CN111566906A - Insulator, stator including the same, and motor including the same - Google Patents
Insulator, stator including the same, and motor including the same Download PDFInfo
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- CN111566906A CN111566906A CN201880085592.8A CN201880085592A CN111566906A CN 111566906 A CN111566906 A CN 111566906A CN 201880085592 A CN201880085592 A CN 201880085592A CN 111566906 A CN111566906 A CN 111566906A
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- coil
- stator
- insulator
- winding
- teeth
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/10—Applying solid insulation to windings, stators or rotors
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/32—Windings characterised by the shape, form or construction of the insulation
- H02K3/34—Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/46—Fastening of windings on the stator or rotor structure
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 tooth (42) radially inner end side of the coil winding portion (50) around which the coil (7) is wound. A movement stopper (54) comprising a projection and recess (54a) is provided on the surface of the coil winding section (50) from the root of the first flange section (51) to the inside in the radial direction. The average length of the uneven portion (54a) is shorter than the wire diameter of the coil (7), and the arithmetic average roughness Ra of the uneven portion (54a) is larger than the arithmetic average roughness Ra' of the smooth surface portion (55) which is a portion of the coil winding portion (50) other than the movement stopper portion (54).
Description
Technical Field
The present invention relates to an insulator on which a coil is wound, a stator including the insulator, and a motor including the insulator.
Background
In recent years, as the demand for industrial and vehicle-mounted motors has increased, it has been required to improve the efficiency of the motors and reduce the cost.
It is known that: one of the methods of improving the efficiency of the motor is to increase the space factor of the coils disposed in the stator slots of the stator. 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.
A so-called aligned winding coil, which is a state in which a coil is wound in alignment around a plurality of teeth (teeth) of a stator, is known as a structure for increasing a space factor of the coil. Various structures have been proposed to realize the aligned winding coil (see, for example, patent documents 1 to 4). Patent document 1 proposes the following configuration: a step or a slope is formed at the end of a cylinder of an insulated coil winding pipe for winding a coil or inside a flange part formed at both ends of the cylinder to realize the winding of the coil in an array. Patent document 2 discloses the following configuration: a receiving groove for receiving a wound coil is formed on a surface of an insulator mounted on the plurality of teeth (teeth) and insulating the coil from the plurality of teeth (teeth), thereby realizing an array of wound coils.
Patent document 1: japanese laid-open patent publication No. Hei 11-122855
Patent document 2: japanese laid-open patent publication No. 2006-115565
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
In general, the insulator and the coil bobbin are obtained by molding a resin material with a mold. On the other hand, since motor performance varies depending on user specifications, even if the same stator core or a plurality of teeth are used, the motor performance is often adjusted to each specification by changing the wire diameter or the number of turns of the coil to adjust the current value passing through the coil.
In the conventional structures disclosed in patent documents 1 and 2, it is necessary to change the width of the receiving groove or the width of the step or the angle of inclination depending on the wire diameter of the coil, and to form the insulator by newly manufacturing a mold each time, which causes an increase in cost.
The present invention has been made to solve the above problems, and an object of the present invention is to: provided is an insulator which can make the wound coil be wound in a whole column even if the wire diameter of the coil is changed.
Technical solution for solving technical problem
In order to achieve the above object, in the insulator according to the present invention, a surface of a coil winding portion around which a winding start portion of a coil is wound is surface-treated to restrict a winding wire wound from moving in a radial direction.
Specifically, an insulator according to the present invention includes a coil winding portion that covers an axial end surface and at least a part of circumferential both side surfaces of a tooth protruding from a core segment and around which a coil formed of a winding wire is wound, and a first flange portion that is provided next to one of a tooth base end side and a tooth radially inner end side of the coil winding portion and that has a coil introduction groove that guides the coil to the coil winding portion, the insulator being characterized in that: a movement restricting portion including an uneven portion that restricts movement of the winding wire in a radial direction is provided on a surface of the coil winding portion in the vicinity of the first flange portion, an average length of the uneven portion is shorter than a wire diameter of the coil, and an arithmetic average roughness of the uneven portion is larger than an arithmetic average roughness of a surface of the coil winding portion other than the movement restricting portion.
According to this configuration, the coil can be wound in an aligned manner with the winding wire wound around the movement restricting portion as a position reference while the movement of the winding start portion of the coil to the outside or inside in the radial direction of the insulator is restricted. By appropriately selecting the width of the movement restricting portion and the arithmetic average roughness of the concave-convex portion, it is possible to wind coils in an aligned manner even when coils having different wire diameters are wound on the insulator.
