CN117280572A - Insulator, stator, rotating electrical machine, method for manufacturing stator, and method for manufacturing rotating electrical machine - Google Patents
Insulator, stator, rotating electrical machine, method for manufacturing stator, and method for manufacturing rotating electrical machine Download PDFInfo
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- CN117280572A CN117280572A CN202180098058.2A CN202180098058A CN117280572A CN 117280572 A CN117280572 A CN 117280572A CN 202180098058 A CN202180098058 A CN 202180098058A CN 117280572 A CN117280572 A CN 117280572A
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- insulator
- stator core
- stator
- portions
- columnar
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- 239000012212 insulator Substances 0.000 title claims abstract description 162
- 238000000034 method Methods 0.000 title claims abstract description 28
- 238000004519 manufacturing process Methods 0.000 title claims description 26
- 238000004804 winding Methods 0.000 claims abstract description 36
- 230000008878 coupling Effects 0.000 claims description 36
- 238000010168 coupling process Methods 0.000 claims description 36
- 238000005859 coupling reaction Methods 0.000 claims description 36
- 230000002093 peripheral effect Effects 0.000 claims description 28
- 239000011347 resin Substances 0.000 claims description 14
- 229920005989 resin Polymers 0.000 claims description 14
- 229910052751 metal Inorganic materials 0.000 claims description 4
- 239000002184 metal Substances 0.000 claims description 4
- 239000011810 insulating material Substances 0.000 claims description 2
- 229910044991 metal oxide Inorganic materials 0.000 claims 1
- 150000004706 metal oxides Chemical class 0.000 claims 1
- 230000008569 process Effects 0.000 abstract description 11
- 230000007246 mechanism Effects 0.000 description 15
- 238000009413 insulation Methods 0.000 description 12
- 238000000465 moulding Methods 0.000 description 9
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical group [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 6
- 230000000712 assembly Effects 0.000 description 3
- 238000000429 assembly Methods 0.000 description 3
- 230000005489 elastic deformation Effects 0.000 description 3
- 229910000576 Laminated steel Inorganic materials 0.000 description 2
- 230000008859 change Effects 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000005304 joining Methods 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000003466 welding Methods 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 230000002452 interceptive effect Effects 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 210000001503 joint Anatomy 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000000123 paper Substances 0.000 description 1
- 230000036316 preload Effects 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000004080 punching Methods 0.000 description 1
- 239000002990 reinforced plastic Substances 0.000 description 1
- 238000009420 retrofitting Methods 0.000 description 1
- 239000005060 rubber Substances 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/12—Stationary parts of the magnetic circuit
- H02K1/18—Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
-
- 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
- H02K15/04—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings, prior to mounting into machines
-
- 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
- H02K15/08—Forming windings by laying conductors into or around core parts
- H02K15/095—Forming windings by laying conductors into or around core parts by laying conductors around salient poles
-
- 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
Landscapes
- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Insulation, Fastening Of Motor, Generator Windings (AREA)
- Iron Core Of Rotating Electric Machines (AREA)
Abstract
Since the distance between the teeth after the connection is determined in accordance with the shape of the stator core, the winding cannot be wound with high density in the winding process depending on the shape of the teeth. Therefore, the stator core (10) is provided with two arm-shaped connecting parts (25 a, 25 b), a column part (251) and a guide part (252), wherein the two arm-shaped connecting parts (25 a, 25 b) protrude to the two circumferential sides of the stator core (10), the column part (251) is formed on one connecting part (25 a), the guide part (252) is formed on the other connecting part (25 b), the column part (251) of one insulator is movably engaged with the guide part (252) of the other adjacent insulator, and the distance between the adjacent insulators is variable, so that the distance between the teeth (11) after connection can be variable according to the shape of the stator core (10), and the stator core can be wound in a high density in a winding process irrespective of the shape of the teeth (11).
Description
Technical Field
The present application relates to an insulator, a stator, a rotating electrical machine, a method of manufacturing a stator, and a method of manufacturing a rotating electrical machine.
Background
In a stator (stator) of a rotating electrical machine, a structure is disclosed in which core pieces (split cores) split in units of teeth are connected to each other so as to be bendable in a direction perpendicular to an axis (see, for example, patent documents 1 and 2). In the above-described structure, the adjacent teeth in the stator are close to each other on the inner side in the radial direction, but by changing the angle of the connecting portion so that the teeth are positioned on the outer diameter side, the adjacent core pieces can be wound without interference, and the space factor of the coil can be improved.
Prior art literature
Patent literature
Patent document 1: japanese patent laid-open No. 2000-201458
Patent document 2: japanese patent laid-open No. 2006-254569
Disclosure of Invention
Problems to be solved by the invention
However, in patent document 1, since the laminated steel plates of adjacent iron core pieces are engaged with each other at the joint portion, there is a problem in that two kinds of laminated steel plates need to be prepared, punching and riveting for joining are required, and the number of kinds of components increases and the process is complicated. Further, in patent document 2, a mechanism for inserting and extracting in the axial direction is provided for connection and rotation, but when the teeth are made to face outward, a holding mechanism and the like are required to be prepared for preventing positional displacement in the axial direction after connection, and there is a problem that the manufacturing process becomes complicated. Further, in patent document 1 and patent document 2, since the distance between the teeth after connection is determined in accordance with the shape of the stator core, the winding cannot be wound with high density in the winding step depending on the shape of the teeth.
The present application discloses a technique for solving the above-described problems, and an object thereof is to obtain a stator and a motor capable of winding a wire at high density without increasing the number of components and manufacturing steps.
