CN111213304A

CN111213304A - Insulator, stator including the insulator, and motor

Info

Publication number: CN111213304A
Application number: CN201880067003.3A
Authority: CN
Inventors: 菱田光起; 国友浩胜; 米田博
Original assignee: Panasonic Intellectual Property Management Co Ltd
Current assignee: Panasonic Intellectual Property Management Co Ltd
Priority date: 2017-12-14
Filing date: 2018-12-12
Publication date: 2020-05-29
Also published as: JPWO2019117207A1; WO2019117207A1

Abstract

The insulator (5) includes a first flange portion (51) and a second flange portion (52), the first flange portion (51) is provided on the core segment (41) side of a coil winding portion (50) around which the coil (7) is wound and has a coil introduction groove (53) for introducing the coil (7) to the coil winding portion (50), and the second flange portion (52) is provided on the tip side of the teeth (42). A coil holding section (54) comprising a plurality of grooves (55) is provided on both circumferential side surfaces (50c, 50d) of a coil winding section (50), and no groove (55) is provided on an axial end surface (50a) of the coil winding section (50). The plurality of grooves (55) are formed by a plurality of protrusions (56) extending in the axial direction and protruding in the circumferential direction, and the end portions (56a) of the protrusions (56) are inclined such that the height of the protrusions decreases toward the outer peripheral surface (50 a).

Description

Insulator, stator including the insulator, and motor

Technical Field

The present invention relates to an insulator on which a coil is wound, and a stator and a motor including the insulator.

Background

In recent years, there has been an increasing demand for electric motors for industrial and vehicle-mounted applications. Among them, it is highly desirable to improve the efficiency of the motor and to reduce the cost thereof.

As a method of improving the motor efficiency, a method of increasing the space factor of the coils disposed in the slots of the stator is known. By increasing the space factor of the coil, it is possible to suppress loss of the motor due to the current flowing through the coil when the motor is in operation.

As a structure for increasing the space factor of the coil, a so-called aligned winding coil in which a coil is wound in an aligned manner on a tooth portion (teeth) of a stator is known, and various structures have been proposed for realizing the aligned winding coil (for example, see patent documents 1 to 4). For example, patent document 1 proposes the following configuration: flange parts are arranged at the end part of a cylinder body or the two ends of the cylinder body of the insulating coil framework for winding the coil, and steps or slopes are arranged on the inner sides of the flange parts to realize the arrangement and winding of the coil. Patent document 2 discloses the following configuration: on the upper surface of a split type insulator which is mounted on the axial upper end surface of the tooth portion (teeth) and insulates the coil from the tooth portion (teeth), a holding portion which is formed of a plurality of slots and holds the wound coil is provided, thereby realizing the winding of the coil in an array.

Patent document 1: japanese laid-open patent publication No. Hei 11-122855

Patent document 2: japanese laid-open patent publication No. 2013-243835

Patent document 3: specification of U.S. Pat. No. 6356001

Patent document 4: international publication No. 2011/118357

Disclosure of Invention

Technical problems to be solved by the invention

However, generally, when the coil is wound around the insulator by passing the coil through the introduction groove formed in the flange portion of the insulator, the coil is bent at the outlet of the introduction groove, and thus the coil is wound from the upper end surface in the axial direction of the insulator in a state of forming a predetermined angle with respect to the radial direction.

In such a case, when the conventional insulator shown in patent document 2 is used as the insulator attached to the axial upper end surface of the tooth and the insulator attached to the lower end surface thereof, for example, the slots for holding the coils are formed obliquely in the respective insulators.

However, since the direction in which the coil is inclined with respect to the insulator is opposite to the radial direction at the axial upper end surface and the lower end surface, it is necessary to separately manufacture two insulators attached to the teeth in the axial direction, and there is a problem in that the manufacturing cost of the insulator increases.

The present invention has been made in view of the above problems, and an object of the present invention is to provide: provided is an insulator on which a wound coil can be wound in an aligned manner and the cost of which can be reduced.

Technical solution for solving technical problem

In order to achieve the above object, the insulator according to the present invention has coil holding portions for positioning and fixing the coil only on both circumferential side surfaces of the coil winding portion.

