C (see fig. 4) that cover the inner side surface of the back yoke 52 and the circumferential side surface of the tooth portion 53.
The detailed structure of the insulating member 60 will be described with reference to fig. 4 to 9. In fig. 4 to 9, for convenience of explanation, the first insulating sheet 60B is separated from the second insulating sheet 60C, and the second insulating sheet 60C is separated from the stator core 51, but actually, the first insulating sheet 60B is in contact with the second insulating sheet 60C, and the second insulating sheet 60C is in contact with the stator core 51.
As shown in fig. 4 and 5, the first insulation sheet 60B and the second insulation sheet 60C are inserted into the respective slot portions 56 of the stator core 51 in a state of being overlapped with each other. The first insulating sheet 60B is disposed on the coil 55 side, and the second insulating sheet 60C is disposed on the stator core 51 side. As shown in fig. 5, the second insulating sheet 60C is arranged at the position closest to the tooth portions 53 side of the plurality of insulating sheets. The first insulation sheet 60B is thicker than the second insulation sheet 60C. In one example, the thickness of the first insulation sheet 60B is 2 times or more the thickness of the second insulation sheet 60C. More specifically, the thickness of the first insulating sheet 60B is 2 times or more and 3 times or less the thickness of the second insulating sheet 60C. The first insulating sheet 60B and the second insulating sheet 60C are formed of a resin material such as polyethylene terephthalate (PET).
As shown in fig. 4 and 5, the shape of the first insulating sheet 60B and the shape of the second insulating sheet 60C are different from each other in plan view. Specifically, the first insulating piece 60B covers the side surface of the back yoke 52 in the slot portion 56 from the side surface to the tip of the tooth portion 53, that is, the side surface in the circumferential direction of the wide portion 53 a. The second insulation sheet 60C covers a side surface of the portion of the slot portion 56 on the back yoke 52 side from the side surface of the back yoke 52 to the tip of the tooth portion 53 in the circumferential direction. That is, the second insulation sheet 60C does not cover the circumferential side surfaces of the wide portions 53a, which are the tips of the tooth portions 53.
More specifically, as shown in fig. 5 and 6, the first insulating sheet 60B has: a pair of tooth cover portions 64A that cover circumferentially opposite side surfaces of the circumferentially adjacent tooth portions 53; a back yoke cover portion 65A that covers an inner side surface of the back yoke 52, the back yoke 52 connecting circumferentially adjacent teeth 53 in the circumferential direction; and a tip cover portion 66 that covers circumferential side surfaces of the tip of the tooth portion 53. The first insulating sheet 60B also has an extension portion 67, and the extension portion 67 extends in the circumferential direction while being bent radially outward from the end cover portion 66. The first insulating sheet 60B is formed by bending a sheet-shaped base material with a press die, and integrally includes a pair of tooth cover portions 64A, a back yoke cover portion 65A, a pair of end cover portions 66, and a pair of extension portions. As shown in fig. 6, the first insulating sheet 60B has six folds of FA1 to FA 6. The pair of tooth cover portions 64A are bent with respect to the back yoke cover portion 65A, respectively, to form creases FA1, FA 2. The end cover portions 66 are bent with respect to the respective tooth cover portions 64A, thereby forming creases FA3, FA 4. The extension 67 is bent with respect to each end cover 66, thereby forming creases FA5, FA 6.
As shown in fig. 5 and 7, the second insulating sheet 60C has a substantially U-shape in plan view. The second insulating sheet 60C has: a pair of tooth cover portions 64B that cover circumferentially opposite side surfaces of the circumferentially adjacent tooth portions 53; and a back yoke cover portion 65B that covers an inner side surface of the back yoke 52, the back yoke 52 connecting circumferentially adjacent teeth 53 in the circumferential direction. In the second insulating sheet 60C, a pair of tooth cover portions 64B and a back yoke cover portion 65B are integrally formed by bending a single sheet-shaped base material with a press die. As shown in fig. 5, the pair of tooth cover portions 64B do not cover the tip ends (wide portions 53a) of the tooth portions 53. That is, the tooth cover portion 64B covers a portion of the tooth portion 53 radially outward (the back yoke 52 side) of the wide portion 53 a. As shown in fig. 7, the second insulation sheet 60C has two folds FB1 and FB 2. That is, the number of bends of the second insulating sheet 60C is smaller than the number of bends of the first insulating sheet 60B. The pair of tooth cover portions 64B are bent with respect to the back yoke cover portion 65B, respectively, to form fold lines FB1, FB 2.