Means for solving the problems
The insulator disclosed in the present application is mounted on a stator core and electrically insulates a coil from the stator core, and is characterized in that the insulator is provided with a columnar portion, a guide portion, and two arm-shaped connecting portions, the two arm-shaped connecting portions protrude to both sides in the circumferential direction of the stator core, the columnar portion is formed at one connecting portion, the guide portion is formed at the other connecting portion and movably guides the columnar portion, and the columnar portion of one insulator is engaged so as to be movable in the guide portion of the adjacent other insulator, so that the distance between the adjacent insulators is variable.
Effects of the invention
In the stator and the motor, the winding wire can be wound with high density without increasing the number of components and manufacturing procedures.
Drawings
Fig. 1 is a perspective view of a stator core.
Fig. 2 is a perspective view of the stator core annular assembly.
Fig. 3 is a perspective view of the insulator of embodiment 1.
Fig. 4 is a rear view of the insulator of fig. 3 as seen from the radially outer peripheral side.
Fig. 5 is a plan view of the insulator of fig. 3 as viewed from the axial direction.
Fig. 6 is a plan view showing a state in which the stator core coupling body of embodiment 1 is wound and then the coupling portion is modified to be assembled in the state of the stator core annular assembly.
Fig. 7 is a perspective view showing a fitted state of one insulator in a state of perspective view 6.
Fig. 8 is a perspective view of the insulator of embodiment 1 as seen from the radially inner peripheral side.
Fig. 9 is a perspective view of fig. 8 from the axially lower side toward the upper side.
Fig. 10 is a flowchart illustrating a process for manufacturing a stator according to embodiment 1.
Fig. 11 is a perspective view of a stator connecting body obtained by connecting the insulators of embodiment 1.
Fig. 12 is a plan view showing a state in which a stator core coupled body according to embodiment 1 is wound by a flying fork type winding device.
Fig. 13 is a plan view showing a state in which stator cores having different sizes are wound by the same winding device as in fig. 12.
Fig. 14 is a plan view showing a state in which a stator core connecting body according to embodiment 1 is wound by a winding device different from that of fig. 12.
Fig. 15 is a perspective view showing a state in which the stator core coupling body of embodiment 1 is wound and then the coupling portion is modified to be assembled in the state of the stator core annular assembly.
Fig. 16 is a radial rear view of fig. 15.
Fig. 17 is a plan view showing a state in which semicircular stator core coupled bodies according to embodiment 1 are coupled.
Fig. 18 is a perspective view showing a state in which the semicircular stator core coupling bodies of fig. 17 are coupled.
Fig. 19 is a perspective view of a stator core annular assembly according to embodiment 1.
Fig. 20 is a perspective view of a completed stator product obtained by covering the stator core annular assembly of embodiment 1 with a molding resin.
Fig. 21 is a cross-sectional view of the motor of embodiment 1.
Fig. 22 is a plan view of the insulator of embodiment 2.
Fig. 23 is a perspective view of an insulator according to embodiment 2.
Fig. 24 is a plan view of a stator connecting body obtained by connecting the insulators of embodiment 2 by the first fitting portion.
Fig. 25 is another plan view of the stator connecting portion obtained by connecting the insulators of embodiment 2 by the first fitting portion.
Fig. 26 is a plan view of a stator connecting portion obtained by connecting the insulators of embodiment 2 by the second fitting portion.
Fig. 27 is a perspective view of an insulator according to embodiment 3.
Fig. 28 is a bottom view of the insulator of fig. 27 as viewed from the axial lower side.
Fig. 29 is a perspective view showing a state in which the stator core coupling body of embodiment 3 is wound and then the coupling portion is modified to be assembled in the state of the stator core annular assembly.
Fig. 30 is a perspective view of the state of fig. 29 from another angle.
Fig. 31 is a cross-sectional view of the motor according to embodiment 4.
Fig. 32 is a flowchart showing a stator manufacturing process according to embodiment 4.
Fig. 33 is a perspective view showing a stator core insulation assembly according to embodiment 5.
Fig. 34 is a plan view showing a state in which a stator core coupled body according to embodiment 6 is wound by a flying fork type winding device.
Fig. 35 is a perspective view of an insulator according to embodiment 7.
Fig. 36 is a perspective view of a split joint according to embodiment 7.
Fig. 37 is a perspective view of a stator connecting body obtained by connecting the insulators of embodiment 7.
Fig. 38 is a plan view of a stator connecting body obtained by connecting the insulators of embodiment 7.
Fig. 39 is a perspective view showing a state in which the stator core coupling body of embodiment 7 is wound and then the coupling portion is modified to be assembled in the state of the stator core annular assembly.
Fig. 40 is a perspective view of a stator core annular assembly according to embodiment 7.
Fig. 41 is a perspective view of another split joint according to embodiment 7.
Fig. 42 is a plan view of a stator connecting body obtained by connecting the insulators of embodiment 7 by another separate connecting portion.
Fig. 43 is a perspective view showing a state in which the stator core connecting body obtained by connecting the insulators of embodiment 7 by another split connecting portion is wound and then the connecting portion is modified to be assembled in the posture of the stator core annular assembly.
Detailed Description
Hereinafter, preferred embodiments of the insulator of the present application will be described with reference to the accompanying drawings. The same reference numerals are given to the same content and corresponding parts, and detailed description thereof is omitted. In the following embodiments, the same reference numerals are used to omit redundant description.
Embodiment 1.
First, the shape of each component of the present embodiment will be described.
The stator core 10 of fig. 1 is a stator core obtained by dividing an annular stator of an inner rotor type motor (see fig. 21) by the number of slots, and includes teeth 11 and a back yoke 12. The parting surface 13, which is a butt joint portion with the adjacent tooth, is a simple plane, and does not have a mechanism for joining between stator core units. Since the stator core 10 has a simple shape, a mold for the stator core 10 is prepared, and the manufacturing is easy.
Fig. 2 shows a stator core annular assembly 300 described later. In the following description, the axial direction (X), the circumferential direction (θ), and the radial direction (R) respectively represent directions shown in fig. 2.
