CN117063376A - Stator, rotating electrical machine, method for manufacturing stator, and method for manufacturing rotating electrical machine - Google Patents

Abstract

A plurality of pole pieces (10) to which a pair of resin insulators (25) are attached are wound and attached with a lead wire (20) and are arranged in a circular ring shape, the insulators (25) are provided with a snap-in female part (37) at one circumferential end of an axial end part, and a snap-in male part (38) at the other circumferential end, the snap-in female part (37) has an open-loop part (37 a) formed with an opening, the snap-in male part (38) has a columnar part (38 b) extending in the axial direction from a base part (38 a), the pole pieces (10) adjacent to each other are coupled to each other in a swingable manner by snap-fitting the columnar part (38 b) to the open-loop part (37 a), and a coupling part coupled to each other is welded to form a welded part (40).

Description

Stator, rotating electrical machine, method for manufacturing stator, and method for manufacturing rotating electrical machine

Technical Field

The present application relates to a stator, a rotating electrical machine, a method of manufacturing a stator, and a method of manufacturing a rotating electrical machine.

Background

A stator of a rotating electric machine has been disclosed in which pole pieces each formed by dividing an iron core in teeth are connected to each other by an insulator so as to be bendable in a direction perpendicular to a rotation output shaft direction (hereinafter, abbreviated as an axial direction) (for example, refer to patent document 1).

According to this configuration, in order to wind the teeth of the pole pieces, the angle of the connecting portions between the insulators is changed so that the teeth are positioned on the outer diameter side, and the wire can be wound around the teeth without causing interference between the adjacent pole pieces, so that the space factor of the winding can be increased.

Prior art literature

Patent literature

Patent document 1: japanese patent laid-open No. 2006-254569

Disclosure of Invention

Problems to be solved by the invention

However, in patent document 1, in order to connect adjacent pole pieces to each other using insulators, two kinds of insulators having different shapes need to be prepared. Therefore, there is a problem that the number of kinds of components increases and the process is complicated.

Further, although a mechanism for inserting and extracting each pole piece in the axial direction is provided for connection and rotation of the pole pieces, when the teeth are arranged radially outward in a V-shape with a reverse warp for winding the teeth of the pole pieces, a holding mechanism and the like must be prepared for preventing the pole pieces after connection from being displaced in the axial direction, which results in a problem that the manufacturing process becomes complicated.

If a plurality of pole pieces are wound continuously with a connection wire, the connection wire may be moved and difficult to be fixedly disposed at a fixed position when the teeth of the pole pieces are disposed radially inward to be looped, and a step of fixedly disposing the connection wire at a predetermined position may be required.

The present application has been made to solve the above-described problems, and an object thereof is to provide a low-cost and high-performance stator, a rotary electric machine, a method of manufacturing the stator, and a method of manufacturing the rotary electric machine, which do not increase the number of components and manufacturing steps.

Means for solving the problems

The stator disclosed by the application comprises a plurality of magnetic pole pieces, wherein teeth are integrally formed by protruding from an arc-shaped yoke part towards the inner side in the radial direction, a pair of resin insulators are respectively arranged on each magnetic pole piece in the axial direction perpendicular to the radial direction, the magnetic pole pieces on which the insulators are arranged are in a circular ring shape in a state of winding and installing wires,

one of the insulators adjacent to each other and attached to the pole pieces in the annular arrangement is provided with a snap-fit female portion, the other insulator is provided with a snap-fit male portion having an open-loop portion formed with an opening portion opening in a direction perpendicular to an axial direction, the snap-fit male portion has a columnar portion extending in an axial direction from a base portion bulging in a circumferential direction and a radial direction, the pole pieces are coupled to each other swingably by snap-fitting the columnar portion to the open-loop portion, and a fixing portion for fixing the coupling portion is formed at least one of coupling portions coupled to each other by the snap-fit coupling.

The rotating electrical machine disclosed by the application is provided with the stator with the structure and the rotor, wherein the rotor is rotatably and coaxially arranged on the inner peripheral surface side of the stator.

The manufacturing method of the stator disclosed by the application comprises the following steps:

an insulating assembly step of attaching the insulator to the pole piece;

a wiring step of repeating a winding step of intensively winding a wire around one of the pole pieces after the insulating assembly step and a connecting step of guiding the wire as a connecting wire to the next pole piece to be wound without cutting the wire after the winding step;

an annular step of arranging each of the magnetic pole pieces in an annular shape after the winding of the lead wire around all the magnetic pole pieces is completed in the wiring step, and connecting all the magnetic pole pieces adjacent to each other by the snap-fit connection of the insulator; and

and a fixing step of fixing the connecting parts which are mutually buckled and combined.

The manufacturing method of the rotating electrical machine disclosed by the application comprises the following steps: after the stator manufacturing process, a rotor is rotatably and coaxially arranged on the inner peripheral surface side of the stator.

Effects of the application

According to the stator, the rotating electrical machine, the method of manufacturing the stator, and the method of manufacturing the rotating electrical machine disclosed by the present application, it is possible to obtain a low-cost, small-sized, and high-performance product without unnecessarily increasing the number of components. Further, according to the method for manufacturing a stator and the method for manufacturing a rotating electrical machine disclosed in the present application, manufacturing can be performed without increasing the number of manufacturing steps, and thus manufacturing costs can be suppressed.

Drawings

Fig. 1 is a schematic cross-sectional view showing a stator of a rotary electric machine according to embodiment 1.

Fig. 2 is a perspective view showing one pole piece constituting the stator of embodiment 1.

Fig. 3 is a wiring diagram showing a wiring state of each pole piece of the stator of embodiment 1.

Fig. 4 is a wiring diagram schematically showing a wiring state in which all the pole pieces constituting the stator of embodiment 1 are arranged in a straight line.

Fig. 5 is a perspective view of embodiment 1 in which two insulators are attached to a pole piece as seen from the inside in the radial direction of a stator.

Fig. 6 is a front view of the state in which two insulators are attached to a pole piece as seen from the radial outside of a stator in embodiment 1.

Fig. 7 is a perspective view of one insulator attached to a pole piece as seen from the radially inner side in embodiment 1.

Fig. 8 is a perspective view of the insulator as seen from the radially outer side in embodiment 1.

Fig. 9 is a plan view showing a state in which two adjacent pole pieces to which insulators are attached in embodiment 1 are engaged and arranged in a straight line.

Fig. 10 is a perspective view showing a state in which the members of the structure of fig. 9 are bent and arranged in a V-shape.

Fig. 11 is a view in the A-A direction of fig. 9.

Fig. 12 is a schematic configuration diagram of an automatic winding machine used for manufacturing a stator of a rotating electric machine.

Fig. 13 is an explanatory diagram showing a state in which the wire is wound continuously around 4 pole pieces corresponding to one phase (V-phase in this case) of the three-phase alternating current in embodiment 1.

Fig. 14 is an explanatory diagram showing a state in which the wire is wound continuously around 4 pole pieces corresponding to the other phase (here, U-phase) of the three-phase alternating current in embodiment 1.

Fig. 15 is a view showing a state in which the columnar portion and the open-loop portion of the insulator are welded from the state shown in fig. 11.

Fig. 16 is a flowchart showing an example of a method for manufacturing a stator according to embodiment 1.

Fig. 17A in fig. 17 is a schematic cross-sectional view of a rotating electrical machine obtained by the method for manufacturing a stator according to embodiment 1, and fig. 17B in fig. 17 is an enlarged view of a portion A1 in fig. 17A.

Fig. 18 is a perspective view of one insulator attached to a pole piece as seen from the radially inner side in embodiment 2.

Fig. 19 is a perspective view of the insulator of embodiment 2 as viewed from the radially outer side.