As shown in fig. 8, the length L1 of the first insulating sheet 60B is longer than the length L3 of the stator core 51 (L1> L3). The axial length L2 of the second insulation sheet 60C is shorter than the axial length L1 of the first insulation sheet 60B (L1> L2). Preferably, the axial length L2 of the second insulation sheet 60C is equal to the axial length L3 of the stator core 51 (tooth 53) (L2 — L3). More preferably, both end surfaces in the axial direction of the second insulation sheet 60C are coplanar with both end surfaces in the axial direction of the stator core 51 (the tooth portions 53).
As shown in fig. 9(a), the cover member 60A is made of a resin material, and includes: a ring-shaped back yoke cover portion 61 that covers the back yoke 52; and a linear tooth cover portion 62 covering each tooth portion 53. The back yoke cover portion 61 and the tooth cover portion 62 are integrally formed. The tooth cover portion 62 extends radially inward from the back yoke cover portion 61. The width dimension in the circumferential direction of the tooth cover portion 62 is equal to the width dimension in the circumferential direction of the tooth portion 53. In the tooth cover portion 62, a tip cover portion 63 is provided at a tip of the tooth cover portion 62, that is, a portion covering a tip of each tooth portion 53. The tip cover portion 63 extends from the tooth cover portion 62 in the axial direction. That is, the tip cover portion 63 covers the tip of the tooth portion 53 and at least a part of the wide portion 53a from the axial direction. The tip cover 63 of the present embodiment covers a portion of the tooth portion 53 slightly radially outward of the tip edge of the tooth portion 53. The shape of the tip cover 63 is different from the shape of the tip (wide part 53a) of the tooth part 53.
As shown in fig. 9(B), a groove 63a into which the first insulating sheet 60B is inserted is formed on the rear surface side of the distal end cover portion 63 of the cover member 60A. The position of the first insulating sheet 60B in the axial direction is determined by this groove 63 a. Further, in order to suppress a decrease in strength of the terminal cover portion 63 caused by the groove 63a, the radial width of the terminal cover portion 63 increases toward the end of the terminal cover portion 63 in the circumferential direction. Therefore, the tip cover portions 63 extend radially outward (toward the back yoke 52) of the wide portions 53a of the teeth 53. The lead wires 54 constituting the coil 55 are in contact with the radially outer surface of the end cover 63. Therefore, the lead wires 54 constituting the coil 55 are not present on the wide portion 53a side of the end cover portion 63. That is, a space S wider than a space between the tip cover portion 66 of the first insulating sheet 60B and the wide portion 53a of the tooth portion 53 is formed between the lead 54 and the wide portion 53 a.
In this way, the shortest distance between the lead wire 54 (coil 55) and the wide portions 53a of the teeth 53 becomes longer compared to the shortest distance between the lead wire 54 and the wide portions 53a of the teeth 53 in a case where the lead wire 54 is assumed to be in contact with the tip cover portions 66 of the first insulating sheets 60B. This reduces the capacitor capacitance between the lead 54 and the wide portion 53 a. Therefore, the leakage current is reduced in the wide portions 53a of the tooth portions 53, and therefore, the leakage current can be suppressed from flowing to the wide portions 53a of the tooth portions 53 by only one first insulating sheet 60B.
A method of manufacturing the stator 50 and an operation of the present embodiment will be described with reference to fig. 10. In the following description, the first comparative stator is a stator using a second insulating sheet having a distal end cover portion 66 and an extension portion 67 in the same manner as the first insulating sheet 60B. Further, the second comparative stator is a stator using a second insulating sheet as follows: the second insulation sheet has an axial length equal to the axial length L1 of the first insulation sheet 60B, and has the same shape as the second insulation sheet 60C of the present embodiment when viewed from above.
