JP2023053644A - Stator, motor with the same, and manufacturing method of stator - Google Patents

Abstract

To prevent breakage of a conductor wire in manufacturing a stator.SOLUTION: A stator comprises a stator core, an insulator 40, and a conductor wire 50. The insulator 40 comprises a core back cover part 411, a tooth cover part, and a projection 413. The core back cover part 411 covers one end surface in an axial direction of a divided core back. The tooth cover part covers one end surface in the axial direction of teeth. The projection 413 projects from the one end surface in the axial direction of the core back cover part to the outside in the axial direction. The conductor wire 40 has a crossover line 51. The crossover line 51 connects a plurality of coils C by passing through the outside in a radial direction of the projection 413. The crossover line 51 has a curved part 51a. The curved part 51a convexly curves radially inward between itself and the projection 413 adjacent in a circumferential direction.SELECTED DRAWING: Figure 6

Description

The present invention relates to a stator, a motor including the same, and a method of manufacturing the stator.

A conventional stator, for example, comprises a stator core, an insulator, and conductors. The stator core includes a yoke (core back) and winding portions (teeth). The yoke is formed in an annular shape by connecting a plurality of arc-shaped yoke-constituting portions (divided core backs) in the circumferential direction to surround the central axis.

A plurality of winding winding portions are arranged in the circumferential direction extending radially inward from each yoke-constituting portion. The conducting wire is wound around the winding wound portion via an insulator to form a coil. The yoke is formed by connecting the yoke-constituting parts in a state where the coil is formed on the winding part. At this time, the conducting wire extends in the circumferential direction and connects the plurality of coils (see, for example, Patent Document 1).

Japanese Patent Application Laid-Open No. 2001-161048

However, in the conventional stator, there is a possibility that a part of the conductive wire extending in the circumferential direction is left over when the yoke forming portions are connected to each other and bulges outward in the radial direction. As a result, there is a possibility that the conducting wire will come into contact with other members or the like during manufacture and assembly of the stator. For this reason, there is a possibility that the conducting wire will be damaged and a short circuit will occur.

SUMMARY OF THE INVENTION An object of the present invention is to provide a stator that can prevent damage to conductor wires.

An exemplary stator of the present invention comprises a stator core, insulators and conductors. The stator core has a core back and teeth. The core back is formed by connecting a plurality of arc-shaped split core backs in the circumferential direction and is formed in an annular shape surrounding the central axis. A plurality of teeth are arranged in the circumferential direction extending radially inward from each split core back. The insulator covers the core back and teeth. The conducting wire is wound around the teeth to form a coil. The insulator has a core back cover portion, a tooth cover portion, and a protruding portion. The core-back cover portion covers one axial end face of the split core-back. The tooth cover portion covers one axial end face of the tooth. The protruding portion protrudes axially outward from one axial end surface of the core back cover portion. The conducting wire has a connecting wire. The crossover wire connects the plurality of coils through the radially outer side of the projecting portion. The crossover has a curved portion. The curved portion is convexly curved radially inward between circumferentially adjacent protrusions.

An exemplary stator manufacturing method of the present invention includes an insulator mounting step, a coil forming step, and a connecting step in this order. In the insulator mounting step, a split core having an arcuate split core-back and teeth extending radially inward from the split core-back is covered with an insulator. In the coil forming step, a coil is formed by winding a conductive wire around the tooth via an insulator. In the connecting step, a plurality of split cores are connected in the circumferential direction. The insulator has a core back cover portion, a tooth cover portion, and a protruding portion. The core-back cover portion covers one axial end face of the split core-back. The tooth cover portion covers one axial end surface of the tooth portion. The protruding portion protrudes axially outward from one axial end surface of the core back cover portion. The conducting wire has a connecting wire. The crossover wire extends in the circumferential direction through the radially outer side of the projecting portion and connects the plurality of coils. The method further includes a forming step of curving the connecting wire to project radially inwardly between circumferentially adjacent protrusions.

According to an exemplary embodiment of the present invention, it is possible to provide a stator capable of preventing breakage of conductive wires, a motor including the same, and a method of manufacturing the stator.