Preferably, the movement stopper portion is provided at a position which is more than half of the wire diameter of the coil and less than 1/3 of the radial length of the coil winding portion from the first flange portion toward the radially inner side.
According to this configuration, the movement of the wire wound around the movement restricting portion can be reliably restricted.
Preferably, the movement restricting portion has an arithmetic average roughness of the concave-convex portion of 10 μm or more and 100 μm or less.
The uneven portion of the movement restricting portion may be formed by sandblasting a surface of the coil winding portion. The concavo-convex portion may also be formed by subjecting the surface of the coil-wound portion to a thermal aluminum spraying process, and the concavo-convex portion may also be formed by subjecting the surface of the coil-wound portion to an etching process.
According to the above configuration, the uneven portion can be formed by a simple method, and an increase in the manufacturing cost of the insulator can be suppressed.
Preferably, it is constituted such that: the coil wound around the movement restricting portion is restricted from moving in a radial direction, and when the coil is wound, the coil wound around the coil winding portion other than the movement restricting portion is pushed radially outward by the last turn of the coil in the first layer of the coil and moves, thereby winding the first layer of the coil in an aligned manner.
According to this configuration, the coil wound around the portion other than the movement restricting portion abuts against the coil wound around the movement restricting portion, and thereby the coil is sequentially moved radially inward to eliminate the gap between the coils, and the first layer of coils can be wound in an aligned manner around the coil winding portion.
The stator according to the present invention is characterized in that: the stator is configured such that the plurality of stator segments are connected in a ring shape and the teeth protrude inward in a radial direction of the ring, and the plurality of stator segments are configured such that the insulator is provided on each axial end surface of the teeth of the core segment, and the coil is wound around the coil wound portion of the insulator.
According to this configuration, the space factor of the coil in the stator can be increased.
Preferably, the coil is wound in an array on the coil winding part.
Preferably, gaps between the teeth adjacent in the circumferential direction are configured as stator slots that house the coils, and in the stator slots, insulating paper that insulates the core segments from the coils and the teeth from the coils is arranged so as to cover side surfaces of the teeth and to partially overlap the first flange portion and the second flange portion of the insulator in the axial direction, respectively, and the second flange portion is provided so as to be adjacent to the other of the tooth base end side and the tooth radially inner end side of the coil wound portion.
According to this configuration, the teeth adjacent to each other in the circumferential direction of the stator can be reliably electrically insulated from each other.
The motor of the present invention is characterized in that: the stator includes a plurality of stator segments having the insulator on each axial end surface of the teeth of the core segment and the coil wound around the coil wound portion of the insulator, the stator includes a ring-shaped connection of the plurality of stator segments and a configuration in which the teeth protrude inward in a radial direction of the ring, and the rotor includes a rotating shaft, and the rotor is provided on the inner side in the radial direction of 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, even when coils having different wire diameters are wound, it is possible to realize winding of coils in an aligned row while suppressing occurrence of winding disorder.
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 view of the stator.
Fig. 4A is a perspective view illustrating a portion enclosed by a dotted line shown in fig. 1.
Fig. 4B is a side view of the configuration shown in fig. 4A, viewed from the radial direction.
Fig. 4C is a side view of the configuration shown in fig. 4A, as viewed 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 view of the insulator as viewed from the axial direction.
Fig. 5C is a schematic cross-sectional view taken along line VC-VC of fig. 5B.
Fig. 6 is a schematic diagram showing a process of winding a coil in an array on an insulator according to an embodiment.
Detailed Description
Embodiments of the present invention will be described in detail below with reference to the accompanying 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 of 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 view of a stator, which is a view of a stator 4 viewed from an axial direction of a shaft 2. For convenience of explanation, illustration and explanation of some constituent components and their functions are omitted in fig. 1 and 3. For example, frames, bus bars, and the like are not shown. 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 cylindrical body, a substantially square body, a substantially rectangular parallelepiped body, a polygonal columnar body, or the like made of metal, and can be appropriately selected according to the specification of the motor 1. The structural components shown in the drawings are also simplified, 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, the sign + indicates the start of coil winding, and the sign-indicates 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 thereof 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 thereof, i.e., the side on which the stator core 40 is provided, 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 a plurality of teeth (teeth: plural form of tooth) and tooth (tooth) are used in a differentiated manner. A plurality of teeth projecting in the center direction of the annular stator core 40 are referred to as a plurality of teeth (tooth: complex form) 42. One of the plurality of tooth portions of the stator core 40 is denoted as a tooth 42. Similarly, a plurality of teeth of the core segment 41 described later are referred to as a plurality of teeth 42. One of the plurality of teeth of the core segment 41 is denoted as a tooth 42. Patent documents 3 and 4 are well-known documents that use words such as a plurality of teeth and teeth separately.