Fig. 3 is a perspective view of the insulator according to embodiment 1, fig. 4 is a rear view seen from the radially outer peripheral side, and fig. 5 is a plan view seen from the axial direction.
The insulator 20 electrically insulating the coil from the stator core in fig. 3 to 5 has a core fitting portion 21 and a bobbin portion 22, the core fitting portion 21 being fitted to the stator core 10, the bobbin portion 22 supporting the wound coil. The insulator 20 of fig. 3 shows an upper insulator (see the insulator 20a of fig. 11) fitted up and down from the axial direction of the stator core 10. The bobbin 22 includes a portion covering the stator core 10, and an inner peripheral flange 23 and an outer peripheral flange 24 protruding in the axial direction, and the inner peripheral flange 23 and the outer peripheral flange 24 are supported so that the coil does not protrude from the radial direction R (see fig. 2).
The outer peripheral flange 24 is formed with an introduction groove for introducing the end wire of the coil and a discharge groove for discharging the end wire of the coil. The outer peripheral flange 24 has coupling portions 25a and 25b at positions facing the adjacent stator core 10, and the coupling portions 25a and 25b protrude from the Zhou Xiang end surfaces of the stator core 10.
The connecting portion 25a has a columnar portion 251 extending in the axial direction at the end thereof, and as will be described later, the connecting portion 25b has a guide portion that movably guides the columnar portion 251 of the other insulator. In the present embodiment, the slotted opening 252 corresponds to the guide portion. The columnar portion 251 has a shape (cutout portion 251 a) in which a part of the cylinder is cut out. Since the diameter of the columnar portion 251 is smaller than the width of the coupling portion 25a, a step 253 is formed at the boundary between the columnar portion 251 and the coupling portion 25 a. The step 253 is preferably formed on the entire circumference of the columnar portion 251, but even if it is formed on a part of the entire circumference, the step 253 may be formed at a position where the axial movement of the stator core 10 is restricted when the stator core coupling body 200 to be described later is formed. Further, the end surface of the columnar portion 251 has a projection 254, and the projection 254 projects outward from the cylindrical surface of the columnar portion 251.
The structure is as follows: the first circular arc portion 252a having the same diameter as the columnar portion 251 is provided on the inlet side of the slot-shaped opening portion 252 of the coupling portion 25b, and is fitted to the columnar portion 251 so as to be rotatable about the columnar portion 251. That is, the columnar portion 251 is rotatably fitted in the first circular arc portion 252a which is the fitting portion of the insulators 20 which is the farthest from each other. The second circular arc portion 252b having the same diameter is also provided on the terminal end side of the opening 252, and the columnar portion 251 is disposed at a position where the second circular arc portion 252b is fitted in a state where the divided surfaces 13 of the stator core 10 are abutted.
The first arc portion 252a and the second arc portion 252b are connected by a long hole portion 252c connecting the arc portions, and the width of the long hole portion 252c is the same as the diameter of the columnar portion 251 or larger than the diameter of the columnar portion 251. The width of the opening 252 formed by the first circular arc portion 252a, the long hole portion 252c, and the second circular arc portion 252b is substantially the same as the diameter of the columnar portion 251, but as shown in fig. 5 (a) and (b), the first circular arc portion 252a and the second circular arc portion 252b have projections 252d, and the projections 252d are used to form portions having a width smaller than the diameter of the columnar portion 251.
Since the insulator 20 is made of an insulating material having elasticity such as resin, rubber, paper, or wood, even if the width of the opening 252 is locally smaller than the columnar portion 251, the columnar portion 251 can be moved to the second circular arc portion 252b through the first circular arc portion 252a and the long hole portion 252c by temporarily elastically deforming the insulator 20. The opening side of the second circular arc portion 252b has a surface that fits into the cutout portion 251a of the columnar portion 251. This surface is perpendicular to the direction in which the columnar portion 251 is removed from the second circular arc portion 252b (the direction of opening).
The base side of the connecting portion 25a including the columnar portion 251 has a protrusion 255. In fig. 6 and 7, a state is shown in which the insulator 20 is coupled to form the stator core coupling body 200 and the coupling portion is modified to be assembled in the attitude of the stator core annular assembly 300. In this way, the side surface of the protrusion 255 on the first circular arc portion 252a side is positioned at a position that contacts the end surface of the long hole portion 252c on the first circular arc portion 252a side in a state where the columnar portion 251 and the second circular arc portion 252b are fitted, and the protrusion 255 has a guide slope in which the height of the protrusion 255 becomes lower toward the columnar portion 251. With this shape, the holding force of the coupled state can be enhanced.
By these means, the columnar portion 251 can fix the adjacent insulator 20 and stator core 10 at a predetermined angle in the second circular arc portion 252b, which is the fitting portion where the insulators 20 are closest to each other. The fitting of the columnar portion 251 to the first circular arc portion 252a or the second circular arc portion 252b is formed in a snap-fit shape by elastic deformation of the insulator, and thus, assembly can be performed easily. The buckle can be assembled and disassembled in a plane vertical to the axial direction. Fig. 7 shows an insulator in perspective for explaining the fitted state.
As shown in fig. 8 from the radially inner peripheral side, the insulator 20 has inner peripheral flange fitting portions 23a, 23b on the peripheral end surface of the inner peripheral flange portion 23, and the inner peripheral flange fitting portions 23a, 23b are fitted to the adjacent insulator 20. The inner peripheral flange fitting portions 23a, 23b are formed in a claw-like shape that opens in the axial direction as viewed from the inner peripheral side, and the inner peripheral flange fitting portions 23a, 23b do not restrict movement of the insulator 20 in the radial direction.