Fig. 20 is a schematic side view of a coupling portion of the snap-fit coupling of mutually adjacent pole pieces to which the insulator of embodiment 2 is attached, as viewed from the circumferential direction.

Fig. 21 is a view showing a state in which the fastening portion of the snap-fit coupling is welded from the state shown in fig. 20 using a welding tool.

Fig. 22 is a schematic side view of a state in which a coupling portion of the snap-coupling of pole pieces adjacent to each other to which an insulator is attached is fixed using a screw as viewed from the circumferential direction.

Fig. 23A and 23B in fig. 23 are plan views showing modifications of insulators attached to pole pieces adjacent to each other.

Fig. 24 is a schematic cross-sectional diagram of a rotary electric machine according to a modification of embodiment 1.

Fig. 25 is a schematic cross-sectional diagram of a rotary electric machine according to another modification of embodiment 1.

Fig. 26 is a schematic side view showing an example of welding the coupling portions of the snap-coupling of the pole pieces adjacent to each other.

Fig. 27 is a schematic side view showing another example of welding the coupling portions of the snap-coupling of the pole pieces adjacent to each other.

Detailed Description

Embodiment 1.

Fig. 1 is a schematic cross-sectional view showing a stator of a rotary electric machine according to embodiment 1, fig. 2 is a perspective view showing one pole piece constituting the stator according to embodiment 1, fig. 3 is a wiring diagram showing a wiring state of each pole piece constituting the stator according to embodiment 1, and fig. 4 is a wiring diagram schematically showing a wiring state in which all pole pieces constituting the stator according to embodiment 1 are arranged in a straight line. In fig. 4, the pole piece is simplified, and the lead wire and the insulator wound around the tooth portion are omitted.

In the rotary electric machine 1 of embodiment 1, the stator 2 is a stator for a 10-pole 12-tooth three-phase DC brushless motor, and includes a plurality of (12 in this example) pole pieces 10 each including a laminated core in which a plurality of thin plates are laminated in the axial direction and fixed by caulking, welding, or the like, as an example.

Each pole piece 10 has: a back yoke 11; and a tooth portion 12 protruding radially inward from the back yoke portion 11. Further, an attachment groove 13 is formed on the radial outer peripheral surface side of the back yoke 11, and the attachment groove 13 is used for attaching the pole piece 10 to a holding jig 52 of a rotational positioning mechanism 51 described later when manufacturing the stator 2.

Further, insulators 25 of the same shape are attached to the respective pole pieces 10 from both ends in the axial direction. The details of the structure of the insulator 25 will be described later. Then, a wire 20 made of copper wire or the like is wound continuously from above the insulator 25 onto two sets (4 in total) of two magnetic pole pieces 10 adjacent to each other, each of which is provided with the insulator 25. A total of 4 pole pieces 10 of the two-to-one set correspond to one of the respective phases U, V, W of the three-phase alternating current.

The two pole pieces 10 of the group of 4 pole pieces 10 around which the lead wire 20 is wound are arranged in a circular shape so that the two pole pieces 10 are arranged opposite to each other at point symmetry positions with respect to the center O of the circle therebetween, and the two pole pieces 10 of the group are arranged in order so as to alternate each phase in the circumferential direction. The circumferential butt ends of the back yoke 11 of each of the pole pieces 10 arranged in the annular shape are coupled to each other by a snap coupling described later, which is achieved by the insulator 25.

Thus, a stator 2 for a three-phase DC brushless motor having 10 poles and 12 teeth is formed.

In fig. 1, 3, and 4, a reference numeral U, V, W given to each pole piece 10 corresponds to each of three-phase ac, and N is a neutral point. The corner marks for the respective phases U, V, W are shown for distinguishing the respective lead wires 20 wound around the tooth portions 12 of the respective adjacent two of the pole pieces 10, and the difference between U1 and U1' indicates that the winding directions are opposite to each other. For example, in fig. 3, U1 represents a left hand and U1' represents a right hand, as viewed from the back yoke 11 side. Further, the difference between U1 and U2 indicates that U1 is a wire 20 wound around a first group of two sets of pole pieces 10 and U2 is a wire 20 wound around a second group of two sets of pole pieces 10.

The lead wire 20 wound around the tooth 12 of each pole piece 10 is referred to as a winding 21, and the lead wire 20 wound between the pole pieces 10 without cutting is referred to as a connecting wire 22. In this case, when it is necessary to intentionally distinguish the connection line 22, the connection line between the two pole pieces 10 in one group is denoted by reference numeral 22a, and the connection line between the respective groups of the two pole pieces 10 in one group is denoted by reference numeral 22 b.

In embodiment 1, as shown in fig. 4, when the lead wire 20 is continuously wound in the same phase, it is only necessary to continuously wind the lead wire 20 in the unit via the connection line 22a connected between two sets of adjacent pole pieces 10 and the connection line 22b connected between each set of two sets of pole pieces 10, with respect to any one of the phases U, V, W, with respect to each phase, by taking 4 pole pieces 10 as a unit, and therefore, it is advantageous in that the number of times of connection of the winding terminal portions can be reduced, and the manufacturing can be performed at low cost.

Fig. 5 is a perspective view of a state in which two insulators are mounted on one pole piece as viewed from the radial inside of the stator, and fig. 6 is a front view of a state in which two insulators are mounted on one pole piece as viewed from the radial outside of the stator. Fig. 7 is a perspective view of the insulator attached to the pole piece as seen from the radial inner side, and fig. 8 is a perspective view of the insulator attached to the pole piece as seen from the radial outer side.

The insulator 25 is integrally molded of, for example, an insulating thermoplastic resin, and 1 insulator having the same shape is used for all the pole pieces 10. Further, if the insulator 25 is made of a thermoplastic resin, even when it is manufactured by injection molding, it can be welded to each pole piece 10 by applying heat thereafter.

Next, the structure of the insulator 25 will be described.

The insulator 25 has: a tooth fitting portion 27 that fits with the tooth portion 12 of each pole piece 10; and a back yoke fitting portion 32 that fits with the back yoke portion 11.

The tooth engaging portion 27 has a dome-shaped winding portion 28, and the dome-shaped winding portion 28 covers half of the circumferential side surface of the tooth portion 12 of the pole piece 10 in the axial direction, and the winding stopper portion 29 protrudes from the radially inner end of the winding portion 28 in the circumferential direction and the axial direction, respectively.

The inner Zhou Mianzhao portions 33 of the back yoke fitting portion 32, which cover the inner peripheral surface of the back yoke portion 11, are formed on the left and right sides of the winding portion 28 in the circumferential direction. A quadrangular protruding portion 34 protruding in the circumferential direction and the radial direction is formed at one axial end of each inner peripheral surface cover portion 33. Further, an intermediate protruding portion 35 protruding in the axial direction is provided between the two protruding portions 34. Further, winding escape grooves 36 are formed between the protruding portion 34 and the intermediate protruding portion 35, respectively. The winding escape groove 36 is a member for escaping the winding start portion and the winding end portion of the wire 20 to the radial outside so as to prevent the winding start portion and the winding end portion of the wire 20 from interfering with the winding.

Further, an open-loop portion 37a having a substantially C-shape is integrally formed by bulging from one (right side in fig. 5 and 7) of the protruding portions 34 to the circumferential direction and the radial direction. The open-loop portion 37a is provided with an opening 37b that opens in a direction perpendicular to the axial direction, and a cutout 37c is provided on a side facing the opening 37 b. The snap-in female portion 37 is constituted by an open-loop portion 37a formed with the cutout 37c and the opening 37 b. As shown in fig. 6, the open-loop portion 37a is provided so that a gap corresponding to the axial thickness D of the base portion 38a described later exists between the axial direction and the axial end portion of the pole piece 10.

