JP2004112861A - Motor and its manufacturing method - Google Patents

Motor and its manufacturing method Download PDF

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JP2004112861A
JP2004112861A JP2002268172A JP2002268172A JP2004112861A JP 2004112861 A JP2004112861 A JP 2004112861A JP 2002268172 A JP2002268172 A JP 2002268172A JP 2002268172 A JP2002268172 A JP 2002268172A JP 2004112861 A JP2004112861 A JP 2004112861A
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insulating material
slot
teeth
coil
shape
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JP3819350B2 (en
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Keiji Noma
野間　啓二
Toru Sakai
酒井　亨
Tomoaki Chizuzono
地頭園　智昭
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Hitachi Industrial Equipment Systems Co Ltd
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Hitachi Industrial Equipment Systems Co Ltd
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Abstract

<P>PROBLEM TO BE SOLVED: To improve the reliability on insulation and the productivity by simple and low-cost constitution without degrading the motor efficiency, in a concentrated winding coil type motor. <P>SOLUTION: A sheet-shaped insulating material is bent continuously in T shape, and is provided within a slot. A section extended longitudinally out of the section forming the T-shaped part of the insulating material is arranged between adjacent coil phases within the slot. Moreover, a section extended laterally out of the section forming the T-shaped part is arranged between each of the adjacent coils and the end of a tooth corresponding to the coil. <P>COPYRIGHT: (C)2004,JPO

Description

【０００１】
【発明の属する技術分野】
本発明は、ステータコアに対しコイルを集中巻き状態で設ける電動機の構成に関する。
【０００２】
【従来の技術】
一般に、電動機は、ステータに配置された巻線コイルに電流を通電することで磁界を発生してロータを回転駆動する。従来、電動機は、自身が磁界やロータ回転等に起因して振動の発生源となるが、その他、使用環境下によっては、外部から振動を受けることもある。また、ステータに配置された巻線コイル間には電動機に供給される電源電圧以上の電位差を生ずる。これはいずれも絶縁破壊要因となる。また、ロータに永久磁石を用いる電動機では、永久磁石を所定の極性に磁化するための着磁が必要となる。この着磁方法としては、着磁装置を用いた外部着磁方式と、電動機の組立て後に電源装置よりステータの巻線コイルに通電して着磁を行う巻線着磁方式とがある。図６は巻線着磁方式の説明図である。図６（ａ）は電源装置への接続状態を示す。ステータは、Ｕ相コイルとしてＵ１コイルとＵ２コイルを直列接続し、Ｖ相コイルとしてＶ１コイルとＶ２コイルを直列接続し、Ｗ相コイルとしてＷ１コイルとＷ２コイルの各々を直列接続し、さらにこれらＵ、Ｖ、Ｗの各相コイルを３相星形に結線してある。電源装置には、一方にＵ相コイルを接続し、他方に、Ｖ相コイルとＷ相コイルとを並列接続する。この状態で、電源装置をステータＵ側プラス、Ｖ、Ｗ側マイナスとして電流を通電した場合、ステータの巻線コイルへ通電される電流の向きを図６（ｂ）に示す。図６（ｂ）の構成においては、ステータコア２０は６個のスロット４を備え、スロット相互間に形成された６個のティース部２ａ〜２ｆには６個の巻線コイル３ａ〜３ｆが直接巻装されている。該巻線コイル３ａ〜３ｆのうち隣接するものは互いに異なった相となるため、１つのスロット内で互いに接触しないように配置されている。励磁用電流は、Ｕ端子→Ｕ１コイル３ａ−Ｕ２コイル３ｄ−Ｖ２コイル３ｅ−Ｖ１コイル３ｂ→Ｖ端子、Ｕ端子→Ｕ１コイル３ａ−Ｕ２コイル３ｄ−Ｗ２コイル３ｆ−Ｗ１コイル３ｃ→Ｗ端子へと通電される。この通電方向を、〇（向こう側から手前側に向かう場合）と×（手前側から向こう側に向かう場合）で示すと、Ｕ１コイル３ａ−Ｖ１コイル３ｂ、Ｕ２コイル３ｄ−Ｖ２コイル３ｅ間は×、Ｕ１コイル３ａ−Ｗ２コイル３ｆ、Ｕ２コイル３ｄ−Ｗ１コイル３ｃ間は〇となる。つまり、上記通電された巻線コイルには、着磁時に同一スロット内の異相コイル間に同方向の電流が通電されるため、該異相コイル間には吸引力が発生し、この力によってコイルに瞬間的な動きが発生する。この現象により、異相コイルが接触し、その結果、巻線コイルの絶縁層が破壊されてレアショートに至る場合がある。なお、この着磁方式では、次の段階として、ロータを所定角度回転させた後、電源装置へのステータのＵ、Ｖ、Ｗ相コイルの接続をプラス、マイナス逆転させてから、電流を通電する。このように、少なくとも２回の着磁工程を経て巻線着磁作業を終える。
【０００３】
電動機において、上記のような諸要因に基づく巻線コイルや絶縁材の絶縁破壊を防ぐための従来技術としては、例えば、特開２０００−１７５３９４号公報（特許文献１）に記載されたものがある。該公報には、スロット絶縁物の配置形態により巻線コイルとティース端部（ティース部の端部）との間の絶縁の信頼性向上を図るとする技術が記載されている。また、他の従来技術としては例えば図７に示すものがある。図７（ａ）は電動機のステータの斜視図、図７（ｂ）は同平面図である。図７に示すステータは、ステータコア２０に６個のスロット４と６個のティース部２ａ〜２ｆを有し、該ティース部２ａ〜２ｆのそれぞれに絶縁物（図示せず）を介して巻線コイル３ａ〜３ｆ（図では３ａ、３ｂのみを示す）を集中巻きした集中巻きステータである。互いに隣り合う巻線コイル、例えば３ａ、３ｂ間の絶縁性を確保するために、図７（ａ）に示すように、巻線の巻終りコイル１０にポリエステル等の筒状絶縁材１１をかぶせ、図７（ｂ）に示すように、該筒状絶縁物１１を、巻終りコイル１０が筒内に収納された状態でスロット４内の隣り合う巻線コイル、例えば３ａ、３ｂ間に挿入し、該両巻線コイル３ａ、３ｂ間で絶縁破壊が起きないようにしている。６ａはティース部２ａの端部（ティース端部）、６ｂはティース部２ｂの端部（ティース端部）である。また、図８に示す技術は、隣り合った巻線コイル、例えば３ａ、３ｂ間の距離Ｓを十分長くすることで該両巻線コイル３ａ、３ｂ間の絶縁破壊を防ぐようにしている。他の巻線コイルについても同様である。図８においても、６ａはティース部２ａの端部（ティース端部）、６ｂはティース部２ｂの端部（ティース端部）を示す。
【０００４】
【特許文献１】
特開２０００−１７５３９４号公報
【０００５】
【発明が解決しようとする課題】
上記従来技術のうち、筒状絶縁材を用いるものは、機械による筒状絶縁材の巻終りコイル１０への自動挿入が困難であるため、手作業に頼らざるを得ない。このため、生産効率が低く、低コスト化も難しい。また、筒状絶縁材がスロット開口部からステータの内径側の領域に突出しないようにするとともに、接触の危険性がある巻線コイル間を十分に絶縁するには、多くの作業工数を必要とし、かつ、作業のばらつきのために筒状絶縁材の挿入位置も安定せず、絶縁の信頼性を損なうおそれもある。また、スロット内で巻線コイル間の距離を十分長くとる技術では、巻線コイルの巻数の減少化や線径の縮小化を余儀なくされる。このため、コイル導体のスロット内における占積率（スロット占積率）が低下し、電動機の電流値の増大化や巻線コイルの抵抗値の増大化により、銅損が増加し、電動機の効率が低下する。
本発明の課題点は、上記従来技術の状況に鑑み、ステータにコイルが集中巻き状態で設けられる電動機において、簡易で低コストな手段により、スロット占積率や電動機効率を損なわずに、絶縁の信頼性向上と生産性向上とを図れるようにすることである。
本発明の目的は、かかる課題点を解決できる技術の提供にある。
【０００６】
【課題を解決するための手段】