Fig. 9 is a view of fig. 8 from the axially lower side toward the upper side, in which the bobbin portion 22 obtained by dividing the insulator 20 into two in the axial direction has overlapping portions 22a, 22b where the insulators overlap each other. The overlap portions 22a and 22b have a function of increasing the insulation distance between the stator core 10 and the coil 30. The overlapping portions 22a, 22b are stepped, and the direction of the step of the overlapping portion 22a on one side in the circumferential direction is the same as the direction of the step of the overlapping portion 22b on the other side. That is, the step on one axial end side and the step on the other axial end side of the insulator 20 are fitted to each other on one side or the other side in the circumferential direction.
Next, a method of assembling the stator according to the present embodiment shown in fig. 10 will be described.
Stator core insulation Process S1-
As shown in fig. 11, two insulators 20 (insulator 20a, insulator 20 b) shown in fig. 3 are assembled to one stator core 10 shown in fig. 1 as a stator core insulation assembly 100. The axially opposite side of the columnar portion 251 of one insulator 20a faces the opening 252 (the first circular arc portion 252 a) of the other insulator 20b, and the insulators 20a and 20b having the same shape can be assembled to one stator core 10 to constitute the stator core insulation assembly 100.
Further, depending on the specifications of the stator, a part of the mold members of the insulators 20a and 20b may be changed to change the shape of a part of one insulator (for example, the insulator 20 a), but in order to minimize the change portion of the mold, it is preferable to arrange the columnar portion 251 and the opening 252 so as to face each other in the axial direction.
Since the step shapes of the overlapping portions 22a and 22b of the insulator 20 are oriented to be identical on one side and the other side in the circumferential direction, the insulators 20a and 20b are rotationally symmetrical to each other, and therefore the other insulator 20b can be formed to face each other in the same shape as the one insulator 20a, and the stator core insulation assembly 100 can be constituted by the insulator 20 having the same shape. Depending on the insulation specifications of the stator, the overlap portions 22a and 22b may be unnecessary, and when the overlap portions 22a and 22b are unnecessary, the conditions of the connecting portions 25a and 25b and the inner peripheral flange fitting portions 23a and 23b may be satisfied.
Insulator connection Process S2-
As shown in fig. 11, a plurality of stator core insulating assemblies 100 are connected by fitting the columnar portions 251 of the insulators 20a and 20b to the first circular arc portions 252a, and the stator core connecting body 200 is formed. Since the stator core coupling body 200 is coupled by the first circular arc portion 252a and the columnar portion 251, the stator core coupling body can be rotated about the columnar portion 251 as described above. The step 253 formed by the columnar portion 251 and the coupling portion 25a enters a gap between the adjacent stator core 10 and the axial direction of the opening portion 252, thereby restricting the movement of the opening portion 252 in the axial direction. With the projection 254 provided on the end face of the columnar portion 251, movement in the opposite direction to the restriction achieved by the step 253 is restricted.
Winding step S3-
As shown in fig. 12, the stator core connecting body 200 is attached to the core holding mechanism 51 of the winding device 50, and winding is performed. Since the stator core coupling body 200 is rotatable about the columnar portion 251, the stator core 10b adjacent to the stator core 10a to be wound can be gripped by the core gripping mechanism 51 of the winding device 50 in a state in which the stator core is rotated to a position where the stator core does not interfere with the flying fork 52. As shown in fig. 13, even in the stator cores 10c having different sizes, the same winding device 50 can be used to perform winding by aligning the positions of the columnar portions 251 of the insulators.
Even when the winding is performed by moving the nozzle 53 on a rectangular rail while approaching the stator cores 10a and 10b without using a fly fork mechanism, as shown in fig. 14 (a), the stator core 10c having a size different from that of the stator core 10a can be wound by using a common core holding mechanism, as shown in fig. 14 (b). In this case, since the space between teeth of the stator core can be enlarged, the diameter of the nozzle 53 can be increased, the curvature of the rounded shape connecting the outlet from the inner periphery of the nozzle 53 can be increased, and degradation of the coating film of the coil can be suppressed.
Annular ring assembling Process S4-
As shown in fig. 15 and 16, the connecting portion of the wound stator core connecting body 200 is set to a state assembled as the stator core annular assembly 300, and is connected in an annular shape as shown in fig. 17 as the stator core annular assembly 300. At this time, as shown in fig. 18, the columnar portion 251 is slid in the direction of arrow a to the second circular arc portion 252b, thereby forming an annular shape as shown in fig. 19. In this case, since the connecting portions 25a and 25b of the insulator 20 are housed inside the outer diameter of the stator core 10, the thickness of the molded resin to be described later can be ensured.
At this time, the notched portion 251a of the columnar portion 251 is fitted to the surface of the second circular arc portion 252b, which is perpendicular to the direction in which the columnar portion 251 is removed from the second circular arc portion 252b (the direction of opening), as described with reference to fig. 3, so that even if a load is applied to decompose the stator core connecting body 200, a component force that opens the opening portion 252 does not occur, and the stator core connecting body is not easily decomposed.
Further, since the inner peripheral flange fitting portions 23a, 23b provided in the inner peripheral flange portion 23 described with reference to fig. 8 are fitted and hooked to the adjacent insulator 20, the stator core annular assembly 300 is prevented from being disassembled with assistance. Thereby, the retention force after assembling the stator core 10 into a circular ring is enhanced. The inner peripheral flange fitting portions 23a, 23b are formed in a shape (same cross-sectional shape in the radial direction) that does not restrict movement of the insulator in the radial direction, and therefore do not hinder alignment of the connecting portions 25a, 25b on the outer peripheral side in the radial direction.
In addition, the stator core annular assembly 300 can be easily assembled without the need for a welding device, a press-fitting device, or the like. Since the material is not easily decomposed, a special auxiliary tool for conveying to a subsequent process is not required.
Wiring step S5-
The end wires of the coil 30 are electrically connected according to the stator specification.
