JP2008148515A - Stator and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a stator that prevents the occurrence of winding collapse or winding disorder while allowing a wiring to be multilayeredly wound, and its manufacturing method. <P>SOLUTION: The stator 1 is formed by joining a plurality of stator pieces 1a respectively provided with a bobbin 2 formed of an insulating body and a winding 4 wound around the bobbin 2. A part in the bobbin 2 where the wiring 4 is wound around has a protrusion 5 that prevents winding collapse of the wiring 4. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a stator and a method for manufacturing the stator, and more particularly, to a stator that can be used for a motor of an electric vehicle and the like and that can prevent a winding from being collapsed, and a method for manufacturing the stator.

  In a stator used for a motor of an electric vehicle or the like, a stator is often configured by winding a rectangular wire having a hook-like cross section around a cylindrical stator piece and connecting the stator pieces in a circular shape. In a stator winding formed by winding a wire such as a rectangular wire, the space factor (winding density) must be increased in order to improve motor performance. Need to be aligned and wound.

  However, for example, when the amount of winding outside the stator piece is increased in order to taper the inner peripheral side of the stator, it is necessary to change the winding position like stroking across a plurality of windings. In such a case, there is a problem in that the winding is collapsed (position is shifted or unwinded) due to the tension or spring back of the winding, and the winding cannot be wound in an aligned state. In addition, when such a winding collapse occurs, the coil shape of the winding is not maintained, which causes a problem that the coil vibrates during the manufacturing process or during the operation of the electric vehicle.

For this reason, in the conventional stator and the manufacturing method thereof, a gap is provided in the flat wire wound in the first layer, and the flat wire is held at an angle so that the flat wire wound last is buried in the gap (for example, Patent Document 1).
Japanese Patent Laying-Open No. 2005-20875 (second page, FIG. 2)

  However, in the conventional stator and its manufacturing method (for example, refer to Patent Document 1), since a flat wire is wound on a flat wire that is wound obliquely, winding disturbance is likely to occur, and in particular, a multi-layer such as winding a flat wire into five layers. There is a problem that it is unsuitable when wound around.

  The present invention has been made in view of the above-described problems, and an object of the present invention is to provide a stator capable of winding windings in multiple layers without causing collapse or turbulence and a method for manufacturing the same. To do.

  A stator according to the present invention includes a bobbin formed of an insulator and a stator formed by combining a plurality of stator pieces each having a winding wound around the bobbin. The portion has a protrusion for preventing the winding from collapsing.

  Since the stator according to the present invention has a protrusion for preventing the winding from collapsing in the portion where the winding of the bobbin is wound, the winding wound on the upper surface of the protrusion protrudes more than the winding of the other portion. It is possible to wind the winding in an aligned state without causing the winding to be caught in the protruding portion and causing collapse. Further, since the step of correcting the turbulence can be omitted, the manufacturing cost and the manufacturing time can be reduced.

(Embodiment 1)
Hereinafter, a stator according to Embodiment 1 of the present invention will be described with reference to the drawings.

  FIG. 1 is a plan view showing a part of a stator according to Embodiment 1 of the present invention. A stator (stator) 1 according to the first embodiment is used for a motor of an electric vehicle, for example, and is a rotor (rotor, not shown) formed of a permanent magnet or the like at the center of a stator 1 formed in an annular shape. ) To rotate the rotor using a magnetic field. Although only three stator pieces 1a of the stator 1 are shown in FIG. 1, the stator 1 is generally formed by connecting the stator pieces 1a shown in FIG. 1 in an annular shape or a semi-arc shape. In the present embodiment, it is assumed that the stator 1 is formed by connecting the stator pieces 1a in an annular shape.

  FIG. 2 is an enlarged cross-sectional view showing the stator piece 1a of the stator 1 according to the first embodiment. A stator piece 1a shown in FIG. 2 includes a bobbin 2 (see FIG. 5) formed of, for example, an insulator, and an iron core 3 that penetrates the body of the bobbin 2. A winding 4 is provided on the outer peripheral side of the body of the bobbin 2. Is wound. In the present embodiment, a rectangular wire is used as the winding 4. A flat wire is, for example, an outer periphery of a copper wire covered with an insulator, and generally has a cross-sectional shape like a bowl. In FIG. 2, the cross-sectional shape of the winding 4 that is a flat wire is shown as a rectangle.