上記課題点を解決するために、本発明では、基本的に、ステータにコイルが集中巻き状態で設けられる電動機において、Ｔ字形状に連続状に折り曲げられたシート状の絶縁材をスロット内に設け、該絶縁材のＴ字形状を形成する部分のうち縦方向に伸びた部分が、上記スロット内において、隣り合うコイル相互間に配されるようにする。また、該絶縁材のＴ字形状を形成する部分のうち横方向に伸びた部分が、上記スロット内において、隣り合うコイルそれぞれとこれらコイルに対応するティース部の端部との間に配されるようにする。具体的には、ステータにコイルが集中巻き状態で設けられる電動機として、（１）複数のティース部を有し、ティース部間にスロットが形成されるステータコア（該当実施例：符号２０）と、該複数のティース部にそれぞれ集中巻きされた複数のコイルと、Ｔ字形状に連続状に折り曲げられたシート状の絶縁材であって、Ｔ字形状を形成する部分のうち縦方向に伸びた部分（該当実施例：符号５ａ１、５ａ２）が、上記スロット内において、互いに隣り合うコイル相互間に配された絶縁材（該当実施例：符号５）とを備えた構成とする。（２）複数のティース部を有し、ティース部間にスロットが形成されるステータコアと、該複数のティース部にそれぞれ集中巻きされた複数のコイルと、Ｔ字形状に連続状に折り曲げられたシート状の絶縁材であって、Ｔ字形状を形成する部分のうち横方向に伸びた部分（該当実施例：符号５ｂ１、５ｂ２）が、上記スロット内において、隣り合うコイルそれぞれとそれに対応するティース部の端部との間に配された絶縁材（該当実施例：符号５）とを備えた構成とする。（３）複数のティース部を有し、ティース部間にスロットが形成されるステータコアと、該複数のティース部にそれぞれ集中巻きされた複数のコイルと、Ｔ字形状に連続状に折り曲げられたシート状の絶縁材であって、Ｔ字形状を形成する部分のうち縦方向に伸びた第１の部分（該当実施例：符号５ａ１、５ａ２）が、上記スロット内において、互いに隣り合うコイル相互間に配され、Ｔ字形状を形成する部分のうち横方向に伸びた第２の部分（該当実施例：符号５ｂ１、５ｂ２）が、上記スロット内において、隣り合うコイルそれぞれとそれに対応するティース部の端部との間に配された絶縁材（該当実施例：符号５）とを備えた構成とする。（４）上記（１）、（２）または（３）において、上記絶縁材を、ポリエステル材で構成する。また、ステータコアに対しコイルを集中巻き状態で設ける電動機の製造方法として、（５）ステータコアに形成された複数のティース部間のスロット内に第１の絶縁材を設ける第１のステップと、該複数のティース部のそれぞれに導線を集中巻きしてコイルを形成する第２のステップと、Ｔ字形状に連続状に折り曲げられたシート状の第２の絶縁材を上記スロット内に挿入し、Ｔ字形状を形成する部分のうち縦方向に伸びた部分を、隣り合うコイル相互間に配する第３のステップとを経てステータを形成し、電動機を組立てるようにする。（６）ステータコアに形成された複数のティース部間のスロット内に第１の絶縁材を設ける第１のステップと、該複数のティース部のそれぞれに導線を集中巻きしてコイルを形成する第２のステップと、Ｔ字形状に連続状に折り曲げられたシート状の第２の絶縁材を上記スロット内に挿入し、そのＴ字形状を形成する部分のうち横方向に伸びた部分を、隣り合うコイルそれぞれとそれに対応するティース部の端部との間に配する第３のステップとを経てステータを形成し、電動機を組立てるようにする。（７）ステータコアに形成された複数のティース部間のスロット内に第１の絶縁材を設ける第１のステップと、該複数のティース部のそれぞれに導線を集中巻きしてコイルを形成する第２のステップと、Ｔ字形状に連続状に折り曲げられたシート状の第２の絶縁材を上記スロット内に挿入し、そのＴ字形状を形成する部分のうち縦方向に伸びた第１の部分を、隣り合うコイル相互間に配するとともに、Ｔ字形状を形成する部分のうち横方向に伸びた第２の部分を、隣り合うコイルそれぞれとそれに対応するティース部の端部との間に配する第３のステップとを経てステータを形成し、電動機を組立てるようにする。
【０００７】
【発明の実施の形態】
以下、本発明の実施例につき、図面を用いて説明する。
図１は本発明の第１の実施例の説明図で、電動機のステータ構造の一部を示す。
図１において、２０はステータコア、４はスロット、１は、スロット４内でステータコア２０の壁に沿って配され、ポリエステルフィルムや樹脂成形絶縁材などで構成される第１の絶縁材、２ａ、２ｂはステータコア２０のティース部、３ａ、３ｂはそれぞれ、ティース部２ａ、２ｂに集中巻きした巻線コイル、５は、Ｔ字形状に連続状に折り曲げられたシート状のポリエステル材などから成る第２の絶縁材、５ａ１、５ａ２は、該第２の絶縁材５のＴ字形状を形成する部分のうち縦方向に伸びた部分（折返し部分（第１の部分））、５ｂ１、５ｂ２は、該第２の絶縁材５のＴ字形状を形成する部分のうち横方向に伸びた部分（第２の部分）、６ａはティース部２ａのティース端部、６ｂはティース部２ｂのティース端部である。第２の絶縁材５は各スロット４内に略同じ状態で配される。また、該第２の絶縁材５としては、厚さ０．１〜０．４ｍｍ程度のものが一般の電動機用として考えられるが、場合によってはこれよりも厚いものでも、または薄いものでもよい。複数個のスロット４のうち、図１に示すように巻線コイル３ａ、３ｂが通るスロット４内においては、Ｔ字形状を形成する部分のうち縦方向に伸びた部分（折返し部分）５ａ１、５ａ２は、隣り合う巻線コイル３ａ、３ｂ相互間の隙間部に挿入され、また、Ｔ字形状を形成する部分のうち横方向に伸びた部分５ｂ１は、スロット４内において、巻線コイル３ａと該巻線コイル３ａに対応するティース部２ａの端部（ティース端部）６ａとの間であって、該巻線コイル３ａと上記第１の絶縁材１との間に配され、横方向に伸びた部分５ｂ２は、スロット４内において、巻線コイル３ｂと該巻線コイル３ｂに対応するティース部２ｂの端部（ティース端部）６ｂとの間であって、該巻線コイル３ｂと上記第１の絶縁材１との間に配される。上記第２の絶縁材５の第１の部分５ａ１、５ａ２は、隣り合う巻線コイル３ａ、３ｂ相互間の絶縁抵抗の確保等、絶縁性向上のためのものであり、該第２の絶縁材５の第２の部分のうち５ｂ１は、巻線コイル３ａとティース端部）６ａとの間の絶縁抵抗の確保等、絶縁性向上のためのものであり、該第２の絶縁材５の第２の部分のうち５ｂ２は、巻線コイル３ｂとティース端部）６ｂとの間の絶縁抵抗の確保等、絶縁性向上のためのものである。電動機の製造にあたり、本図１のステータの製作は次の手順で行う。すなわち、（１）ステータコアに形成された複数のティース部２ａ、２ｂ、…間のスロット４内に第１の絶縁材１を設ける。（２）該複数のティース部２ａ、２ｂ、…のそれぞれに導線を集中巻きして巻線コイル３ａ、３ｂ、…を形成する。（３）Ｔ字形状に連続状に折り曲げられたシート状の第２の絶縁材５を上記各スロット４内に挿入し、そのＴ字形状を形成する部分のうち縦方向に伸びた第１の部分５ａ１、５ａ２を、隣り合う巻線コイル相互間に配するとともに、Ｔ字形状を形成する部分のうち横方向に伸びた第２の部分５ｂ１、５ｂ２を、隣り合う巻線コイル３ａ、３ｂ、…それぞれとそれに対応するティース部の端部（ティース端部）６ａ、６ｂ、…との間に配する。（４）巻線コイルのコイル端末の処理を行う。かかる手順で製作したステータにロータを組合わせて電動機として組立てる。
【０００８】
上記第１の実施例構成によれば、各スロット内において、第２の絶縁材５を、隣り合う巻線コイル（例えば巻線コイル３ａ、３ｂ）間や、該巻線コイルとそれに対応するティース端部（例えば、巻線コイル３ａとそれに対応するティース端部６ａ、巻線コイル３ｂとそれに対応するティース端部６ｂ）との間に、自動化技術等によっても容易に挿入することが可能となる。しかも、第２の絶縁材５はフィルム状を含む薄いシート状にできるため、スロット内において、隣り合う巻線コイル相互間の隙間や、各巻線コイルとそれに対応するティース端部との間の隙間を狭くした状態でも、各隙間への該第２の絶縁材５の挿入が可能である。このため、各スロット内において、巻線コイルの占めるスペースを増大させた状態下で、巻線コイル相互間の絶縁性や、巻線コイルとそれに対応するティース端部との間の絶縁性を向上させることができるようになる。絶縁性の向上化によっては、絶縁層の破壊防止をより一層確実に行うことができ、レアショートなどをなくすことが可能となる。巻線コイルの占めるスペースの増大化によっては、スロット内における巻線コイルの導体部の占積率（スロット占積率）の増大が可能となり、巻線コイルの導線断面積の増大やコイル巻数の増大が可能となる。導線断面積の増大すなわち太線化によっては、銅線の抵抗を減らして電動機の銅損を減らすことができる。コイル巻数の増大化によっては、所定のトルクを発生させる電動機の駆動電流値を低減させて必要電力を減らすことができる。銅損の低減や必要電力の減少は電動機の効率を向上させる。また、第２の絶縁材１は、簡易構成で、容易に製作でき、かつスロット内への組込みも容易に自動化等できるため、絶縁性能や効率を向上させた電動機を低コストにまたはコストを増大させずに実現できる。
【０００９】
図２は本発明の第２、第３及び第４の実施例の説明図で、電動機のステータ構造の一部を示す。図２（ａ）は第２の実施例、図２（ｂ）は第３の実施例、図２（ｃ）は第４の実施例の説明図である。
本第２、第３及び第４の実施例は、第２の絶縁材では主に、巻線コイル相互間の絶縁性能の確保を行うことを目的とする場合の構成例であって、該第２の絶縁材のＴ字形状を形成する部分のうち縦方向に伸びた部分（第１の部分）は、隣り合う巻線コイル間に挿入されるように十分な高さを有する構成とし、一方、該第２の絶縁材のＴ字形状を形成する部分のうち横方向に伸びた部分（第２の部分）は、その幅（ＷＬ）を、絶縁材装着後のズレ抑制、及び製造上必要な程度に小さくしてある。また、スロットの開口部側における該第１の絶縁材の開口幅（ＷＳ）も、スロットの開口幅（ＷＴ）よりも小さくしてある。図２（ａ）の第２の実施例、図２（ｂ）の第３の実施例、図２（ｃ）の第４の実施例のそれぞれにおいて、上記図１の第１の実施例と同様の部分には同じ符号を付した。