The motor 1 includes, inside an outer housing body not shown: a rotor 3 having a shaft 2 as a rotation shaft of the motor 1, a stator 4, and coils U1 to W4.
The rotor 3 includes a shaft 2 and magnets 31, the magnets 31 being arranged to oppose the stator 4 with N poles and S poles alternating with each other along the outer circumferential direction of the shaft 2. In the present embodiment, the magnet 31 used for the rotor 3 is a neodymium magnet, but the material, shape, and material thereof may be appropriately changed in accordance with the output of the motor or the like. The rotor 3 is disposed radially inside the stator 4 with a certain space from the stator 4 as viewed in the axial direction.
The stator 4 is a cylindrical body formed 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, respectively, and insulators such as insulating paper 6 are further 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 (see fig. 4A to 4C) of the insulators such as the insulating paper 6. The stator segment 40a having the above-described configuration has a cylindrical shape having a substantially fan-shaped cross section.
The stator 4 and the stator segment 40a have a plurality of core segments 41 and teeth 42 projecting radially inward from the inner periphery of each of the core segments 41. An electromagnetic steel sheet containing silicon or the like is punched into a substantially annular stator core plate (stator core sheet), the stator core plate is punched into an independent sheet-shaped core segment plate (core segment sheet) constituting a part of the stator core plate, and the core segment plates are laminated in multiple layers to form a laminated body, which is the core segment 41. The core segment 41 having the above-described configuration has an external appearance of a columnar body having a sectional shape of an independent sheet constituting a part of a substantially annular stator core plate. 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 protruding 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 projection 41b formed in the other side surface, and the recess 41a and the projection 41b extend in the entire axial direction on each side surface. When one core segment 41 is described, 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. By fitting and connecting the core segments 41 adjacent in the circumferential direction to each other in this way, the annular stator core 40 can be formed.
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 stator slot 43.
The stator 4 has 12 coils U1 to W4, which are attached to the respective teeth 42 via insulators 5 and insulating paper 6 (see fig. 4A to 4C) and arranged in the respective stator slots 43 as viewed in the axial direction. 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 having an insulating film coated on the surface thereof, wound in a row around the insulator 5, and wound in multiple layers, not shown. The multilayer winding refers to a state in which the coil 7 is wound on the insulator 5 in multiple layers. 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 is meant in the following description. In the following description, the coils U1 to W4 are not particularly specified, and when the structure and the like are described by selecting one, they will be referred to as the 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 the three phases U, V, and W are connected by a star connection method. 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, to rotate.
In the present embodiment, the number of magnetic poles of the rotor 3 is 10 in total, and the number of stator slots 43 is 12, with 5N poles and 5S poles facing the stator 4, but the present invention is not limited to this, and other combinations of the number of magnetic poles and the number of stator slots are also applicable.
[ constitution of main portion of stator segment ]
Fig. 4A to 4C show a perspective view of a portion encircled by a broken line of fig. 1, and side views viewed from the radial direction and the circumferential direction, respectively. For convenience of explanation, the coil 7 is not shown in fig. 4A to 4C. Although 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, they are shown in a state before they are bent and housed in the stator slots 43.
As shown in fig. 4A to 4C, insulators 5 having the same shape are attached to teeth 42 protruding from one core segment 41 from both upper and lower end faces in the axial direction, respectively; 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 includes a coil winding portion 50 around which the coil 7 (see fig. 6) 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 radial inner end of the tooth 42 located on the radial inner side of the stator 4. A coil introduction groove 53 (see fig. 5A and 5B) is formed in the first flange portion 51, and when the coil 7 is wound around the coil winding portion 50, the coil forming the coil 7 is guided toward the coil winding portion 50 by the coil introduction groove 53, and the winding start portion is brought into contact with an inner surface 51a of the first flange portion 51 facing the second flange portion 52 (hereinafter, referred to as an inner surface 51a of the first flange portion 51, see fig. 5A to 5C) and guided to the coil winding portion 50. The inner surface 51a of the first flange 51 is parallel to a surface perpendicular to the axial upper end surface or the axial lower end surface of the teeth 42. 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.