Specifically, an insulator according to the present invention includes a coil winding portion that covers one end surface in an axial direction of a tooth protruding from a core segment and a part of both side surfaces in a circumferential direction and on which a coil formed of a winding wire is wound, and is characterized in that: the coil winding device is characterized in that a plurality of coil holding portions, which are formed of a plurality of grooves and position and fix the coil, are provided on both circumferential side surfaces of the coil winding portion, while no groove is provided on one axial end surface of the coil winding portion, and a plurality of protrusions, which extend in the axial direction and protrude in the circumferential direction, are formed on both circumferential side surfaces of the coil winding portion at predetermined intervals, respectively, thereby forming a plurality of grooves, and one axial end portion of the protrusion is inclined such that the height of the protrusion decreases toward one axial end surface of the coil winding portion.

According to this configuration, the coil is positioned and fixed by the coil holding portions provided on both circumferential side surfaces of the coil winding portion, and since no groove is provided on the axial end surface of the coil winding portion, it is possible to use insulators having the same shape on the axial upper end surface and the axial lower end surface of the tooth without being affected by the inclination angle of the coil when the coil is wound obliquely. This can realize sharing of the insulator, thereby reducing the cost. In the coil winding portion, when the coil is wound from the axial end surface to the circumferential side surface, the coil can be wound so as to be prevented from being raised at the corner portion of the coil winding portion.

It is preferable that: one axial end of the projection is located at a predetermined distance from one axial end of the coil winding portion.

According to this configuration, the coil can be more reliably prevented from being wound up with the coil wound around the corner portion of the coil wound portion.

The stator according to the present invention is characterized in that: the stator includes a plurality of stator segments each including the insulator on each axial end surface of the teeth of the core segment, and a coil formed of a wire is wound around and mounted on the coil winding portion of the insulator, and is configured such that: the plurality of stator segments are connected in a ring shape, and the teeth protrude toward a radially inner side of the ring.

According to this configuration, the space factor of the coil in the stator can be increased.

It is preferable that: the insulators having the same shape are respectively attached to the respective axial end surfaces of the teeth.

According to this configuration, all of the insulators attached to the teeth of the stator can be shared, and the cost of the stator can be reduced.

The coil is wound around the coil winding portion such that the winding is inclined with respect to a radial direction. Further, it is preferable that: the coils are wound in an aligned manner around the coil winding portion.

According to this configuration, when the coil is wound obliquely with respect to the coil winding portion, it is possible to realize a stator in which the coil is wound in an aligned row while reducing the cost.

It is preferable that: the gap between the teeth adjacent in the circumferential direction is configured to receive a slot of the coil, and an insulating paper having a function of insulating the core segment from the coil and insulating the teeth from the coil is disposed in the slot so as to cover a side surface of the teeth and to partially overlap a first flange portion and a second flange portion provided in the insulator in the axial direction.

According to this configuration, it is possible to reliably electrically insulate teeth adjacent in the circumferential direction of the stator.

The motor of the present invention is characterized in that: the motor includes at least the stator and a rotor, the rotor includes a rotating shaft, and the rotor is disposed radially inside the stator with a predetermined gap from the stator.

According to this configuration, the space factor of the coil in the stator can be increased, and the efficiency of the motor can be improved.

Effects of the invention

As described above, according to the present invention, it is possible to realize winding coils in an aligned row and to reduce the cost of an insulator.

Drawings

Fig. 1 is a plan view of a motor according to an embodiment.

Fig. 2 is an equivalent circuit diagram of the motor shown in fig. 1.

Fig. 3 is a schematic diagram of a stator.

Fig. 4A is a perspective view showing a portion enclosed by a broken line shown in fig. 1.

Fig. 4B is a side view of the configuration shown in fig. 4A, viewed radially.

Fig. 4C is a side view of the configuration shown in fig. 4A, as seen from the circumferential direction.

Fig. 5A is a perspective view showing a main part of an insulator according to an embodiment.

Fig. 5B is a schematic sectional view showing a portion enclosed by a broken line shown in fig. 5A.

Fig. 5C is a schematic cross-sectional view taken along line VC-VC of fig. 5A.

Fig. 6 is a schematic diagram of a midway process of winding the coil in an array on the insulator.

Detailed Description

Embodiments of the present invention will be described in detail below with reference to the drawings. The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.