  The stator piece 1a of the stator 1 according to the first embodiment of the present invention has a protrusion 5 that prevents the winding 4 from being collapsed at a portion where the winding 4 of the bobbin 2 is wound. The protrusion 5 forms a portion protruding from the wound winding 4 by winding the winding 4 around the upper surface of the protrusion 5 (the left side surface in FIG. 1). Prevents the wire 4 from collapsing. Here, the collapse of winding means, for example, that the wound winding 4 is partially unwound when the winding 4 wound around the portion A in FIG. And

  In the present embodiment, the height of the protrusion 5 (width in the left-right direction on the paper surface) is lower than the minor axis a of the winding 4 that is a flat wire. Thereby, the space factor of the coil | winding 4 can be raised and the stator piece 1a can be reduced in size.

  Further, in the present embodiment, the width of the cross section of the protrusion 5 (the length in the vertical direction on the paper) is an integral multiple of the major diameter b of the winding 4 that is a flat wire. The width of the cross section of the protrusion 5 shown in FIG. 2 is twice the major diameter b of the winding 4 that is a flat wire. As a result, it is possible to wind the winding wire 4 that is a flat wire exactly on the upper surface of the protrusion 5, and to wind the winding wire 4 around the outer periphery of the body portion of the bobbin 2 without a gap.

  Further, in the stator piece 1a of the stator 1 according to the first embodiment, the winding 4 that is a flat wire is wound so as to contact the upper surface of the protrusion 5 and the surface that is on the left and right with respect to the upper surface. As a result, the wound winding 4 does not sag, and a protruding portion of the wound winding 4 can be formed. In the present embodiment, the width of the cross section of the protrusion 5 is an integral multiple of the long diameter b of the winding 4 that is a flat wire, and the winding 4 is in contact with the left and right surfaces of the protrusion 5. For example, the width of the cross section of the protrusion 5 is slightly smaller than an integral multiple of the long diameter b of the winding 4 that is a flat wire, so that a gap is formed between the left and right surfaces of the winding 4 and the protrusion 5. Good.

  In the present embodiment, the lateral width of the cross section of the protrusion 5 is smaller than the entire width c of the winding 4 wound on the outer peripheral side of the bobbin 2 arranged in a circumferential shape with respect to the protrusion 5. Thereby, the stator piece 1a can be reduced in size and the space factor of the coil | winding 4 can be raised.

  In the present embodiment, the protrusion 5 is formed integrally with the bobbin 2, thereby making it possible to reduce the manufacturing time and manufacturing cost of the bobbin 2 and the protrusion 5.

  In the present embodiment, the windings 4 that are rectangular wires are laminated in five layers on the outer peripheral side of the stator 1, and are laminated in three layers on the inner peripheral side of the stator 1. This is to increase the space factor by winding the winding 4 in multiple layers.

  Here, an example of a procedure when winding the winding 4 that is a flat wire around the bobbin 2 in the present embodiment will be described. First, the winding 4 is wound from the position B on the outer peripheral side of the bobbin 2 arranged in a circumferential direction toward the position C on the inner peripheral side. At this time, the winding 4 is also wound on the upper surface of the protrusion 5. Then, the winding 4 is wound from the position of D adjacent to C toward the position of E on the outer peripheral side of the bobbin 2 arranged circumferentially.

  Then, similarly, the winding 4 is wound from the position adjacent to E toward the position F on the inner peripheral side of the bobbin 2 arranged circumferentially. Here, the winding 4 is wound from the position F to the position G on the right side in FIG. 2, but the winding 4 is wound from the position G to the position H across the plurality of windings 4 ( (Dotted line in FIG. 2). At this time, since the lower right winding 4 at the H position protrudes, the winding 4 at the H position is caught by this winding 4 and the collapse of the winding can be prevented. Thereafter, similarly, the winding 4 is wound from the inner peripheral side to the outer peripheral side and from the outer peripheral side to the inner peripheral side of the bobbins 2 arranged in a circumferential manner, whereby the stator piece 1a as shown in FIGS. 1 and 2 is completed. To do.