On the outer peripheral surfaces 50a to 50d of the coil winding portion 50 (hereinafter, may be simply referred to as the surface of the coil winding portion 50), a movement restricting portion 54 extending radially inward from the root portion of the first flange portion 51 is formed. As will be described later, the movement restricting portion 54 is surface-treated to ensure that the arithmetic average roughness Ra (see fig. 5C) is larger than the surface of the coil winding portion 50 other than the movement restricting portion 54 (hereinafter referred to as a smooth surface portion 55). The coil winding portion 50 is formed to have a thickness of, for example, about 0. several mm to several mm in order to maintain electrical insulation between the coil 7 and the teeth 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 the teeth 42 from the coil 7. The insulator 5 also 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 is provided so as to cover both circumferential side surfaces of the teeth 42 or to partially overlap the first flange portion 51 and the second flange portion 52 of the insulator 5 in the axial direction. When assembling the motor 1, the insulating paper 6 is bent to cover the inside of the stator groove 43, and is not shown. 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 perspective view showing a main part of an insulator according to the present embodiment, fig. 5B is a schematic view showing a main part of an insulator on which a coil is wound as viewed in an axial direction, and fig. 5C is a schematic cross-sectional view taken along line VC-VC of fig. 5B. The insulator 5 shown in fig. 5A to 5C is the same as that shown in fig. 4A to 4C, and for convenience of explanation, the structure of the insulator 5 is simplified and shown in fig. 5A to 5C.
As shown in fig. 5A to 5C, a movement stopper portion 54 is provided on the surface of the coil wound portion 50 of the insulator 5 with a predetermined width W from the root portion of the first flange portion 51, that is, from the axial lower end of the inner surface 51a of the first flange portion 51 toward the radial inner side. As shown in fig. 5C, the movement stopper portion 54 is formed of a randomly formed uneven portion 54a, and the uneven portion 54a is formed such that the arithmetic average roughness Ra of the surface thereof is 2 μm or more and 200 μm or less. On the other hand, the arithmetic average roughness Ra 'of the surface of the smooth surface portion 55 is smaller than the arithmetic average roughness Ra of the uneven portion 54a, and is about several tens to several hundreds of Ra, and in the present embodiment, Ra' is about 0.25 μm to 0.30 μm, for example. The average length L of the concave-convex portion 54a is a value of the same degree as the arithmetic average roughness Ra, and the concave-convex portion 54a is formed so that the average length L is shorter than the wire diameter of the coil 7 wound around the coil winding portion 50. As shown in fig. 5C, the average length L corresponds to, for example, an average value of pitches between the convex portion and the convex portion adjacent thereto or an average value of pitches between the concave portion and the concave portion adjacent thereto in the concave-convex portion 54 a. Generally, the coil 7 is formed by forming an insulating coating on the surface of an electric wire made of copper or the like. Therefore, when referring to the wire diameter of the coil 7, it means the wire diameter including the thickness of the insulating coating. In the present embodiment, the wire diameter of the wire used for the coil 7 is, for example, about 0.3mm to 2.3mm, and the wire diameter of the coil 7 is a value obtained by adding 2 times the thickness of the insulating coating to the wire diameter of the wire.
The uneven portion 54a is formed by surface-treating the surface of the coil-wound portion 50. The surface treatment can be carried out by various methods. For example, a portion of the surface of the coil winding portion 50 other than the portion where the movement stopper portion 54 is to be formed is covered with a protective material (not shown). The uneven portion 54a can be formed by performing blasting on the surface not covered with the protective material. The arithmetic average roughness Ra of the concave-convex portion 54a can be brought to a desired value by adjusting the average particle diameter, the blasting speed, the processing time, and the like of the blasted abrasive. The uneven portion 54a can be formed by spraying particles obtained by melting and softening aluminum on the surface of the coil wound portion 50 not covered with the protective material. By performing the thermal aluminum spraying treatment, the arithmetic average roughness Ra of the concave-convex portion 54a can be set to a relatively large value, and for example, Ra can be set to about several tens μm to 100 μm.