【００１０】
図２（ａ）において、ＷＳは、スロット４の開口部側における第１の絶縁材１の開口幅（端部間距離）、ＷＴは、スロット４の開口幅（ティース端部６ａ、６ｂ間の隙間寸法）、ＷＬは、第２の絶縁材５におけるＴ字形状を形成する部分のうち横方向に伸びた部分（第２の部分）５ｂ１、５ｂ２の幅、ＷＨは、第２の絶縁材５におけるＴ字形状を形成する部分のうち縦方向に伸びた部分（第１の部分）５ａ１、５ａ２の高さである。本第２の実施例は、スロット４の開口部側において、第１の絶縁材１の開口側端部が直線状のままとされた構成である。上記第１の実施例の場合と同様、スロット４内において、第２の絶縁材５のＴ字形状を形成する部分のうち縦方向に伸びた部分（折返し部分＝第１の部分）５ａ１、５ａ２は、隣り合う巻線コイル３ａ、３ｂ相互間の隙間部に挿入され、また、Ｔ字形状を形成する部分のうち横方向に伸びた部分（第２の部分）５ｂ１は、スロット４内において、巻線コイル３ａと該巻線コイル３ａに対応するティース部２ａの端部（ティース端部）６ａとの間であって、該巻線コイル３ａと上記第１の絶縁材１との間に配され、横方向に伸びた部分（第２の部分）５ｂ２は、スロット４内において、巻線コイル３ｂと該巻線コイル３ｂに対応するティース部２ｂの端部（ティース端部）６ｂとの間であって、該巻線コイル３ｂと上記第１の絶縁材１との間に配される。上記第２の絶縁材５の第１の部分５ａ１、５ａ２は、隣り合う巻線コイル３ａ、３ｂ相互間の絶縁抵抗の確保等、絶縁性向上のために設けられ、該第２の絶縁材５の第２の部分のうち５ｂ１は、巻線コイル３ａとティース端部）６ａとの間の絶縁抵抗の確保等、絶縁性向上のために設けられ、該第２の絶縁材５の第２の部分のうち５ｂ２は、巻線コイル３ｂとティース端部）６ｂとの間の絶縁抵抗の確保等、絶縁性向上のために設けられる。第１の部分５ａ１、５ａ２の高さＷＨは、隣接する巻線コイル間の絶縁を目的に必要に応じて寸法調整を行えばよい。電動機の製造にあたっての本第２の実施例におけるステータの製作手順は上記第１の実施例の場合と同様である。
【００１１】
上記第２の実施例構成においても、上記第１の実施例の場合と同様の作用・効果が得られる。特に、第２の実施例構成の場合は、スロット４の開口幅ＷＴが、第１の絶縁材１の開口幅ＷＳに対して大幅に大きい場合に、巻線コイルとティース端部との間の必要な絶縁抵抗の確保等を行い、絶縁の信頼性向上を図ることができる。この場合も、第２の絶縁材５における第２の部分５ｂ１、５ｂ２の幅ＷＬは大きい程、巻線コイルとティース端部との間の絶縁の信頼性を向上させることができる。
【００１２】
図２（ｂ）に示す本発明の第３の実施例では、スロット４の開口部側において、第１の絶縁材１の開口側端部を曲げ、該曲げた部分を、第２の絶縁材５のＴ字形状を形成する部分のうち縦方向に伸びた部分（折返し部分＝第１の部分）５ａ１、５ａ２に挿入した場合の構成例である。本第３の実施例においても、上記第１の実施例の場合と同様、スロット４内において、第２の絶縁材５の第１の部分５ａ１、５ａ２は、隣り合う巻線コイル３ａ、３ｂ相互間の隙間部に挿入され、第２の部分のうち一方の部分５ｂ１は、巻線コイル３ａと該巻線コイル３ａに対応するティース部２ａの端部（ティース端部）６ａとの間であって、該巻線コイル３ａと上記第１の絶縁材１との間に配され、第２の部分のうち他方の部分５ｂ２は、巻線コイル３ｂと該巻線コイル３ｂに対応するティース部２ｂの端部（ティース端部）６ｂとの間であって、該巻線コイル３ｂと上記第１の絶縁材１との間に配される。上記第２の絶縁材５の部分５ａ１、５ａ２は、隣り合う巻線コイル３ａ、３ｂ相互間の絶縁性を向上させ、該第２の絶縁材５の第２の部分５ｂ１、５ｂ２はそれぞれ、巻線コイル３ａとティース端部６ａとの間、巻線コイル３ｂとティース端部）６ｂとの間の絶縁抵抗の確保等絶縁性向上のために設けられる。電動機の製造にあたっての本第３の実施例におけるステータの製作手順も、上記第１の実施例の場合と同様である。
【００１３】
上記第３の実施例構成においても、上記第１の実施例の場合と同様の作用・効果が得られる。特に、本第３の実施例構成では、第２の絶縁材５がスロット４内の所定位置に確実に固定されるため、巻線コイル相互間、または巻線コイルとティース端部との間の絶縁の確保をし易い。また、スロット４内へのロータ側（ステータコア２０の内径側空間部）からの異物の侵入を抑えられる。
【００１４】
図２（ｃ）に示す本発明の第４の実施例では、スロット４の開口部側において、第１の絶縁材１の開口側端部を曲げ、該曲げた部分を、スロット４の開口部内に挿入した場合の構成例である。本第４の実施例においても、上記第１、第２、第３の実施例の場合と同様、スロット４内において、第２の絶縁材５の第１の部分５ａ１、５ａ２は、隣り合う巻線コイル３ａ、３ｂ相互間の隙間部に挿入され、第２の部分のうち５ｂ１は、巻線コイル３ａと該巻線コイル３ａに対応するティース部２ａの端部（ティース端部）６ａとの間であって、該巻線コイル３ａと上記第１の絶縁材１との間に配され、第２の部分のうち５ｂ２は、巻線コイル３ｂと該巻線コイル３ｂに対応するティース部２ｂの端部（ティース端部）６ｂとの間であって、該巻線コイル３ｂと上記第１の絶縁材１との間に配される。上記第２の絶縁材５の部分５ａ１、５ａ２は、隣り合う巻線コイル３ａ、３ｂ相互間の絶縁性を向上させ、該第２の絶縁材５の第２の部分５ｂ１、５ｂ２はそれぞれ、巻線コイル３ａとティース端部６ａとの間、巻線コイル３ｂとティース端部）６ｂとの間の絶縁性を向上させるために設けられる。電動機の製造にあたっての本第４の実施例におけるステータの製作手順も、上記第１の実施例の場合と同様である。
【００１５】
上記第４の実施例構成においても、上記第１の実施例の場合と同様の作用・効果が得られる。特に、本第４の実施例構成では、第１の絶縁材１がスロット４の開口部において確実に固定されるため、第２の絶縁材５の組込みスペースが確保される。このため、該固定後に第２の絶縁材５をスロット４内に組込む場合には、該第２の絶縁材５の組込みが容易となる。また、第１の絶縁材１がスロット４の開口部を一部埋めることになるため、実質的に開口部が狭くなる。このため、本第４の実施例においても、スロット４内へのロータ側（ステータコア２０の内径側空間部）からの異物の侵入を抑えられる。
【００１６】
図３は本発明の第５及び第６の実施例の説明図で、（ａ）は第５の実施例、（ｂ）は第の実施例の説明図である。
本第５、第６の実施例は、第２の絶縁材のＴ字形状を形成する部分のうち横方向に伸びた部分（第２の部分）を、第１の絶縁材と巻線コイルとの間に配するとともに、該第２の部分の幅を大きくし、かつ、スロットの開口部側における該第１の絶縁材の開口幅を、スロットの開口幅よりは小さいが該スロットの開口幅に近い寸法とした場合の構成例である。図３（ａ）の第５の実施例は、第２の絶縁材５では主に、巻線コイルとティース端部間の絶縁性能を確保することを目的とした場合の構成例であって、該第２の絶縁材のＴ字形状を形成する部分のうち縦方向に伸びた部分（第１の部分）５ａ１、５ａ２は、隣り合う巻線コイル間に短い長さで挿入されるように高さ（ＷＨ）を低くし、一方、該第２の絶縁材のＴ字形状を形成する部分のうち横方向に伸びた部分（第２の部分）５ｂ１、５ｂ２は、その幅（ＷＬ）を、十分に大きくしてある。図３（ｂ）の第６の実施例は、第２の絶縁材５では、巻線コイル相互間と、巻線コイルとティース端部間の、両方における絶縁性能を確保することを目的とした場合の構成例であって、第１の部分５ａ１、５ａ２の高さ（ＷＨ）を十分高くし、第２の部分５ｂ１、５ｂ２の幅（ＷＬ）も十分大きくしてある。図３（ｂ）の第６の実施例のそれぞれにおいて、上記図１の第１の実施例と同様の部分には同じ符号を付した。図３（ａ）の第５の実施例、図３（ｂ）の第６の実施例のそれぞれにおいて、上記図１の第１の実施例と同様の部分には同じ符号を付した。
本第５の実施例によれば、第２の絶縁材５の第１の部分５ａ１、５ａ２の高さＷＨを小さくしているため、該第２の絶縁材５の剛性が増加し、スロット４内の所定位置への組込み作業がし易くなる。その他の作用・効果は、上記第１の実施例等の場合と同様である。
また、第６の実施例によれば、巻線コイル相互間と、巻線コイルとティース端部間の、両方における絶縁性能を確保することができる。その他の作用・効果は、上記第１の実施例等の場合と同様である。
【００１７】
図４は、上記第１〜第６の実施例において用いる第２の絶縁材５の斜視図である。
図４において、Ｔ字形状を形成する部分のうち縦方向に伸びた第１の部分５ａ１、５ａ２は、折り返し状の部分であるため、絶縁強度を他の部分よりも高くすることができる。該第１の部分５ａ１、５ａ２は、スロット内において、隣り合う巻線コイル相互間の隙間に挿入される。ステータコアの各スロット内への挿入にあたっては、必要に応じて、４つの角部８ａ〜８ｄに対し、面取り加工またはＲ処理等を施す。該第２の絶縁材５は、第１の部分５ａ１、５ａ２の高さＷＨと第２の部分の幅ＷＬを、目的や状況に応じて調整することで、必要な絶縁性能を確保することができる。
【００１８】
図５は、上記図４の第２の絶縁材５を長尺母材９から、自動化された連続切出し加工により製作する場合の概念図である。長尺母材９はポリエステル材等から形成される。かかる加工方法によると加工の自動化が容易となり、生産性を高めることができる。
【００１９】
