JP2019041569A - Manufacturing method of stator, manufacturing method of motor, winding method, stator and motor - Google Patents

Abstract

To restrain interference of the nozzle of a winding machine with winding, without preparing a stator separately for the wire of different wire size.SOLUTION: An insulator has a step part, projecting in the axial direction of the stator, at the tip of a tooth in the extension direction, on the wound surface where a wire is wound, and has a step of forming a first wire layer wound on the insulator by winding a wire on the insulator and a second wire layer wound on the first wire layer. When (L1+D)tan(θ/2)cos(θ/2)-Acos(θ/2)>D, the first wire layer is formed by winding a wire on the top face of the step part. A=B/2+(1+√3/2)D, B is the width of the insulator, D is the wire size, θ is the angle formed by the medial axis of a tooth adjoining in the hoop direction, L1 is the distance from the medial axis of the stator to the radial inside end of the top face of the step part, and L2 is the distance from the medial axis of the stator to the radial outside end of the top face of the step part.SELECTED DRAWING: Figure 3

Description

  The present invention relates to a stator manufacturing method, a motor manufacturing method, a winding method, a stator, and a motor.

  Conventionally, motors have been used as drive sources for various devices and products. For example, a motor is used for a power source of a moving object including an automobile or an electric vehicle such as an electric assist bicycle or an electric wheelchair. Such a device may require a high-output motor.

  In an inner rotor brushless motor, in order to increase the output of the motor, it may be desired to increase the number of windings of the teeth. Since increasing the number of turns increases the resistance between the terminals, it is desirable to use a wire having a large wire diameter. The spacing between adjacent teeth is narrowed at the tip of the teeth, so when using a wire with a large wire diameter, the teeth blades are used to prevent interference between the adjacent teeth winding and the winding machine nozzle. It may be necessary to stop the winding of the first layer before the winding and to wind the second layer. When a wire having a large wire diameter is used, a high tension is applied, so that the first layer of wire may be displaced toward the blade tip.

In order to loosen the winding of the coil winding, a technique is known in which the insulator is provided in a step shape (see, for example, Patent Document 1).
Patent Document 1 Japanese Patent Application Laid-Open No. 2006-174470

  In the technique described in Patent Document 1, for example, when a wire having a large wire diameter is used, it may not be possible to prevent interference between the nozzle of the winding machine and the winding. In addition, when using a wire with a large wire diameter, the first-layer wire is easily displaced as described above. However, if a groove for engaging the wire is provided in the insulator, it is necessary to create an insulator for each wire diameter. End up.

  This invention is made | formed in view of such a condition, The objective suppresses that the nozzle of a winding machine interferes with a coil | winding, without preparing an insulator separately with respect to the wire material of a different wire diameter. It is to provide a stator capable of this.

  In order to solve the above-described problem, in the first aspect of the present invention, a stator core having a plurality of teeth arranged in the circumferential direction and extending radially inward is wound around an insulator attached to the plurality of teeth. The insulator has a stepped portion protruding in the axial direction of the stator at the tip end in the extending direction of the teeth on the winding surface on which the wire is wound, A step of winding a wire around the insulator to form a first wire layer wound on the insulator and a second wire layer wound on the first wire layer. The step of forming the first wire layer and the second wire layer is performed when the level difference portion is (L1 + D) tan (θ / 2) × cos (θ / 2) −Acos (θ / 2)> D. A wire is wound on the upper surface to form a first wire layer, and (L1 + D) tan (θ / 2) × cos (θ / 2) −Acos (θ / 2) <D and (L2 + D) tan (θ / 2) × cos (θ / 2) −Acos (θ / 2)> D, the first wire layer is formed without winding the wire on the upper surface of the stepped portion. A is B / 2 + (1 + √3 / 2) D, B is the width of the insulator in the plane orthogonal to the axial direction, D is the diameter of the wire, and θ is a plurality of teeth. L1 is a distance from the central axis of the stator to the radially inner end of the upper surface of the stepped portion, and L2 is a step from the central axis of the stator. This is the distance to the radially outer end of the upper surface of the part.

  According to this aspect, it is possible to appropriately determine whether or not there is a possibility of interference between the nozzle of the winding machine and the wire rod layer near the tip of the tooth. Therefore, whether or not to wind the wire on the step can be appropriately determined according to the wire diameter so that the nozzle of the winding machine and the wire layer do not interfere with each other. For example, when winding a wire having a large wire diameter, the interference between the nozzle and the winding can be suppressed by winding the second wire layer without winding on the stepped portion. On the other hand, when winding a wire rod having a small wire diameter, the wire rod space can be maintained by winding the wire rod on the step portion to form the first wire rod layer. Moreover, it is not necessary to manufacture an insulator for every wire diameter of a wire, and an insulator can be made common with respect to a wire with a different wire diameter.

  An insulator may have a level | step-difference part only in the end surface which cross | intersects an axial direction among the several end surfaces which an insulator has. Thereby, when a wire diameter is small and it winds on a level | step difference, the fall of wire rod space can be suppressed.