The uneven portion 54a can also be formed by etching the surface of the coil-wound portion 50. The "etching treatment" referred to herein includes both so-called physical etching and chemical etching. Examples of physical etching are: the uneven portion 54a can be formed by plasma etching the surface of the coil-wound portion 50 not covered with the protective material using argon gas or the like. Examples of chemical etching are: the uneven portion 54a can be formed by etching the surface of the coil-wound portion 50 not covered with the protective material with a chemical solution. If the material of the insulator 5 is, for example, a polyamide resin, the irregularities 54a can be formed by surface treatment using a chemical solution containing a strong acid such as concentrated hydrochloric acid or concentrated sulfuric acid. The method of forming the uneven portion 54a is not limited to the above method, and other methods may be appropriately employed depending on the desired Ra value, the material of the insulator 5, and the like. Of course, after the surface treatment for forming the concave-convex portion 54a is performed, the protective material is removed.
Fig. 6 is a schematic diagram showing a process of winding a coil in an aligned manner on an insulator according to the present embodiment. Note that, in fig. 6, a winding process of the first layer of the coil 7 is shown.
As shown in fig. 6 (a), when the coil 7 is wound around the movement restricting portion 54, the coil is restricted from moving in the radial direction due to friction between the coil and the movement restricting portion 54. If the winding process is continued, the winding of the coil 7 is also wound on the smooth surface portion 55 as shown in fig. 6 (b), and the winding process of the coil 7 is continued to wind the coil 7 for the last one turn. In this winding step, as shown in fig. 6 (c), the i-th winding (i is an integer, 2 ≦ i ≦ n, and n is the number of windings of the first layer of the coil 7) is wound while being superimposed on the (i-1) -th winding by a predetermined offset amount and inclined at a predetermined angle with respect to the axial direction at the winding start portion of the coil 7. Particularly, the operation is performed in accordance with the above points when winding the winding wire of the nth circumference. As described above, by winding the coil of the coil 7 around the coil winding portion 50, the coil of the (i-1) th circumference is pushed outward by the coil of the i-th circumference, and a force directed radially outward is applied. The amount of shift is adjusted to be equal to or less than half the wire diameter of the coil 7.
Here, since the arithmetic average roughness Ra' of the smooth surface portion 55 is smaller than the arithmetic average roughness Ra of the concave-convex portion 54a, the friction generated between the winding and the smooth surface portion 55 is also smaller than the friction generated between the winding and the movement stopper portion 54. That is, the smooth surface portion 55 has a smooth surface, the degree of smoothness of which ensures: when the wound wire is subjected to an external force in the radial direction, the coil 7 can move in the radial direction along the surface. Therefore, the winding on the smooth surface portion 55 pushed back by the winding of the last round moves radially outward along the surface of the smooth surface portion 55 together with the winding of the last round. At this time, as described above, the movement of the winding wound around the movement restricting portion 54 in the radial direction is restricted. Therefore, the windings wound on the smooth surface portion 55 and positioned on the outermost side in the radial direction abut against the windings wound on the movement restricting portion 54, and the windings wound on the smooth surface portion 55 move in sequence with the abutting position as a reference, so that the gaps between the windings are eliminated, and the coils 7 of the first layer are wound in the coil winding portion 50 in an aligned manner.
After the last turn of the coil 7, the coil 7 of the second layer is wound from the side opposite to the first layer, that is, from the second flange portion 52 toward the first flange portion 51. In the case of single-layer winding, the last winding turn is further pulled toward the first flange 51 in order to draw the winding turn to the outside. The wire wound on the smooth surface portion 55 is pushed back toward the radially outer side by the last turn of the wire by the tensile force at this time. As described above, the position of the winding of the coil 7 of the first layer is also corrected and wound in an aligned manner. When the length of the coil winding portion 50 in the radial direction is substantially equal to an integral multiple of the wire diameter of the coil 7, the last winding of one turn abuts against the inner surface of the second flange portion 52 and is forced radially outward. As described above, the position of the winding of the coil 7 of the first layer is also corrected and wound in an aligned manner. Since the coil 7 can be wound in a row by radially moving the winding wire wound on the smooth surface portion 55 in contact with the last winding wire in the circumferential direction outward in the radial direction, it is not necessary to give the offset amount when winding the coil 7 as described above as long as the winding condition satisfies the external force applied to the winding wire wound on the smooth surface portion 55 outward in the radial direction.
In order to restrict the movement of the coil 7, the predetermined width W of the movement restricting portion 54 may be equal to or more than half the wire diameter of the wound coil 7. However, in order to correspond to the coils 7 having different wire diameters, the predetermined width W is preferably set to be equal to or larger than the maximum wire diameter of the coil 7 to be used. The predetermined width W is preferably set to be equal to or less than 1/3 of the radial length of the coil winding portion 50. This is because if the width of the movement stopper portion 54 in the radial direction is made longer, the winding disorder of the winding wire by the movement stopper portion 54 cannot be ignored, and the coil 7 cannot be wound in a good array. Therefore, the movement stopper 54 is preferably provided at a position radially inward from the first flange 51, which is equal to or more than half the wire diameter of the coil 7 and equal to or less than 1/3 the radial length of the coil winding portion 50.