Molding process S6-
The wound and wired stator core annular assembly 300 is set in a resin molding die and molded. Thus, the stator shown in fig. 20 is completed (the molded resin is only described in an outline in a perspective manner). As shown in fig. 21, the stator core 10 is pressed radially inward by the pressure of the resin 400 at the time of molding, and the divided surfaces 13 of the stator core are abutted to form a magnetic circuit.
The stator manufactured in the above-described steps is assembled with the rotor 60 having bearings mounted on both axial sides, and the motor 70 shown in fig. 21 can be formed by fitting brackets.
According to the above configuration, stator cores of different shapes can be wound without modifying or retrofitting the winding machine, and the divided stator cores can be easily connected and assembled into a circular ring shape, and a part or all of the insulators divided in the axial direction can be formed into a common shape. In addition, in the conventional insulator structure, it is necessary to prepare a mechanism for gripping teeth in a tooth shape and replace the mechanism in the manufacturing apparatus, but in the present embodiment, the distance between adjacent insulators can be variably adjusted by using the columnar portion and the opening portion provided in the connecting portion of the insulator, so that various stator cores can be wound without changing manufacturing equipment, and a high-performance stator and motor can be obtained. Thus, the stator and the motor can be wound with high density without increasing the number of components and manufacturing steps.
In patent document 2, the coupling portion is disposed outside the outer diameter of the stator core, and it is necessary to reduce the efficiency of the motor by making a part of the yoke portion thinner so that adjacent yoke portions of the stator core do not interfere with each other during winding. On the other hand, in the present embodiment, a stator and a motor that can secure a magnetic circuit of a stator core can be obtained.
Embodiment 2.
Fig. 22 and 23 illustrate a structure of a connecting portion 25b having the same function as the guide portion of the slotted opening 252 of embodiment 1. The connecting portion 25b may be formed by connecting two arm portions 25b1 and 25b2 extending in parallel by a connecting portion 25b 3. The arm portions 25b1 and 25b are formed with projections 252d, and first and second fitting portions 25b4 and 25b5 having the same functions as the first and second circular arc portions 252a and 252b described in embodiment 1 are formed. The connection portion 25b3 may be formed at the bottom of the two arm portions 25b1 and 25b2 between the first fitting portion 25b4 and the second fitting portion 25b5 so as not to interfere with the movement of the columnar portion 251. As described with reference to fig. 11, since the insulators 20a and 20b having the same shape are assembled on axially opposite sides to form the stator core insulator, the positional relationship between the columnar portion 251 and the first fitting portion 25b4 and the positional relationship between the columnar portion 251 and the second fitting portion 25b5 are reversed in the insulators 20a and 20b, and therefore, the positions of the bottoms are reversed, which means that the connecting portion 25b3 is formed on the upper portions of the two arm portions 25b1 and 25b 2.
The columnar portion 251 of the connecting portion 25a of the present embodiment is not formed in a cylindrical shape as in embodiment 1, but is formed in a polygonal shape such as a hexagonal prism, for example. The first fitting portion 25b4 and the second fitting portion 25b5 are formed along the outer periphery of the columnar portion 251. As can be understood from the plan view of fig. 22, the shape of the first fitting portion 25b4 is based on a shape identical or similar to the shape pattern of the columnar portion 251, and the triangular groove 25b7 may be formed to engage with the corner portion of the polygonal shape to lock the rotation so as to fit at a predetermined plurality of angles.
Further, the columnar portion 251 can fix the adjacent insulator 20 and stator core 10 at a predetermined angle in the second fitting portion 25b5 where the insulators 20 are closest to each other. The fitting of the columnar portion 251 to the first fitting portion 25b4 or the second fitting portion 25b5 is formed in a snap-fit shape by elastic deformation of the insulator, whereby assembly can be performed easily. The buckle can be assembled and disassembled in a plane vertical to the axial direction.
As in the case described with reference to fig. 11 and 12 of embodiment 1, fig. 24 is a state in which a plurality of stator core insulation assemblies 100 are connected by fitting the columnar portions 251 to the first fitting portions 25b4 in the insulator connecting step of the present embodiment, and are mounted as the stator core connecting body 200 to the core holding mechanism 51 in the winding step, and are wound. When the insulator 20 is rotated in a state where the polygonal shape of the columnar portion 251 is fitted to the first fitting portion 25b4, the opening portion of the first fitting portion 25b4 is elastically deformed and rotated by a rotation load of a certain or more. Thus, the auxiliary mechanism for selectively maintaining the angle of the iron core is provided in the winding process.
As in the case described in fig. 15 and 16 of embodiment 1, in this embodiment, a process for forming the connection portion of the wound stator core connection body 200 into the stator core annular assembly 300 is shown in fig. 25 and 26. After the columnar portion 251 fitted to the first fitting portion 25b4 is turned from the state of fig. 24 to the state of fig. 25, the columnar portion 251 is moved in the direction of the second fitting portion 25b5, whereby the columnar portion 251 is fitted to the second fitting portion 25b5 over the protrusion 252d as shown in fig. 26.
By forming the connecting portions 25a and 25b in the shape as in the present embodiment, the deformation occurring when the first fitting portion 25b4 having the farthest distance from the insulator 20 and the second fitting portion 25b5 having the closest distance from the insulator 20 are engaged can be made the same. In addition, as in embodiment 1, since the connecting portions 25a and 25b of the insulator 20 are housed inside the outer diameter of the stator core 10, the thickness of the molded resin to be described later can be ensured.
Embodiment 3.