A base portion 38a is integrally formed by bulging from the other (left side in fig. 5 and 7) protruding portion 34 in the circumferential direction and the radial direction, and a columnar portion 38b extending in the axial direction is formed in the base portion 38 a.

In this case, in order to fit the columnar portion 38b into the open-loop portion 37a through the opening 37b when the insulators 25 are disposed adjacent to each other as described later, the thickness D of the base portion 38a of the snap-fit male portion 38 in the axial direction is set to correspond to the gap in the axial direction of the open-loop portion 37a of the snap-fit female portion 37 as described above. The axial length of the columnar portion 38b is set to be longer than the axial thickness of the open-loop portion 37a. The base portion 38a and the columnar portion 38b constitute a snap-fit male portion 38.

The outer diameter of the columnar portion 38b is preferably set to be equal to or larger than the inner diameter of the open-loop portion 37a in a free state in which no external force is applied to the open-loop portion 37a of the snap-fit female portion 37. This is to prevent the columnar portion 38b from being easily detached from the open-loop portion 37a when the columnar portion 38b is fitted into and coupled to the open-loop portion 37 a.

The opening 37b of the open ring 37a provided in the snap-in female portion 37 is set so that the slit width is equal to or smaller than the diameter of the columnar portion 38b in a free state in which no external force is applied. This is also to prevent the columnar portion 38b from being easily detached from the open-loop portion 37a when the columnar portion 38b is fitted into and coupled to the open-loop portion 37 a.

A cutout 37c is provided on the side of the open-loop portion 37a facing the opening 37 b. By providing such a slit 37c, the force to expand the opening 37b can be reduced, the columnar portion 38b can be smoothly fitted into the open-loop portion 37a, and even when a force is accidentally applied from the inner peripheral surface side toward the outer peripheral surface side of the open-loop portion 37a, breakage of the open-loop portion 37a can be prevented.

By using the insulator 25 having the above-described structure, the columnar portion 38b of the snap-fit male portion 38 is inserted into the opening 37b of the open-loop portion 37a of the snap-fit female portion 37 from the direction perpendicular to the axial direction, on the basis of disposing the insulators 25 adjacent to each other as described later, whereby a firm snap-fit coupling portion is formed, and the columnar portion 38b is held rotatably in the open-loop portion 37 a.

Further, as long as the columnar portion 38b is rotatable, the inner peripheral surface of the open-loop portion 37a does not necessarily need to be circular arc. The columnar portion 38b does not need to be a cylinder as long as a desired rotation range can be secured, and for example, when it is desired to hold the columnar portion at a certain angle, the cross-sectional shape may be changed to an elliptical shape or a shape with a part cut away.

Next, a description will be given of an operation of attaching the insulator 25 to one pole piece 10 (hereinafter, referred to as an insulating assembly operation).

As shown in fig. 5 and 6, insulators 25 shown in fig. 7 and 8 are attached to one pole piece 10 from both ends in the axial direction thereof. At this time, the snap-in female portion 37 and the snap-in male portion 38 are arranged at positions opposite to each other in the circumferential direction. As a result, the circumferential surrounding surface of the tooth 12 of the pole piece 10 is covered with the winding portion 28 of the insulator 25 as an insulating material.

As shown in fig. 7 and 8, the two insulators 25 attached from the both ends in the axial direction of the pole piece 10 are identical in shape, and the types of resin molding dies can be suppressed as compared with the case where the shapes of the insulators 25 inserted from the front and rear in the axial direction are made different from each other, so that an inexpensive product can be provided.

In this case, the pair of insulators 25 is separately attached to the pole piece 10, but instead, the pole piece 10 may be placed in a molding machine and directly covered with resin to integrally mold the insulators 25.

Next, an operation of connecting the pole pieces 10 to which the insulators 25 are attached to each other by snap-fit coupling will be described.

In this case, for ease of understanding, a case in which a pair of adjacent pole pieces 10 are connected to each other will be described as an example, but the same applies to a case in which 3 or more pole pieces 10 are connected to each other.

Fig. 9 is a plan view showing a state in which two pole pieces adjacent to each other on which an insulator is mounted are joined by a snap fit and are arranged in a straight line, fig. 10 is a perspective view showing a state in which members of the structure of fig. 9 are bent and arranged in a V-shape, and fig. 11 is A-A view of fig. 9.

As shown in fig. 9 and 10, the back yokes 11 of the pair of pole pieces 10 to which the insulators 25 are attached are arranged in parallel so as to be adjacent to each other. Then, at both axial end portions between the adjacent pole pieces 10, the columnar portion 38b of the snap-fit male portion 38 faces the opening 37b of the open-loop portion 37a provided in the snap-fit female portion 37.

Here, the angle between the pole pieces 10 is adjusted, and the columnar portion 38b is pushed into the open-loop portion 37 a. As a result, the pair of pole pieces 10 adjacent to each other, to which the insulator 25 is attached, are simultaneously snap-coupled at both ends in the axial direction, and as a result, the pole pieces 10 adjacent to each other are coupled to each other so as to be rotatable about the coupling portion. The connection between the columnar portion 38b and the open-loop portion 37a can be assembled by manual work, but may be performed by fitting with a jig or the like.

As described above, the open-loop portions 37a of the snap-fit female portions 37 are provided so as to have a gap corresponding to the thickness D of the base portion 38a of the snap-fit male portion 38 between the adjacent insulators 25 attached to the pole piece 10 in the axial direction.

Therefore, as shown in fig. 11, when the pole pieces 10 adjacent to each other, on which the insulator 25 is mounted, are joined by snap-fit, the base 38a is sandwiched in the gap D.

Therefore, even when the movement in the axial direction is generated, the movement is restricted by the mutual abutment of the open-loop portion 37a and the base portion 38 a. Therefore, the separation caused by the axial displacement generated between the pole pieces 10 adjacent to each other can be prevented. As a result, the state in which the plurality of pole pieces 10 are connected to each other can be easily maintained (see fig. 9 and 10), and the pole pieces can be easily connected to each other in a ring shape as shown in fig. 1.

Since the axial length of the columnar portion 38b is set to be longer than the axial thickness of the open-loop portion 37a, the axial end portion of the columnar portion 38b protrudes a predetermined length L in the axial direction from the open-loop portion 37a as shown in fig. 11. This is to ensure a material for welding the protruding portion of the columnar portion 38b to be fixed to the open-loop portion 37a in advance in a welding operation or a partial welding operation to be described later. In addition, the opposite sides with respect to the axial direction are also snap-coupled in the same manner.

Fig. 12 is a schematic configuration diagram of an automatic winding machine used for forming a stator of a rotating electrical machine having the above-described structure.

The automatic winding machine 50 includes: a rotational positioning mechanism 51 for positioning each of the pole pieces 10; and the wire 20 is supplied to the fly fork 54 for winding. In the following, the structure in which the insulator 25 is attached to the pole piece 10 will be simply referred to as the pole piece 10 for convenience of explanation when the wire 20 is wound by the automatic winding machine 50.

The rotation positioning mechanism 51 has a disk-shaped holding jig 52, and the holding jig 52 fixes each pole piece 10. The holding jig 52 is provided with a plurality of mounting pins, not shown, along the circumferential direction thereof, and is provided with a winding start line fixing pin 53 which is inserted into the mounting groove 13 formed in each pole piece 10, and the winding start line fixing pin 53 is used for fixing a winding start portion of the lead wire 20. The holding jig 52 is rotatable about its center O1 as a rotation center.