上記各実施例における上記第２の絶縁材は、Ｔ字形状として、Ω字形状、Ｕ字形状、Ｖ字形状、さらにはこれらが変形した形状なども含むとする。また、該第２の絶縁材はＴ字形状のものを複数枚重ねるなどした構成であってもよい。さらに、該Ｔ字形状の絶縁材は、例えば、Ｌ字形状の絶縁材を２枚組合わせることで構成してもよい。また、上記各実施例における上記第１の絶縁材も、１枚に限らず複数枚を重ねる等して構成してもよい。また、上記各実施例では、スロットの開口部側において、上記第２の絶縁材の第２の部分を、巻線コイルと上記第１の絶縁材との間に配する構成としたが、本発明はこれに限定されず、第２の絶縁材の該第２の部分を、該第１の絶縁材とステータコアのティース端部との間にはさむ構成としてもよい。
なお、本発明における上記第２の絶縁材を設ける構成は、コイルとして集中巻きされたものでないものを用いる電動機の場合にも有効である。
【００２０】
【発明の効果】
本発明によれば、簡易で低コストな構成により電動機効率を損なわずに、集中巻きコイル型電動機のステータの絶縁性向上と生産性向上を図ることができる。
【図面の簡単な説明】
【図１】本発明の第１の実施例の説明図である。
【図２】本発明の第２、第３及び第４の実施例の説明図である。
【図３】本発明の第５及び第６の実施例の説明図である。
【図４】本発明に用いる第２の絶縁材の構成例の斜視図である。
【図５】第２の絶縁材の製作方法例を示す図である。
【図６】巻線着磁方式の説明図である。
【図７】電動機における従来の絶縁構成例を示す図である。
【図８】電動機における従来の他の絶縁構成例を示す図である。
【符号の説明】
１…第１の絶縁材、　２ａ、２ｂ、２ｃ、２ｄ、２ｅ、２ｆ…ティース部、　３ａ、３ｂ…集中巻きされた巻線コイル、　４…スロット、　５…Ｔ字形状の第２の絶縁材、　５ａ１、５ａ２…第２の絶縁材の第１の部分、　ＷＨ…第２の絶縁材の第１の部分の高さ、　５ｂ１、５ｂ２…第２の絶縁材の第２の部分、　ＷＬ…第２の絶縁材の第２の部分の幅、　６ａ、６ｂ…ティース端部、９…長尺母材、２０…ステータコア。[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a configuration of an electric motor in which coils are wound around a stator core in a concentrated winding state.
[0002]
[Prior art]
In general, an electric motor generates a magnetic field by applying a current to a winding coil disposed on a stator, and drives the rotor to rotate. Conventionally, an electric motor itself is a source of vibration due to a magnetic field, rotation of a rotor, and the like, but may also be externally vibrated depending on the use environment. Further, a potential difference between the winding coils arranged on the stator and the power supply voltage supplied to the motor is generated. This is a cause of dielectric breakdown. Further, in an electric motor using a permanent magnet for the rotor, it is necessary to magnetize the permanent magnet to a predetermined polarity. As the magnetizing method, there are an external magnetizing method using a magnetizing device, and a winding magnetizing method in which a motor is assembled to energize a winding coil of a stator from a power supply device after the motor is assembled. FIG. 6 is an explanatory diagram of the winding magnetization method. FIG. 6A shows a connection state to the power supply device. The stator connects a U1 coil and a U2 coil in series as a U-phase coil, connects a V1 coil and a V2 coil in series as a V-phase coil, and connects a W1 coil and a W2 coil as a W-phase coil in series. , V, and W are connected in a three-phase star shape. A U-phase coil is connected to one side of the power supply device, and a V-phase coil and a W-phase coil are connected in parallel to the other side. In this state, when a current is supplied with the power supply unit being plus on the stator U side and minus on the V and W sides, the direction of the current supplied to the winding coil of the stator is shown in FIG. 6B. In the configuration shown in FIG. 6B, the stator core 20 has six slots 4 and six winding coils 3a to 3f are directly wound around six teeth portions 2a to 2f formed between the slots. Is equipped. Adjacent ones of the winding coils 3a to 3f have different phases, so that they are arranged so as not to contact each other in one slot. The exciting current is U terminal → U1 coil 3a-U2 coil 3d-V2 coil 3e-V1 coil 3b → V terminal, U terminal → U1 coil 3a-U2 coil 3d-W2 coil 3f-W1 coil 3c → W terminal. It is energized. When this energizing direction is indicated by 〇 (when going from the near side to the near side) and × (when going from the near side to the far side), the space between the U1 coil 3a-V1 coil 3b and the U2 coil 3d-V2 coil 3e is × , U1 coil 3a-W2 coil 3f, and U2 coil 3d-W1 coil 3c. In other words, in the energized winding coil, a current in the same direction is applied between the different-phase coils in the same slot at the time of magnetization, so that an attractive force is generated between the different-phase coils, and this force is applied to the coil. Instantaneous movement occurs. Due to this phenomenon, the out-of-phase coils come into contact with each other, and as a result, the insulating layer of the winding coil may be broken, resulting in a rare short circuit. In this magnetizing method, as the next step, after rotating the rotor by a predetermined angle, the connection of the U, V, and W phase coils of the stator to the power supply device is plus / minus reverse, and then the current is supplied. . Thus, the winding magnetizing operation is completed through at least two magnetizing steps.
