JP2004135466A - Split core and stator core - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a split core wherein row transfer between adjacent windings can be carried out, not on an insulating member on the core surface. <P>SOLUTION: The split core 1 is obtained by splitting an annular stator core provided with a plurality of salient poles on a pole-by-pone basis. The split core 1 comprises a wound portion 11 which is formed on the salient pole and on which flat wires 2a and 2b are wound, an insulating member 12 which covers the surface of the wound portion 11, windings 20a and 20b obtained by winding the flat wires 2a and 2b on the rim of the wound portion 11 in a plurality of rows with the insulating member 12 between, and a lead wire 3a connected with the winding start portions of the windings. The lead wire 3a is connected with the winding end portions 22b of the next windings 20b. <P>COPYRIGHT: (C)2004,JPO

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a split core and a stator core obtained by combining a plurality of split cores, and more particularly to a split core and a stator core in which a plurality of windings are wound around a salient pole portion in a plurality of rows.
[0002]
[Prior art]
2. Description of the Related Art Conventionally, as a stator (also referred to as a stator) of an electric motor, a motor using a winding formed by laminating a rectangular wire in a stacked manner has been known.
[0003]
As such a winding, for example, a flat wire is wound in a plurality of rows, and two adjacent rows of windings are continuously connected in a one-stroke manner in a non-connected state without mechanical connection. There is a type in which each winding is electrically connected (for example, see Patent Document 1).
[0004]
In addition, there is another type in which adjacent two rows of windings are wound in the opposite direction, and these are brazed by a crossover at a winding start end of each winding and are electrically connected. (For example, see Patent Document 2).
[0005]
[Patent Document 1]
JP-A-5-243036 (FIG. 1)
[Patent Document 2]
JP-A-8-317610 (prior art, FIG. 3)
[0006]
[Problems to be solved by the invention]
However, the winding has the following problems.
[0007]
In the winding described in Patent Literature 1, the winding is wound with one stroke without providing a connection portion between the two windings. Therefore, if the cross-sectional area of the rectangular wire is small, the winding from one winding to the adjacent winding is not used. It is easy to change the line into a line, but if the cross-sectional area of a flat wire such as 1 mm x 2 mm becomes relatively large, the force required for forming during the line change increases, and the insulation force attached to the core surface by the reaction force due to the forming There is also a high possibility that the member will be damaged. Also, forming the flat wire may cause forming wrinkles, the flat wire wound on the wrinkles may not be stable, and the winding may be broken.
[0008]
In the winding described in Patent Literature 2, the winding start end is brazed with a crossover. Therefore, the flat wire in the first row is brazed with the crossover at the start end, and then the winding is performed. Before winding the rectangular wire in the second row, it is necessary to perform a brazing operation on the insulating member on the core surface, and there is a problem that the insulating member is deteriorated by the heat of brazing. Although it is highly possible that the insulation member can withstand high heat resistance, if the core is molded and insulated with PPS (polyphenylene sulfide) resin or the like, the resin softens and loses its shape. It may not be stable.
[0009]
The present invention has been made in view of the above circumstances, and has a split core and a stator core in which the split cores can be combined without performing row switching between adjacent windings on an insulating member on the core surface. It is to provide.
[0010]
[Means for Solving the Problems]
The above object of the present invention is achieved by the following means.
[0011]
The split core of the present invention is a split core obtained by splitting an annular stator core having a plurality of salient pole portions for each pole, formed on the salient pole portion, and a winding portion around which a conductive wire is wound, An insulating member that covers the surface of the winding portion, a plurality of windings in which the plurality of conductors are wound around the winding portion in a plurality of rows via the insulating member, and a winding start end of the winding; And a lead wire connected to the section.
[0012]
【The invention's effect】
According to the split core of the present invention, since the lead wire is connected to the winding start end of the winding, this connection can be made by winding the lead wire and joining it to the starting end before winding the winding. Often, it is not necessary to perform a connection work on the insulating member on the surface of the split core. Also, when connecting the lead wire to the terminal end of the adjacent winding and electrically connecting the adjacent windings, the terminal end of the winding and the lead wire are joined without being connected on the insulating member. can do. Therefore, the insulation member is not damaged during the connection work, and the insulation reliability of the winding can be increased.