FIG. 1 is a vertical cross-sectional view of a motor according to a first exemplary embodiment of the invention. 2 is a perspective view of a stator according to a first exemplary embodiment of the present invention; FIG. FIG. 3 is an exploded perspective view of a stator according to the first exemplary embodiment of the present invention; FIG. FIG. 4 is a perspective view of split cores and insulators of the stator according to the first exemplary embodiment of the present invention. FIG. 5 is an exploded perspective view of the split core and insulator of the stator according to the first exemplary embodiment of the present invention. FIG. 6 is a top view showing an enlarged part of the stator according to the first exemplary embodiment of the invention. FIG. 7 is a flow chart showing the manufacturing process of the stator according to the first exemplary embodiment of the present invention. FIG. 8 is an explanatory diagram illustrating the manufacturing process of the stator according to the exemplary first embodiment of the present invention. FIG. 9 is a top view showing an enlarged part of a stator according to a second exemplary embodiment of the invention.

Exemplary embodiments of the invention are described in detail below with reference to the drawings. In this specification, the direction parallel to the central axis of the motor is referred to as "axial direction," the direction orthogonal to the central axis of the motor is referred to as "radial direction," and the direction along an arc around the central axis of the motor is referred to as "circumferential direction." direction”, respectively. Further, in the present application, the axial direction is defined as the vertical direction, and the shape and positional relationship of each part will be described with the lower insulator 42 positioned below the upper insulator 41 . Note that the vertical direction is merely a name used for explanation, and does not limit the actual positional relationship and direction.

Further, in the present application, the term “parallel direction” includes substantially parallel directions. In addition, in the present application, the term “perpendicular direction” includes a substantially perpendicular direction.

(1. Configuration of motor)
A stator of an exemplary embodiment of the present invention will now be described. FIG. 1 is a longitudinal sectional view of a motor 1 according to a first embodiment of the invention. A motor 1 includes a rotor 10 , a stator 20 and a housing 100 .

The rotor 10 has a columnar shaft 11 forming a rotation axis extending along the central axis J, a rotor core 12 and a plurality of magnets 13 . The rotor core 12 is made of laminated steel plates in which annular magnetic steel plates are laminated in the axial direction. The rotor core 12 has an insertion hole 12a extending in the axial direction. The shaft 11 is press-fitted into the insertion hole 12 a and fixed to the rotor core 12 .

A plurality of magnets 13 are fixed to the outer peripheral surface of the rotor core 12 with an adhesive, for example. The plurality of magnets 13 are arranged in the circumferential direction so that N poles and S poles are alternately arranged.

Housing 100 is formed in a tubular shape and accommodates stator 20 . The housing 100 has a bottom plate portion 101 and a top plate portion 102 . The bottom plate portion 101 is arranged axially below the stator 20 and holds the bearing 81 . The top plate portion 102 is arranged axially above the stator 20 and holds the bearing 82 .

Bearings 81 and 82 rotatably support shaft 11 with respect to housing 100 . Ball bearings, for example, are used for the bearings 81 and 82 .

The stator 20 is arranged radially outside the rotor 10 and fixed to the housing 100 . Torque is generated between the stator 20 and the magnet 13 when the motor 1 is driven.

(2. Configuration of stator)
A stator of an exemplary embodiment of the present invention will now be described. 2 is a perspective view of the stator 20, and FIG. 3 is an exploded perspective view of the stator 20. FIG. Note that the coil C is not shown in FIG. Stator 20 includes stator core 30 , insulator 40 , and conducting wire 50 .

(2-1. Configuration of stator core)
The stator core 30 is formed by laminating a plurality of magnetic bodies such as electromagnetic steel sheets in the axial direction. The stator core 30 is formed by connecting a plurality of split cores 31 in the circumferential direction. For example, the number of split cores 31 in this embodiment is twelve. The split core 31 has a split core back 32 and teeth 33 integrally formed.