  Assuming that the height of the step is H, the first wire layer may be formed on the upper surface of the step portion without winding the wire on the further condition that D / 2 ≦ H. Thereby, when winding a wire on the 1st wire rod layer, it can prevent that the wire which forms the 1st wire rod layer shifts.

  In a second aspect of the present invention, a stator having a stator core having a plurality of teeth arranged in the circumferential direction and extending radially inward, and a wire wound around an insulator attached to the plurality of teeth is provided. A method of manufacturing a motor, wherein an insulator has a stepped portion protruding in the axial direction of a stator at a tip end in a tooth extending direction on a winding surface around which the wire is wound, and the wire is wound around the insulator. And rotating to form a first wire layer wound on the insulator and a second wire layer wound on the first wire layer. The step of forming the first wire layer and the second wire layer is performed when the level difference portion is (L1 + D) tan (θ / 2) × cos (θ / 2) −Acos (θ / 2)> D. A wire is wound on the upper surface to form a first wire layer, and (L1 + D) tan (θ / 2) × cos (θ / 2) −Acos (θ / 2) <D and (L2 + D) tan (θ / 2) × cos (θ / 2) −Acos (θ / 2)> D, the first wire layer is formed without winding the wire on the upper surface of the stepped portion. A is B / 2 + (1 + √3 / 2) D, B is the width of the insulator in the plane orthogonal to the axial direction, D is the diameter of the wire, and θ is a plurality of teeth. L1 is a distance from the central axis of the stator to the radially inner end of the upper surface of the stepped portion, and L2 is a step from the central axis of the stator. This is the distance to the radially outer end of the upper surface of the part. According to this aspect, it is possible to provide a motor having the same effect as that described in relation to the stator manufacturing method described above.

  The insulator does not have to have a stepped portion protruding in the axial direction of the stator at the end opposite to the tip in the extending direction of the teeth on the winding surface. By not having a step at the end opposite to the tip, the wire space factor can be improved.

  According to a third aspect of the present invention, there is provided a winding method in which a wire is wound around an insulator attached to a stator core tooth provided in a stator, wherein a plurality of teeth are arranged in the circumferential direction and provided radially inward. The insulator has a stepped portion protruding in the axial direction of the stator at the tip end in the tooth extending direction on the winding surface on which the wire is wound, and the wire is wound on the upper surface of the stepped portion. On the wire layer obtained by winding the wire on the winding surface including the upper surface of the step portion when it is determined that the wire is wound on the upper surface of the step portion Winding the wire on the winding surface without winding the wire on the upper surface of the step portion when it is determined that the wire is not wound on the upper surface of the step portion. Providing a stage. The step of determining whether or not to wind the wire on the upper surface of the stepped portion is when (L1 + D) tan (θ / 2) × cos (θ / 2) −Acos (θ / 2)> D, It is determined that the wire is wound on the upper surface of the stepped portion, and (L1 + D) tan (θ / 2) × cos (θ / 2) −Acos (θ / 2) <D and (L2 + D) tan (θ / 2) × When cos (θ / 2) −Acos (θ / 2)> D, it is determined that the wire is not wound on the upper surface of the stepped portion. A is B / 2 + (1 + √3 / 2) D, B is the width of the insulator in the plane orthogonal to the axial direction, D is the diameter of the wire, and θ is adjacent in the circumferential direction An angle formed by the central axis of the teeth, L1 is a distance from the central axis of the stator to the radially inner end of the upper surface of the stepped portion, and L2 is a diameter of the upper surface of the stepped portion from the central axis of the stator. This is the distance to the outer edge in the direction. According to this aspect, the same effect as that described in relation to the stator manufacturing method described above can be obtained.

  In the fourth aspect of the present invention, the stator includes a stator core having a plurality of teeth arranged in the circumferential direction and extending radially inward, an insulator attached to the plurality of teeth, and a wire wound around the insulator. The insulator is provided with a first wire rod layer and a second wire rod layer on the first wire rod layer, and the insulator has a shaft of the stator at a distal end portion in a tooth extending direction on a winding surface around which the wire rod is wound. The first wire layer is formed by winding a wire on a winding surface including the upper surface of the step portion, and (L1 + D) tan (θ / 2) × cos (θ / 2) -Acos (θ / 2)> D is satisfied. A is B / 2 + (1 + √3 / 2) D, B is the width of the insulator in the plane orthogonal to the axial direction, D is the diameter of the wire, and θ is a plurality of teeth. L1 is a distance from the central axis of the stator to the radially inner end of the upper surface of the stepped portion, and L2 is a step from the central axis of the stator. This is the distance to the radially outer end of the upper surface of the part. This aspect can also provide a stator having effects similar to those described in relation to the above-described stator manufacturing method.