[0003]
In the electric motor, as a conventional technique for preventing dielectric breakdown of a winding coil and an insulating material based on the above-described factors, for example, there is a technique described in Japanese Patent Application Laid-Open No. 2000-175394 (Patent Document 1). . This publication describes a technique for improving the reliability of insulation between a winding coil and a tooth end (end of a tooth portion) by an arrangement of slot insulators. FIG. 7 shows another conventional technique, for example. FIG. 7A is a perspective view of a stator of the electric motor, and FIG. 7B is a plan view of the same. The stator shown in FIG. 7 has six slots 4 and six teeth portions 2a to 2f in a stator core 20, and each of the teeth portions 2a to 2f has a winding coil via an insulator (not shown). This is a concentrated winding stator in which 3a to 3f (only 3a and 3b are shown in the figure) are concentrated. As shown in FIG. 7 (a), a coiled end coil 10 is covered with a cylindrical insulating material 11 such as polyester to secure insulation between the winding coils adjacent to each other, for example, 3a and 3b. As shown in FIG. 7 (b), the tubular insulator 11 is inserted between adjacent winding coils in the slot 4, for example, between 3a and 3b in a state where the winding end coil 10 is housed in the cylinder, Dielectric breakdown does not occur between the two winding coils 3a and 3b. 6a is an end (tooth end) of the tooth portion 2a, and 6b is an end (tooth end) of the tooth portion 2b. In the technique shown in FIG. 8, the distance S between the adjacent winding coils, for example, 3a and 3b, is made sufficiently long to prevent dielectric breakdown between the two winding coils 3a and 3b. The same applies to other winding coils. Also in FIG. 8, 6a indicates an end (tooth end) of the tooth portion 2a, and 6b indicates an end (tooth end) of the tooth portion 2b.
[0004]
[Patent Document 1]
JP 2000-175394 A
[0005]
[Problems to be solved by the invention]
Among the above prior arts, those using a cylindrical insulating material have to rely on manual work because it is difficult to automatically insert the cylindrical insulating material into the winding end coil 10 by a machine. For this reason, production efficiency is low and cost reduction is difficult. Also, many work steps are required to prevent the cylindrical insulating material from protruding from the slot opening into the region on the inner diameter side of the stator, and to sufficiently insulate between the winding coils where there is a risk of contact. In addition, the insertion position of the tubular insulating material is not stable due to a variation in work, and the reliability of insulation may be impaired. Further, in the technique of sufficiently increasing the distance between the winding coils in the slot, the number of turns of the winding coil and the wire diameter must be reduced. For this reason, the space factor (slot space factor) in the slot of the coil conductor decreases, and the copper value increases due to an increase in the current value of the motor and an increase in the resistance value of the winding coil, thereby increasing the efficiency of the motor. Decreases.
An object of the present invention is to provide an electric motor in which coils are provided in a concentrated winding state on a stator, by a simple and inexpensive means, without impairing the slot occupying rate or the motor efficiency, in view of the above-mentioned state of the art. An object is to improve reliability and productivity.
An object of the present invention is to provide a technique capable of solving such a problem.
[0006]
[Means for Solving the Problems]
In order to solve the above problems, in the present invention, basically, in a motor in which a coil is provided in a concentrated winding state on a stator, a sheet-shaped insulating material continuously bent in a T-shape is provided in a slot. A portion of the insulating material forming the T-shape, which extends in the vertical direction, is disposed between adjacent coils in the slot. A portion of the insulating material forming the T-shape extends in the lateral direction between the adjacent coils and the ends of the teeth corresponding to the coils in the slots. To do. Specifically, as a motor in which the coils are provided in a concentrated winding state on the stator, (1) a stator core having a plurality of teeth portions and a slot formed between the teeth portions (corresponding embodiment: reference numeral 20); A plurality of coils that are respectively concentratedly wound around the plurality of teeth, and a sheet-shaped insulating material that is continuously folded in a T-shape, and a portion that extends in the vertical direction among the portions that form the T-shape ( Applicable embodiment: Reference numeral 5a 1 , 5a 2 ) Is provided with an insulating material (corresponding embodiment: reference numeral 5) disposed between adjacent coils in the slot. (2) A stator core having a plurality of teeth portions, a slot formed between the teeth portions, a plurality of coils concentratedly wound around the plurality of teeth portions, and a sheet bent continuously in a T-shape. -Shaped insulating material, and a portion extending in the lateral direction among the portions forming the T-shape (applicable embodiment: reference numeral 5b 1 , 5b 2 ) Is provided with an insulating material (corresponding embodiment: reference numeral 5) disposed between each adjacent coil and an end of the corresponding tooth portion in the slot. (3) A stator core having a plurality of teeth, and a slot formed between the teeth, a plurality of coils concentratedly wound around the plurality of teeth, and a sheet continuously folded in a T-shape. -Shaped insulating material, a first portion extending in the vertical direction among portions forming a T-shape (applicable embodiment: reference numeral 5a 1 , 5a 2 ) Are arranged between the coils adjacent to each other in the slot, and a second portion extending in the lateral direction among portions forming a T-shape (a corresponding example: reference numeral 5b) 1 , 5b 2 ) Is provided with an insulating material (corresponding embodiment: reference numeral 5) disposed between each adjacent coil and an end of the corresponding tooth portion in the slot. (4) In the above (1), (2) or (3), the insulating material is made of a polyester material. In addition, as a method for manufacturing an electric motor in which coils are wound around a stator core in a concentrated manner, (5) a first step of providing a first insulating material in a slot between a plurality of teeth formed on the stator core; A second step of forming a coil by concentrating a conductive wire around each of the teeth portions, and inserting a sheet-shaped second insulating material continuously bent into a T-shape into the slot, A third step of arranging a vertically extending portion of the portion forming the shape between adjacent coils forms a stator, and assembles an electric motor. (6) A first step of providing a first insulating material in a slot between a plurality of teeth formed in a stator core, and a second step of forming a coil by intensively winding a conductive wire around each of the plurality of teeth. And inserting a sheet-shaped second insulating material continuously bent into a T-shape into the slot, and adjoining the portions extending in the lateral direction among the portions forming the T-shape. A third step is provided between each coil and the corresponding end of the teeth to form the stator and assemble the motor. (7) A first step of providing a first insulating material in a slot between a plurality of teeth formed in a stator core, and a second step of forming a coil by intensively winding a conductive wire around each of the plurality of teeth. And inserting a sheet-like second insulating material continuously bent into a T-shape into the slot, and removing a first portion of the portion forming the T-shape extending in the vertical direction. The second portion extending in the lateral direction among the portions forming the T-shape is arranged between each adjacent coil and the end of the corresponding tooth portion, while being arranged between the adjacent coils. The stator is formed through the third step, and the electric motor is assembled.
[0007]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 is an explanatory view of a first embodiment of the present invention, showing a part of a stator structure of an electric motor.