In the present embodiment, after the first insulation sheet 60B and the second insulation sheet 60C are respectively formed by the production apparatus 100, the first insulation sheet 60B and the second insulation sheet 60C are inserted into the respective slot portions 56 of the stator core 51 in a state of being overlapped with each other (refer to fig. 4). As shown in fig. 10, the production apparatus 100 includes: a first forming portion 110 for forming the first insulating sheet 60B; a second forming portion 120 for forming a second insulating sheet 60C; and an assembly unit 130 for overlapping the first insulating sheet 60B and the second insulating sheet 60C. In one example of the first and second forming portions 110 and 120, the first and second insulating sheets 60B and 60C are formed by hot press forming.
In the first forming portion 110, the first insulating sheet 60B is formed through the following first to fifth steps. In the first step, the first base material DS1 is pressed and bent by the first die MA to form the pair of extension portions 67. In the second step, the first base material DS1 having passed through the first step is pressed by a second die (not shown) and bent to form one end cover portion 66. In the third step, the first base material DS1 having passed through the second step is pressed by a third die (not shown) and bent to form the other end cover portion 66. In the fourth step, the first base material DS1 having passed through the third step is pressed by a fourth die (not shown) and bent to form one tooth cover portion 64A. Finally, in the fifth step, the first base material DS1 having passed through the fourth step is pressed by a fifth die (not shown) and bent to form the other of the tooth cover portion 64A and the back yoke cover portion 65A. In addition, this may be the case: in the first forming portion 110, after the first step, a fourth step of forming one tooth cover portion 64A, a fifth step of forming the other tooth cover portion 64A and the back yoke cover portion 65A, and then a second step of forming one end cover portion 66 and a third step of forming the other end cover portion 66 are sequentially performed.
In the second forming portion 120, the second base material DS2 is pressed and bent by a die MB to form a pair of the tooth cover portions 64B and the back yoke cover portion 65B. Thereby, the second insulation sheet 60C is formed.
In the assembly unit 130, the first insulating sheet 60B and the second insulating sheet 60C are overlapped by inserting the first insulating sheet 60B into the opening portion 68 formed by the distal ends of the pair of the tooth cover portions 64B of the second insulating sheet 60C. The first insulating sheet 60B and the second insulating sheet 60C that are overlapped are inserted into the respective slot portions 56 (both refer to fig. 4) of the stator core 51.
Then, the cover members 60A are attached to both end surfaces of the stator core 51 in the axial direction, and the lead wires 54 are wound around the teeth portions 53 by a winding machine (not shown) to form concentrated windings, thereby forming coils 55 (see fig. 9 a).
In addition, in the manufacturing method of the first comparative stator, since the shape of the second insulation sheet is the same shape as the shape of the first insulation sheet 60B, the second forming portion of the production apparatus for manufacturing the first comparative stator (hereinafter, referred to as "comparative production apparatus") is the same structure as the first forming portion 110. That is, the second forming portion of the comparative production facility includes five types of dies, and the second insulating sheet is manufactured through the first to fifth steps. On the other hand, the second insulation sheet 60C of the present embodiment is formed in one step of bending the second base material DS2 by pressing with the die MB. Therefore, the second forming portion 120 of the production apparatus 100 is provided with a mold. In this way, the structure of the second forming portion 120 in the production apparatus 100 of the present embodiment is simplified as compared with the comparative production apparatus.
In the method of manufacturing the second comparative stator, since the axial length of the second insulating sheet (hereinafter referred to as "second comparative insulating sheet") of the second comparative stator is longer than the axial length L3 of the stator core 51, there is a possibility that a portion (hereinafter referred to as "protruding portion") of the second comparative insulating sheet that protrudes in the axial direction from the end face of the stator core 51 in the axial direction may be sandwiched between the cover member 60A and the end face of the stator core 51 in the axial direction when the cover member 60A is attached to the stator core 51. That is, the cover member 60A bends the projecting portion of the second comparative insulation sheet toward the tooth portion 53 side, and the projecting portion of the second comparative insulation sheet may be sandwiched between the cover member 60A and the end face of the stator core 51 in the axial direction. In particular, since the thickness of the second comparative insulation sheet is smaller than the thickness of the first insulation sheet 60B and the second comparative insulation sheet is formed into a substantially U-shape in plan view, the protruding portion of the second comparative insulation sheet is easily bent by the cover member 60A. Thereby, the possibility that the projecting portion of the second comparative insulation sheet is sandwiched between the cover member 60A and the end face of the stator core 51 in the axial direction is increased. Further, when the projecting portion of the second comparative insulation sheet is sandwiched between the cover member 60A and the end face of the stator core 51 in the axial direction, the first insulation sheet 60B is pressed in a direction away from the tooth portions 53 as the second comparative insulation sheet is bent, and therefore the first insulation sheet 60B is separated from the tooth portions 53. As a result, when the coil 55 is formed by the winding machine, a nozzle (not shown) of the winding machine may interfere with the end cover portion 66 and the extension portion 67 of the first insulating sheet 60B. When the second comparative insulation sheet is sandwiched between the cover member 60A and the axial end face of the stator core 51, there is a possibility that the cover member 60A is lifted from the axial end face of the stator core 51.