  In the fifth aspect of the present invention, the stator includes a stator core having a plurality of teeth arranged in the circumferential direction and extending radially inward, an insulator attached to the plurality of teeth, and a wire wound around the insulator. A first wire rod layer and a second wire rod layer on the first wire rod layer. The insulator has a stepped portion protruding in the axial direction of the stator at the tip end in the extending direction of the teeth on the winding surface around which the wire is wound, and the first wire layer excludes the upper surface of the stepped portion. (L1 + D) tan (θ / 2) × cos (θ / 2) −Acos (θ / 2) <D and (L2 + D) tan (θ / 2) × cos (θ / 2) -Acos (θ / 2)> D is satisfied. A is B / 2 + (1 + √3 / 2) D, B is the width of the insulator in the plane orthogonal to the axial direction, D is the diameter of the wire, and θ is a plurality of teeth. L1 is a distance from the central axis of the stator to the radially inner end of the upper surface of the stepped portion, and L2 is a step from the central axis of the stator. This is the distance to the radially outer end of the upper surface of the part. According to this aspect, the same effect as that described in relation to the stator manufacturing method described above can be obtained.

  In the stator described above, if the height of the step portion is H, D / 2 ≦ H may be satisfied. Thereby, when winding a wire on the 1st wire rod layer, it can prevent that the wire which forms the 1st wire rod layer shifts.

  In the stator described above, the insulator does not have to have a stepped portion projecting in the axial direction of the stator at the end of the winding surface opposite to the tip in the extending direction of the teeth. Thereby, wire rod space can be improved.

  In the sixth aspect of the present invention, the motor includes the stator described above. According to this aspect, it is possible to provide a motor that can obtain the same effects as those described in relation to the stator manufacturing method described above.

  In a seventh aspect of the present invention, a stator is provided that includes a stator core having a plurality of teeth arranged in the circumferential direction and extending radially inward, and a wire wound around an insulator attached to the plurality of teeth. The insulator has a stepped portion projecting in the axial direction of the stator at the tip end in the extending direction of the plurality of teeth on the winding surface on which the wire is wound, and the wire is wound around the insulator. And forming a first wire layer wound on the insulator and a second wire layer wound on the first wire layer. In the step of forming the first wire layer and the second wire layer, the second wire layer is formed on the first wire layer wound up to the radially inner end of the upper surface of the stepped portion. When a half of the shortest distance between the second wire layers on the insulator attached to the teeth adjacent in the circumferential direction among the plurality of teeth is larger than the diameter of the wire, the wire is wound on the upper surface of the step portion. A plurality of teeth in a state where the first wire layer is formed and the second wire layer is formed on the first wire layer wound to the radially inner end of the upper surface of the stepped portion. Until 1/2 of the shortest distance between the second wire layers on the insulator attached to the teeth adjacent to the circumferential direction is smaller than the diameter of the wire material and comes into contact with the stepped surface at the radially outer end of the stepped portion A plurality of tees with the second wire layer formed on the wound first wire layer If 1/2 of the shortest distance between the second wire layers on the insulator attached to the teeth adjacent to each other in the circumferential direction is larger than the diameter of the wire, the first wire is not wound on the upper surface of the stepped portion. The wire layer is formed.

  According to this aspect, it is possible to provide a stator having the same effects as those described in relation to the stator manufacturing method described above.

  Generally, when the shortest distance between the wire layers on adjacent teeth is smaller than twice the diameter of the wire, the nozzle of the winding machine and the wire layer interfere. By shifting the position of the radially inner end of the wire layer in the radially outward direction, interference between the nozzle and the wire layer can be avoided. However, if the diameter of the wire used changes, it is necessary to change the shortest distance between the wire layers on the adjacent teeth in order to avoid interference between the nozzle and the wire layer. Therefore, an insulator suitable for each assumed wire diameter is required. Need to design. On the other hand, in order to deal with wire rods having different diameters with one type of insulator, it is necessary to design the insulator so that interference with the nozzle can be avoided even when a wire rod of the maximum diameter is assumed. When a wire having a diameter smaller than the maximum diameter is used, the space factor decreases.

  Each aspect mentioned above designs the general-purpose insulator which can suppress the fall of a space factor even when it is a case where a wire with a different diameter is used, and uses the insulator to wire to a radial inner end. When the shortest distance between the wire layers on the adjacent teeth is smaller than twice the diameter of the wire in the wound state, the wire can be wound so that the shortest distance is larger than twice the diameter of the wire. For one purpose.

  Therefore, when the shortest distance between the wire layers on adjacent teeth is smaller than twice the wire diameter of the wire in the state where the wire is wound to the radially inner end of the tooth, the shortest distance from the radially inner end is the wire. The insulator is provided with a step portion that enables the wire layer to be formed without winding the wire to a position larger than twice the diameter of the insulator. In other words, the insulator is provided with a step portion that can shift the position of the radially inner end of the wire layer toward the radially outer side so that the nozzle of the winding machine does not interfere with the wire layer. For example, the length of the stepped portion in the radial direction is such that the shortest distance between the wire layers is 2 times the diameter of the wire when the wire having the largest diameter is wound until it contacts the stepped surface at the radially outer end of the stepped portion. Designed to be larger than double. On the other hand, when the shortest distance between the wire layers is larger than twice the diameter of the wire, the step portion can form the wire layer to the radially inner end by winding the wire on the step portion. . Thereby, the fall of a space factor can be suppressed.