On the other hand, the flyer 54 is configured to supply the lead wire 20 and wind the lead wire 20 around the tooth 12 of each pole piece 10, and the flyer 54 is configured such that an arm 54b attached to an axial end of the rotating shaft 54a is provided so as to be rotatable in the forward and reverse directions, respectively, as indicated by an arrow θ about a center O2 of the rotating shaft 54a, and the rotating shaft 54a slides in the axial direction (reference Z direction) in synchronization with the rotation operation to perform regular winding. The supplied wire 20 is connected from the base end side of the arm portion 54b of the fly fork 54 to the tip end portion through the inside of the arm portion 54 b.

Fig. 13 is an explanatory view showing a state in which the lead wire 20 is continuously wound around 4 pole pieces 10 corresponding to one phase (V phase in this case) of three-phase alternating current, and fig. 14 is an explanatory view showing a state in which the lead wire 20 is continuously wound around 4 pole pieces 10 corresponding to the remaining two phases (U phase in this case) of three-phase alternating current, and a portion of the lead wire 20 wound around each tooth 12 is omitted.

As can be seen from a comparison between fig. 13 and 14, the directions of winding the lead wire 20 and the positions of the winding start portion and the winding end portion are opposite in the case of the U-phase and the W-phase as compared with the case of the V-phase. In contrast, a 10-pole 12-tooth stator can be constructed by setting the U-phase and W-phase in fig. 13 and the V-phase in fig. 14.

Next, with reference to fig. 12 and 13, description will be made of a process (hereinafter, referred to as a winding process) of winding the wire 20 around each tooth portion of a total of 4 pole pieces 10 constituting one phase (V-phase in this case) by using the automatic winding machine 50, and a process (hereinafter, referred to as a connecting line process) of winding the wire 20 around the next pole piece without cutting the winding end portion of the wire 20 after the winding process.

The repeated operation of combining the winding operation and the connecting line operation is referred to herein as a wiring operation.

For convenience of explanation, the pole pieces 10a, 10b, 10c, and 10d are denoted by the reference numerals, respectively, so that the pole pieces 10 can be distinguished.

First, the two sets of the pole pieces 10a, 10b and the two sets of the pole pieces 10c, 10d are arranged in substantially point-symmetrical positions with respect to each other across the center O1 of the holding jig 52. At this time, as described above, the pole pieces 10a and 10b and the pole pieces 10c and 10d adjacent to each other are in a state of being coupled to each other by the snap-fit coupling of the insulator 25.

Next, the two pole pieces 10a and 10b and the two pole pieces 10c and 10d of the two adjacent groups are fixed by inserting a mounting pin, not shown, of the holding jig 52 into the mounting groove 13 or the like formed in the back yoke 11 so that the tooth portions 12 are positioned outside the disk-shaped holding jig 52. Thus, the teeth 12 of the two pairs of pole pieces 10a and 10b and the two pairs of pole pieces 10c and 10d disposed adjacent to each other are separated by a V-shape having an increased distance in the circumferential direction.

Then, the holding jig 52 is rotated, and first, one of the pole pieces 10a is moved to a position facing the rotation shaft 54a of the fly fork 54. Next, the terminal portion of the wire 20 extending from the distal end of the arm portion 54b of the fly fork 54 is fixed to a winding start wire fixing pin 53 or the like provided to the holding jig 52, and then the wire 20 is wound around the tooth portion 12 of the pole piece 10a while the fly fork 54 is rotated (here, rotated right as viewed from the back yoke 11 side) along the winding escape groove 36 of the insulator 25 and the rotation shaft is slid in the axial direction (Z direction) in synchronization therewith (hereinafter, referred to as winding operation 1).

At this time, the winding operation is performed by setting the arrangement position of each of the two pole pieces 10a and 10b in a group so that the other pole piece 10b, which does not perform the winding operation of the lead wire 20, and the other pole pieces 10c and 10d in a group are each always located outside the rotation surface Q of the turning end of the fly fork 54 (the positions indicated by reference numerals P2, P3, and P4 in fig. 12). In this way, when the lead wire 20 is wound around one of the pole pieces 10a, interference between the fly fork 54 and the other pole pieces 10b, 10c, and 10d other than the one of the pole pieces 10a can be reliably avoided.

Next, the holding jig 52 is rotated to move the other pole piece 10b to a position facing the pivot shaft 54a of the fly fork 54. At this time, the winding end portion of the lead wire 20 wound around the preceding pole piece 10a is passed through the winding escape groove 36 of the insulator 25 as the connection wire 22a, and then is made to follow the winding escape groove 36 of the pole piece 10b that is the object of the next winding operation (hereinafter, this operation will be referred to as a connection wire operation 1).

Next, the lead wire 20 is wound around the tooth 12 of the pole piece 10b in a direction opposite to the direction in which the pole piece 10a is wound around the front (in this example, left-handed when viewed from the back yoke 11 side) (this operation will be referred to as winding operation 2 hereinafter).

At this time, the winding operation is performed by setting the arrangement positions of the respective pole pieces so that the other pole pieces 10a, 10c, 10d except for the pole piece 10b that is the object of the winding operation of the lead wire 20 are always located outside the rotation surface Q of the turning end of the fly fork 54, so that interference between the fly fork 54 and the other pole pieces 10a, 10c, 10d can be reliably avoided.

Next, the holding jig 52 is rotated to move the pole piece 10c to a position facing the rotation shaft 54a of the fly fork 54. At this time, the winding end portion of the lead wire 20 wound around the preceding pole piece 10b is passed through the winding escape groove 36 without being cut, then a predetermined length of the amount reaching the pole piece 10c as the object of the next winding operation is ensured as the connection wire 22b, and then the lead wire 20 is caused to follow the winding escape groove 36 for the pole piece 10c as the object of the winding operation (hereinafter, this operation will be referred to as the connection wire operation 2).

Next, the lead wire 20 is wound in the same direction as the preceding pole piece 10b (left-hand when viewed from the back yoke 11 side) (this operation will be referred to as winding operation 3 hereinafter).

In this case, by performing the winding operation such that all of the other pole pieces 10d, 10a, 10b other than the pole piece 10c that is the object of the winding operation of the lead wire 20 are always located outside the rotation surface Q of the turning end of the flyer 54, interference of the flyer 54 with the other pole pieces 10d, 10a, 10b can be reliably avoided.

Finally, the holding jig 52 is rotated to move the pole piece 10d to a position facing the pivot shaft 54a of the fly fork 54. At this time, the winding end portion of the lead wire 20 wound around the preceding pole piece 10c is passed through the winding escape groove of the insulator 25 as the connection wire 22a, and then is made to follow the winding escape groove 36 of the pole piece 10d that is the object of the next winding operation (hereinafter, this operation will be referred to as a connection wire operation 3).

Next, the lead wire 20 is wound around the tooth 12 of the pole piece 10d in a direction opposite to the winding direction around the front pole piece 10c (in this example, left and right in the view of the back yoke 11) (this operation will be referred to as winding operation 4 hereinafter).

In this case, by performing the winding operation such that all of the other pole pieces 10c, 10a, 10b other than the pole piece 10d that is the object of the winding operation of the lead wire 20 are always located outside the rotation surface Q of the turning end of the flyer 54, interference of the flyer 54 with the other pole pieces 10c, 10a, 10b can be reliably avoided.

In this way, after wiring work (winding work and connecting work) is performed on a total of 4 pole pieces 10a, 10b, 10c, 10d of each group, these pole pieces 10a, 10b, 10c, 10d are removed from the holding jig 52. Then, as shown in fig. 13, the teeth 12 of each of the two (4 total) pole pieces 10a, 10b and 10c, 10d are restored from the reverse-warped V-shaped state to an arc shape (hereinafter, this operation will be referred to as a partial ring-shaped operation). Thus, the lead wire 20 is continuously wound around the 4 pole pieces 10a, 10b, 10c, and 10d corresponding to V.