[0013]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the drawings. It should be noted that the layer thickness in the drawings used in this description is exaggerated for clarity of the specification.
[0014]
The split core according to the present embodiment is a split core obtained by splitting an annular stator core including a plurality of salient pole portions for each pole, formed on the salient pole portions, and a winding portion around which a conductive wire is wound. An insulating member covering the surface of the winding portion, a plurality of windings formed by winding a plurality of conductors around the winding portion in a plurality of rows via the insulating member, and connecting to a winding start end of the winding. And a lead wire to be used.
[0015]
Here, the conductive wire is, for example, a strip-shaped rectangular wire coated with an insulating material, and a winding obtained by winding the wire is hereinafter referred to as a rectangular wire winding. Further, the lead wire is a crossover wire for electrically connecting adjacent windings finally. In the present embodiment, an example in which the rectangular wire winding is wound in two rows will be described.
[0016]
Referring to FIG. 1 to FIG. 6, the manner in which a rectangular wire is wound around a divided core in a plurality of rows, and the rectangular wires in adjacent rows are connected to each other will be described.
[0017]
FIG. 1 is a perspective view showing a split core 1 and a flat wire 2 wound around the split core 1.
[0018]
First, the divided core 1, the flat wire 2a and the lead wire 3a are prepared.
[0019]
The split core 1 is formed by laminating electromagnetic steel sheets punched into a predetermined shape and joining them by caulking, laser welding, or the like. Further, since the split core 1 is obtained by dividing the stator core of the stator of the electric motor for each salient pole portion, each has a salient pole portion, and one stator core is formed by combining a plurality of salient pole portions. A winding portion 11 around which the rectangular wire 2 is wound is provided in the salient pole portion, and an insulating member 12 is molded on the surface of the winding portion 11.
[0020]
The insulating member 12 has an exposed portion that exposes the wound portion 11 to a size that fits a lead wire 3a described later. In the present embodiment, two exposed portions are formed in the insulating member 12 in order to wind two rows of flat wire windings 20a and 20b described later around the winding portion 11. Regarding the two exposed portions, when the split cores 1 are combined to form a stator core, the one on the outer peripheral side is referred to as an outer exposed portion 13a, and the one on the inner peripheral side is referred to as an inner exposed portion 13b.
[0021]
The insulating member 12 is provided with a flange so as to cover the side surfaces of the rectangular wire windings 20a and 20b. However, if the flange is illustrated, the state of the rectangular wire winding cannot be expressed, so that the illustration of the flange is omitted. ing.
[0022]
For the rectangular wire 2a, the insulating coating of the winding start end 21a, which is the winding start end, is removed in advance by a grinder or the like. The lead wire 3a is obtained by cutting another rectangular wire into a predetermined length and bending the wire into an L shape. The width of the L-shaped bottom surface is substantially equal to the width of the flat wire 2a, and the insulating films on both surfaces are removed by a grinder or the like.
[0023]
As shown in the figure, the flat wire 2a and the lead wire 3a are brought into contact with the winding start end 21a of the flat wire 2a from which the insulating film has been removed and the L-shaped bottom surface of the wire 3a, and the ultrasonic welding horn 8 and the anvil 9 and is welded by the ultrasonic welding horn 8.
[0024]
FIG. 2 is a perspective view showing a state where the flat wire 2a joined to the lead wire 3a is attached to the split core 1. FIG.
[0025]
The integrated rectangular wire 2a and lead wire 3a are transferred, and the lead wire 3a is incorporated into the outer peripheral side exposed portion 13a as shown in FIG. Thereby, the winding start end 21a of the flat wire 2a is positioned. In this state, the split core 1 is rotated in the direction of the arrow to wind the flat wire 2a.
[0026]
FIG. 3 is a perspective view showing a state in which the rectangular wires 2a and 2b are wound around the split core 1 in two rows.