  The above summary of the present invention does not enumerate all of the features of the present invention. A sub-combination of these feature groups can also be an invention.

It is a front view showing a part of stator 10 with which the motor concerning one embodiment is provided. The front view of the wire winding part 11 in which the insulator was provided is shown. A part of AA cross section of FIG. 2 is expanded and shown. It is a figure explaining the judgment conditions which judge whether a wire is wound around the upper surface 302 of the level | step-difference part. An example of the coil | winding structure at the time of using a φ1.2 wire is shown typically. The AA cross section in FIG. 5 is shown. An example of the coil | winding structure at the time of using a wire rod of (phi) 1.1 is shown typically. The AA cross section in FIG. 7 is shown. It is a flowchart which shows the process in the manufacturing method of a motor.

  Hereinafter, the present invention will be described through embodiments of the invention, but the following embodiments do not limit the invention according to the claims. In addition, not all the combinations of features described in the embodiments are essential for the solving means of the invention.

  FIG. 1 is a front view showing a part of a stator 10 included in a motor according to an embodiment. The motor of this embodiment is a brushless motor. Specifically, the motor of this embodiment is an inner rotor type brushless motor. The stator 10 includes a plurality of wire winding parts including a wire winding part 11 and a wire winding part 12, and a winding 40. Winding 40 includes a U-phase winding, a V-phase winding, and a W-phase winding.

  The winding 40 is formed by winding a wire around the insulator 30 attached to the stator core. The insulator 30 is formed with two or more wire layers. Specifically, the first wire layer 41 is a layer wound on the insulator 30. That is, the first layer. The second wire layer 42 is a layer wound on the first wire layer 41. That is, the second layer.

  FIG. 2 shows a front view of the wire winding part 11. The wire winding part 11 is formed by the teeth of the stator core and the portion of the insulator 30 that covers the teeth. FIG. 3 shows an enlarged part of the AA cross section of FIG. FIG. 3 particularly shows an AA cross section of the insulator 30.

  The stator 10 is a cylindrical member. A rotor is disposed inside the stator 10. The rotor has a rotating shaft that serves as an output shaft of the motor. In the description of the present embodiment, the direction along the central axis AX of the motor is referred to as “axial direction” unless otherwise specified. The axial direction coincides with the thrust direction. The central axis of the motor coincides with the central axis of the stator 10. The centers of the “circumferential direction” and “radial direction” are the central axes of the motor.

  The stator core has an annular yoke and a plurality of teeth. The plurality of teeth included in the stator core are provided on the inner peripheral side of the yoke, arranged in the circumferential direction, and extend radially inward. Each of the plurality of teeth extends toward the center of the stator 10. The center position of the stator 10 is the position of the central axis of the motor. Specifically, in the motor, the rotor is provided such that the central axis of the rotating shaft coincides with the center of the stator 10.

  As shown in FIG. 3, the insulator 30 has a stepped portion 32 having a height H. The step portion 32 is formed at the distal end portion in the extending direction of the teeth so as to protrude in the axial direction of the stator 10. The step portion 32 is formed by the lower surface 301 of the step portion 32, the upper surface 302 of the step portion 32, and the step surface 303. The lower surface 301 of the step portion 32 and the upper surface 302 of the step portion 32 are winding surfaces on which the wire can be wound in the insulator 30. The step portion 32 is formed in the axial direction. For example, the step portion 32 is not provided on the side surface 35 that is horizontal in the axial direction. For example, the step portion 32 is not provided on the side surface 35 facing the adjacent wire winding portion. Specifically, on the side surface 35, the lower surface 301 of the step portion 32 and the upper surface 302 of the step portion 32 have the same height. As described above, the insulator 30 may have the stepped portion 32 only on the end surface intersecting in the axial direction among the plurality of end surfaces of the insulator 30.

  In this embodiment, when winding a wire having a diameter D exceeding a predetermined threshold value, the wire is wound up to the stepped surface 303 to form a first wire layer, and folded to form a second-phase wire layer. Wind. As a result, the wire rod can be prevented from shifting by the step surface 303 while preventing the nozzle of the winding machine from interfering with the winding layer at the radially inner tip of the wire winding portion 11. On the other hand, when winding a wire having a diameter D that does not exceed a predetermined threshold value, the wire is wound over the upper surface 302 of the stepped portion 32 beyond the step surface 303 and is folded back to be the second phase wire. Wind the layer.

  Insulator 30 does not have a stepped portion protruding in the axial direction of stator 10 at the end opposite to the tip in the extending direction of the teeth on lower surface 301 serving as the winding surface. For example, as shown in FIG. 3, it has an inclined surface that protrudes from the opposite end and is inclined toward the lower surface 301. In addition, since it does not need to have a level | step-difference part, it is not limited to an inclined surface, For example, the edge part on the opposite side can also be formed in one plane. In other words, the insulator 30 has a stepped portion 32 only at the tip in the extending direction of the teeth. Thereby, a wire rod space factor can be improved.