(embodiment mode)

[ Structure of Motor and stator ]

Fig. 1 is a plan view showing a motor according to the present embodiment, fig. 2 is an equivalent circuit diagram of the motor shown in fig. 1, and fig. 3 is a schematic diagram of a stator, that is, a view of a stator 4 viewed from an axial direction of a shaft 2. For convenience of explanation, in fig. 1 and 3, some constituent members and functions thereof are not shown and described. For example, the frame, the bus bar, and the like are not illustrated. In fig. 3, the insulator 5 is not shown. An outer housing for housing the stator 4 is not shown. The shape of the outer housing is, for example, a cylinder made of metal, a substantially rectangular parallelepiped, a polygonal columnar body, or the like, and the shape can be appropriately selected according to the specification of the motor 1. The constituent members shown in the drawings are also simplified, and for example, the insulator 5 shown in fig. 1 is partially different from the actual shape, and the coils U1 to W4 shown in fig. 3 and the lead terminals 71 of these coils are greatly different from the actual shape. In fig. 2, reference numeral + denotes the start of coil winding, and reference numeral-denotes the end of coil winding.

In the following description, the longitudinal direction of the shaft 2 is sometimes referred to as the axial direction, the radial direction of the stator 4 is sometimes referred to as the radial direction, and the circumferential direction of the stator 4 is sometimes referred to as the circumferential direction. In the axial direction, the side of the coils U1 to W4 on which the lead terminals 71 are provided is referred to as "up", the opposite side is referred to as "down", the center side of the stator 4, i.e., the side on which the shaft 2 and the rotor are provided is referred to as "inside", and the opposite side, i.e., the side of the stator core 40 is referred to as "outside".

The stacking direction of the electromagnetic steel sheets described later is the same as the axial direction, and means the same.

In the following description, terms such as tooth (teeth) and tooth (tooth) are used separately. A plurality of teeth projecting toward the center of the annular stator core 40 are referred to as teeth 42 (a complex form of teeth). One of the plurality of teeth of the stator core 40 is referred to as a tooth 42. Similarly, a plurality of teeth in the core segment 41 described later are referred to as teeth. One of the plurality of teeth in the core segment 41 is referred to as a tooth 42. Incidentally, patent documents 3 and 4 are known documents expressed by using terms such as tooth portions and teeth separately.

The motor 1 includes a rotor 3, a stator 4, and coils U1 to W4 inside an external housing, not shown, the rotor 3 having a shaft 2, the shaft 2 being a rotation shaft of the motor 1.

The rotor 3 includes a shaft 2 and magnets 31, the magnets 31 being opposed to the stator 4, and N poles and S poles being alternately arranged along the outer circumferential direction of the shaft 2. In the present embodiment, a neodymium magnet is used as the magnet 31 used for the rotor 3, but the material, shape, and material thereof may be changed as appropriate depending on the output of the motor, and the like. The rotor 3 is disposed radially inward of the stator 4 with a certain space from the stator 4 as viewed from the axial direction.

The stator 4 is a cylindrical body configured by annularly connecting a plurality of stator segments 40 a. The specific structure of the stator segment 40a is as follows: the insulators 5 are attached to the teeth 42 of the core segment 41 from the upper and lower end surfaces in the axial direction, and further insulators such as insulating paper 6 are attached between the insulators 5, and a coil U1, for example, is formed by winding a wire around the coil winding portion 50 of the insulator 5 and the arrangement portion of the insulators such as the insulating paper 6 (see fig. 4A to 4C). The stator segment 40a configured as described above has a columnar shape whose cross-sectional shape is substantially a sector.

The stator 4 and the stator segment 40a have teeth 42 and a plurality of core segments 41, and the teeth 42 protrude radially inward from the respective inner peripheries of the core segments 41. An electromagnetic steel sheet containing silicon or the like is punched into a core segment plate (core segment sheet) having a single piece shape constituting a part of a stator core plate (stator core sheet) having a substantially annular shape, and the core segment plate (core segment sheet) is laminated in a plurality of layers to form a laminated body, which is the core segment 41. The core segment 41 configured as described above has an external appearance of a columnar body having a sectional shape of a single piece constituting a part of a stator core plate (stator core sheet) having a substantially annular shape. The stacking direction of the plate bodies is a normal direction to the plate surfaces of the plate bodies. The core segment 41 includes a yoke portion 41c and teeth 42, and the teeth 42 protrude from a substantially central portion of the yoke portion 41 c.

The core segment 41 has a recess 41a formed in one side surface of a yoke portion 41c located in the circumferential direction, a protrusion 41b formed in the other side surface, and the recess 41a and the protrusion 41b extend in the entire axial direction on each side surface. When attention is paid to one core segment 41, the concave portion 41a of the core segment 41 is fitted into the convex portion 41b of the core segment 41 adjacent to one side in the circumferential direction and connected to each other, and the convex portion 41b of the core segment 41 is fitted into the concave portion 41a of the core segment 41 adjacent to the other side in the circumferential direction and connected to each other. The core segments 41 adjacent in the circumferential direction as described above are fitted and connected to each other, thereby constituting the annular stator core 40.