In FIG. 1, reference numeral 20 denotes a stator core, 4 denotes a slot, and 1 denotes a first insulating material, which is disposed along the wall of the stator core 20 in the slot 4 and is made of a polyester film or a resin-molded insulating material. Is a second part made of a sheet-like polyester material and the like, and 5 is a winding coil concentratedly wound around the teeth part 2a, 2b, and 5 is a sheet-like polyester material bent continuously in a T-shape. Insulation material, 5a 1 , 5a 2 Are portions extending in the vertical direction (returned portions (first portions)) of the portions forming the T-shape of the second insulating material 5; 1 , 5b 2 Is a portion (second portion) of the portion of the second insulating material 5 forming the T-shape extending in the lateral direction (second portion), 6a is a tooth end of the tooth portion 2a, and 6b is a tooth end of the tooth portion 2b. Department. The second insulating material 5 is disposed in each slot 4 in substantially the same state. The second insulating material 5 may have a thickness of about 0.1 to 0.4 mm for a general electric motor, but may be thicker or thinner in some cases. Of the plurality of slots 4, as shown in FIG. 1, in the slot 4 through which the winding coils 3a and 3b pass, a portion (a folded portion) 5a extending in the vertical direction among the portions forming the T-shape. 1 , 5a 2 Is inserted into the gap between the adjacent winding coils 3a and 3b, and a portion 5b extending in the lateral direction among the portions forming the T-shape 1 Is located between the winding coil 3a and the end (tooth end) 6a of the tooth portion 2a corresponding to the winding coil 3a in the slot 4, and the winding coil 3a and the first insulation A portion 5b arranged between the material 1 and extending in the lateral direction 2 Is in the slot 4 between the winding coil 3b and the end (tooth end) 6b of the tooth portion 2b corresponding to the winding coil 3b, and the winding coil 3b and the first insulation It is arranged between the material 1. The first portions 5a1 and 5a2 of the second insulating material 5 are provided for improving insulation properties such as securing insulation resistance between the adjacent winding coils 3a and 3b. 5b of the second part of 5 1 Are provided for improving insulation properties such as securing insulation resistance between the winding coil 3a and the tooth end 6a, and 5b of the second portion of the second insulating material 5 2 Are for improving insulation properties such as securing insulation resistance between the winding coil 3b and the teeth end 6b. In manufacturing the motor, the stator shown in FIG. 1 is manufactured in the following procedure. That is, (1) the first insulating material 1 is provided in the slot 4 between the teeth 2a, 2b,... Formed on the stator core. (2) Conductive wires are concentratedly wound around each of the teeth portions 2a, 2b,... To form winding coils 3a, 3b,. (3) A sheet-like second insulating material 5 continuously bent in a T-shape is inserted into each of the slots 4, and the first portion extending in the vertical direction among the portions forming the T-shape. Part 5a 1 , 5a 2 Is disposed between adjacent winding coils, and a second portion 5b extending in the lateral direction among the portions forming the T-shape 1 , 5b 2 Are arranged between the adjacent winding coils 3a, 3b,... And the corresponding ends of the teeth (teeth ends) 6a, 6b,. (4) Processing of the coil terminal of the winding coil is performed. The rotor is assembled to the stator manufactured by the above procedure and assembled as an electric motor.
[0008]
According to the configuration of the first embodiment, in each slot, the second insulating material 5 is provided between the adjacent winding coils (for example, the winding coils 3a and 3b) or between the winding coil and the corresponding tooth. It can be easily inserted between the ends (for example, between the winding coil 3a and the corresponding tooth end 6a, and the winding coil 3b and the corresponding tooth end 6b) by an automated technique or the like. . In addition, since the second insulating material 5 can be formed into a thin sheet shape including a film shape, a gap between adjacent winding coils or a gap between each winding coil and a corresponding tooth end in the slot. The second insulating material 5 can be inserted into each gap even in a state where is narrowed. For this reason, the insulation between the winding coils and the insulation between the winding coil and the corresponding tooth end are improved under the condition that the space occupied by the winding coil in each slot is increased. Will be able to do that. Depending on the improvement of the insulating property, the destruction of the insulating layer can be more reliably prevented, and rare shorts and the like can be eliminated. By increasing the space occupied by the winding coil, it is possible to increase the space factor (slot occupancy ratio) of the conductor portion of the winding coil in the slot. Increase is possible. Depending on the increase in the cross-sectional area of the conductive wire, that is, the increase in the thickness of the wire, the resistance of the copper wire can be reduced to reduce the copper loss of the motor. Depending on the increase in the number of coil turns, the required electric power can be reduced by reducing the drive current value of the electric motor that generates the predetermined torque. The reduction of copper loss and the required power increase the efficiency of the motor. In addition, the second insulating material 1 has a simple configuration, can be easily manufactured, and can be easily integrated into a slot. For example, a motor with improved insulating performance and efficiency can be manufactured at a low cost or an increased cost. It can be realized without doing it.
[0009]
FIG. 2 is an explanatory view of the second, third and fourth embodiments of the present invention, showing a part of the stator structure of the electric motor. FIG. 2A is an explanatory diagram of the second embodiment, FIG. 2B is an explanatory diagram of the third embodiment, and FIG. 2C is an explanatory diagram of the fourth embodiment.
The second, third, and fourth embodiments are configuration examples in the case where the second insulating material is mainly intended to ensure insulation performance between the winding coils. The portion (first portion) extending in the vertical direction of the T-shaped portion of the second insulating material is configured to have a sufficient height so as to be inserted between adjacent winding coils. The width (WL) of the portion (the second portion) extending in the lateral direction of the T-shaped portion of the second insulating material is required to reduce the width (WL) after the mounting of the insulating material, and to manufacture. It is so small. The opening width (WS) of the first insulating material on the opening side of the slot is also smaller than the opening width (WT) of the slot. Each of the second embodiment of FIG. 2A, the third embodiment of FIG. 2B, and the fourth embodiment of FIG. 2C is the same as the first embodiment of FIG. Are given the same reference numerals.
[0010]
In FIG. 2A, WS is the opening width (distance between ends) of the first insulating material 1 on the opening side of the slot 4, and WT is the opening width of the slot 4 (between the teeth ends 6a and 6b). The gap dimension) and WL are the portions (second portions) 5b extending in the lateral direction of the T-shaped portion of the second insulating material 5 1 , 5b 2 Of the T-shaped portion of the second insulating material 5 (the first portion) 5a 1 , 5a 2 Height. The second embodiment has a configuration in which the opening-side end of the first insulating material 1 remains linear on the opening side of the slot 4. As in the case of the first embodiment, in the slot 4, the portion of the second insulating material 5 that forms the T-shape and extends in the vertical direction (turned portion = first portion) 5 a 1 , 5a 2 Is inserted into the gap between the adjacent winding coils 3a and 3b, and a portion (second portion) 5b extending in the lateral direction among the portions forming the T-shape 1 Is located between the winding coil 3a and the end (tooth end) 6a of the tooth portion 2a corresponding to the winding coil 3a in the slot 4, and the winding coil 3a and the first insulation A portion (second portion) 5b disposed between the material 1 and extending in the lateral direction 2 Is in the slot 4 between the winding coil 3b and the end (tooth end) 6b of the tooth portion 2b corresponding to the winding coil 3b, and the winding coil 3b and the first insulation It is arranged between the material 1. First portion 5a of second insulating material 5 1 , 5a 2 Is provided for improving insulation properties such as securing insulation resistance between the adjacent winding coils 3a and 3b, and 5b of the second portion of the second insulating material 5 1 Is provided for improving insulation properties such as securing insulation resistance between the winding coil 3a and the teeth end 6a, and 5b of the second portion of the second insulating material 5 is provided. 2 Is provided for improving insulation properties such as securing insulation resistance between the winding coil 3b and the teeth end 6b. First part 5a 1 , 5a 2 The height WH may be adjusted as needed for the purpose of insulation between adjacent winding coils. The procedure for manufacturing the stator in the second embodiment in manufacturing the motor is the same as that in the first embodiment.
[0011]
In the configuration of the second embodiment, the same operation and effect as those of the first embodiment can be obtained. In particular, in the case of the configuration of the second embodiment, when the opening width WT of the slot 4 is significantly larger than the opening width WS of the first insulating material 1, the distance between the winding coil and the tooth end is reduced. It is possible to secure necessary insulation resistance or the like, and to improve insulation reliability. Also in this case, the second portion 5b of the second insulating material 5 1 , 5b 2 Is larger, the reliability of insulation between the winding coil and the end of the tooth can be improved.
[0012]
In the third embodiment of the present invention shown in FIG. 2B, the opening side end of the first insulating material 1 is bent at the opening side of the slot 4, and the bent portion is replaced with the second insulating material. 5, a portion (vertical portion = first portion) 5a extending in the vertical direction among the portions forming the T-shape 1 , 5a 2 It is an example of a configuration in the case of inserting it into a. In the third embodiment, as in the case of the first embodiment, the first portion 5a of the second insulating material 5 is provided in the slot 4. 1 , 5a 2 Is inserted into the gap between the adjacent winding coils 3a and 3b, and one of the second portions 5b 1 Is between the winding coil 3a and the end (tooth end) 6a of the tooth portion 2a corresponding to the winding coil 3a, and between the winding coil 3a and the first insulating material 1. And the other part 5b of the second part 2 Is between the winding coil 3b and the end (tooth end) 6b of the tooth portion 2b corresponding to the winding coil 3b, and between the winding coil 3b and the first insulating material 1. Distributed to Part 5a of the second insulating material 5 1 , 5a 2 Improves the insulation between the adjacent winding coils 3a and 3b, and improves the second portion 5b of the second insulating material 5. 1 , 5b 2 Are provided for improving insulation properties such as securing insulation resistance between the winding coil 3a and the tooth end 6a and between the winding coil 3b and the tooth end 6b. The procedure for manufacturing the stator in the third embodiment in manufacturing the motor is the same as that in the first embodiment.