In this regard, in the present embodiment, the axial length L2 of the second insulation sheet 60C is equal to the axial length L3 of the stator core 51. Therefore, the axial length of the portion of the second insulation sheet 60C protruding from the end face in the axial direction of the stator core 51 is shorter than the axial length of the protruding portion of the second comparative insulation sheet, or the second insulation sheet 60C does not protrude from the end face in the axial direction of the stator core 51. Therefore, the second insulation sheet 60C is less likely to be sandwiched between the cover member 60A and the end surface of the stator core 51 in the axial direction.
According to the present embodiment, the following effects can be obtained.
(1) The insulating member 60 disposed between the coil 55 and the tooth portion 53 includes a first insulating sheet 60B and a second insulating sheet 60C. Accordingly, the first insulating sheet 60B ensures insulation between the coil 55 and the stator core 51, and the second insulating sheet 60C reduces the capacitor capacity between the coil 55 and the stator core 51. Therefore, the electrical insulation of the coil 55 from the stator core 51 is ensured by the first and second insulation sheets 60B and 60C, and the leakage current between the coil 55 and the stator core 51 is reduced.
In the first insulating sheet 60B and the second insulating sheet 60C, the second insulating sheet 60C is formed in a substantially U shape in plan view, so that the second insulating sheet 60C can be formed in one step of the mold MB as shown by the second forming portion 120 of the production facility 100 shown in fig. 10. Therefore, the production apparatus 100 can be simplified.
(2) The first insulating sheet 60B covers the wide portions 53a that are the ends of the teeth 53, while the second insulating sheet 60C does not cover the wide portions 53a of the teeth 53. According to this configuration, the first insulating sheet 60B can ensure insulation between the coil 55 and the stator core 51 at the wide portions 53a of the teeth 53, and can suppress leakage current from flowing to the wide portions 53 a.
(3) The first insulating sheet 60B has an extension portion 67, and the extension portion 67 extends toward the circumferentially adjacent tooth portion 53 more than the wide portion 53a of the tooth portion 53. Therefore, the insulation distance between the coil 55 and the tooth portion 53 can be extended. Therefore, the insulation resistance between the coil 55 and the stator core 51 can be improved.
(4) The tip cover portion 63 of the cover member 60A is located radially outward of the wide portion 53a of the tooth portion 53. Further, the coil 55 is in contact with the end cover 63. According to this structure, the shortest distance between the coil 55 at the tip of the tooth 53 and the wide portion 53a of the tooth 53 is longer than the shortest distance between the coil 55 and the tooth 53 at the other portion of the tooth 53. Therefore, the leakage current between the coil 55 and the stator core 51 can be further reduced.
(5) The thickness of the second insulating sheet 60C disposed on the tooth portion 53 side is thinner than the thickness of the first insulating sheet 60B disposed on the coil 55 side. According to this configuration, since the second insulating sheet 60C on the thin tooth portion 53 side can be pressed against the side surfaces of the tooth portion 53 by the first insulating sheet 60B on the thick coil 55 side, the first insulating sheet 60B and the second insulating sheet 60C can be arranged along the side surfaces of the tooth portion 53. Therefore, when the lead wire 54 is wound around the tooth portion 53 by the winding machine, the nozzle of the winding machine can be suppressed from contacting the first insulating sheet 60B.