As shown in fig. 1 and 3, the teeth 42 can be arranged at equal intervals along the inner circumference of the stator core 40 by forming the annular stator core 40 by connecting the core segments 41. Each interval between circumferentially adjacent teeth 42 constitutes a tooth space 43.

The stator 4 has twelve coils U1 to W4, which are attached to each tooth 42 via an insulator 5 and an insulating paper 6 (see fig. 4A to 4C) and arranged in each slot 43 as viewed in the axial direction. Although not shown, the coils U1 to W4 are each formed of a wire having a circular cross section, which is made of a metal material such as copper with an insulating film coated on the surface thereof, and is wound around the insulator 5 in an aligned manner and in a multi-layer manner. The multilayer winding refers to a state in which the multilayer coil 7 is wound around the insulator 5. The "round shape" includes a machining tolerance of the winding wire and a deformation of the winding wire when the winding wire is wound on the teeth 42, and the same applies to the following description. In the following description, when one coil is selected without specifying coils U1 to W4 and the structure thereof and the like are described, it is referred to as coil 7.

As shown in fig. 2, coils U1 to U4, coils V1 to V4, and coils W1 to W4 are connected in series, and three phases of U phase, V phase, and W phase are star-connected. Three-phase currents of U-phase, V-phase, and W-phase having a phase difference of 120 ° in electrical angle are supplied to coils U1 to U4, coils V1 to V4, and coils W1 to W4, respectively, and are excited, thereby generating a rotating magnetic field. The rotating magnetic field generates a torque in the rotor 3, and the shaft 2 is supported by a bearing, not shown, for rotation.

In the present embodiment, the number of magnetic poles of the rotor 3 is ten in total, five N poles and five S poles facing the stator 4 are provided, and twelve tooth grooves 43 are provided, but the present invention is not limited to this, and other combinations of the number of magnetic poles and the number of tooth grooves are also applicable.

[ constitution of main portion of stator segment ]

Fig. 4A to 4C respectively show a perspective view of a portion enclosed by a broken line in fig. 1, and side views seen from the radial direction and the circumferential direction. For convenience of explanation, the coil 7 is not shown in fig. 4A to 4C. The insulating paper 6 interposed between the insulator 5 and the core segment 41 and the insulating paper 6 interposed between the insulator 5 and the teeth 42 are also shown, but they are shown in a state before they are bent and stored in the slots 43.

As shown in fig. 4A to 4C, the insulators 5 having the same shape are attached to the teeth 42 protruding from one core segment 41 from the upper and lower end surfaces in the axial direction, respectively, and the insulating paper 6 is sandwiched between the core segment 41 and the insulator 5 and between the teeth 42 and the insulator 5. Thus, the insulator 5 is provided so as to cover both end surfaces in the axial direction of the teeth 42 and portions in the vicinity of both end surfaces.

The insulator 5 is an insulating member obtained by molding an insulating resin material, and has a coil winding portion 50 around which the coil 7 (see fig. 5C) is wound, a first flange portion 51 formed at one end of the coil winding portion 50, and a second flange portion 52 formed at the other end of the coil winding portion 50. In the present embodiment, the first flange portion 51 is attached to the core segment 41 side, and the second flange portion 52 is attached to the tip of the tooth 42 positioned on the radially inner side of the stator 4. A coil introduction groove 53 is formed in the first flange 51, and when the coil is wound around the coil wound portion 50, the coil constituting the coil 7 is guided toward the coil wound portion 50 through the coil introduction groove 53, and at this time, the winding start portion comes into contact with an inner surface 51a of the first flange 51 facing the second flange 52 (hereinafter referred to as an inner surface 51a of the first flange 51). In this specification, the winding start portion of the coil 7 refers to a portion of the coil 7 near the first turn of the first layer coil wound on the coil winding portion 50.