  FIG. 4 is a diagram illustrating a determination condition for determining whether or not a wire is wound around the upper surface 302 of the step portion 32. In the present embodiment, it is determined whether or not a wire is wound around the upper surface 302 of the step portion 32 based on the distance Δ between the windings adjacent in the circumferential direction. For example, the distance Δ1 when the wire is wound around the upper surface 302 of the stepped portion 32 and then folded back and wound in the second layer is longer than a predetermined value necessary for inserting the nozzle of the winding machine. As a condition, it is determined that the wire is wound around the upper surface 302 of the wire winding portion stepped portion 32.

In particular,
(L1 + D) tan (θ / 2) × cos (θ / 2) −Acos (θ / 2)> D (conditional expression 1)
When satisfy | filling, a wire is wound on the upper surface of the level | step-difference part 32, and the 1st wire layer 41 is formed. on the other hand,
(L1 + D) tan (θ / 2) × cos (θ / 2) −Acos (θ / 2) <D (conditional expression 2) and (L2 + D) tan (θ / 2) × cos (θ / 2) −Acos ( θ / 2)> D (conditional expression 3)
When satisfy | filling, the 1st wire layer 41 is formed on the upper surface 302 of the level | step-difference part 32, without winding a wire. Here, A is B / 2 + (1 + √3 / 2) D. B is the width of the insulator 30 in a plane orthogonal to the axial direction. D is the diameter of the wire. θ is an angle formed by the central axes of teeth adjacent in the circumferential direction among the plurality of teeth. L1 is the distance from the center axis AX of the stator to the radially inner end of the upper surface 302 of the stepped portion 32. L2 is the distance from the center axis AX of the stator to the radially outer end of the upper surface 302 of the stepped portion 32.

  In addition to conditional expression 2 and conditional expression 3, when D / 2 ≦ H is further satisfied, the first wire layer 41 may be formed on the upper surface 302 of the stepped portion 32 without winding the wire. When D / 2 ≦ H is further satisfied, even if the wire is wound around the first wire layer 41, the wire forming the first wire layer 41 can be reliably prevented from shifting.

  Referring to FIG. 4, the left side of conditional expression (1) represents Δ1 shown in FIG. On the other hand, in order to insert the nozzle of the winding machine, a gap of about 2D is required between the windings. Therefore, if conditional expression 1 is satisfied, it can be determined that the nozzle can be prevented from interfering with the wire layer even if the wire is wound around the upper surface 302 of the stepped portion 32 and folded to form the second layer.

  Similarly, when the conditional expression 2 and the conditional expression 3 are satisfied, the wire is wound up to the step surface 303 located at a position separated from the central axis AX by L2, and can be folded without being wound around the upper surface 302 of the step portion 32. For example, it can be determined that the nozzle of the winding machine can be prevented from interfering with the wire layer.

  FIG. 5 schematically shows an example of a winding configuration in the case of using a wire with φ1.2. FIG. 6 shows an AA cross section of the insulator 30 in FIG. 5 together with the wire layer. Here, it is assumed that L1 = 21.5 mm, L2 = 22.5 mm, and θ = 30 °. However, A = 4.7295 mm. Here, the value 1.268 mm including the film thickness of the wire is used as the diameter D of the wire of φ1.2. Since the left side of conditional expression 1 is 1.1442, conditional expression 1 is not satisfied and conditional expression 2 is satisfied. Since the left side of conditional expression 3 is 1.40302, conditional expression 3 is satisfied. Therefore, it is determined that no wire is wound around the upper surface 302 of the step portion 32. By folding the wire rod around the upper surface 302 of the stepped portion 32 at the stepped surface 303 without winding it, the nozzle 1000 of the winding machine can be prevented from coming into contact with the winding as shown in FIG. Moreover, it can suppress that the wire which forms the 1st wire layer is shifted.

  FIG. 7 schematically shows an example of a winding configuration in the case of using a wire rod of φ1.1. FIG. 8 shows an AA cross section of the insulator 30 in FIG. 7 together with the wire layer. Here, similarly to the example of FIG. 5, it is assumed that L1 = 21.5 mm, L2 = 22.5 mm, and θ = 30 °. However, it is assumed that A = 4.7295 mm. Here, the value 1.168 including the film thickness of the wire is used as the diameter D of the wire of φ1.1. Conditional expression 1 is satisfied because the left side of conditional expression 1 is 1.29856. Therefore, it is determined that the wire is wound around the upper surface 302 of the step portion 32. In the case of using a φ1.1 wire, even if the wire is wound around the upper surface 302 of the stepped portion 32 and folded, the nozzle 1000 of the winding machine can be prevented from coming into contact with the winding as shown in FIG. it can. Furthermore, since the number of turns can be increased by winding a wire around the upper surface 302 of the stepped portion 32, the necessary number of turns can be ensured even if the insulator 30 having the stepped portion 32 is used.