As shown in fig. 27 and 28, the long side of the long hole portion 252c of the insulator 20 is a tangent line to the arc of the second arc portion 252b, and the retaining mechanism for restricting the circumferential movement by the second arc portion 252b when the long hole portion is the stator core connecting body 200 is not provided. Therefore, the coupling portions 25a and 25b have the mooring portions 256 on the side surfaces thereof. When combined with the adjacent stator cores 10a and 10b as shown in fig. 29, fig. 30 is a view showing the stator core in perspective, and the anchor 256 is caught by the anchor 256 of the adjacent insulator and is provided at a position where the circumferential movement of the insulator and the stator core insulation assembly is restricted. As shown in fig. 27, the adjacent insulator mooring portion 256 has a portion protruding from the coupling portions 25a and 25 b. Opposite sides of the protruding portion of one or both of the tie down portions 256 are notched to facilitate elastic deformation upon insertion.
The tie down portions 256 are provided on the side surfaces of the coupling portions 25a, 25b to be elastically deformed, and the tie down portions 256 restrict movement in the circumferential direction of the stator cores 10a, 10b, and the long hole portions 252c restrict movement in the radial direction of the stator cores 10a, 10 b. In the case of embodiment 1, there is a constraint that the size of the second circular arc portion 252b is the same as the size of the first circular arc portion 252a, but in the case of the present embodiment, there is no constraint of the size of the anchor portion 256, and it can be configured according to the required strength. The mooring portion 256 of the present embodiment may be added to the shape of embodiment 1. By forming such a tie down 256, an enhancement in the holding force after assembling the stator core 10 into a circular ring is achieved.
Embodiment 4.
As in the motor 70 of fig. 31, the final fixing of the stator core 10 uses the frame 80 instead of the resin 400. The frame 80 is made of a material for construction such as metal such as iron or aluminum, reinforced plastic, or the like. The frame 80 has a cylindrical shape, and has an inner diameter smaller than an outer diameter of the stator core coupling body, and is a dimension that applies preload to the stator core radially inward in a state where the frame 80 is combined with the stator core 10. As shown in fig. 19 or 26, the connecting portions 25a and 25b of the insulator 20 are housed inside the outer diameter of the stator core 10, and therefore, the insulator can be prevented from interfering with the frame when the frame is assembled.
The method of assembling the frame 80 to the stator includes a method of heat press-fitting the frame 80 by expanding the diameter by thermal expansion and fitting the frame 80 in the frame press-fitting or heat press-fitting step S7 of fig. 32, and then shrinking and fixing the frame 80 by cooling the frame 80, or a method of press-fitting the frame 80 without heating the frame 80. In addition, there is a method of dividing the frame 80 into a plurality of structures and fastening the structures by screws, welding, or bonding.
According to this structure, a mold or a molding machine for molding is not required, and the stator can be manufactured with a simpler manufacturing apparatus.
Embodiment 5.
As shown in fig. 33, the stator core 10 is insert molded in a resin molding die without dividing the insulator 20 in the axial direction. Thereby, the insulation distance can be ensured regardless of the step of the overlap portion. In the case where there is a step of the overlapped portion, it is necessary to set the thin wall side of the step portion to the minimum thickness of the resin molding, and the wall thickness of the insulator at the portion where the overlapped portion is not present is twice the minimum thickness. On the other hand, since the overlapping portion is not provided in the present embodiment, the thickness of the insulator can be made to be the minimum thickness of the resin molding, the space for accommodating the coil can be increased, and the copper loss of the stator can be reduced.
Embodiment 6.
As shown in fig. 34, the stator core insulating assemblies 100, which are connected in excess of the number corresponding to 1 stator, are mounted on the plurality of core holding mechanisms 51 as the stator core connecting bodies 200, whereby the coils of the respective phases are continuously wound by the plurality of flyers 52 without cutting the electric wires in the middle. This shortens the time for cutting the electric wire in the cycle time of the winding device, and improves the operation rate of the winding device. In addition, the stator core insulation assembly 100 can be supplied one by one during winding, so that waiting time for workpiece supply can be eliminated, and the operation rate can be improved.
The stator core after winding is moved in the arrow direction in fig. 34, is assembled in a circular shape in advance at the time of discharge, and is cut off from the stator core connecting body 200 during winding at the stage of 1 stator core preparation, thereby forming the stator core circular ring assembly 300, whereby the labor and time for rearranging the stator cores of each phase can be saved. Fig. 34 shows a case where two coils of different phases are arranged between coils of the same phase, such as a 9-pole 12 slot, but even in a case where two coils of the same phase are adjacent to each other and two pairs of coils of different phases are interposed between two pairs of coils of the same phase, such as a 10-pole 12 slot, the same structure can be wound by changing the number of stator cores between different flyers to an appropriate number.
Embodiment 7.
The connecting portions 25a and 25b according to embodiments 1 to 5 are provided in the insulator 20, but in this embodiment, separate connecting portions are provided separately from the insulator. Fig. 35 is a perspective view of the insulator 20 of the present embodiment. Fig. 36 is a perspective view of the split connecting portion 25 c. The insulator 20 has projections 27a, 27b, and the projections 27a, 27b are formed with columnar portions 26a, 26b. As shown in fig. 37, the split coupling portion 25c is formed with openings 252e and 252f, and the columnar portion 26b formed on the protrusion 27b of the insulator 20a is fitted into the opening 252e of the split coupling portion 25c, and the columnar portion 26a formed on the protrusion 27a of the insulator 20b adjacent to the insulator 20a is fitted into the opening 252f of the split coupling portion 25c, thereby being coupled rotatably.
As a result, as shown in fig. 38, as in fig. 11, the stator core coupling body 200 is configured to be rotatable about the columnar portions 26a and 26b. With such a configuration, as in the configuration shown in fig. 12 or 34, the stator core adjacent to the stator core to be wound can be gripped by the core gripping mechanism 51 of the winding device 50 in a state in which the stator core is rotated to a position where the stator core does not interfere with the flying fork 52, and winding can be performed by the winding device 50. Then, as shown in fig. 39, the connection portion of the wound stator core connection body 200 is set to a posture in which the stator core annular assembly 300 is assembled, and is connected in an annular shape as shown in fig. 40. In this case, the split connecting portion 25c of the insulator 20 may be housed inside the outer diameter of the stator core 10, and thus, as in embodiment 1, the thickness of the molded resin can be ensured.