The lead wire 20 may be wound continuously around at least two of the 4 pole pieces 10a, 10b, 10c, and 10d via the connection wire 22, and the portion where the connection wire 22 is not provided may be compensated for by a connection wire. The lead wire 20 is preferably wound continuously around all the pole pieces 10a, 10b, 10c, 10d of each phase via the connection wire 22, in order to reduce man-hours and the number of components.

In the following, similarly, the wiring operation and the partial ring-forming operation are performed on the 4 pole pieces 10 corresponding to the U-phase and the W-phase, and two pole pieces 10 of a group, which are arranged adjacent to each other, of the 4 pole pieces 10 of the respective phases are alternately and sequentially arranged in the circumferential direction to form a ring shape as shown in fig. 1. Then, the end surfaces of the respective pole pieces 10 adjacent to each other are integrally connected to each other by snap-fit coupling using the insulator 25 (hereinafter, this operation will be referred to as a circularization operation).

Next, the wiring process is performed so as to be in the wiring state shown in fig. 3 and 4. Then, the outer periphery of the pole piece 10 arranged in a circular ring shape is molded with the resin 5, etc., to obtain the desired stator 2 for the 10-pole 12-tooth three-phase DC brushless motor.

In the example shown in fig. 13 and 14, the connection line 22b connecting the groups of two adjacent pole pieces 10 is formed along the outer periphery of the stator 2, but there is no particular limitation on how the connection line 22b is wound, as long as it is possible to avoid interference with each pole piece 10 when all the pole pieces 10 are joined in a circular shape. For example, the connection line 22b may be located radially inward of each of the pole pieces 10 arranged in a circular ring shape, or radially outward of each of the pole pieces 10 arranged in a circular ring shape.

As shown in fig. 11, when the pole pieces 10 to which the insulator 25 is attached are coupled to each other by snap-fit coupling, the axial end portions of the columnar portions 38b protrude from the open-loop portions 37a by a certain length L in the axial direction. Accordingly, next, heat is applied to all the columnar portions 38b of the insulator 25, and as shown in fig. 15, the axial end portions of the columnar portions 38b are welded to the open-loop portions 37a to produce welded portions 40 (hereinafter, this operation is referred to as a welding operation). The welded portion 40 corresponds to a fixed portion in the claims.

Since the welded portion 40 is formed by melting a part of the columnar portion 38b, it is unnecessary to use other materials (adhesive, screw, etc.). The welding portion 40 bulges in the circumferential direction and the radial direction to cover the axial end face of the open ring portion 37 a. Therefore, even if a load is applied to the coupling portions coupled to each other by the snap-coupling due to vibration or the like, the coupling portions are not easily broken, and the coupling portions can be reliably fixed.

In the above description, the welding portions are all the connecting portions to be snap-coupled in the welding operation, but the present invention is not limited thereto. In the circularization operation, the operation is easy, and therefore, the number of positions may be not 24 on both end surfaces in the axial direction, but may be 12 on one end surface or 6 less than the number.

In the above description, the welding operation is performed after the completion of the annular operation for forming all the pole pieces 10 into the annular shape, but the present invention is not limited thereto. That is, after the wiring operation for the two pole pieces in a group is completed, welding may be performed at the time of completion of the partial looping operation for disposing the adjacent pole pieces 10a, 10b and 10c, 10d with the tooth 12 facing the inner diameter (hereinafter, this operation will be referred to as a partial welding operation).

By performing such a partial welding operation, the adjacent pole pieces 10a, 10b and 10c, 10d are not moved at the time of the operation for performing the annular operation in which the pole pieces 10 are alternately arranged in order to be annular, and all the pole pieces 10 adjacent to each other are integrally connected by snap-coupling using the insulator 25. That is, during operation, for example, even if one of the pair of pole pieces 10a, 10b is gripped and moved, the relative positions of the pole pieces 10a, 10b to each other are fixed without positional displacement. Therefore, the handling of the device or the jig can be facilitated.

As described above, by applying the automatic winding machine 50 as shown in fig. 11, the pole piece 10 attached to the rotation positioning mechanism 51 can be sequentially moved to a position facing the rotation shaft 54a of the fly fork 54 by simply rotating the mechanism. Then, after the pole piece 10 is moved to a predetermined position, the fly fork 54 is rotated while keeping the position of the pole piece 10 fixed, whereby the wire 20 can be wound. That is, since the rotation positioning mechanism 51 is separated from the fly fork 54, the movement of the pole piece 10 to the supply side of the wire 20 and the winding of the wire 20 can be performed simultaneously by one mechanism, and therefore the structure of the device is simplified, the trouble is less, and the device can be manufactured at low cost.

Further, since the flyer 54 is rotated to wind the wire 20, the pole piece 10 itself does not rotate at a high speed, and thus, there is no problem that the alignment of the wound wire 20 is deteriorated due to vibration or deflection occurring when the wire 20 is wound, and thus, the working time is shortened, and the throughput per unit time can be increased.

In addition, in the case where two sets of pole pieces 10 are attached to the holding jig 52, as compared with the case where the number of pole pieces 10 fixed to the holding jig 52 is large, the occurrence of the following problems can be eliminated because each of the pole pieces 10 can be opposed to the fly fork 54 by merely rotating the rotation positioning mechanism 51 after attaching the pole pieces 10 at a desired interval in a V-shaped manner: the angle of the adjacent pole pieces 10 becomes smaller to become an obstacle when winding the lead wire 20, and the length of the connecting wire 22a cannot be freely set.

In addition, in the aspect of constituting the stator 2, the two sets of pole pieces 10 are often arranged alternately in order along each circumferential direction to form a circular ring shape, and in this case, although the distance of the connecting line 22b connecting the sets of the two sets of pole pieces 10 is long, the respective pole pieces 10 can be sequentially positioned at the position where the winding operation is performed by merely rotating the rotation positioning mechanism 51, so that the length of the connecting line 22b can be freely set.

In addition, when the winding 21 is performed, interference between the adjacent pole pieces 10 and the flying fork 54 can be avoided, and the alignment of the winding 21 can be improved. Further, the connecting line 22b can be applied to the pole pieces 10 existing at discrete positions, so that productivity can be improved.

Fig. 16 is a flowchart showing an example of a method for manufacturing a stator in the rotating electrical machine according to embodiment 1.

First, in the insulating assembly step of step S10, the insulating assembly operation described above is performed, and the insulators 25 are mounted on the respective pole pieces 10. In this insulating assembly step, instead of attaching a pair of insulators 25 to the pole piece 10, the pole piece 10 may be integrally molded by being directly covered with resin in a molding machine.

When the insulating assembly step of step S10 is completed, next, a pair of adjacent pole pieces 10 to which the insulator 25 is attached are coupled by snap-coupling to each other, and the coupled two pole pieces 10 are set as one group, and these two groups (4 total) are set as any one of the U-phase, V-phase, and W-phase.

Next, the process proceeds to a wiring step, and the above-described wiring operation (the winding operation and the connecting operation of the lead wire 20) is performed on the 4 respective pole pieces 10 corresponding to one pole piece.

As a specific process step, a process for producing a semiconductor device,

first, in the winding step 1 of step S11, the above-described winding operation 1 is performed, and the lead wire is intensively wound around one pole piece 10a via the insulator 25.

Next, in the connecting wire step 1 of step S12, the connecting wire operation 1 is performed, and the wire is continuously formed as a connecting wire to the next pole piece 10b to be wound without cutting the wire.