(6) The axial length L2 of the second insulation sheet 60C is shorter than the axial length L1 of the first insulation sheet 60B that is longer than the axial length L3 of the teeth 53. According to this structure, the length of the second insulation sheet 60C protruding from the end surface in the axial direction of the tooth portion 53 is shorter than in the case where the axial length L1 of the first insulation sheet 60B and the axial length L2 of the second insulation sheet 60C are equal to each other. Therefore, the second insulating sheet 60C is not easily sandwiched between the end surfaces of the teeth 53 in the axial direction and the cover member 60A. Therefore, since the second insulating sheet 60C can be prevented from being bent by the cover member 60A, the first insulating sheet 60B can be prevented from being pressed in a direction away from the teeth portions 53 by the second insulating sheet 60C. Therefore, the nozzle of the winding machine can be inhibited from interfering with the first insulating sheet 60B when the nozzle revolves around the tooth 53.
(7) The axial length L2 of the second insulation sheet 60C is equal to the axial length L3 of the teeth 53. According to this configuration, the length of the second insulation sheet 60C protruding from the end surface in the axial direction of the tooth portion 53 in the axial direction becomes shorter, or the second insulation sheet 60C does not protrude from the end surface in the axial direction of the tooth portion 53. Therefore, the second insulating sheet 60C is less likely to be sandwiched between the end surfaces of the teeth 53 in the axial direction and the cover member 60A.
(8) The first insulation sheet 60B is inserted in the radial direction through the opening portion 68 of the second insulation sheet 60C, so that the first insulation sheet 60B and the second insulation sheet 60C overlap. Therefore, the first insulation sheet 60B and the second insulation sheet 60C are easily overlapped as compared with a case where the first insulation sheet 60B is inserted into the second insulation sheet 60C in the axial direction.
(modification example)
The above embodiments are illustrative of the stator, the motor provided with the stator, the compressor provided with the motor, and the air conditioner provided with the compressor according to the present invention, and are not intended to limit the embodiments. The stator, the motor provided with the stator, the compressor provided with the motor, and the air conditioner provided with the compressor according to the present invention can be combined with the above embodiments in modifications such as those shown below and at least two modifications that are not inconsistent with each other.
In the above embodiment, the following may be used: after the cover member 60A is attached to one of the two end surfaces in the axial direction of the stator core 51, the first insulating sheet 60B and the second insulating sheet 60C are inserted into the respective slot portions 56 in a state of being overlapped by the production equipment 100. In this case, after the first insulating sheet 60B and the second insulating sheet 60C are inserted into the respective slot portions 56, the cover member 60A is attached to the other of the two end surfaces in the axial direction of the stator core 51.
In the above embodiment, the axial length L1 of the first insulating sheet 60B and the axial length L2 of the second insulating sheet 60C can be arbitrarily changed. For example, the length L1 of the first insulation sheet 60B and the length L2 of the second insulation sheet 60C may also be equal to each other. Further, for example, the axial length L2 of the second insulation sheet 60C may be shorter than the axial length L3 of the stator core 51.
In the above embodiment, the thickness of the first insulating sheet 60B and the thickness of the second insulating sheet 60C can be arbitrarily changed. For example, the thickness of the first insulation sheet 60B and the thickness of the second insulation sheet 60C may be equal to each other.
In the above embodiment, the following may be used: the first insulating sheet 60B is disposed on the tooth portion 53 side, and the second insulating sheet 60C is disposed on the coil 55 side.
In the above embodiment, as in the stator 50A shown in fig. 11, when the insulation between the coil 55 and the tooth portions 53 is maintained, the first insulation sheet 60D and the second insulation sheet 60E covering one side surface in the circumferential direction of the predetermined tooth portion 53X, and the first insulation sheet 60F and the second insulation sheet 60G covering one side surface facing in the circumferential direction of the tooth portion 53X in the tooth portion 53Y adjacent to the tooth portion 53X may be formed separately from each other.
In the above embodiment, the insulating member 60 may have three or more insulating sheets. As an example, the insulating member 60 has a first insulating sheet 60B, a second insulating sheet 60C, and a third insulating sheet 60H as in the stator 50B shown in fig. 12. In the stator 50B, the third insulating sheet 60H is disposed between the first insulating sheet 60B and the second insulating sheet 60C. In the stator 50B shown in fig. 12, the shape of the third insulation sheet 60H is equal to the shape of the first insulation sheet 60B. Further, the thickness of the third insulation sheet 60H is equal to that of the first insulation sheet 60B. Further, the axial length of the third insulation sheet 60H is equal to the axial length L1 of the first insulation sheet 60B.