[ Effect and the like ]
As described above, the insulator 5 according to the present embodiment includes the coil winding portion 50 and the first flange portion 51, the coil winding portion 50 covers a part of one axial end surface and both circumferential side surfaces of the teeth 42 protruding from the core segment 41 and winds the coil 7 formed of a winding, and the first flange portion 51 is provided next to the base end side of the teeth 42 of the coil winding portion 50 and includes the coil introduction groove 53 that guides the coil 7 to the coil winding portion 50.
On the surface of the coil winding portion 50, a movement restricting portion 54 formed of an uneven portion 54a extending radially inward is formed with a predetermined width W from the root portion of the first flange portion 51 corresponding to the winding start portion of the coil 7, and the movement restricting portion 54 restricts the movement of the wound wire radially outward or inward. On the surface of the coil winding portion 50, next to the movement restricting portion 54, there is provided a smooth surface portion 55 having a smooth surface of a degree ensuring: the windings of the coil 7 can move in the radial direction.
In this way, when winding the coil 7, the position of the coil 7 pushed outward in the radial direction by the last winding is restricted by the winding wound around the movement restricting portion 54, and the coil 7 is wound around the coil winding portion 50 in an aligned manner. In this manner, the insulator 5 according to the present embodiment is useful when the coils 7 wound in a single layer or in multiple layers are wound in an aligned manner.
By appropriately selecting the width W of the movement restricting portion 54, it is possible to cope with a case where the wire diameter of the wound coil 7 is changed. For example, if the length of the coil winding portion 50 in the radial direction is about ten mm to several tens of mm, the coils 7 can be wound in an aligned manner on the coil winding portion 50 by setting the width W of the movement restricting portion 54 to about 3mm even if the wire diameter of the coil 7 to be used varies in the range of 0.3mm to 2.3 mm. In this way, even if the wire diameter of the wound coil 7 is changed, it is not necessary to change the width of the coil accommodating groove provided in the insulator as disclosed in patent document 2, or to change the width and inclination angle of the step portion provided in the insulator as disclosed in patent document 1, and thus it is possible to suppress an increase in the manufacturing cost of the insulator 5. Further, since the movement stopper 54 can be formed by performing a simple surface treatment, the manufacturing cost of the insulator 5 can be suppressed. Further, when the wire diameter of the coil 7 is changed, the core segments 41 and the teeth 42 of the same specification can be dealt with by one kind of the insulator 5, and development cost can be reduced when developing various motors.
From the viewpoint of easily forming the concave-convex portion 54a, the arithmetic average roughness Ra of the concave-convex portion 54a is preferably 2 μm or more and 100 μm or less. From the viewpoint of increasing the friction between the winding and the concave-convex portion 54a, the arithmetic average roughness Ra of the concave-convex portion 54a is several tens μm, for example, preferably 30 μm or more, and from the viewpoint of ease of formation, the arithmetic average roughness Ra is more preferably 30 μm or more and 100 μm or less.
Note that: 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 radially inner end side of the teeth 42 of the coil winding portion 50.
In this case, a movement restricting portion 54 composed of an uneven portion 54a for restricting the movement of the coil in the radial direction is provided on the surface of the coil winding portion 50 near the first flange portion 51. The average length L of the uneven portion 54a is shorter than the wire diameter of the coil 7, and the arithmetic average roughness Ra of the uneven portion 54a is larger than the arithmetic average roughness Ra' of the surface of the smooth surface portion 55, which is a portion of the coil winding portion 50 other than the movement stopper portion 54.
(other embodiments)
In the above embodiment, the example in which the coil 7 is wound from the first flange portion 51 located closer to the base end of the tooth 42, that is, closer to the core segment 41, has been described, but the present invention is not limited thereto, and the winding may be started from the second flange portion 52 located closer to the radially inner end of the tooth 42. In this case, the second flange portion 52 is provided with a coil introduction groove 53, and a movement restricting portion 54 is formed from the root portion of the second flange portion 52 with a predetermined width W.
The winding method of the coil 7 is not particularly limited, and a general nozzle winding method, a fly winding method, or the like can be used.