The divided core backs 32 are formed in an arc shape, and are connected in the circumferential direction to form an annular core back 34 surrounding the central axis J. As shown in FIG. Circumferentially adjacent split core backs 32 are in contact with each other at their outer ends in the circumferential direction. The core back 34 is press-fitted into a tubular body (not shown), and held in a state in which a plurality of split core backs 32 are connected in the circumferential direction.

Teeth 33 extend radially inward from each split core-back 32 . A plurality of teeth 33 are arranged at equal intervals in the circumferential direction in a state in which the plurality of divided core-backs 32 are connected in the circumferential direction.

(2-2. Structure of insulator)
4 is a perspective view of split core 31 and insulator 40, and FIG. 5 is an exploded perspective view of split core 31 and insulator 40. As shown in FIG. The insulator 40 is made of an insulating resin molding covering the core back 34 and the teeth 33 (see FIGS. 2 and 3).

The insulator 40 is divided into an upper insulator 41 and a lower insulator 42 that vertically sandwich each split core 31 . The upper insulator 41 includes an upper core back cover portion (core back cover portion) 411, an upper tooth cover portion (teeth cover portion) 412, a projecting portion 413, a first guide portion 414, a second guide portion 415, have

The lower insulator 42 has a lower core back cover portion 421 and a lower tooth cover portion 422 . A side cover portion 43 divided in the axial direction is provided on each of the upper insulator 41 and the lower insulator 42 .

The upper core back cover portion 411 covers the upper surface (one end surface in the axial direction) of the split core back 32 . The upper tooth cover portion 412 covers the upper surface (one end face in the axial direction) of the tooth 33 .

The projecting portion 413 projects axially outward from the upper surface (one end surface in the axial direction) of the upper core back cover portion 411 and is arranged on the boundary between the upper core back cover portion 411 and the upper teeth cover portion 412 .

The protruding portion 413 is formed in a substantially trapezoidal shape when viewed from the axial direction, and the inner angle of the corner portions 413a at both circumferential ends on the radial outer side is larger than 90° (see FIG. 6).

The first guide portion 414 and the second guide portion 415 are integrally formed and protrude axially outward from the upper surface (one end surface in the axial direction) of the upper core-back cover portion 411 . A pair of first guide portions 414 are arranged on both sides in the circumferential direction with the second guide portion 415 interposed therebetween. Although the first guide portion 414 and the second guide portion 415 are integrally formed in this embodiment, the first guide portion 414 and the second guide portion 415 may be formed separately.

The second guide portion 415 is arranged on the radial outer edge of the upper core-back cover portion 411 and faces the projecting portion 413 in the radial direction. That is, the second guide portion 415 protrudes axially outward from the upper surface (one end surface in the axial direction) of the upper core-back cover portion 411 and is arranged radially outward of the projecting portion 413 .

The first guide portion 414 is arranged on the outer side of the projecting portion 413 in the circumferential direction. The radial inner surface 414b of the first guide portion 414 is located radially inward of the radial outer surface 413b of the projecting portion 413 (see FIG. 6). Further, in the present embodiment, the first guide portions 414 of the upper insulators 41 adjacent in the circumferential direction are in contact with each other, and the adjacent radial inner surfaces 414b are formed flush with each other (see FIG. 6). At this time, the first guide portion 414 is arranged between the protrusions 413 adjacent in the circumferential direction.

Further, the first guide portion 414 has an inclined surface 414a. The inclined surface 414a faces the protruding portion 413 in the circumferential direction, and is inclined in a direction away from the protruding portion 413 in the circumferential direction toward the inner side in the radial direction when viewed from the axial direction. In addition, when viewed from the axial direction, the inclined surface 414a is inclined at an angle larger than 90° with respect to the radial inner surface 414b of the first guide portion 414 .

The upper end (outer end in the axial direction) of the projecting portion 413 is positioned axially above (outer in the axial direction) than the upper ends (outer ends in the axial direction) of the first guide portion 414 and the second guide portion 415 .