Outer peripheral surfaces 50a and 50b of the outer peripheral surface of the coil winding portion 50, which cover the axial upper end surfaces of the teeth 42, are smooth surfaces without grooves or the like formed on the surfaces. However, irregularities (not shown) that are generated when the insulator 5 is molded using a mold or the like also remain on the outer peripheral surfaces 50a, 50 b. The arithmetic mean roughness of the irregularities is, for example, about 3 to 6 μm. Surfaces 50C, 50d of the outer peripheral surface of the coil winding portion 50, which cover both circumferential end surfaces of the teeth 42, are formed so as to be orthogonal to the axial upper end surfaces of the teeth 42, and a coil holding portion 54 is formed, the coil holding portion 54 holding the coil 7 and fixing the winding position thereof (see fig. 5A to 5C). The shape of the outer peripheral surfaces 50a to 50d of the insulator 5 including the coil holding portion 54 (hereinafter, may be referred to as the surface of the coil wound portion 50) is as follows. Note that "orthogonal" means "orthogonal" including a machining tolerance of the insulator 5, a machining tolerance of the teeth 42, and an assembly tolerance when the insulator 5 is attached to the teeth 42, and "parallel" means "parallel" including a machining tolerance of the insulator 5 and an assembly tolerance when the insulator 5 is attached to the teeth 42, and the same applies to the following description.

The inner surface 51a of the first flange 51 is a surface provided in parallel with a surface orthogonal to the axial upper end surface or the axial lower end surface of the tooth 42.

The insulator 5 and the insulating paper 6 both have a function of electrically insulating the core segment 41 from the coil 7 and a function of electrically insulating the teeth 42 from the coil 7. The insulator 5 has a function of stably maintaining the winding of the coil 7 in an aligned state as described later.

The insulating paper 6 is impregnated with insulating oil, for example, and the insulating paper 6 is provided so as to cover both side surfaces of the teeth 42 in the circumferential direction and partially overlap the first flange portion 51 and the second flange portion 52 of the insulator 5 in the axial direction. Although not shown, when the motor 1 is assembled, the insulating paper 6 is bent so as to cover the slots 43. In this way, the core segments 41 and the coils 7 and the teeth 42 and the coils 7 can be electrically insulated from each other, and the core segments 41 and the teeth 42 adjacent to each other in the circumferential direction can be electrically insulated from each other.

[ constitution of the main portion of the insulator ]

Fig. 5A is a schematic view showing a main part of the insulator according to the present embodiment as viewed in an axial direction, fig. 5B is a schematic cross-sectional view showing a part enclosed by a broken line shown in fig. 5A, and fig. 5C is a schematic cross-sectional view showing a cross-section taken along line VC-VC in fig. 5A. Further, fig. 6 is a schematic diagram showing a midway process of winding the coil in an array on the insulator. The insulator 5 shown in fig. 5A to 5C is the same as the insulator shown in fig. 4A to 4C, but for convenience of explanation, the structure of the insulator 5 is simplified in fig. 5A to 5C. Fig. 5B and 5C illustrate a part of the coil 7.

As shown in fig. 5A to 5C, a coil holding portion 54 formed of a plurality of grooves 55 is provided on outer circumferential surfaces 50C and 50d corresponding to circumferential side surfaces of the surface of the coil wound portion 50 of the insulator 5. The coil holding portion 54 is provided over the entire radial direction of the outer circumferential surfaces 50c and 50d, and a plurality of grooves 55 are formed to extend in the axial direction. The radial width of the slot 55 is formed to coincide with the wire diameter of the wound coil 7. Note that the term "match" is meant to include a machining tolerance of the wire diameter of the coil 7 and a machining tolerance of the groove 55, and is the same in the following description. The coil 7 is usually formed by forming an insulating film on the surface of a wire made of copper or the like. Thus, the wire diameter of the coil 7 is a value obtained by adding 2 times the thickness of the insulating film to the wire diameter of the wire.

The plurality of grooves 55 are formed by forming a plurality of protrusions 56 extending in the axial direction and protruding in the circumferential direction at a pitch corresponding to the wire diameter of the coil 7 on the outer circumferential surfaces 50c and 50d of the coil wound portion 50. The adjacent projections 56 correspond to a groove 55. As shown in fig. 5C and 6, the winding of the coil 7 is fitted into each of the plurality of slots 55, and the coil 7 is positioned and fixed to the coil winding portion 50. As shown in fig. 6, the winding of the coil 7 is wound on the coil winding portion 50 in a manner inclined with respect to the radial direction. As shown in fig. 5C and 6, the protrusion 56 may have an approximately triangular shape in a cross-sectional view taken along the radial direction, or may have another shape. For example, the sectional shape may be approximately quadrangular or approximately circular. The shape of the projection 56 can also be changed as appropriate in accordance with the sectional shape of the wound coil 7. The protrusion 56 is integrally formed when the insulator 5 is formed.