Next, in the winding step 2 of step S13, the above-described winding operation 2 is performed, and the lead wire is intensively wound around one pole piece 10b via the insulator 25.

Next, in the connecting wire step 2 of step S14, the connecting wire operation 2 is performed, and the wire is continuously formed as a connecting wire to the pole piece 10c to be wound separately without cutting the wire.

Next, in the winding step 3 of step S15, the above-described winding operation 3 is performed, and the lead wire is intensively wound around one pole piece 10c via the insulator 25.

Next, in the connecting wire step 3 of step S16, the connecting wire operation 3 is performed, and the lead wire 20 is continuously formed as a connecting wire to the next pole piece 10d to be wound without cutting the lead wire.

Next, in the winding step 4 of step S17, the above-described winding operation 4 is performed, and the lead wire 20 is intensively wound around one pole piece 10d via the insulator 25.

When the wiring process (the winding process 1 to 4 and the connecting process 1 to 3) of the 4 respective pole pieces 10 corresponding to any one of the U-phase, the V-phase and the W-phase is completed, the wiring process (the winding process 1 to 4 and the connecting process 1 to 3) is repeated similarly for the remaining 4 respective pole pieces 10.

Then, when the wiring steps (the winding steps 1 to 4 and the connecting steps 1 to 3 of the lead wires 20) of the 4 respective pole pieces 10 are completed for all the phases, the process proceeds to the next partial looping step.

In the partial cyclization step of step S18, the above-described partial cyclization operation is performed for each of the 4 pole pieces 10 corresponding to each of them, and each of the teeth 12 is restored from the reverse-warped V-shaped state to the arc shape.

In the partial welding step of step S19, the above-described partial welding operation is performed on the two (total of 4) sets of pole pieces 10 corresponding to each, and at least one or more welding is performed on the fastening portion to be fastened.

For example, two portions of the axial end surfaces of the coupling portions of the pair of pole pieces 10a and 10b adjacent to each other are welded to each other, or one of the axial end surfaces of the coupling portions of the pair of pole pieces 10c and 10d adjacent to each other is welded to each other.

By performing such a partial welding operation, even if one of the pair of pole pieces 10a and 10b is gripped and moved, for example, during an operation in the subsequent looping process, the relative positions of the pole pieces 10a and 10b can be fixed, and the operation becomes easy.

That is, if a partial welding step is performed before the cyclization step of the cyclization operation, the degree of freedom between the pole pieces 10 becomes small. That is, when the pole pieces 10 of the respective phases are welded, there are 12 points at which the connecting portions of the snap-fit connection move without a partial welding step, and therefore, when the pole pieces 10 are alternately arranged in turn in the circumferential direction in the annular shape, the rigidity of the whole is weak and it may be difficult to maintain the annular shape. In contrast, when the adjacent pole pieces 10 of each phase are welded, the movable portion at the time of the looping operation is 6. Therefore, more firm fixation can be performed.

Then, when the partial welding process of step S19 is completed for all the pole pieces 10 of the phases, the process proceeds to the looping process of step S20. As shown in fig. 1, in the cyclization step of step S20, the above-described cyclization operation is performed, and after all the pole pieces 10 are alternately and sequentially arranged in each phase in the circumferential direction to form a circular ring shape, the end surfaces of the pole pieces 10 adjacent to each other are integrally connected to each other by snap-fit connection using the insulator 25.

In the next welding step S21, the above welding operation is performed, and the remaining fastening portions of the snap-fit coupling, which are not welded in the partial welding step S19, are welded.

This suppresses the movement of each pole piece 10, and makes it easy to maintain the annular shape that is supposed to be the stator 2. Therefore, the pole pieces 10 are not scattered during the operation from the subsequent molding step to the molding step using the resin, and the shape is maintained when the pole pieces are put into the molding die, so that the insertion performance is improved.

In addition, the welding process may be performed only without performing the partial welding process. In this case, since the welding process can be integrated into one process, productivity can be improved.

Finally, in the molding step of step S22, a molding operation is performed to mold the entire stator 2 including the pole piece 10, the lead wire 20, the open-loop portion 37a of the insulator 25, the columnar portion 38b, and the like, which are arranged in a circular ring, with the resin 5. Thus, even if a part of the insulator 25 (in embodiment 1, the columnar portion 38b serving as the rotation center of the coupling portion of the snap-fit connection) is disposed on the outer diameter side of the pole piece 10, the fixing of each pole piece 10 can be easily performed. That is, if a tubular metal ring is to be arranged on the outer diameter of the pole piece 10 by press fitting, adhesion, or the like, interference occurs at the connection portion of the snap-fit connection of the insulator 25 protruding to the outer diameter side than the pole piece 10, but this can be avoided by molding and covering with the resin 5 as in the present application. Further, the lead wires 20 as a heat generating source can be covered with the resin 5, so that heat radiation can be improved, and downsizing of the rotary electric machine 1 using the stator 2 can be facilitated.

After the process of manufacturing the stator shown in fig. 16, a rotor is rotatably and coaxially arranged on the inner diameter side of the stator 2, whereby a desired rotary electric machine having low cost, small size, and high performance can be obtained.

Fig. 17A is a schematic cross-sectional view of the rotating electrical machine thus obtained, and fig. 17B is an enlarged view of a portion A1 of fig. 17A.

The rotor 3 of the rotary electric machine 1 is rotatably and coaxially arranged on the inner diameter side of the stator 2 having the structure shown in fig. 1, and the outer periphery of the stator 2 is molded with a resin 5. The rotor 3 is composed of a rotary output shaft 4, a rotor core 6 inserted into the rotary output shaft 4, and a permanent magnet 7 disposed on the outer periphery of the rotor core 6 from the inner diameter side, and the permanent magnet 7 is magnetized to 10 poles.

The permanent magnet 7 is annular in this embodiment, but is not limited to this configuration, and for example, a magnet divided into a plurality of magnets may be used. The rotor 3 is configured as a surface-mounted magnet structure (SPM; surface Permanent Magnet), but the present invention is not limited thereto, and for example, a buried magnet structure (IPM; interior Permanent Magnet) may be employed.

Here, the entire stator 2 including the lead wire 20, the open-loop portion 37a of the insulator 25, the columnar portion 38b, and the like is molded with the resin 5. That is, the inner peripheral surface 5a of the resin 5 molded on the stator 2 is formed to a position of an inner diameter contour formed by extending the inner peripheral surface of the pole piece 10 in the circumferential direction, and the outer peripheral surface 5b of the resin 5 molded on the stator 2 is formed to a position where the open-loop portion 37a and the columnar portion 38b of the insulator 25 protruding radially outward from the pole piece 10 are entirely covered.

With this configuration, even if the columnar portion 38b serving as the rotation center of the insulator 25 is disposed on the outer diameter side of the pole piece 10, the fixing of each pole piece 10 can be easily performed. That is, if a tubular metal ring is to be arranged on the outer diameter of the pole piece 10 by press fitting, adhesion, or the like, interference occurs at the connecting portion of the insulator 25 protruding to the outer diameter side than the pole piece 10, but this can be avoided by molding with the resin 5 as in embodiment 1, and the divided pole piece 10 is fixed in a ring shape. In addition, even if oil or the like adheres to the outer surface of the stator 2, damage to the lead wire 20 and the pole piece 10 can be suppressed.

In addition, in embodiment 1, since the stator 2 of the rotating electrical machine 1 for a three-phase DC brushless motor having 10 poles and 12 teeth is assumed, the case where two pole pieces 10 are wound continuously as pole pieces 10 adjacent to each other has been described, but the present invention is not limited thereto, and the present invention is applicable to a configuration in which 3 or more pole pieces 10 are adjacent to each other.