(2-3. Conducting wire structure)
FIG. 6 is a top view showing an enlarged part of the stator 20. FIG. Conducting wire 50 is covered with an insulating coating and wound around tooth 33 via insulator 40 to form coil C. As shown in FIG. The coil C is formed by winding the conducting wire 50 around the tooth 33 multiple times, for example, clockwise when viewed radially outward from the central axis J. As shown in FIG. Stator core 30 and conducting wire 50 are insulated via insulator 40 . The coils C are arranged, for example, in the order of U-phase, V-phase, and W-phase in the circumferential direction, and coils of the same phase are not adjacent in the circumferential direction. Since the phases of the coils C adjacent to each other in the circumferential direction are different, the rotation unevenness of the rotor 10 can be suppressed, and the vibration of the rotor 10 can be reduced.

Conducting wire 50 has crossover wire 51 . The crossover wire 51 extends in the circumferential direction through between the projecting portion 413 and the second guide portion 415 and between the projecting portion 413 and the first guide portion 414 . That is, the connecting wire 51 extends in the circumferential direction through the radially outer side of the projecting portion 413 and connects the multiple coils C of the same phase.

The crossover wire 51 has a curved portion 51a. The curved portion 51a is convexly curved radially inward between the protrusions 413 adjacent in the circumferential direction. A radial inner end of the curved portion 51 a is located radially inward of a radial inner surface 413 c of the projecting portion 413 .

In addition, the radial inner surface 414 b of the first guide portion 414 is positioned radially inward of the radial outer surface 413 b of the projecting portion 413 . In addition, the radially inner end of the curved portion 51 a is positioned radially inward of the first guide portion 414 . Therefore, between the projecting portions 413 adjacent in the circumferential direction, the connecting wire 51 is formed with a curved portion 51 a along the inner surface side of the first guide portion 414 .

In the present embodiment, the first guide portion 414 is arranged between the projecting portions 413 adjacent in the circumferential direction, and the connecting wire 51 is arranged radially inside the first guide portion 414 . Accordingly, it is possible to prevent the connecting wire 51 from bulging radially outward from the radial outer edge of the stator core 30 and coming into contact with other members or the like. Therefore, it is possible to prevent short-circuiting due to breakage of the connecting wire 51 during manufacture and assembly of the stator 20 . Moreover, it is possible to prevent the stator 20 from increasing in size in the radial direction.

(2. Manufacturing method of stator)
FIG. 7 is a flow chart showing the manufacturing process of the stator 20, and FIG. 8 is an explanatory diagram explaining the manufacturing process of the stator 20. As shown in FIG. The manufacturing method of the stator 20 has an insulator mounting process, a coil forming process, and a connecting process in order, and the connecting process and the forming process are performed simultaneously.

In the insulator mounting step, the split core 31 is vertically sandwiched between the upper insulator 41 and the lower insulator 42 (see FIG. 5), and the split core 31 is covered with the insulator 40 (step S1).

In the coil forming process, the conductor wire 50 is wound around the teeth 33 via the insulator 40 to form the coil C (step S2). In the coil forming step, after the connecting wire 51 is hooked on the upper end portion of the projecting portion 413 from the radial outside, the connecting wire 51 is moved downward in the axial direction (arrow X) (see FIG. 8). Thereby, the connecting wire 51 can be easily guided between the projecting portion 413 and the second guide portion 415 and between the projecting portion 413 and the first guide portion 414 .

At this time, the upper end (outer end in the axial direction) of the projecting portion 413 is positioned axially above (outer in the axial direction) than the upper ends (outer ends in the axial direction) of the first guide portion 414 and the second guide portion 415 . Thereby, the connecting wire 51 can be easily hooked on the projecting portion 413 without being caught on the first guide portion 414 and the second guide portion 415 . Therefore, workability in the coil forming process can be improved.

In addition, when viewed from the axial direction, the inner angle of the circumferential corner portion 413 a on the radially outer side of the projecting portion 413 is larger than 90°, so that the connecting wire 51 is aligned along the circumferential corner portion 413 a of the projecting portion 413 . It can be gently bent radially inward. Thereby, the load applied to the crossover wire 51 can be reduced.