In the above configuration, the opening is provided in the separate connection portion 25c and two columnar portions are provided in the insulator 20, but similar effects can be obtained by providing the columnar portions in the separate connection portion 25c and the opening in the insulator 20.
The split connecting portion 25c is rotatably connected to both of the columnar portions 26a and 26b having two positions, but may be configured such that one of them is rotatably connected.
As shown in fig. 41, the openings 252e and 252f formed in the split connecting portion 25c may have a third arc portion 252g and a fourth arc portion 252h. With this configuration, as shown in fig. 42 and 43, the lengths of the split connection portions are adjusted according to types of machines, so that the distances between adjacent stator cores during winding can be shared, and the stator cores can be manufactured with common manufacturing equipment without changing production.
As described above, since the insulator 20 is connected by the split connection portion 25c, and the split connection portion 25c is housed within the core outer diameter in the state of the stator core annular assembly 300, the winding can be performed at high density in the same assembling method as in embodiment 1 and embodiment 3. Further, since the fitting portions that rotatably couple the columnar portions 26a and 26b of the insulator 20 and the opening portions 252e and 252f of the split coupling portion 25c can be disposed at arbitrary positions with respect to the insulator and the stator core, various stator cores can be wound without changing the manufacturing equipment, and a high-performance stator and motor can be obtained, as in embodiment 1. Thus, the stator and the motor can be wound with high density without increasing the number of components and manufacturing steps.
The motor 70 as a rotating electric machine may be manufactured by the method described in embodiment 1 or embodiment 3 using a stator assembled in this way.
While various illustrative embodiments and examples have been described herein, the various features, aspects, and functions described in one or more embodiments are not limited to application to particular embodiments, and can be applied to embodiments alone or in various combinations.
Accordingly, numerous modifications not illustrated are conceivable within the scope of the technology disclosed in the present specification. For example, the case where at least one component is deformed, the case where addition is performed or the case where omission is performed, and the case where at least one component is extracted and combined with the components of other embodiments are included.
Description of the reference numerals
10: a stator core; 11: a tooth portion; 12: a back yoke; 13: a dividing surface; 20: an insulator; 21: an iron core embedding part; 22: a coil frame portion; 23: an inner peripheral flange portion; 23a, 23b: an inner peripheral flange fitting portion; 24: an outer peripheral flange portion; 25a, 25b: a connecting part; 25b3: a connection part; 25b4: a first fitting portion; 25b5: a second fitting portion; 25c: a split connecting part; 26a, 26b: a columnar portion; 30: a coil; 50: a winding device; 51: an iron core holding mechanism; 52: a flying fork; 53: a nozzle; 60: a rotor; 70: a motor; 80: a frame; 100: a stator core insulation assembly; 200: a stator core connecting body; 251: a columnar portion; 252. 252e, 252f: an opening portion; 252a: a first arc portion; 252b: a second arc portion; 252c: a long hole portion; 252g: a third arc portion; 252h: a fourth arc portion; 253: a step; 254. 255: a protrusion; 300: a stator core ring assembly; 400: and (3) resin.
Claims (24)
1. An insulator which is mounted to a stator core and electrically insulates a coil from the stator core, characterized in that,
the insulators are provided with columnar portions, guide portions, and two arm-shaped connecting portions, the two arm-shaped connecting portions protrude to two sides in the circumferential direction of the stator core, the columnar portions are formed in one connecting portion, the guide portions are formed in the other connecting portion and guide the columnar portions in a movable manner, the columnar portions of one insulator are engaged in the guide portions of the other adjacent insulator in a movable manner, and the distance between the adjacent insulators is variable.
2. The insulator of claim 1, wherein the insulator comprises a plurality of metal layers,
the guide portion is a slot-shaped portion, and the slot-shaped portion is formed with a plurality of fitting portions, and the fitting portions are capable of being fitted with the columnar portions.
3. The insulator of claim 1, wherein the insulator comprises a plurality of metal layers,
the guide portion has a plurality of fitting portions formed between two members extending in a circumferential direction with a space between which the columnar portion is movable, and a connecting portion that connects the two members is formed between the fitting portions at a position that does not interfere with movement of the columnar portion.
4. An insulator according to claim 2 or 3, characterized in that,
the columnar portion is rotatably fitted in a first fitting portion of the insulator which is farthest from each other.
5. The insulator according to claim 2 to 4,
the columnar portion is fixed at a predetermined angle in a second fitting portion where the insulators are closest to each other.
6. The insulator according to any one of claims 2 to 5, wherein,
the columnar portion and the fitting portion are detachably engaged with each other.
7. An insulator according to claim 2, wherein,
the columnar portion has a cutout portion, and the fitting portion of the insulators closest to each other has a projection portion, the projection portion being fitted into the cutout portion.
8. An insulator according to claim 3, wherein,
the columnar portion is a prism having a polygonal cross section, is rotatably fitted to a first fitting portion of the insulator which is farthest from each other, and has a groove formed therein, and the groove engages with a corner of the prism to lock rotation of the columnar portion.
9. The insulator according to any one of claims 1 to 8, characterized in that,
the insulator has flange portions formed on an inner peripheral side and an outer peripheral side of the insulator for restricting the coil, and a cutout portion to be fitted to an adjacent insulator is formed on a circumferential side surface of the flange portion on the inner peripheral side.
10. The insulator of claim 1, wherein the insulator comprises a plurality of metal layers,
the side surface of the connecting portion is provided with a mooring portion.