Further, an example is shown in which the insulator 5 is a so-called split insulator and is mounted thereon from the axial upper and lower directions of the teeth 42, respectively, but not limited thereto, and may be: the coil winding portion 50 is cylindrical and has an integral structure covering the entire outer peripheral surface of the teeth 42. For example, when the stator 4 is constructed such that the teeth 42 are later attached to the core segments 41, the insulator 5 of the integral structure may be employed. Further, the insulator 5 attached to one tooth from the upper and lower directions may be different in shape. By using the insulator 5 having the same shape as the insulator 5 attached to one tooth 42 from the upper and lower directions, the number of types of insulators 5 can be reduced, and the manufacturing cost can be reduced.
The outer peripheral surfaces 50a and 50b of the coil winding portion 50 may be substantially parallel to the axial upper end surfaces of the teeth 42. The inner surface 51a of the first flange 51 may be inclined radially outward with respect to a plane perpendicular to the axial upper end surface or the axial lower end surface of the tooth 42.
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 wound portion 50, but the insulator 5 may be attached to each tooth 42 of the annular stator core 40 and the coil 7 may be wound around the coil wound 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 multiple teeth (teeth)).
In the above embodiment, the embodiment has been described in which each core segment 41 has one tooth portion (so-called tooth), but a plurality of tooth portions (so-called teeth) may be provided for each core segment 41.
The motor 1 of the above embodiment has been described as being used for an inner rotor motor, but it is obvious that the insulator 5 of 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 radially inner ends (radially inner ends). The concave groove is also referred to as 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 and noise of the motor.
The winding wire of the above embodiment is also referred to as a wire for winding, and is a commercially available product. The wire or the conductor part of the wire for winding contains copper or aluminum containing inevitable impurities. The inevitable impurities are trace impurity elements that are inevitably mixed into copper and aluminum during the production process. In the case of copper, unavoidable impurities are arsenic (As), bismuth (Bi), antimony (Sb), lead (Pb), iron (Fe), sulfur (S), oxygen, etc. In the case of aluminum, 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 any of 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), boron (B), and at least one of scandium (Sc), yttrium (Y), and a lanthanoid element, or the material composition of magnet 31 in the present embodiment 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, 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 be applied to a motor or the like which requires high efficiency because it can be wound in an aligned manner by accommodating coils having different wire diameters.
-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 stator slot
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 movement limiting part
54a uneven part
55 smooth surface section
Coil U1-W4
Width of the W movement stopper 54 in the radial direction
Claims (8)
1. An insulator including a coil winding portion for winding a coil formed of a wire so as to cover an axial end surface and at least a part of both side surfaces in a circumferential direction of a tooth protruding from a core segment, and a first flange portion provided next to one of a tooth base end side and a tooth radially inner end side of the coil winding portion and having a coil introduction groove for guiding the coil to the coil winding portion, the insulator characterized in that:
a movement restricting portion formed of an uneven portion is provided on a surface of the coil winding portion in the vicinity of the first flange portion, the movement restricting portion restricting the movement of the winding wire in the radial direction,
the average length of the uneven portion is shorter than the wire diameter of the coil, and the arithmetic average roughness of the uneven portion is larger than the arithmetic average roughness of the surface of the coil winding portion other than the movement restricting portion.
2. The insulator of claim 1, wherein:
the movement stopper is provided at a position radially inward from the first flange at least half of the wire diameter of the coil and at most 1/3 of the radial length of the coil winding part.
3. The insulator of claim 1, wherein:
the movement stopper has an arithmetic average roughness of the concave-convex portion of 10 μm to 100 μm.
4. The insulator of claim 1, wherein:
the structure is as follows: the coil wound around the movement restricting portion is restricted from moving in a radial direction, and when the coil is wound, the coil wound around the coil winding portion other than the movement restricting portion is pushed radially outward by the last turn of the coil in the first layer of the coil and moves, thereby winding the first layer of the coil in an aligned manner.
5. A stator, characterized by:
the stator core of the present invention is characterized by comprising a plurality of stator segments each having the insulator according to claim 1 on each axial end face of the teeth of the core segment, the stator segments being formed by winding and attaching the coil on the coil winding portion of the insulator,
the stator is formed by connecting a plurality of stator segments into a ring shape, and the teeth protrude radially inward of the ring.