  The configuration in the case where the wire is wound on the upper surface 302 of the step portion 32 and the configuration in the case where the wire is not wound on the upper surface 302 of the step portion 32 have been specifically described above. Specifically, as shown in FIG. 4 and the like, the first wire layer 41 and the second wire layer 42 are wound on the insulator 30 in a close-packed manner in one cross section orthogonal to the axial direction. It was formed by doing. Specifically, the first wire rod layer 41 is formed by sequentially winding the wire rod so as to abut along the extending direction of the insulator 30. Moreover, the 2nd wire layer 42 is formed by winding the wire which forms the 2nd wire layer 42 in the trough of the said wire contact | abutting. In other words, the center of each of the pair of wire portions that are in contact with each other in the first wire layer 41 and the center of the wire of the second wire layer 42 that is in contact with the pair of wire portions are each an equilateral triangle having a side length D. It was assumed that the wire was wound so as to form. In such a winding state, when conditional expression 1 is satisfied, a wire is wound on the upper surface of the stepped portion 32 to form the first wire layer 41, and when conditional expression 2 and conditional expression 3 are satisfied The first wire layer 41 is formed on the upper surface 302 of the step portion 32 without winding the wire.

  More generally, when the first wire layer 41 and the second wire layer 42 are formed, the first wire layer 41 is wound on the first wire layer 41 wound up to the radially inner end of the upper surface 302 of the step portion 32. In a state in which the two wire layers 42 are formed, ½ of the shortest distance between the second wire layers 42 on the insulator 30 attached to the teeth adjacent in the circumferential direction among the plurality of teeth is larger than the diameter of the wire. In this case, the first wire layer 41 is formed by winding a wire on the upper surface 302 of the step portion 32. On the other hand, in the state where the second wire layer 42 is formed on the first wire layer 41 wound to the radially inner end portion of the upper surface 302 of the stepped portion 32, the plurality of teeth are adjacent to each other in the circumferential direction. Until half of the shortest distance between the second wire layers 42 on the insulator 30 attached to the teeth is smaller than the diameter of the wire and comes into contact with the step surface 303 at the end portion on the radially outer side of the step portion 32. Between the second wire rod layers 42 on the insulator 30 attached to the teeth adjacent in the circumferential direction among the plurality of teeth in a state where the second wire rod layer 42 is formed on the wound first wire rod layer 41. When 1/2 of the shortest distance is larger than the diameter of the wire rod, the first wire rod layer 41 is formed on the upper surface 302 of the stepped portion 32 without winding the wire rod.

  In addition, it adjoins to the circumferential direction among several teeth in the state which formed the 2nd wire rod layer 42 on the 1st wire rod layer 41 wound to the radial inside edge part of the upper surface 302 of the level | step-difference part 32. Whether or not 1/2 of the shortest distance between the second wire layers 42 on the insulator 30 attached to the teeth is larger than the diameter of the wire, at least the width of the insulator in the plane orthogonal to the axial direction, the diameter of the wire The angle formed by the central axes of the teeth adjacent in the circumferential direction among the plurality of teeth, the distance from the central axis of the stator to the radially inner end of the upper surface 302 of the stepped portion 32, and the first wire layer 41 and the first wire layer 41 The determination may be made based on the lamination mode of the two wire layers 42. Further, in the state where the second wire layer 42 is formed on the first wire layer 41 wound to the radially inner end of the upper surface 302 of the stepped portion 32, the plurality of teeth are adjacent to each other in the circumferential direction. Until half of the shortest distance between the second wire layers 42 on the insulator 30 attached to the teeth is smaller than the diameter of the wire and comes into contact with the step surface 303 at the end portion on the radially outer side of the step portion 32. Between the second wire rod layers 42 on the insulator 30 attached to the teeth adjacent in the circumferential direction among the plurality of teeth in a state where the second wire rod layer 42 is formed on the wound first wire rod layer 41. Whether or not 1/2 of the shortest distance is larger than the diameter of the wire is determined by at least the width of the insulator in the plane orthogonal to the axial direction, the diameter of the wire, and the central axis of the teeth adjacent in the circumferential direction among the plurality of teeth. Angle to make, stator Distance from the center axis to the step surface 303 of the radially outer end of the stepped portion 32, and may be determined based on a first lamination type of the wire layer 41 and the second wire layer 42.

  FIG. 9 is a flowchart showing steps in a method for manufacturing a motor.

  In S902, a stator core, an insulator 30, and a wire are prepared. In S904, the insulator 30 is attached to the stator core. In S906, it is determined whether or not a wire is wound on the upper surface 302 of the stepped portion 32. In S908, the operating condition of the winding machine is set based on the determination in S906. In S910, the stator core to which the insulator 30 is mounted is set in the winding machine, and the wire is wound around the insulator 30 according to the operating conditions set in S908, thereby obtaining the stator 10.

  In S912, motor components are prepared. Components of the motor include a rotor, a bracket, a lead wire, and the like. In S914, the motor components are assembled to the stator 10 manufactured in S910 to obtain a motor.