11. An insulator which is mounted to a stator core and electrically insulates a coil from the stator core, characterized in that,
the insulator includes a split coupling portion formed in a circumferential direction of the stator core and protruding radially outward, and two protrusions formed on the two protrusions, the split coupling portion being fitted to a fitting portion formed on the two protrusions, and the split coupling portion being rotated about the fitting portion so as to vary a distance between adjacent insulators.
12. The insulator of claim 11, wherein the insulating material is,
the fitting portion is a fitting portion in which a columnar portion formed on the protrusion is fitted to an opening formed on the split connecting portion, or a fitting portion in which an opening formed on the protrusion is fitted to a columnar portion formed on the split connecting portion.
13. The insulator of claim 12, wherein the insulator comprises a metal oxide,
the opening and the columnar portion are formed in plural.
14. A stator is characterized in that,
a coil is mounted on the stator core by being wound around the insulator according to any one of claims 1 to 13, and the stator core is connected in a circular ring shape and molded with resin.
15. A stator is characterized in that,
a coil is mounted on the stator core by being wound around the insulator according to any one of claims 1 to 13, the stator core being coupled in a circular ring shape, and an outer periphery of the stator core being covered with a frame and being preloaded in a radial direction.
16. The stator according to claim 14 or 15, wherein,
the connection portion or the connection split portion is housed inside the outer periphery of the stator core.
17. The stator according to claim 14 or 15, wherein,
the insulators are assembled in two in the axial direction of the tooth portion of the stator core, and a guide portion is arranged on one insulator on the opposite side in the axial direction corresponding to the columnar portion of the other insulator.
18. The stator as claimed in claim 17 wherein,
in the two insulators assembled and fitted, the core fitting portion of the one insulator has two 1 st and 2 nd overlapping portions in a circumferential direction of the core fitting portion of the other insulator on an opposite side in the axial direction, the 1 st and 2 nd overlapping portions are formed of steps, and orientations of the steps are the same in the left and right directions.
19. A rotating electrical machine, wherein the rotating electrical machine includes:
the stator of any one of claims 14 to 18; and a rotor disposed to be radially opposed to the stator.
20. A method for manufacturing a stator including an insulator that is attached to a stator core and electrically insulates a coil from the stator core, characterized in that,
the insulator includes a columnar portion formed in one of the connecting portions, a guide portion formed in the other connecting portion, and two arm-shaped connecting portions, the columnar portion of one insulator movably engaging with the guide portion of the other insulator so that the distance between the adjacent insulators is variable, and a plurality of fitting portions are formed in the guide portion, the fitting portions being capable of being fitted to the columnar portions, and the insulator is mounted to the winding device in a state in which the columnar portion is moved according to the size of the stator core and is fitted to one of the fitting portions.
21. A method for manufacturing a stator is characterized in that,
the stator includes an insulator that is attached to a stator core and electrically insulates a coil from the stator core, and the insulator is engaged with another adjacent insulator in a rotatable manner by an arm-shaped coupling portion protruding in a circumferential direction of the stator core, and the stator cores, the number of which exceeds 1 stator, are coupled to each other to be wound.
22. A method for manufacturing a stator including an insulator that is attached to a stator core and electrically insulates a coil from the stator core, characterized in that,
the insulator is mounted on the winding device by rotatably engaging one insulator with the other insulator by a separate coupling member so that the distance between the adjacent insulators is variable.
23. The method of manufacturing a stator according to claim 22, wherein,
the insulator or the separate connection member is formed with a plurality of fittable portions capable of fitting, and the insulator is attached to the winding device in a state in which the fitting portions are moved according to the size of the stator core and fitted to one of the fitting portions.
24. A method for manufacturing a rotary electric machine, characterized in that,
the method for manufacturing a stator according to any one of claims 20 to 23, wherein the rotors are arranged so as to face each other in a radial direction of the manufactured stator.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2021086736 | 2021-05-24 | ||
| JP2021-086736 | 2021-05-24 | ||
| PCT/JP2021/048900 WO2022249525A1 (en) | 2021-05-24 | 2021-12-28 | Insulator, stator, dynamo-electric machine, method for manufacturing stator, and method for manufacturing dynamo-electric machine |
Publications (1)
| Publication Number | Publication Date |
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| CN117280572A true CN117280572A (en) | 2023-12-22 |
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| CN202180098058.2A Pending CN117280572A (en) | 2021-05-24 | 2021-12-28 | Insulator, stator, rotating electrical machine, method for manufacturing stator, and method for manufacturing rotating electrical machine |
Country Status (3)
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| JP (1) | JPWO2022249525A1 (en) |
| CN (1) | CN117280572A (en) |
| WO (1) | WO2022249525A1 (en) |
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| WO2020039682A1 (en) * | 2018-08-24 | 2020-02-27 | ミネベアミツミ株式会社 | Motor and method for manufacturing motor |
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| JP4444639B2 (en) * | 2003-05-08 | 2010-03-31 | アスモ株式会社 | Stator for rotating electrical machine and method for manufacturing the same |
| JP5785863B2 (en) * | 2011-12-02 | 2015-09-30 | 株式会社日立産機システム | Electric motor stator and permanent magnet rotating electric machine |
| JP6200720B2 (en) * | 2013-01-28 | 2017-09-20 | アスモ株式会社 | Brushless motor and method for manufacturing brushless motor |
| JP6831615B2 (en) * | 2016-07-28 | 2021-02-17 | 三星電子株式会社Ｓａｍｓｕｎｇ Ｅｌｅｃｔｒｏｎｉｃｓ Ｃｏ．，Ｌｔｄ． | Stator and brushless motor |
| WO2021033496A1 (en) * | 2019-08-20 | 2021-02-25 | 三菱電機株式会社 | Stator and rotating electrical machine, and manufacturing method for same |
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2021
- 2021-12-28 JP JP2023523957A patent/JPWO2022249525A1/ja active Pending
- 2021-12-28 WO PCT/JP2021/048900 patent/WO2022249525A1/en active Application Filing
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