6. A stator, characterized by:
the stator core of the present invention is characterized by comprising a plurality of stator segments each having the insulator according to claim 1 on each axial end face of the teeth of the core segment, the stator segments being formed by winding and attaching the coil on the coil winding portion of the insulator,
the stator includes a plurality of stator segments connected in a ring shape and the teeth protrude radially inward of the ring,
the coils are wound in an array on the coil winding part.
7. A stator, characterized by:
the stator core of the present invention is characterized by comprising a plurality of stator segments each having the insulator according to claim 1 on each axial end face of the teeth of the core segment, the stator segments being formed by winding and attaching the coil on the coil winding portion of the insulator,
the stator includes a plurality of stator segments connected in a ring shape and the teeth protrude radially inward of the ring,
gaps between the teeth adjacent in the circumferential direction are configured as stator slots that receive the coils,
in the stator slot, an insulating paper for insulating the core segment from the coil and the teeth from the coil is disposed so as to cover side surfaces of the teeth, and is partially overlapped with the first flange portion and the second flange portion of the insulator in the axial direction, respectively, and the second flange portion is provided so as to be bonded to the other of the tooth base end side and the tooth radially inner end side of the coil winding portion.
8. An electric motor characterized by:
the stator includes at least a stator and a rotor, the stator including a plurality of stator segments each having the insulator according to claim 1 on each axial end face of the teeth of the core segment, the stator segments being formed by winding and mounting the coil on the coil winding portion of the insulator, the stator including a plurality of stator segments connected in a ring shape, the teeth protruding radially inward of the ring,
the rotor includes a rotating shaft, and is disposed radially inward of the stator with a predetermined gap from the stator.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2018007174 | 2018-01-19 | ||
| JP2018-007174 | 2018-01-19 | ||
| PCT/JP2018/046804 WO2019142584A1 (en) | 2018-01-19 | 2018-12-19 | Insulator, and stator and motor comprising same |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN111566906A true CN111566906A (en) | 2020-08-21 |
Family
ID=67301009
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201880085592.8A Withdrawn CN111566906A (en) | 2018-01-19 | 2018-12-19 | Insulator, stator including the same, and motor including the same |
Country Status (3)
| Country | Link |
|---|---|
| JP (1) | JPWO2019142584A1 (en) |
| CN (1) | CN111566906A (en) |
| WO (1) | WO2019142584A1 (en) |
Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH05258940A (en) * | 1992-03-12 | 1993-10-08 | Murata Mfg Co Ltd | Coil |
| JP2000341896A (en) * | 1999-05-25 | 2000-12-08 | Mitsubishi Electric Corp | Rotating machine |
| JP2008206322A (en) * | 2007-02-21 | 2008-09-04 | Mitsubishi Electric Corp | Armature insulating sheet and armature |
| JP2013243836A (en) * | 2012-05-21 | 2013-12-05 | Mitsubishi Electric Corp | Insulator of armature and armature |
| CN205864122U (en) * | 2016-06-17 | 2017-01-04 | 珠海格力节能环保制冷技术研究中心有限公司 | A kind of insulation framework and servomotor |
Family Cites Families (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS5926567Y2 (en) * | 1976-02-05 | 1984-08-02 | 日本テクニカル株式会社 | coil bobbin |
-
2018
- 2018-12-19 CN CN201880085592.8A patent/CN111566906A/en not_active Withdrawn
- 2018-12-19 JP JP2019565777A patent/JPWO2019142584A1/en active Pending
- 2018-12-19 WO PCT/JP2018/046804 patent/WO2019142584A1/en active Application Filing
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH05258940A (en) * | 1992-03-12 | 1993-10-08 | Murata Mfg Co Ltd | Coil |
| JP2000341896A (en) * | 1999-05-25 | 2000-12-08 | Mitsubishi Electric Corp | Rotating machine |
| JP2008206322A (en) * | 2007-02-21 | 2008-09-04 | Mitsubishi Electric Corp | Armature insulating sheet and armature |
| JP2013243836A (en) * | 2012-05-21 | 2013-12-05 | Mitsubishi Electric Corp | Insulator of armature and armature |
| CN205864122U (en) * | 2016-06-17 | 2017-01-04 | 珠海格力节能环保制冷技术研究中心有限公司 | A kind of insulation framework and servomotor |
Also Published As
| Publication number | Publication date |
|---|---|
| WO2019142584A1 (en) | 2019-07-25 |
| JPWO2019142584A1 (en) | 2021-01-07 |
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| PB01 | Publication | ||
| PB01 | Publication | ||
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Application publication date: 20200821 |