  As described above, according to the stator 10, when the insulator 30 having the step portion 32 is used and wound on the step portion 32, it is determined whether or not the nozzle of the winding machine interferes with the winding. It can be determined appropriately according to the wire diameter. For this reason, it is possible to suppress the nozzle of the winding machine from interfering with the winding without separately preparing a stator for wires having different wire diameters. Moreover, when using a wire with a small wire diameter, the number of turns can be maintained because the wire is wound around the step portion 32.

  As mentioned above, although this invention was demonstrated using embodiment, the technical scope of this invention is not limited to the range as described in the said embodiment. It will be apparent to those skilled in the art that various modifications or improvements can be added to the above-described embodiment. It is apparent from the scope of the claims that the embodiments added with such changes or improvements can be included in the technical scope of the present invention.

DESCRIPTION OF SYMBOLS 10 Stator 11, 12 Wire winding part 30 Insulator 32 Step part 35 Side surface 40 Winding 41 1st wire layer 42 2nd wire layer 301 Lower surface 302 Upper surface 303 Step surface 1000 Nozzle

Claims (12)

A stator manufacturing method comprising a stator core having a plurality of teeth arranged in the circumferential direction and extending radially inward, and a wire wound around an insulator attached to the plurality of teeth,
The insulator has a stepped portion projecting in the axial direction of the stator at a distal end portion in the extending direction of the plurality of teeth on a winding surface around which the wire is wound,
Winding the wire around the insulator, and forming a first wire layer wound on the insulator and a second wire layer wound on the first wire layer;
The step of forming the first wire layer and the second wire layer includes
(L1 + D) tan (θ / 2) × cos (θ / 2) −Acos (θ / 2)> D
When the wire is wound on the upper surface of the step portion, the first wire layer is formed,
(L1 + D) tan (θ / 2) × cos (θ / 2) −Acos (θ / 2) <D and (L2 + D) tan (θ / 2) × cos (θ / 2) −Acos (θ / 2)> D
And forming the first wire layer without winding the wire on the upper surface of the stepped portion,
A is B / 2 + (1 + √3 / 2) D,
B is the width of the insulator in a plane perpendicular to the axial direction;
D is the diameter of the wire,
θ is an angle formed by a central axis of teeth adjacent in the circumferential direction among the plurality of teeth.
L1 is the distance from the central axis of the stator to the radially inner end of the upper surface of the stepped portion,
L2 is a manufacturing method which is the distance from the central axis of the stator to the radially outer end of the upper surface of the stepped portion. The said insulator is a manufacturing method of Claim 1 which has the said level | step-difference part only in the end surface which cross | intersects the said axial direction among the several end surfaces which the said insulator has. The manufacturing method according to claim 1, wherein D / 2 ≦ H, where H is a height of the stepped portion. A method for producing a motor comprising a stator core having a plurality of teeth arranged in a circumferential direction and extending radially inward, and a wire wound around an insulator attached to the plurality of teeth,
The insulator has a stepped portion projecting in the axial direction of the stator at a distal end portion in the extending direction of the plurality of teeth on a winding surface around which the wire is wound,
Winding the wire around the insulator, and forming a first wire layer wound on the insulator and a second wire layer wound on the first wire layer;
The step of forming the first wire layer and the second wire layer includes
(L1 + D) tan (θ / 2) × cos (θ / 2) −Acos (θ / 2)> D
When the wire is wound on the upper surface of the step portion, the first wire layer is formed,
(L1 + D) tan (θ / 2) × cos (θ / 2) −Acos (θ / 2) <D and (L2 + D) tan (θ / 2) × cos (θ / 2) −Acos (θ / 2)> D
And forming the first wire layer without winding the wire on the upper surface of the stepped portion,
A is B / 2 + (1 + √3 / 2) D,
B is the width of the insulator in a plane perpendicular to the axial direction;
D is the diameter of the wire,
θ is an angle formed by a central axis of teeth adjacent in the circumferential direction among the plurality of teeth.
L1 is the distance from the central axis of the stator to the radially inner end of the upper surface of the stepped portion,
L2 is a manufacturing method which is the distance from the central axis of the stator to the radially outer end of the upper surface of the stepped portion. A stator manufacturing method comprising a stator core having a plurality of teeth arranged in the circumferential direction and extending radially inward, and a wire wound around an insulator attached to the plurality of teeth,
The insulator has a stepped portion projecting in the axial direction of the stator at a distal end portion in the extending direction of the plurality of teeth on a winding surface around which the wire is wound,
Winding the wire around the insulator, and forming a first wire layer wound on the insulator and a second wire layer wound on the first wire layer;
The step of forming the first wire layer and the second wire layer includes
In a state where the second wire layer is formed on the first wire layer wound to the radially inner end of the upper surface of the stepped portion, the teeth adjacent in the circumferential direction among the plurality of teeth. When the half of the shortest distance between the second wire layers on the installed insulator is larger than the diameter of the wire, the wire is wound on the upper surface of the step portion, and the first wire layer Form the