As shown in fig. 5B, an axial upper end portion 56a (hereinafter simply referred to as an end portion 56a) of the projection 56 is located at a predetermined distance L from the outer peripheral surface 50a in the axial direction. The projection 56 is formed as: the end portion 56a is inclined so that the height of the projection 56 decreases toward the outer peripheral surface 50a, and the inclination angle θ is 45 °. Although not shown, the insulator 5 attached to the axially lower end surface of the tooth 42 has the axially lower end of the projection 56 positioned at a predetermined distance L from the outer peripheral surface 50b in the axial direction. Further, the projection 56 is formed such that: the projection 56 is inclined so that its height decreases toward the outer peripheral surface 50b, and the inclination angle θ is 45 °. The inclination angle θ is not particularly limited to this value, and may be appropriately changed according to the size of the coil winding portion 50, the wire diameter of the winding of the coil 7, the bending rigidity, and the like.

[ Effect and the like ]

As described above, the insulator 5 according to the present embodiment includes the coil winding portion 50, and the coil winding portion 50 covers one end surface in the axial direction and a part of both side surfaces in the circumferential direction of the teeth 42 protruding from the core segment 41, and the coil 7 formed of a winding is wound. Coil holding portions 54 each including a plurality of grooves 55 are provided on outer circumferential surfaces 50c and 50d which are both circumferential side surfaces of the coil winding portion 50, while no grooves are provided on outer circumferential surfaces 50a and 50b which are axial end surfaces of the coil winding portion 50.

By setting the insulator 5 to the above configuration, the coil 7 can be positioned and fixed to the coil winding portion 50 by the coil holding portion 54. Since the outer peripheral surfaces 50a and 50b positioned on the axial upper end surfaces or the axial lower end surfaces of the teeth 42 are smooth surfaces provided with no grooves, the shapes of the outer peripheral surfaces 50a and 50b do not need to be changed particularly even when the winding of the coil 7 is wound obliquely with respect to the coil winding portion 50. Thus, the extending direction of the groove 55 of the coil holding portion 54 can be set in the same direction in the insulator 5 attached to the axial upper end surface of the tooth 42 and the insulator 5 attached to the axial lower end surface. This allows the same insulator 5 to be used for the upper and lower axial end surfaces of the teeth 42, thereby making it possible to share the insulator and reduce the manufacturing cost of the insulator 5.

When the coil 7 is wound with the winding bent at the corner of the coil winding portion 50, the curvature thereof changes depending on the bending rigidity and the wire diameter of the winding of the coil 7. When the end 56a of the projection 56 extends to the position of the outer peripheral surface 50a by a predetermined height, the coil 7 may protrude from the groove 55 due to the curvature of the winding wire and bulge at the corner of the coil wound portion 50. When the coil 7 is wound in a plurality of layers, winding disorder may occur in the coil 7 wound around the swelling portion, and the entire coil 7 may not be wound in a row.

As shown in the present embodiment, by inclining the end 56a of the projection 56 constituting the groove 55 so that the height thereof is lowered toward the outer peripheral surface 50a of the coil wound portion 50, the coil 7 can be prevented from bulging at the corner of the coil wound portion 50 when the coil 7 is wound from the outer peripheral surface 50a to the outer peripheral surface 50c or the outer peripheral surface 50 d.

Similarly, the coil 7 can be prevented from bulging at the corner of the coil-wound portion 50 by positioning the end 56a of the projection 56 at a position spaced apart from the outer peripheral surface 50a of the coil-wound portion 50 by a predetermined distance L. Note that, as for the shape and position of the end portion 56a of the protrusion 56, the above definition may be applied only to either one. For example, the end portion 56a may be positioned at a predetermined distance L from the outer peripheral surface 50a without being inclined.

The insulator 5 according to the present embodiment can cope with a case where the winding direction of the coil 7 is clockwise or a case where the winding direction of the coil 7 is counterclockwise. In the motor 1 shown in fig. 1, depending on specifications, for example, there are cases where the coils U1, U2 of the U-phase are wound with the same winding, and the coil U1 is wound in the clockwise direction and the coil U2 is wound in the counterclockwise direction. According to the present embodiment, even when the coils U1 and U2 are wound around the insulator 5 having the same structure, the coils can be wound in the same manner in the same row.