[0027]
When the rectangular wire 2a is wound, a rectangular wire winding (hereinafter, referred to as an outer peripheral winding) 20a is formed on the outer peripheral side of the split core 1 as shown in FIG. Then, another set in which the rectangular wire 2b is welded to the L-shaped lead wire 3b described with reference to FIG. 1 is made and incorporated into the inner peripheral side exposed portion 13b of the insulating member 12, and the inner peripheral side is also formed. The flat wire 2b is wound.
[0028]
FIG. 4 is a perspective view showing a state where the lead wire 3a is bent.
[0029]
When winding is performed also on the inner peripheral side of the split core 1, as shown in FIG. 4, a flat wire winding (hereinafter referred to as an inner peripheral side winding) 20b is also formed on the inner peripheral side. As a result, two rectangular wire windings 20a and 20b are formed on the outer peripheral side and the inner peripheral side. Thereafter, the lead wire 3a incorporated in the outer peripheral side exposed portion 13a is bent toward the inner peripheral side. At this time, as shown in the drawing, the inner peripheral side winding 20b is not wound up to the end portion (hereinafter referred to as the winding end portion) 22b where the winding of the flat wire 2 is completed.
[0030]
FIG. 5 is a perspective view showing a state in which the outer winding 20a is connected to the inner winding 20b via the lead wire 3a.
[0031]
In the lead wire 3a, the insulating film on the surface opposite to the surface facing the inner peripheral winding 20b is removed in advance by a grinder or the like. In addition, the insulating coating on the inside of the wound end portion 22b of the inner winding 20b is also removed in advance by a grinder or the like.
[0032]
Here, as shown in FIG. 5, the lead wire 3 a and the winding end portion 22 b abut on the surfaces from which the insulating film has been removed, and are sandwiched between the ultrasonic welding horn 8 and the anvil 9. It is welded by the ultrasonic welding horn 8.
[0033]
FIG. 6 is a perspective view showing a state where the connection portion of the flat wire 2 is subjected to insulation treatment.
[0034]
As shown in FIG. 5, the lead wire 3a and the inner winding 20b are welded and connected. As for the connected portion, a portion that is not insulated is partially exposed by removing the insulating film. Therefore, as shown in FIG. 6, the insulating process is performed by covering with a resin cap 4 and fixing with an adhesive or the like. Apply.
[0035]
As described above, according to the split core 1 of the present embodiment, the winding start end 21a of the outer winding 20a is connected to the winding end 22b of the adjacent inner winding 20b by the lead wire 3a. I do. Accordingly, the lead wire 3a must be joined to the winding start end 21a of the outer winding 20a and the winding end 22b of the inner winding 20b. Therefore, it is free, and the wound end portion 22b is not completely wound and is free, so that there is no need to perform a connection work on the insulating member 12 on the surface of the split core 1 when joining with either of them. . As described above, the connection work can be safely performed on the anvil 9. Therefore, the insulation member 12 is not damaged during the connection work, and the insulation reliability of the winding can be increased.
[0036]
Further, according to the split core 1 of the present embodiment, since the lead wire 3a is arranged between the outer peripheral winding 20a and the inner peripheral winding 20b, a gap between the windings can be reliably ensured. As a result, when the divided core 1 is used as a product and the gap between the windings is used as a coolant passage, a coolant passage can be secured.
[0037]
Further effects of the present embodiment will be described with reference to FIG.
[0038]
FIG. 7 is a diagram showing a current flow of the winding wound around the split core 1.
[0039]
In the winding wound around the conventional split core 100, as shown on the left side of FIG. 7, the outer winding 100a and the inner winding 100b are wound and connected at the start ends 101a and 101b. Are connected at the lowermost layer of the stacked rectangular wires 2.
[0040]
When a plurality of the conventional split cores are combined and incorporated into a motor as a stator core, a current flows as indicated by an arrow on the left side of FIG. Here, comparing the potential difference between the columns of the outer winding 100a and the inner winding 100b, the potential difference is equivalent to the voltage drop at the winding portion where the potential difference is large.