In the stator 50B shown in fig. 12, the third insulating sheet 60H may have a substantially U-shape in the same manner as the second insulating sheet 60C. Thereby, the production equipment can be simplified.
In the stator 50B shown in fig. 12, the thickness of the third insulation sheet 60H can be arbitrarily changed. In one example, the thickness of the third insulation sheet 60H may also be equal to the thickness of the second insulation sheet 60C.
In the stator 50B shown in fig. 12, the axial length of the third insulation sheet 60H can be arbitrarily changed. In one example, the axial length of the third insulating sheet 60H is equal to the axial length L2 of the second insulating sheet 60C.
In the above embodiment, the wide portions 53a may be omitted from the teeth portions 53. In this case, the end cap portions 66 may be omitted from the first insulating sheet 60B. The first insulating sheet 60B from which the end cover portion 66 is omitted is formed so that the tooth cover portion 64A is continuous with the extension portion 67.
In the above embodiment, the motor 30 may be a so-called outer rotor type motor in which a rotor core is disposed radially outward of a stator core.
The air conditioner 1 of the above embodiment can perform both the cooling operation and the heating operation, but is not limited to this, and the air conditioner 1 may be capable of only either the cooling operation or the heating operation.
In the above embodiment, when the axial length of the insulating sheet closest to the tooth portions 53 among the plurality of insulating sheets is shorter than the axial length of at least one of the other insulating sheets, the shape of the insulating sheet closest to the tooth portions 53 may be a shape covering the wide portions 53a of the tooth portions 53 as in the first insulating sheet 60B of fig. 8.
(attached note)
Next, technical ideas that can be understood from the above-described embodiment and the above-described modifications will be described. .
(attached note 1)
A stator (50) having: a stator core (51) having an annular back yoke (52) and a plurality of teeth (53) extending radially from the back yoke (52); a coil (55) formed by winding a conductive wire (54) around the plurality of teeth (53); and an insulating member (60) that is disposed between the plurality of teeth (53) and the coil (55) and electrically insulates the stator core (51) and the coil (55), wherein the insulating member (60) has: cover members (60A) that cover both axial end surfaces of the tooth section (53); and the multiple insulation sheets (60B, 60C), they cover the side of the part that forms the slot part (56) in the stated stator core (51), the axial length of the insulation sheet that disposes in the side closest to the stated tooth part (53) in the multiple insulation sheets (60B, 60C) is shorter than the axial length of at least one of the other insulation sheets.
When the cover members are attached to both end surfaces in the axial direction of the tooth portions after the plurality of insulating sheets are inserted into the slot portions, the insulating sheet closest to the tooth portion among the plurality of insulating sheets is highly likely to contact the cover members. Since the insulating sheet closest to the teeth portion side is in contact with the cover member, the insulating sheet is bent and may be sandwiched between the cover member and the end face of the teeth portion in the axial direction. Thereby, the insulating sheet closest to the teeth portion side presses the other insulating sheet in a direction away from the teeth portion. As a result, when the coil is formed by the winding machine, the nozzle of the winding machine may interfere with the portion of the insulating sheet covering the end of the tooth portion. When the insulating sheet closest to the teeth is sandwiched between the cover member and the end surface of the stator core in the axial direction, the cover member may be lifted from the end surface of the stator core in the axial direction.
In this regard, according to the above configuration, since the axial length of the insulating sheet closest to the tooth portion among the plurality of insulating sheets is shorter than the axial lengths of the other insulating sheets, when the cover members are attached to both end surfaces in the axial direction of the tooth portion, the insulating sheet closest to the tooth portion comes into contact with the cover members, and the insulating sheet is bent and sandwiched between the cover members and the end surfaces in the axial direction of the tooth portion.
Description of the reference symbols
1: air conditioner
10: compressor with a compressor housing having a plurality of compressor blades
20: compression mechanism
30: motor with a stator having a stator core
40: rotor
50: stator
51: stator core
52: back yoke
53: toothed section
53 a: broad width part
54: conducting wire
55: coil
56: slot part
60: insulating member
60A: cover component
60B: first insulating sheet
60C: second insulating sheet
63: end cover part
L1: axial length of first insulating sheet
L2: axial length of second insulating sheet
L3: the axial length of the teeth.