The insulator 5 according to the present embodiment includes a coil winding portion 50, a first flange portion 51, and a second flange portion 52, the coil winding portion 50 covering a part of one axial end surface and both circumferential side surfaces of the teeth 42 protruding from the core segment 41 and around which the coil 7 formed of a winding is wound, the first flange portion 51 being provided next to the base end side of the teeth 42 of the coil winding portion 50 and having a coil introduction groove 53 for guiding the coil 7 to the coil winding portion 50, and the second flange portion 52 being provided next to the tip end side of the teeth 42 of the coil winding portion 50. Coil holding portions 54 each including a plurality of grooves 55 are provided on outer circumferential surfaces 50c and 50d which are both circumferential side surfaces of the coil winding portion 50, while no groove is provided on outer circumferential surfaces 50a and 50b which are axial end surfaces of the coil winding portion 50. A plurality of projections 56 extending in the axial direction and protruding in the circumferential direction are formed at predetermined intervals on both circumferential side surfaces of the coil winding portion 50, thereby forming a plurality of grooves 55. The axial end 56a of the projection 56 is inclined such that the height of the projection 56 decreases toward the outer peripheral surface 50a, which is one end surface in the axial direction of the coil-wound portion 50.

By applying the insulator 5 according to the present embodiment to the stator 4 of the motor 1 shown in fig. 1, for example, the coils 7 can be wound in a row, and the dead space of the coil winding portion 50 where the coils 7 are not wound can be reduced. This can increase the space factor of the coil 7 in the slot 43, and can improve the efficiency of the motor 1.

(other embodiments)

In the above embodiment, the example in which the coil 7 is wound from the first flange portion 51 located on the base end side of the teeth 42, that is, on the core segment 41 side, has been described, but the present invention is not limited to this, and the winding may be started from the second flange portion 52 located on the tip end side of the teeth 42. At this time, the second flange portion 52 is provided with a coil introduction groove 53. The winding method of the coil 7 is not particularly limited, and a general nozzle winding method, a flying winding method, or the like can be used.

The outer peripheral surfaces 50a and 50b of the coil winding portion 50 may be provided substantially parallel to the axial upper end surfaces of the teeth 42. The inner surface 51a of the first flange portion 51 may be provided with: the surface orthogonal to the axial upper end surface or the axial lower end surface of the tooth 42 is used as a reference surface and inclined radially outward.

The insulator 5 in the above embodiment can be applied to a case where the coil 7 is wound in one layer or the coils 7 are wound in multiple layers.

In the above embodiment, the stator segment 40a is configured by attaching the insulator 5 to the teeth 42 of the core segment 41 and winding the coil 7 around the coil winding portion 50, but the insulator 5 may be attached to each of the teeth 42 of the annular stator core 40 and the coil 7 may be wound around the coil winding portion 50. Here, the annular stator core is formed by laminating annular plate bodies formed by punching electromagnetic steel plates. The annular stator core has a plurality of teeth (so-called teeth).

In the above embodiment, the description has been given of the form in which each core segment 41 has one tooth (so-called tooth), but a form in which each core segment 41 has a plurality of teeth (so-called teeth) may be adopted.

The case where the motor 1 in the above embodiment is used for an inner rotor type motor has been described, but it is needless to say that the insulator 5 in the present embodiment can be applied to other types of motors.

As shown in fig. 3, the teeth 42 have two concave grooves at their tips (radially inner ends). Such a concave groove is also called an auxiliary groove (auxiliary grooves) in the specification of U.S. Pat. No. 6104117 and Japanese patent application laid-open No. Hei 10-42531, etc. The auxiliary groove has an effect of suppressing cogging torque and torque ripple during rotation of the rotor 3 of the motor 1, and contributes to reduction in vibration, noise, and the like of the motor in terms of motor characteristics.

The coil 7 of the above embodiment is also referred to as a wire for winding, and is a commercially available coil. The conductor of the wire or the wire for winding contains copper or aluminum containing inevitable impurities. The inevitable impurities are trace impurity elements inevitably mixed into copper and aluminum in the production process. In the case of copper, the inevitable impurities are arsenic (As), bismuth (Bi), antimony (Sb), lead (Pb), iron (Fe), sulfur (S), oxygen, and the like. When aluminum is contained, inevitable impurities are silicon (Si), manganese (Mn), titanium (Ti), vanadium (V), zirconium (Zr), iron (Fe), copper (Cu), and the like. The conductor portion of the winding is covered with an insulating layer made of an insulating resin. The insulating resin can be selected from, for example, polyimide, polyamideimide, polyesterimide, polyesteramideimide, polyamide, polyhydantoin, polyurethane, polyacetal, epoxy resin, and the like, as appropriate according to the specification of the motor 1. The cross-sectional shape of the winding may be various shapes such as a substantially square shape and a substantially rectangular shape, in addition to the circular shape in the present embodiment.