[0041]
On the other hand, in the split core 1 of the present embodiment, as shown on the right side of FIG. 7, the winding start end 21a of the outer winding 20a and the winding end 22b of the inner winding 20b are connected to each other. As a result, the lowermost layer of the flat wire 2 of the outer winding 20a is connected to the uppermost layer of the flat wire 2 of the outer winding 20a.
[0042]
When a plurality of split cores 1 according to the present embodiment are combined in a motor as a stator core, a current flows as shown by an arrow on the right side of FIG. Comparing the potential difference between the column and the inner peripheral side winding 20b, there is only about 50% of the voltage drop in the winding even at a large place.
[0043]
As described above, in the split core 1 of the present embodiment, since there is no place where the potential difference between the windings becomes large as a whole, the insulation performance at the winding portions is high, and a more efficient motor stator is provided. Can be configured.
[0044]
As described above, the present invention has been described with the above embodiment, but the present invention is not limited to this, and various modifications can be made by those skilled in the art.
[0045]
A modified example will be described with reference to FIGS.
[0046]
FIG. 8 is a cross-sectional view showing a state where the rectangular wire 2 of two rows of windings is wound with the same number of turns, and FIG. 9 is a view showing a state where the rectangular wire 2 starts to be wound simultaneously.
[0047]
As a modification, for example, as shown in FIG. 8, the outer winding 20a and the inner winding 20b can have the same number of turns. When the number of turns is the same, it is possible to make the inner peripheral side winding 20b and the outer peripheral side winding 20a different in cross-sectional area, and to wind the inner peripheral side and outer peripheral side flat wires 2 at the same time.
[0048]
In this case, as shown in FIG. 9, first, two rectangular wires 2a and 2b attached to the lead wires 3a and 3b and made conductive are prepared, and the inner peripheral side exposed portions 13b of the insulating member 12 are respectively provided. And the outer peripheral side exposed portion 13a. Then, each of the winding start ends 21a and 21b is fixed with a jig and wound.
[0049]
As described above, the cross-sectional areas of the outer winding 20a and the inner winding 20b are made different, for example, the cross-sectional area of the outer winding 20a is made larger than the cross-sectional area of the inner winding 20b. And the number of turns of both windings is the same. With this structure, since the number of turns is the same, the winding of the flat wire 2 can be started and ended at the same time, and the end can be cut at the same time, so that the working efficiency can be improved.
[0050]
Another modification will be described with reference to FIG. FIG. 10 is a cross-sectional view of the insulating member 12 on the winding portion 11 of the split core 1.
[0051]
As another modification, for example, as shown in FIG. 10, the thickness of the insulating member 12 covering the winding portion 11 of the split core 1 can be made different. When winding the flat wire 2a around the split core 1 by rotating the split core 1 in the direction indicated by the black arrow while pulling the flat wire 2a in the direction indicated by the white arrow, particularly in the vicinity of the exposed portion of the insulating member 12, The stress concentrates on the corner 14 in the direction opposite to the direction in which the tension of the flat wire 2a acts.
[0052]
In the present embodiment, the direction in which the flat wire 2a or 2b is wound is a fixed direction. Therefore, each time tension is applied to the flat wire 2a or 2b at the start of winding, stress is concentrated on the corner portion 14 and a large amount of stress is applied. Force acts. In order to withstand this stress, the thickness of the insulating member 12 is increased in the direction where the corners 14 are present, that is, in the direction opposite to the direction in which tension acts on the winding of the flat wire 2a or 2b (12a in the figure). Keep it. Conversely, in the direction in which the tension acts (12b in the figure), a small amount of stress is not applied, so that the thickness of the insulating member 12 can be reduced.
[0053]
In this way, the thickness of the insulating member 12 is reduced to a necessary minimum by reducing the thickness of the non-stressed side 12b, thereby increasing the effective area between the salient pole portions when applied to a motor, and Output performance can be improved by improving the space factor. In addition, by setting the thickness to the minimum necessary, the length of the flat wire 2 required for winding can be shortened, which can contribute to a reduction in copper loss when an electric motor is applied. Can be improved.