Claims (12)

1. A stator (50) having: a stator core (51) having an annular back yoke (52) and a plurality of teeth (53) extending radially from the back yoke (52); a coil (55) formed by winding a conductive wire (54) around the plurality of teeth (53); and an insulating member (60) disposed between the plurality of teeth (53) and the coil (55) and electrically insulating the stator core (51) from the coil (55),
the insulating member (60) includes a plurality of insulating sheets (60B, 60C),
the side surface of the stator core (51) constituting the slot portion (56) is covered with the plurality of insulation sheets (60B, 60C),
the plurality of insulating sheets (60B, 60C) at least include: a first insulating sheet (60B) of a first number of bends; and a second insulating sheet (60C) having a number of bends less than the first number of bends,
the first insulating sheet (60B) is bent into a shape such that, when the stator (50) is viewed from above: along the shape of the portion of the slot portion (56) from the back yoke to the tip of the tooth portion (53),
the second insulating sheet (60C) is bent into a shape such that, when the stator (50) is viewed from above: the shape of the portion of the slot portion (56) closer to the back yoke (52) than the tip of the tooth portion (53).
2. The stator according to claim 1,
the tooth part (53) has a wide part (53a) expanding in the circumferential direction at the tip thereof,
the first insulating sheet (60B) covers the wide width portion (53a) and extends toward circumferentially adjacent teeth (53).
3. The stator according to claim 2,
the insulating member (60) has cover members (60A) that cover both end surfaces of the tooth portion (53) in the axial direction,
the cover member (60A) includes a tip cover portion (63), the tip cover portion (63) covering a tip of the tooth portion (53) and at least a part of the wide-width portion (53a),
the end cover portion (63) protrudes from the wide width portion (53a) toward the back yoke (52),
the coil (55) is in contact with the end cover part (63) in the radial direction.
4. The stator according to any one of claims 1 to 3,
the first insulating sheet (60B) is disposed on the coil (55) side,
the second insulating sheet (60C) is arranged on the tooth (53) side,
the second insulating sheet (60C) has a thickness thinner than that of the first insulating sheet (60B).
5. The stator according to any one of claims 1 to 4,
the insulating member (60) has cover members (60A) that cover both end surfaces of the tooth portion (53) in the axial direction,
the axial length of the insulating sheet disposed closest to the tooth portion (53) among the plurality of insulating sheets (60B, 60C) is shorter than the axial lengths of the other insulating sheets.
6. The stator according to claim 5,
the second insulating sheet (60C) is disposed closest to the teeth (53),
an axial length (L1) of the first insulating piece (60B) is longer than an axial length (L3) of the tooth portion (53),
the axial length (L2) of the second insulating sheet (60C) is shorter than the axial length (L1) of the first insulating sheet (60B).
7. The stator according to claim 6,
an axial length (L2) of the second insulation sheet (60C) is equal to an axial length (L3) of the tooth portion (53).
8. The stator according to any one of claims 1 to 7,
the length of the first insulation sheet (60B) is longer than the length of the second insulation sheet (60C) in the circumferential direction of the slot portion (56).
9. The stator according to any one of claims 1 to 8,
the first insulating piece (60B) has a tip end portion that is arranged on the tip end side of the tooth portion (53) and that is turned back toward the back yoke (52).
10. A motor includes:
a stator (50) according to any one of claims 1 to 9; and
and a rotor (40) that faces the stator (50) in the radial direction and that rotates by a magnetic field generated by the stator (50).
11. A compressor is provided with:
the motor (30) of claim 10; and
a compression mechanism (20) driven by the motor (30).
12. An air conditioner comprising the compressor (10) according to claim 11.
CN201880050812.3A 2017-08-22 2018-07-19 Stator, motor provided with the stator, compressor provided with the motor, and air conditioner provided with the compressor Active CN111033953B (en)

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JP2017159641A JP6489175B2 (en) 2017-08-22 2017-08-22 Stator, motor equipped with this stator, compressor equipped with this motor, and air conditioner equipped with this compressor
JP2017-159641 2017-08-22
PCT/JP2018/027049 WO2019039143A1 (en) 2017-08-22 2018-07-19 Stator, motor provided with stator, compressor provided with motor, and air conditioner provided with compressor

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CN111033953B (en) 2021-02-09

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