As described above, according to embodiment 1, the insulator 25 formed in the same shape is used, the insulator 25 is attached to each pole piece 10, and the insulator 25 is used to form the coupling portion that allows each pole piece 10 to swing by snap-coupling and restricts displacement in the axial direction. After the pole pieces 10 are circularized, the coupling portions to be joined by snap-fitting are welded to fix the pole pieces to each other, and a manufacturing method is adopted. Therefore, the rotating electrical machine 1 having the stator 2 with high performance can be obtained without increasing the number of components used. Further, since the manufacturing process can be performed without unnecessarily increasing the manufacturing steps, the manufacturing cost can be suppressed and the manufacturing operation can be easily performed.

Embodiment 2.

Fig. 18 is a perspective view of one insulator attached to a pole piece as seen from the radial inner side in embodiment 2, fig. 19 is a perspective view of the insulator of embodiment 2 as seen from the radial outer side, and fig. 20 is a schematic side view of a coupling portion of the pole pieces adjacent to each other to which the insulator of embodiment 2 is attached as seen from the circumferential direction. The same reference numerals are given to the constituent parts corresponding to those of fig. 7, 8 and 11 in embodiment 1.

Embodiment 2 is characterized in that a slit 38f is provided by cutting an axial end portion of the columnar portion 38b of the insulator 25. A chamfer 38h is formed on the axial end face of the slit 38f. Other constituent parts are the same as those in embodiment 1.

Fig. 21 is a view showing a state in which the fastening portion of the snap-fit coupling is welded from the state shown in fig. 20 using a welding tool.

The welding tool 60 includes a cylindrical portion 60a having a cylindrical shape, and a pressing portion 60b provided concentrically inside the cylindrical portion 60 a. The inner diameter of the cylindrical portion 60a is set slightly larger than the outer diameter of the open-loop portion 37 a. The pressing portion 60b is disposed so as to be axially retracted from the open end of the cylindrical portion 60a by a predetermined dimension, and a slit fitting projection 60c is provided at the center of the end face thereof, and the slit fitting projection 60c is fitted into the slit 38f.

When welding the connection portions of the magnetic pole pieces 10 adjacent to each other, the welding tool 60 is pressed against the cylindrical portion 60a in the axial direction and heated. At this time, since the chamfer 38h is formed in advance in the cylindrical portion 60a, the slot-fitting protrusion 60c is easily fitted into the slot 38f without positional displacement. Then, when the welding tool 60 is pressed against the cylindrical portion 60a and heated, the tip of the columnar portion 38b melts and changes shape, thereby forming the welded portion 40.

The welded portion 40 formed in this case is in a state of covering not only the axial end face of the open-loop portion 37a but also a part of the outer peripheral surface of the open-loop portion 37 a. Thus, the snap-bonded joint portions are firmly welded. In this way, by performing a single operation of pressing the welding tool 60 against the cylindrical portion 60a and heating, the fastening portion to be fastened by the snap-fit can be firmly fixed, and therefore, the operation can be performed efficiently in the partial welding step or the welding step.

In embodiment 1 and embodiment 2, the welded portion 40 is formed by welding the connecting portion of the snap-fit connection, and the welded portion is fixed. In this way, it is preferable to use no other material for welding, but the manner of fixing the fastening portion by the snap-fastening is not limited to this.

For example, as shown in fig. 22, the length of the columnar portion 38b in the axial direction may be set to be slightly smaller than the thickness of the open-loop portion 37a in the axial direction, and the columnar portion 38b may be fixed by, for example, screwing a screw 62.

Even in the case where the insulator 25 uses a thermosetting resin, the connecting portion can be fixed by such means. In order to form the fixing portion by another method, for example, the open loop portion 37a may be melted and welded. Thus, even if an external force acts to separate the pole pieces 10 in a direction away from each other, the open loop 37a can be closed to suppress this. In order to form the fixing portion by another method, for example, an adhesive may be placed in the connecting portion to fix the fixing portion.

In embodiment 1 and embodiment 2 described above, only 1 type of insulator formed in the same shape is used for the insulator 25 attached to each pole piece 10. That is, the insulator 25 is configured such that a snap-in female portion 37 having an open-loop portion 37a is formed at one end side in the circumferential direction, and a snap-in male portion 38 having a columnar portion 38b is formed at the other end side in the circumferential direction. However, the present application is not limited to such a structure.

For example, as shown in fig. 23A and 23B, two kinds of insulators having symmetrical shapes with respect to the center of the tooth 12 of the pole piece 10 in the circumferential direction may be used. That is, as shown in fig. 23A, the one insulator 25a is formed with snap-in female portions 37 having open-loop portions 37a at both ends in the circumferential direction. As shown in fig. 23B, the other insulator 25B has snap-fit male portions 38 each having a columnar portion 38B formed at both ends in the circumferential direction.

The two insulators 25a and 25b are attached to the pole pieces 10 adjacent to each other, and the pole pieces 10 are rotatably coupled to each other by fitting the columnar portion 38b to the open-loop portion 37a and fastening them.

In addition, one insulator 25b is provided with a hole 39 which is not provided in the other insulator 25 a. The hole 39 is connected to a terminal to which a terminal of the lead wire 20 is connected to supply power. By providing the plurality of insulators 25a and 25b in this way, the insulators can have different shapes, and the advantage of increasing the degree of freedom is obtained. However, since there is a concern that the number of components increases, it is possible to determine which one is advantageous for use.

Further, the following modifications can be considered for the above-described embodiments 1 and 2.

Modification 1.

In embodiment 1 (fig. 17), the entire stator 2 including the lead wire 20, the open-loop portion 37a of the insulator 25, the columnar portion 38b, and the like is molded with the resin 5.

In contrast, in the modification shown in fig. 24, the inner peripheral surface 5a of the resin 5 molded on the stator 2 is formed to a position of an inner diameter contour formed by extending the inner peripheral surface of the pole piece 10 in the circumferential direction, but unlike the case of embodiment 1 (fig. 17), the position of the outer peripheral surface 5b (shown by a broken line in the drawing) of the resin 5 molded on the stator 2 is formed to a position inside the position of an outer diameter contour formed by extending the outer peripheral surface of the pole piece 10 in the circumferential direction. Therefore, in this structure, the open-loop portion 37a, the columnar portion 38b, and the like of the insulator 25 are not molded with the resin 5.

By forming the outer peripheral surface 5b of the resin 5 to be molded at a position inside the position of the outer diameter contour formed by extending the outer peripheral surface of the pole piece 10 in the circumferential direction in this way, it is possible to keep the divided pole piece 10 in a ring-like fixed state, and to suppress the amount of resin 5 to be molded, thereby realizing weight reduction and reduction in material cost.

Modification 2.

In the modification (fig. 24), the molded outer peripheral surface 5b of the resin 5 is formed at a position inside the position of the outer diameter contour formed by extending the outer peripheral surface of the pole piece 10 in the circumferential direction, and the open-loop portion 37a, the columnar portion 38b, and the like of the insulator 25 are not molded with the resin 5.

In contrast, in the modification shown in fig. 25, the outer peripheral surface 5b (shown by a broken line) of the resin 5 to be molded is formed at a position slightly inside the position of the outer diameter contour formed by extending the outer peripheral surface of the pole piece 10 in the circumferential direction. However, unlike the case of the modification (fig. 24), the open-loop portion 37a and the columnar portion 38b of the insulator 25 protruding radially outward from the pole piece 10 are partially molded with the resin 5 c. Thereby, a connection line, not shown, is also molded.