[0054]
In the above-described embodiment, the flat wire 2a is wound first from the outer circumference side, and then the flat wire 2b is wound next to the inner circumference side. However, the present invention is not limited to this, and the flat wire 2b is wound from the inner circumference side. You can turn it. In this case, the lead wire 3b joined to the flat wire 2b on the inner peripheral side is incorporated into the inner peripheral side exposed portion 13b such that the L-shaped side surface is on the outer peripheral side.
[0055]
Also, a case has been described in which the windings are wound in two rows around the split windings, but the invention is not limited to this, and the windings may be wound in three or more rows. In this case, the windings can be sequentially connected by the lead wire 3a in the same manner as the relationship between the windings on the outer circumferential side and the inner circumferential side described above.
[0056]
By combining a plurality of split cores 1 of the present invention into an annular shape, a stator core utilizing the advantageous characteristics of the split cores can be manufactured.
[Brief description of the drawings]
FIG. 1 is a perspective view showing a split core and a flat wire wound around the split core.
FIG. 2 is a perspective view showing a state in which a flat wire joined to a lead wire is attached to a split core.
FIG. 3 is a perspective view showing a state where a rectangular wire is wound around a split core in two rows.
FIG. 4 is a perspective view showing a state where a lead wire is bent.
FIG. 5 is a perspective view showing a state in which an outer winding is connected to an inner winding via a lead wire;
FIG. 6 is a perspective view showing a state where a connection portion of a flat wire is subjected to insulation treatment.
FIG. 7 is a diagram showing a current flow of a winding wound around the split core of FIG.
FIG. 8 is a cross-sectional view showing a state where a rectangular wire of two rows of windings is wound with the same number of turns.
FIG. 9 is a diagram showing a state in which a rectangular wire starts to be wound simultaneously.
FIG. 10 is a cross-sectional view of an insulating member on a winding portion of a split core.
[Explanation of symbols]
1. Split core,
2a, 2b ... rectangular wire,
3a, 3b ... lead wire,
4 ... resin cap,
8 ... Ultrasonic welding horn,
9… Kinashiki,
11 ... winding part,
12 ... insulating members,
13a: outer peripheral side exposed portion,
13b ... inner peripheral side exposed part,
14 ... corner,
20a, 20b ... winding,
21a ... winding start end,
22b: wound end portion.

Claims (8)

A divided core obtained by dividing an annular stator core having a plurality of salient pole portions for each pole,
A winding portion formed on the salient pole portion and around which a conductive wire is wound,
An insulating member that covers the surface of the winding portion,
A plurality of windings formed by winding a plurality of the conductive wires through the insulating member in a plurality of rows around an outer periphery of the winding portion,
A lead wire connected to the winding start end of the winding;
Having a split core. The split core according to claim 1, wherein the lead wire is also connected to a winding end portion of a winding adjacent to the winding to be connected, and electrically connects adjacent windings. The insulating member has an exposed portion that partially exposes the wound portion,
The lead wire is fitted to the exposed portion in a state where the lead wire is joined to the winding start end of one conductor, and then the one winding and the adjacent winding are wound, and the adjacent winding is wound. The split core according to claim 1, wherein the split core is joined to the wound end portion. 4. The insulating member according to claim 1, wherein the insulating member is supported on an external supporting member when the insulating member is joined to a start end of the one conductor and an end of the adjacent conductor. 5. Split core. The split core according to any one of claims 1 to 4, wherein the plurality of windings are wound in the same direction. The split core according to any one of claims 1 to 5, wherein the plurality of windings have the same number of turns. The thickness of the insulating member is thick in a direction opposite to a direction in which the tension of the conductor is applied when winding of the conductor is started, and is thin in a direction in which the tension is applied. Split core. A stator core obtained by combining a plurality of the split cores according to any one of claims 1 to 7.

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