In addition, the inclined surface 414a is inclined at an angle larger than 90° with respect to the radial inner surface 414b of the first guide portion 414 when viewed from the axial direction. Therefore, the connecting wire 51 can be gently bent radially inward along the inclined surface 414 a of the first guide portion 414 .

Further, even when the connecting wire 51 bends between the projecting portion 413 and the second guide portion 415 and curves radially outward, it contacts the second guide portion 415 . Therefore, it is possible to prevent the connecting wire 51 from expanding and curving radially outward from the radial outer edge of the stator core 30 .

In the connecting step, a plurality of split cores 31 having coils C formed thereon are connected in the circumferential direction to form an annular stator core 30 (step 3). At this time, the adjacent first guide portions 414 come into contact with each other, and the connecting wire 51 is arranged along the radial inner surface side of the first guide portions 414 . Thereby, a curved portion 51a is formed in the connecting wire 51 (step 4). That is, the forming step is performed at the same time as the connecting step, and the connecting wire 51 is curved radially inwardly along the inner surface side of the first guide portion 414 between the protrusions 413 adjacent in the circumferential direction. . As a result, the connecting process and the forming process are performed simultaneously, and the manufacturing efficiency of the stator 20 is improved.

<Second embodiment>
Next, a second embodiment of the invention will be described. FIG. 9 is a top view showing an enlarged part of the stator 20. FIG. For convenience of explanation, the same parts as those of the first embodiment shown in FIGS. 1 to 8 are denoted by the same reference numerals. The second embodiment differs from the first embodiment in that the first guide portion 414 is omitted. Other parts are the same as in the first embodiment.

In this embodiment, the forming process is performed after the connecting process. In the forming step, the connecting wire 51 is bent radially inward using a jig or the like to form the curved portion 51a. Accordingly, it is possible to prevent the connecting wire 51 from expanding radially outward from the radial outer edge of the stator core 30 and coming into contact with other members or the like. Therefore, it is possible to prevent short-circuiting due to breakage of the connecting wire 51 during manufacture and assembly of the stator 20 . Moreover, it is possible to prevent the stator 20 from increasing in size in the radial direction.

In addition, since the radially inner end of the curved portion 51a is positioned axially inwardly of the radially inner surface 413c of the projecting portion 413, the connecting wire 51 is prevented from expanding radially outwardly of the radially outer edge of the stator core 30. more controllable.

In addition, you may perform a forming process before a connection process. For example, the curved portion 51a may be formed in advance in the coil forming step, and the annular stator core 30 may be formed by connecting a plurality of split cores 31 in the circumferential direction in the connecting step.

(3. Others)
The above embodiments are merely examples of the present invention. The configuration of the embodiment may be changed as appropriate without departing from the technical idea of the present invention. Also, the embodiments may be implemented in combination within a possible range. For example, the second guide portion 415 may be omitted, or both the first guide portion 414 and the second guide portion 415 may be omitted.

Further, in the above-described embodiment, the projecting portion 413, the first guide portion 414, and the second guide portion 415 project axially upward from the upper surface of the upper core-back cover portion 411, but the projecting portion 413 and the first guide portion 414 And the second guide portion 415 may protrude axially downward from the lower surface of the lower core-back cover portion 421 .

Further, in the above embodiment, one connecting wire 51 passes between the projecting portion 413 and the first guide portion 414, but a plurality of connecting wires 51 may pass therethrough. In that case, a plurality of connecting wires 51 may be bundled and have curved portions 51a having substantially the same shape.

In the above embodiment, the U-phase, V-phase, and W-phase coils are arranged in this order in the circumferential direction, and the coils C of the same phase are not adjacent in the circumferential direction. Therefore, the connecting wire 51 extends through the plurality of projecting portions 413 in the circumferential direction in order to connect the coils C of the same phase. At this time, a plurality of curved portions 51a are formed. However, the coils C of the same phase may be adjacent in the circumferential direction. In this case, the connecting wire 51 passes through the two projecting portions 413 in the circumferential direction to form one curved portion 51a.

INDUSTRIAL APPLICABILITY The motor of the present invention can be used for, for example, a fan.