In a state where the second wire layer is formed on the first wire layer wound to the radially inner end of the upper surface of the stepped portion, the teeth adjacent in the circumferential direction among the plurality of teeth. Winding is performed until 1/2 of the shortest distance between the second wire layers on the installed insulator is smaller than the diameter of the wire and is in contact with the stepped surface at the radially outer end of the stepped portion. Further, the shortest distance between the second wire layers on the insulator mounted on the teeth adjacent in the circumferential direction among the plurality of teeth in a state where the second wire layer is formed on the first wire layer. The manufacturing method of forming the first wire layer without winding the wire on the upper surface of the step portion when 1/2 of the wire is larger than the diameter of the wire. The said insulator does not have a level | step-difference part which protrudes in the axial direction of the said stator in the edge part on the opposite side to the said front-end | tip part in the extension direction of the said teeth in the said winding surface. The manufacturing method according to claim 1. A winding method for winding a wire around an insulator attached to a tooth of a stator core provided in a stator,
A plurality of the teeth are arranged in the circumferential direction and extend radially inward,
The insulator has a stepped portion projecting in the axial direction of the stator at the tip end in the extending direction of the teeth on the winding surface around which the wire is wound,
Determining whether or not to wind the wire on the upper surface of the stepped portion;
When it is determined that the wire is wound on the upper surface of the stepped portion, the wire is wound on the winding surface including the upper surface of the stepped portion, and the wire is wound on the obtained wire layer. And the stage of
Winding the wire on the winding surface without winding the wire on the upper surface of the step when it is determined that the wire is not wound on the upper surface of the step; With
Determining whether to wind the wire on the upper surface of the stepped portion,
(L1 + D) tan (θ / 2) × cos (θ / 2) −Acos (θ / 2)> D
If it is determined that the wire is wound on the upper surface of the stepped portion,
(L1 + D) tan (θ / 2) × cos (θ / 2) −Acos (θ / 2) <D and (L2 + D) tan (θ / 2) × cos (θ / 2) −Acos (θ / 2)> D
If it is determined that the wire is not wound on the upper surface of the stepped portion,
A is B / 2 + (1 + √3 / 2) D,
B is the width of the insulator in a plane perpendicular to the axial direction;
D is the diameter of the wire,
θ is an angle formed by the central axes of the teeth adjacent in the circumferential direction,
L1 is the distance from the central axis of the stator to the radially inner end of the upper surface of the stepped portion,
L2 is a winding method in which L2 is the distance from the central axis of the stator to the radially outer end of the upper surface of the stepped portion. A stator,
A stator core having a plurality of teeth arranged in the circumferential direction and extending radially inward;
An insulator mounted on the plurality of teeth;
A first wire layer in which a wire is wound around the insulator and a second wire layer on the first wire layer;
The insulator has a stepped portion projecting in the axial direction of the stator at a distal end portion in the extending direction of the plurality of teeth on a winding surface around which the wire is wound,
The first wire layer is formed by winding the wire on the winding surface including the upper surface of the step portion, and (L1 + D) tan (θ / 2) × cos (θ / 2) −Acos ( θ / 2)> D is satisfied,
A is B / 2 + (1 + √3 / 2) D,
B is the width of the insulator in a plane perpendicular to the axial direction;
D is the diameter of the wire,
θ is an angle formed by a central axis of teeth adjacent in the circumferential direction among the plurality of teeth.
L1 is the distance from the central axis of the stator to the radially inner end of the upper surface of the stepped portion,
L2 is the distance from the central axis of the stator to the radially outer end of the upper surface of the stepped portion. A stator,
A stator core having a plurality of teeth arranged in the circumferential direction and extending radially inward;
An insulator mounted on the plurality of teeth;
A first wire layer in which a wire is wound around the insulator and a second wire layer on the first wire layer;
The insulator has a stepped portion projecting in the axial direction of the stator at a distal end portion in the extending direction of the plurality of teeth on a winding surface around which the wire is wound,
The first wire layer is formed on the winding surface excluding the upper surface of the stepped portion,
(L1 + D) tan (θ / 2) × cos (θ / 2) −Acos (θ / 2) <D and (L2 + D) tan (θ / 2) × cos (θ / 2) −Acos (θ / 2)> D
The filling,
A is B / 2 + (1 + √3 / 2) D,
B is the width of the insulator in a plane perpendicular to the axial direction;
D is the diameter of the wire,
θ is an angle formed by a central axis of teeth adjacent in the circumferential direction among the plurality of teeth.
L1 is the distance from the central axis of the stator to the radially inner end of the upper surface of the stepped portion,
L2 is the distance from the central axis of the stator to the radially outer end of the upper surface of the stepped portion. The stator according to claim 8 or 9, wherein D / 2≤H, where H is the height of the stepped portion. The said insulator does not have a level | step-difference part which protrudes in the axial direction of the said stator in the edge part on the opposite side to the said front-end | tip part in the extension direction of the said teeth in the said winding surface. The stator according to claim 1.   A motor comprising the stator according to any one of claims 8 to 11.

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