  FIG. 3 is a perspective view showing an example of the bobbin 2 of the stator 1 according to the first embodiment. In the example of the bobbin 2 shown in FIG. 3A, a long protrusion 5 is formed in the vertical direction of the body part (hollow part) of the bobbin 2. Such protrusions 5 can surely prevent collapse. Further, in the example shown in FIG. 3B, the protrusion 5 is formed short only at a portion where the collapse is likely to occur. Needless to say, the shape of the protrusion 5 is not limited to the shape shown in FIG.

  In the first embodiment, since the protrusion 5 that prevents the winding 4 from collapsing is provided at the portion where the winding 4 of the bobbin 2 is wound, the winding 4 wound on the upper surface of the protrusion 5 is the winding of the other portion. It is possible to wind the winding 4 in an aligned state without causing winding collapse by causing the winding 4 to protrude beyond 4 and be caught by this protruding portion. Further, since the step of correcting the turbulence can be omitted, the manufacturing cost and the manufacturing time can be reduced.

(Embodiment 2)
FIG. 4 is an enlarged cross-sectional view showing the stator piece 1b of the stator 1 according to the second embodiment of the present invention. The stator piece 1b of the stator 1 according to the second embodiment is the same as the stator piece 1a of the stator 1 according to the first embodiment except for the following points, and the same components are denoted by the same reference numerals and described. .

  The stator piece 1b of the stator 1 according to the second embodiment is formed on the outer peripheral side of the bobbin 2 in which the protrusions 5 are arranged more circumferentially than the stator piece 1a according to the first embodiment.

  Here, an example of a procedure when winding the winding 4 that is a flat wire around the bobbin 2 in the present embodiment will be described. First, the winding 4 is wound from the position of J on the inner peripheral side of the bobbin 2 arranged in a circumferential direction toward the position of K on the outer peripheral side. At this time, the winding 4 is also wound on the upper surface of the protrusion 5. Then, the winding 4 is wound from the position adjacent to K toward the inner peripheral side of the bobbins 2 arranged circumferentially.

  Here, the winding 4 is wound from the L position to the M position on the right side in FIG. 4, and the winding 4 is wound from the M position to the N position across a plurality of windings 4 ( (Dotted line in FIG. 4). At this time, since the lower right winding 4 at the position N protrudes, the winding 4 at the position N catches on the winding 4 and can prevent collapse. Thereafter, similarly, the winding 4 is wound from the inner peripheral side to the outer peripheral side and from the outer peripheral side to the inner peripheral side of the bobbins 2 arranged in a circumferential manner, whereby the stator piece 1b as shown in FIG. 4 is completed.

  The effect is substantially the same as that of the stator 1 according to the first embodiment.

(Embodiment 3)
FIG. 5 is an enlarged cross-sectional view showing a stator piece 1c and a stator piece 1d of a stator 1 according to Embodiment 3 of the present invention. The stator piece 1c and the stator piece 1d of the stator 1 according to the third embodiment are the same as the stator piece 1a of the stator 1 according to the first embodiment except for the following points, and the same components are denoted by the same reference numerals. Will be explained. FIG. 5 shows only the left side of the stator piece 1c and the stator piece 1d.

  In the stator piece 1c of the stator 1 shown in FIG. 5 (a), the cross section of the protrusion 5 has a wedge shape, and the winding 4 which is a flat wire is in contact with the longer surface of the protrusion 5 at an angle. .

  Further, in the stator piece 1d of the stator 1 shown in FIG. 5B, the protrusion 5 is divided for each winding 4 which is a flat wire, and the lateral width of the cross section of the protrusion 5 is surely a flat wire. It becomes an integral multiple of the major axis.

  The effect is substantially the same as that of the stator 1 according to the first embodiment.