1 Motor 10 Rotor 11 Shaft 12 Rotor Core 12a Insertion Hole 13 Magnet 20 Stator 30 Stator Core 31 Split Core 32 Split Core Back 33 Teeth 34 Core Back 40 Insulator 41 Upper Insulator 42 Lower Insulator 43 Side Cover Part 50 Conducting Wire 51 Crossover Wire 51a Bending Portion 70 Insulator 81 Bearing 81, 82 Bearing 82 Bearing 100 Housing 101 Bottom plate portion 102 Top plate portion 411 Upper core back cover portion (core back cover portion)
412 Upper teeth cover part (teeth cover part)
413 Projecting portion 413a Corner portion 413b Radial outer surface 413c Radial inner surface 414 First guide portion 414a Inclined surface 414b Radial inner surface 415 Second guide portion 421 Lower core back cover portion 422 Lower teeth cover portion C Coil J Center axis X Arrow

Claims (9)

an annular core back formed by connecting a plurality of arc-shaped split core backs in the circumferential direction and surrounding a central axis; and a plurality of teeth extending radially inward from each of the split core backs and arranged in the circumferential direction; a stator core having
an insulator covering the core back and the teeth;
a conductor wound around the teeth via the insulator to form a coil,
The insulator is
a core back cover portion covering one axial end face of the split core back;
a tooth cover portion covering one axial end face of the tooth;
a protruding portion protruding axially outward from one axial end surface of the core back cover portion;
The conducting wire has a connecting wire passing through the radially outer side of the projecting portion and connecting the plurality of the coils,
The stator of the stator, wherein the connecting wire has a curved portion that is convexly curved radially inward between the protrusions that are adjacent in the circumferential direction. 2 . The stator according to claim 1 , wherein the radially inner end of the curved portion is located radially inward of the radially inner surface of the projecting portion. 3. The stator according to claim 1 or 2, wherein said projecting portion has an internal angle of 90 degrees or more at both circumferential ends on the radially outer side when viewed from the axial direction. The insulator is
further comprising a first guide portion protruding axially outward from one axial end surface of the core back cover portion and disposed circumferentially outward from the projecting portion;
the radial inner surface of the first guide portion is positioned radially inwardly of the radial outer surface of the projecting portion;
The stator according to any one of claims 1 to 3, wherein the radial inner end of the curved portion is located radially inward of the first guide portion. The first guide portion has an inclined surface facing the protrusion in the circumferential direction,
5 . The stator according to claim 4 , wherein the inclined surface is inclined radially inward in a direction away from the protrusion in the circumferential direction when viewed from the axial direction. The insulator is
further comprising a second guide portion projecting axially outward from one axial end surface of the core back cover portion and arranged radially outwardly of the projecting portion;
The connecting wire passes between the protruding portion and the second guide portion,
6. The stator according to claim 4, wherein the axially outer end of the projecting portion is located axially outside the axially outer ends of the first guide portion and the second guide portion. The insulator is
further comprising a second guide portion projecting axially outward from one axial end surface of the core back cover portion and arranged radially outwardly of the projecting portion;
The stator according to any one of claims 1 to 3, wherein the connecting wire passes between the projecting portion and the second guide portion. a stator according to any one of claims 1 to 7;
a rotor that rotates around the central axis while facing the stator in a radial direction. an insulator mounting step of covering a split core having an arc-shaped split core back and teeth extending radially inward from the split core back with an insulator;
a coil forming step of forming a coil by winding a conductive wire around the teeth through the insulator;
a connecting step of connecting a plurality of the split cores in the circumferential direction,
The insulator is
a core back cover portion covering one axial end face of the split core back;
a tooth cover portion covering one axial end surface of the tooth portion;
a protruding portion protruding axially outward from one axial end surface of the core back cover portion;
The conducting wire has a connecting wire extending in the circumferential direction through the radially outer side of the projecting portion and connecting the plurality of the coils,
The method of manufacturing a stator, further comprising a forming step of curving the connecting wire to project radially inwardly between the protrusions adjacent in the circumferential direction.

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