[0013]
In the configuration of the third embodiment, the same operation and effect as those of the first embodiment can be obtained. In particular, in the configuration of the third embodiment, since the second insulating material 5 is securely fixed at a predetermined position in the slot 4, the distance between the winding coils or between the winding coil and the tooth end is increased. It is easy to secure insulation. In addition, foreign substances can be prevented from entering the slots 4 from the rotor side (the inner diameter side space of the stator core 20).
[0014]
In the fourth embodiment of the present invention shown in FIG. 2C, the opening-side end of the first insulating material 1 is bent at the opening side of the slot 4, and the bent portion is placed inside the opening of the slot 4. It is an example of a configuration in the case of inserting it into a. In the fourth embodiment, as in the first, second, and third embodiments, the first portion 5a of the second insulating material 5 in the slot 4 is provided. 1 , 5a 2 Is inserted into the gap between the adjacent winding coils 3a and 3b, and 5b of the second portion 1 Is between the winding coil 3a and the end (tooth end) 6a of the tooth portion 2a corresponding to the winding coil 3a, and between the winding coil 3a and the first insulating material 1. And 5b of the second part 2 Is between the winding coil 3b and the end (tooth end) 6b of the tooth portion 2b corresponding to the winding coil 3b, and between the winding coil 3b and the first insulating material 1. Distributed to Part 5a of the second insulating material 5 1 , 5a 2 Improves the insulation between the adjacent winding coils 3a and 3b, and improves the second portion 5b of the second insulating material 5. 1 , 5b 2 Are provided to improve the insulation between the winding coil 3a and the tooth end 6a and between the winding coil 3b and the tooth end 6b. The procedure for manufacturing the stator in the fourth embodiment in manufacturing the motor is the same as that in the first embodiment.
[0015]
In the configuration of the fourth embodiment, the same operation and effect as those of the first embodiment can be obtained. In particular, in the configuration of the fourth embodiment, the first insulating material 1 is securely fixed at the opening of the slot 4, so that a space for assembling the second insulating material 5 is secured. For this reason, when the second insulating material 5 is incorporated into the slot 4 after the fixing, the second insulating material 5 is easily incorporated. Further, since the first insulating material 1 partially fills the opening of the slot 4, the opening is substantially narrowed. For this reason, in the fourth embodiment as well, entry of foreign matter from the rotor side (the inner diameter side space of the stator core 20) into the slot 4 can be suppressed.
[0016]
FIGS. 3A and 3B are explanatory diagrams of the fifth and sixth embodiments of the present invention. FIG. 3A is an explanatory diagram of the fifth embodiment, and FIG.
In the fifth and sixth embodiments, the portion (second portion) extending in the lateral direction of the T-shaped portion of the second insulating material is formed by the first insulating material and the winding coil. And the width of the second portion is increased, and the opening width of the first insulating material on the opening side of the slot is smaller than the opening width of the slot but the opening width of the slot. This is a configuration example in the case of a size close to. The fifth embodiment of FIG. 3A is a configuration example in the case where the second insulating material 5 is mainly intended to ensure the insulation performance between the winding coil and the end of the teeth. A vertically extending portion (first portion) 5a of the portion of the second insulating material forming the T-shape 1 , 5a 2 Reduces the height (WH) so as to be inserted between adjacent winding coils with a short length, while extending horizontally in a portion of the second insulating material forming a T-shape. Part (second part) 5b 1 , 5b 2 Has a sufficiently large width (WL). The sixth embodiment of FIG. 3B aims at securing the insulation performance between the winding coils and between the winding coils and the end portions of the teeth in the second insulating material 5. Configuration example in which the first portion 5a 1 , 5a 2 Height (WH) of the second portion 5b 1 , 5b 2 Is sufficiently large. In each of the sixth embodiment of FIG. 3B, the same parts as those in the first embodiment of FIG. 1 are denoted by the same reference numerals. In each of the fifth embodiment of FIG. 3A and the sixth embodiment of FIG. 3B, the same parts as those in the first embodiment of FIG. 1 are denoted by the same reference numerals.
According to the fifth embodiment, the first portion 5a of the second insulating material 5 1 , 5a 2 Since the height WH of the second insulating material 5 is reduced, the rigidity of the second insulating material 5 is increased, and the assembling work at a predetermined position in the slot 4 becomes easy. Other functions and effects are the same as those of the first embodiment and the like.
Further, according to the sixth embodiment, it is possible to ensure insulation performance between both the winding coils and between the winding coil and the tooth end. Other functions and effects are the same as those of the first embodiment and the like.
[0017]
FIG. 4 is a perspective view of the second insulating material 5 used in the first to sixth embodiments.
In FIG. 4, the first portion 5a extending in the vertical direction among the portions forming the T-shape 1 , 5a 2 Is a folded portion, so that the insulation strength can be made higher than other portions. The first part 5a 1 , 5a 2 Is inserted into the gap between the adjacent winding coils in the slot. When inserting the stator core into each slot, chamfering or R processing is performed on the four corners 8a to 8d as necessary. The second insulating material 5 includes a first portion 5a 1 , 5a 2 By adjusting the height WH and the width WL of the second portion according to the purpose and the situation, required insulation performance can be secured.
[0018]
FIG. 5 is a conceptual diagram in a case where the second insulating material 5 of FIG. 4 is manufactured from the long base material 9 by an automatic continuous cutting process. The long base material 9 is formed from a polyester material or the like. According to such a processing method, automation of the processing is facilitated, and the productivity can be increased.
[0019]
It is assumed that the second insulating material in each of the above embodiments includes, as the T-shape, an Ω-shape, a U-shape, a V-shape, and a deformed shape thereof. Further, the second insulating material may have a configuration in which a plurality of T-shaped insulating materials are stacked. Further, the T-shaped insulating material may be configured by combining two L-shaped insulating materials, for example. Further, the first insulating material in each of the above embodiments is not limited to one, and may be configured by stacking a plurality of sheets. Further, in each of the above embodiments, the second portion of the second insulating material is disposed between the winding coil and the first insulating material on the opening side of the slot. The invention is not limited to this, and the second portion of the second insulating material may be sandwiched between the first insulating material and the teeth end of the stator core.
The configuration in which the second insulating material is provided in the present invention is also effective in the case of an electric motor using a coil that is not concentratedly wound as a coil.
[0020]
【The invention's effect】
ADVANTAGE OF THE INVENTION According to this invention, the insulation of a stator of a concentrated winding coil-type electric motor can be improved, and productivity can be improved, without impairing motor efficiency with a simple and low-cost structure.
[Brief description of the drawings]
FIG. 1 is an explanatory diagram of a first embodiment of the present invention.
FIG. 2 is an explanatory diagram of a second, a third and a fourth embodiment of the present invention.
FIG. 3 is an explanatory view of a fifth and a sixth embodiment of the present invention.
FIG. 4 is a perspective view of a configuration example of a second insulating material used in the present invention.
FIG. 5 is a diagram illustrating an example of a method for manufacturing a second insulating material.
FIG. 6 is an explanatory diagram of a winding magnetization method.
FIG. 7 is a diagram showing an example of a conventional insulation configuration in a motor.
FIG. 8 is a diagram showing another example of a conventional insulating configuration in a motor.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 ... 1st insulating material, 2a, 2b, 2c, 2d, 2e, 2f ... Teeth part, 3a, 3b ... Concentrated winding coil, 4 ... Slot, 5 ... T-shaped 2nd insulating material , 5a 1 , 5a 2 ... the first portion of the second insulating material, WH ... the height of the first portion of the second insulating material, 5b 1 , 5b 2 ... a second portion of the second insulating material, WL ... a width of the second portion of the second insulating material, 6a, 6b ... teeth end portions, 9 ... a long base material, 20 ... a stator core.