In this way, by molding the coupling portions (the open-loop portions 37a and the columnar portions 38 b) at which the pole pieces 10 are coupled to each other by snap-coupling with the resin 5, the rigidity of the stator 2 of the rotating electric machine 1 can be improved, and vibration can be suppressed. In addition, even if oil or the like adheres to the outer surface of the stator 2, damage to the coupling portions that are coupled to each other by the snap-coupling can be suppressed. In addition, since the outer peripheral surface 5b (shown by a broken line in the figure) is formed at a position slightly inside the position of the outer diameter contour formed by extending the outer peripheral surface of the pole piece 10 in the circumferential direction, in addition to the part where the open ring portion 37a and the columnar portion 38b of the insulator 25 protruding radially outward from the pole piece 10 by the resin 5c are partially molded, the amount of resin 5 used for molding can be suppressed as compared with the case of embodiment 1 (fig. 17), and weight reduction and material cost reduction can be achieved.

Modification 3.

In embodiment 2 (fig. 18 to 22), the slit 38f is provided in a part of the columnar portion 38b of the insulator 25, and the axial end portion of the columnar portion 38b is welded, so that the magnetic pole pieces 10 are more firmly joined to each other at the joining portion by the snap-fit.

In contrast, in the modification shown in fig. 26, the connecting wire 22 is disposed in the slit 38f provided in a part of the columnar portion 38b, and the axial end portion of the columnar portion 38b is welded in this state. Further, a portion of the outer peripheral side in the radial direction of the base portion 38a of the snap-fit male portion 38 of the insulator 25 is cut out to form a groove portion 38g having a U-shaped cross section at two upper and lower positions in the axial direction, and the connection wire 22 is deformed by bending, winding, or the like to be disposed so as to pass through the inside of the groove portion 38 g.

In this case, the connecting line 22 passing through the welded portion of the columnar portion 38b is a connecting line corresponding to a certain phase (for example, V-phase) which is led between the pole pieces 10 disposed adjacent to each other, and the connecting line disposed in each groove portion 38g is a connecting line of another phase (for example, U-phase or W-phase) different from the connecting line.

With such a configuration, even if the pole piece 10 is rotated during the looping process, the movement of the connecting wire 22 can be restricted with respect to the connecting wire 22 at the welded portion of the columnar portion 38b, and besides, by passing the connecting wire 22 of another phase through the groove portion 38g, accidental contact between the connecting wires 22 of different phases having a large potential difference can be avoided.

In addition to the configuration shown in fig. 26, as shown in fig. 27, the connecting wire 22 may be fixed by passing the connecting wire 22 through each groove 38g and then welding (33 h) the portion. In this configuration, the connection lines 22 disposed in the columnar portion 38b and the groove portions 38g are also connection lines 22 having different phases from each other.

By configuring such a structure, for example, the connecting wires 22 are disposed in the groove portions 38g after the circularization step, and then the connecting wires 22 are fixed by welding (33 h) the portions, movement of the connecting wires 22 can be restricted, and accidental contact between the connecting wires 22 out of phase with a large potential difference can be reliably avoided.

While various exemplary embodiments and modifications have been described, the various features, aspects, and functions described in one or more embodiments are not limited to the application of the specific embodiments, and may be applied to the embodiments alone or in various combinations.

Accordingly, numerous modifications not illustrated can be envisaged within the scope of the technology disclosed in the present application. For example, the case where at least one component is deformed, added or omitted, or the case where at least one component is extracted and combined with the components of the other embodiments is included.

Description of the reference numerals

1: a rotating electric machine; 2: a stator; 3: a rotor; 5: a resin; 10. 10a, 10b, 10c, 10d: a pole piece; 11: a back yoke; 12: a tooth portion; 20: a wire; 21: winding; 22. 22a, 22b: a connecting wire; 25. 25a, 25b: an insulator; 37: a snap-fit female portion; 37a: an open loop section; 37b: an opening portion; 38: a buckle male part; 38a: a base; 38b: a columnar portion; 38f: a slit; 40: a welding part; 50: an automatic winding machine; 51: a rotary positioning mechanism; 54: and (5) flying forks.

Claims (13)

1. A stator, wherein,

the stator includes a plurality of pole pieces having teeth integrally protruding from an arcuate yoke toward a radial inner side, each of the pole pieces having a pair of resin insulators mounted thereto in an axial direction perpendicular to the radial direction, each of the pole pieces having a lead wire wound therearound and arranged in a circular ring shape,

one of the insulators adjacent to each other and attached to the pole pieces in the annular arrangement is provided with a snap-fit female portion, the other insulator is provided with a snap-fit male portion having an open-loop portion formed with an opening portion opening in a direction perpendicular to an axial direction, the snap-fit male portion has a columnar portion extending in an axial direction from a base portion bulging in a circumferential direction and a radial direction, the pole pieces are coupled to each other swingably by snap-fitting the columnar portion to the open-loop portion, and a fixing portion for fixing the coupling portion is formed at least one of coupling portions coupled to each other by the snap-fit coupling.

2. The stator of claim 1, wherein,

the fixing portion is formed by a welding portion formed by welding connecting portions that are connected to each other by snap-fit connection.

3. The stator according to claim 2, wherein,

the welding portion is formed by welding a portion of the columnar portion that protrudes in the axial direction more than the open-loop portion.

4. The stator according to claim 3, wherein,

the welded portion bulges at least in the circumferential direction and the radial direction.

5. The stator according to any one of claims 1 to 4, wherein,

the open-loop portion is provided so that a gap corresponding to the axial thickness of the base portion exists between the axial direction and the pole piece, and the base portion is sandwiched in the gap to restrict displacement in the axial direction in a state in which the snap-fit is performed.

6. The stator according to any one of claims 1 to 5, wherein,

a part of all the pole pieces, and at least a part of a connecting line connected between the pole pieces are molded with resin.

7. The stator according to any one of claims 1 to 6, wherein,

the connecting wire connected between the pole pieces is locked at least one position of the connecting portions connected to each other by the snap-fit connection, and the at least one position is welded to fix the connecting wire.

8. A rotary electric machine, wherein,

the rotating electric machine includes the stator according to any one of claims 1 to 7, and a rotor rotatably coaxially disposed on an inner peripheral surface side of the stator.

9. A method of manufacturing a stator according to any one of claims 1 to 7, comprising:

an insulating assembly step of attaching the insulator to the pole piece;

a wiring step of repeating a winding step of intensively winding a wire around one of the pole pieces after the insulating assembly step and a connecting step of guiding the wire as a connecting wire to the next pole piece to be wound without cutting the wire after the winding step;

an annular step of arranging each of the magnetic pole pieces in an annular shape after the winding of the lead wire around all the magnetic pole pieces is completed in the wiring step, and connecting all the magnetic pole pieces adjacent to each other by the snap-fit connection of the insulator; and

and a fixing step of fixing the connecting parts which are mutually buckled and combined.

10. The method of manufacturing a stator according to claim 9, wherein,

The fixing step is a welding step of welding the columnar portion and the open-loop portion.

11. The method for manufacturing a stator according to claim 9 or 10, wherein,

the method for manufacturing the stator includes a partial fixing step of fixing at least one portion of a coupling portion of a pair of pole pieces adjacent to each other, the coupling portion being coupled to each other by the snap-coupling, after the wiring step and before the circularization step.

12. The method for manufacturing a stator according to claim 11, wherein,

the partial fixing step is a welding step of welding the columnar portion and the open loop portion.

13. A method of manufacturing a rotary electric machine, wherein,

the method for manufacturing the rotating electrical machine comprises the following steps: after the process of manufacturing the stator according to any one of claims 9 to 12, the rotor is rotatably and coaxially arranged on the inner peripheral surface side of the stator.