The material composition of magnet 31 in the above embodiment contains iron (Fe) and boron (B), and at least one of scandium (Sc), yttrium (Y) and a lanthanoid element, or the material composition of magnet 31 contains iron (Fe), cobalt (Co) and boron (B), and at least one of scandium (Sc), yttrium (Y) and a lanthanoid element. Specifically, magnet 31 is a rare earth sintered magnet, and is called a so-called neodymium sintered magnet or the like. The surface layer of the rare earth sintered magnet has a rust preventive film (rust preventive layer) for preventing rust.

Industrial applicability-

The insulator according to the present invention can realize winding of coils in an aligned manner in accordance with the wire diameters of the coils having different wire diameters, and therefore, is useful when applied to a motor or the like requiring high efficiency.

-description of symbols-

1 electric motor

2 axle

3 rotor

4 stator

5 insulating body

6 insulating paper

7 coil

31 magnet

40 stator core

40a stator segment

41 iron core segment

41c yoke

42 teeth (tooth)

43 tooth groove

50 coil winding part

51 first flange part

51a inner surface of the first flange 51

52 second flange portion

53 coil lead-in groove

54 coil holding part

55 groove

56 projection

56a axial ends of the projection 56

Coil U1-W4

Claims

1. An insulator including a coil winding portion that covers an axial one-end surface and a part of both circumferential side surfaces of a tooth protruding from a core segment and around which a coil formed of a wire is wound, characterized in that:

a coil holding portion which is formed of a plurality of grooves and which positions and fixes the coil is provided on both circumferential side surfaces of the coil winding portion, and no groove is provided on one axial end surface of the coil winding portion,

a plurality of protrusions extending in the axial direction and protruding in the circumferential direction are formed at predetermined intervals on both circumferential side surfaces of the coil wound portion, respectively, thereby forming a plurality of the grooves,

one axial end of the projection is inclined such that the height of the projection decreases toward one axial end surface of the coil winding portion.

2. The insulator of claim 1, wherein:

one axial end of the projection is located at a predetermined distance from one axial end of the coil winding portion.

3. A stator, characterized by:

the stator includes a plurality of stator segments each having the insulator according to claim 1 on each axial end surface of the teeth of the core segment, and the coil is wound around the coil winding portion of the insulator,

the stator is constituted as follows: the plurality of stator segments are connected in a ring shape, and the teeth protrude toward a radially inner side of the ring.

4. A stator, characterized by:

the stator includes a plurality of stator segments each having the insulator according to claim 1 on each axial end surface of the teeth of the core segment, and the coil is wound and attached on the coil winding portion of the insulator, and the stator has the following structure: connecting a plurality of the stator segments into a ring shape, and the teeth protrude toward a radially inner side of the ring,

the insulator includes an insulator having a structure in which one axial end of the protrusion is located at a predetermined distance from one axial end surface of the coil winding portion.

5. A stator, characterized by:

the stator has the following structure: connecting a plurality of the stator segments into a ring shape, and the teeth protrude toward a radially inner side of the ring,

the insulators having the same shape are respectively attached to the respective axial end surfaces of the teeth.

6. A stator, characterized by:

the insulator includes an insulator having a structure in which one axial end of the protrusion is located at a predetermined distance from one axial end surface of the coil winding portion,

7. A stator, characterized by:

the coil is wound around the coil winding portion such that the winding is inclined with respect to a radial direction.

8. A stator, characterized by:

the coils are wound in an aligned manner around the coil winding portion.

9. A stator, characterized by:

gaps between the teeth adjacent in the circumferential direction are configured as slots for receiving the coils,

the insulating paper has a function of insulating the core segment from the coil and insulating the teeth from the coil, and is disposed in the tooth grooves so as to cover side surfaces of the teeth and to partially overlap with first and second flange portions provided on the insulator in an axial direction.

10. An electric motor characterized by:

the electric motor comprises at least a stator and a rotor,

the rotor includes a rotating shaft, and is disposed radially inward of the stator with a predetermined gap from the stator.