(Embodiment 4)
FIG. 6 is an enlarged cross-sectional view showing a stator piece 1e of the stator 1 according to Embodiment 4 of the present invention. The stator piece 1e of the stator 1 according to the fourth embodiment is substantially the same as the stator piece 1a of the stator 1 according to the first embodiment except for the following points, and the same components are denoted by the same reference numerals and described. To do.

  The stator piece 1e of the stator 1 according to the fourth embodiment uses a round wire having a circular cross section as the winding 4. Further, the stator piece 1e of the stator 1 according to the fourth embodiment includes a fitting portion 6 in which the winding 4 that is a round wire is fitted in a portion around which the winding 4 of the bobbin 2 is wound. The fitting portion 6 has a plurality of concave portions having a semicircular cross section, for example, and the winding 4 can be wound in an aligned state by fitting the winding 4 as a round wire. In addition, the fitting part 6 may be provided in a part of the part where the winding 4 of the bobbin 2 is wound, or may be provided in the whole part where the winding 4 of the bobbin 2 is wound.

  Furthermore, the stator piece 1 e of the stator 1 according to the fourth embodiment has a protrusion 5 a that prevents the winding 4 from being collapsed at a part of the fitting portion 6. As in the first embodiment, the protrusion 5a is formed by forming a portion P protruding from the wound winding 4 by winding the winding 4 around the upper surface of the protrusion 5a, and winding the winding 4 there. The winding of the wire 4 is prevented.

  The effect is substantially the same as that of the stator 1 according to the first embodiment.

  Needless to say, the present invention is not limited to the above-described embodiments, and includes various modifications and improvements that can be made within the scope of the technical idea. For example, the stator 1 according to the present invention can be applied not only to an electric vehicle and a fuel cell vehicle but also to a stator used for other purposes.

It is a top view which shows a part of stator which concerns on Embodiment 1 of this invention. 3 is an enlarged cross-sectional view showing a stator piece of the stator according to Embodiment 1. FIG. 3 is a perspective view showing an example of a bobbin of a stator according to Embodiment 1. FIG. 6 is an enlarged cross-sectional view showing a stator piece of a stator according to Embodiment 2. FIG. 10 is an enlarged cross-sectional view showing a stator piece of a stator according to Embodiment 3. FIG. 6 is an enlarged cross-sectional view showing a stator piece of a stator according to Embodiment 4. FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Stator 1a, 1b, 1c, 1d, 1e Stator piece 2 Bobbin 3 Iron core 4 Winding 5, 5a Protrusion 6 Fitting part

Claims (10)

In a stator formed by combining a plurality of stator pieces each having a bobbin formed of an insulator and a winding wound around the bobbin,
A stator having a protrusion for preventing the winding from being collapsed at a portion where the winding of the bobbin is wound.   The stator according to claim 1, wherein the winding is a rectangular wire.   The stator according to claim 2, wherein the flat wire is wound so as to contact an upper surface of the protrusion and a surface on the left and right of the upper surface.   The stator according to claim 3, wherein the flat wire is wound so that a surface parallel to a long axis of the flat wire is in contact with an upper surface of the protrusion.   5. The stator according to claim 3, wherein a lateral width of a cross section of the protrusion is an integral multiple of a long diameter of the rectangular wire.   The stator according to any one of claims 2 to 5, wherein a height of the protrusion is lower than a short diameter of the rectangular wire.   The stator pieces are connected circumferentially, and the lateral width of the cross section of the protrusion is smaller than the entire width of the rectangular wire wound around the outer periphery side of the bobbin arranged in a circumferential direction from the protrusion. The stator according to any one of claims 2 to 6.   The stator according to any one of claims 2 to 7, wherein the flat wire is wound in a state where at least two layers are stacked on the bobbin.   The stator according to claim 1, wherein the protrusion is formed integrally with the bobbin. A step of winding a flat wire around a bobbin formed of an insulator and having a protrusion formed thereon;
In the step of winding the flat wire around the bobbin, the flat wire is wound in such a manner that the flat wire is in contact with the upper surface of the protrusion and a surface on the left and right with respect to the upper surface, and the flat wire is laminated in two or more layers. A stator manufacturing method characterized by the above.