Claims (7)

ステータコアに対しコイルが集中巻き状態で設けられる電動機において、
複数のティース部を有し、ティース部間にスロットが形成されるステータコアと、
該複数のティース部にそれぞれ集中巻きされた複数のコイルと、
Ｔ字形状に連続状に折り曲げられたシート状の絶縁材であって、Ｔ字形状を形成する部分のうち縦方向に伸びた部分が、上記スロット内において、互いに隣り合うコイル相互間に配された絶縁材と、
を備えたことを特徴とする電動機。In an electric motor in which coils are provided in a concentrated winding state with respect to a stator core,
A stator core having a plurality of teeth, wherein a slot is formed between the teeth,
A plurality of coils concentratedly wound around each of the plurality of teeth,
A sheet-shaped insulating material continuously folded in a T-shape, wherein a vertically extending portion of a portion forming the T-shape is arranged between adjacent coils in the slot. Insulation material,
An electric motor comprising: ステータコアに対しコイルが集中巻き状態で設けられる電動機において、
複数のティース部を有し、ティース部間にスロットが形成されるステータコアと、
該複数のティース部にそれぞれ集中巻きされた複数のコイルと、
Ｔ字形状に連続状に折り曲げられたシート状の絶縁材であって、Ｔ字形状を形成する部分のうち横方向に伸びた部分が、上記スロット内において、隣り合うコイルのそれぞれと、該それぞれのコイルに対応するティース部の端部との間に配された絶縁材と、
を備えたことを特徴とする電動機。In an electric motor in which coils are provided in a concentrated winding state with respect to a stator core,
A stator core having a plurality of teeth, wherein a slot is formed between the teeth,
A plurality of coils concentratedly wound around each of the plurality of teeth,
A sheet-shaped insulating material continuously bent in a T-shape, wherein a portion extending in the lateral direction among the portions forming the T-shape includes, in the slot, each of adjacent coils, An insulating material disposed between the end of the teeth corresponding to the coil of
An electric motor comprising: ステータコアに対しコイルが集中巻き状態で設けられる電動機において、
複数のティース部を有し、ティース部間にスロットが形成されるステータコアと、
該複数のティース部にそれぞれ集中巻きされた複数のコイルと、
Ｔ字形状に連続状に折り曲げられたシート状の絶縁材であって、Ｔ字形状を形成する部分のうち縦方向に伸びた第１の部分が、上記スロット内において、互いに隣り合うコイル相互間に配され、Ｔ字形状を形成する部分のうち横方向に伸びた第２の部分が、上記スロット内において、隣り合うコイルそれぞれと該それぞれのコイルに対応するティース部の端部との間に配された絶縁材と、
を備えたことを特徴とする電動機。In an electric motor in which coils are provided in a concentrated winding state with respect to a stator core,
A stator core having a plurality of teeth, wherein a slot is formed between the teeth,
A plurality of coils concentratedly wound around each of the plurality of teeth,
A sheet-shaped insulating material continuously bent in a T-shape, wherein a first portion extending in the vertical direction among the portions forming the T-shape is disposed between the adjacent coils in the slot. And a second portion extending in the lateral direction among the portions forming the T-shape is provided between the adjacent coils and the ends of the teeth corresponding to the respective coils in the slots. With insulating material arranged,
An electric motor comprising: 上記絶縁材は、ポリエステル材で構成される請求項１、２または３に記載の電動機。The electric motor according to claim 1, wherein the insulating material is made of a polyester material. ステータコアに対しコイルを集中巻き状態で設ける電動機の製造方法において、
ステータコアに形成された複数のティース部間のスロット内に第１の絶縁材を設ける第１のステップと、
該複数のティース部のそれぞれに導線を集中巻きしてコイルを形成する第２のステップと、
Ｔ字形状に連続状に折り曲げられたシート状の第２の絶縁材を上記スロット内に挿入し、Ｔ字形状を形成する部分のうち縦方向に伸びた部分を、隣り合うコイル相互間に配する第３のステップと、
を経てステータを形成し、電動機を組立てることを特徴とする電動機の製造方法。In a method for manufacturing an electric motor in which a coil is provided in a concentrated winding state with respect to a stator core,
A first step of providing a first insulating material in a slot between a plurality of teeth formed in the stator core;
A second step of forming a coil by intensively winding a conductive wire around each of the plurality of teeth,
A sheet-shaped second insulating material bent continuously in a T-shape is inserted into the slot, and a vertically extending portion of the portion forming the T-shape is arranged between adjacent coils. A third step to
A method for manufacturing a motor, comprising forming a stator through the steps described above, and assembling the motor. ステータコアに対しコイルを集中巻き状態で設ける電動機の製造方法において、
ステータコアに形成された複数のティース部間のスロット内に第１の絶縁材を設ける第１のステップと、
該複数のティース部のそれぞれに導線を集中巻きしてコイルを形成する第２のステップと、
Ｔ字形状に連続状に折り曲げられたシート状の第２の絶縁材を上記スロット内に挿入し、そのＴ字形状を形成する部分のうち横方向に伸びた部分を、隣り合うコイルそれぞれとそれに対応するティース部の端部との間に配する第３のステップと、
を経てステータを形成し、電動機を組立てることを特徴とする電動機の製造方法。In a method for manufacturing an electric motor in which a coil is provided in a concentrated winding state with respect to a stator core,
A first step of providing a first insulating material in a slot between a plurality of teeth formed in the stator core;
A second step of forming a coil by intensively winding a conductive wire around each of the plurality of teeth,
A sheet-shaped second insulating material continuously bent into a T-shape is inserted into the slot, and a portion of the T-shaped portion extending in the lateral direction is inserted into each of the adjacent coils and the adjacent coil. A third step of disposing between the corresponding teeth ends;
A method for manufacturing a motor, comprising forming a stator through the steps described above, and assembling the motor. ステータコアに対しコイルを集中巻き状態で設ける電動機の製造方法において、
ステータコアに形成された複数のティース部間のスロット内に第１の絶縁材を設ける第１のステップと、
該複数のティース部のそれぞれに導線を集中巻きしてコイルを形成する第２のステップと、
Ｔ字形状に連続状に折り曲げられたシート状の第２の絶縁材を上記スロット内に挿入し、そのＴ字形状を形成する部分のうち縦方向に伸びた第１の部分を、隣り合うコイル相互間に配するとともに、Ｔ字形状を形成する部分のうち横方向に伸びた第２の部分を、隣り合うコイルそれぞれとそれに対応するティース部の端部との間に配する第３のステップと、
を経てステータを形成し、電動機を組立てることを特徴とする電動機の製造方法。In a method for manufacturing an electric motor in which a coil is provided in a concentrated winding state with respect to a stator core,
A first step of providing a first insulating material in a slot between a plurality of teeth formed in the stator core;
A second step of forming a coil by intensively winding a conductive wire around each of the plurality of teeth,
A sheet-shaped second insulating material continuously bent into a T-shape is inserted into the slot, and the first portion extending in the vertical direction among the portions forming the T-shape is connected to an adjacent coil. A third step of arranging the second part extending in the lateral direction among the parts forming the T-shape between each adjacent coil and the end of the corresponding tooth part while arranging them between each other; When,
A method for manufacturing a motor, comprising forming a stator through the steps described above, and assembling the motor.
JP2002268172A 2002-09-13 2002-09-13 Electric motor and manufacturing method thereof Expired - Fee Related JP3819350B2 (en)

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2010115040A (en) * 2008-11-07 2010-05-20 Daikin Ind Ltd Stator, motor and compressor
US7919896B2 (en) 2008-05-21 2011-04-05 Sanyo Denki Co., Ltd. Stator for rotary electric machine
JP2016021807A (en) * 2014-07-14 2016-02-04 ダイキン工業株式会社 Stator, motor, and compressor
JP2016070230A (en) * 2014-09-30 2016-05-09 ダイキン工業株式会社 Compressor
JP7081211B2 (en) 2018-02-28 2022-06-07 株式会社豊田自動織機 Rotating electric machine stator and rotating electric machine

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7919896B2 (en) 2008-05-21 2011-04-05 Sanyo Denki Co., Ltd. Stator for rotary electric machine
US8008831B2 (en) 2008-05-21 2011-08-30 Sanyo Denki Co., Ltd. Stator for rotary electric machine
JP2010115040A (en) * 2008-11-07 2010-05-20 Daikin Ind Ltd Stator, motor and compressor
JP2016021807A (en) * 2014-07-14 2016-02-04 ダイキン工業株式会社 Stator, motor, and compressor
JP2016070230A (en) * 2014-09-30 2016-05-09 ダイキン工業株式会社 Compressor
JP7081211B2 (en) 2018-02-28 2022-06-07 株式会社豊田自動織機 Rotating electric machine stator and rotating electric machine

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