JP5502131B2 - Stator, brushless motor, and stator manufacturing method - Google Patents

Description

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

  Conventionally, as a stator used for a brushless motor, for example, there is the following (for example, see Patent Document 1). That is, in the armature described in Patent Document 1, the yoke is constituted by a plurality of ring-shaped yoke components divided in the axial direction, and each yoke component is directed radially outward. A plurality of protruding tooth portions are integrally formed.

JP-A-9-322441

  However, when the technique described in Patent Document 1 is applied to an armature used for an inner rotor type rotating electrical machine, the plurality of teeth protrudes radially inward of each yoke component. . For this reason, it becomes difficult to wind a coil by the fryer of a fryer apparatus from the radial direction outer side of each yoke structure part. Therefore, it is necessary to wind the coil from the radially inner side of each yoke component by the nozzle of the nozzle device. In this case, since it is necessary to secure a space for the nozzle to pass, It is difficult to reduce the size of the rotating electrical machine. In addition, when using a nozzle device, the winding speed of the winding is lower than when using a flyer device, which is disadvantageous for speeding up the coil winding process and thus reducing the number of equipment. It becomes.

  The flyer device is a device in which the coil is aligned with a variable former and wound around the tooth portion while circularly moving the flyer so as to swivel around the tooth portion. It is an apparatus which winds a coil around a tooth part by repeating alternately the process of making it rotate, and the process of sliding a nozzle in the direction of an axis.

  This invention is made | formed in view of the said subject, Comprising: It aims at implement | achieving size reduction and cost reduction about the stator used for a brushless motor.

In order to solve the above-mentioned problem, the stator according to claim 1 comprises an annular yoke and a plurality of yoke components divided in the circumferential direction of the yoke, and each of the yoke components. A plurality of core components integrally including a plurality of teeth protruding in the radial direction of the yoke; a plurality of windings each including a plurality of winding portions wound around the teeth; and the cores A plurality of insulators that are integrated into a component part and insulate the teeth part and the winding part, and a plurality of insulators that have a connecting part that connects the plurality of insulating parts, and the plurality of insulators, The plurality of core components are assembled to each other to form a plurality of groups of stator components formed independently of each other. In each of the plurality of groups of stator components, A plurality of core components are arranged with at least one gap therebetween, and in a state where the plurality of groups of stator components are assembled to each other, another group of core components is arranged in the gap. Each of the plurality of windings has a connecting wire connecting the plurality of winding portions, and is formed continuously from one end to the other end, and of the connecting wires, the winding start of the winding portion At least one of the connecting wires connected to the end of the winding and the connecting wire connected to the end of the winding end of the winding portion intersect in the vicinity of the connecting portion between the connecting portion and the insulating portion, The insulating part includes an insulating main body part that is integrated with the core constituent part and insulates the teeth part and the winding part, and an extension part that connects the insulating main body part and the connecting part, The extension part includes the stator component part from the connection part. The connecting wire connected to the end of the winding end of the winding portion and the connecting wire connected to the winding start end of the winding portion formed with a radially extending portion extending in the direction Is disposed at a position overlapping the radially extending portion as viewed in the axial direction of the stator component.
Moreover, in order to solve the said subject, the stator of Claim 2 comprised the several yoke structure part divided | segmented into the circumferential direction of the said yoke while comprising the annular yoke, and each said yoke structure A plurality of core constituent portions integrally including a plurality of teeth portions protruding in the radial direction of the yoke from a portion, a plurality of windings each including a plurality of winding portions wound around the teeth portions, and A plurality of insulators that are integrated with each core constituent part and insulate the teeth part and the winding part, and have a plurality of insulators that have connecting parts that connect the plurality of insulating parts. By assembling each of the plurality of core components to each of the insulators, a plurality of groups of stator components formed independently of each other are formed, and each of the plurality of groups of stator components is adjacent to each other. The plurality of core components are arranged with at least one gap therebetween, and when the plurality of groups of stator components are assembled together, another group of core components is arranged in the gap. Each of the plurality of windings has a connecting wire connecting the plurality of winding portions, and is formed continuously from one end to the other end of the connecting portion. At least one of the connecting wires connected to the winding start end portion and the connecting wire connected to the winding end end portion of the winding portion intersect each other in the vicinity of the connecting portion between the connecting portion and the insulating portion. The insulating portion includes an insulating main body portion that is integrated with the core constituent portion and insulates the teeth portion and the winding portion, and an extending portion that connects the insulating main body portion and the connecting portion. The extension portion includes the stator structure from the connection portion. An axially extending portion that extends in the axial direction of the portion is formed, and is connected to the connecting wire connected to the winding start end of the winding portion and the winding end end of the winding portion The intersecting portion with the crossover wire is disposed at a position overlapping the axially extending portion as viewed in the radial direction of the stator constituent portion.

  This stator is manufactured by the following configuration, for example, in the following manner. That is, first, the core constituent part is integrated with the insulating part of each insulator, and a subassembly is formed for each of a plurality of groups. Subsequently, a winding is wound around each tooth portion of each subassembly from the outside in the radial direction by using a flyer device to form a stator constituent portion for each of a plurality of groups. Then, the plurality of stator constituent parts are assembled with each other to form a stator. The stator is manufactured by the above procedure.

  Here, in this stator, the yoke is comprised by the several yoke structure part divided | segmented into the circumferential direction. For this reason, even in the case of a stator used in a brushless motor of a type in which a plurality of teeth are projected in the radial direction of the yoke, as described above, a subassembly is formed for each of a plurality of groups, and each subassembly is formed. A winding can be wound around each of the teeth portions from the outside in the radial direction using a flyer device. Therefore, it is not necessary to secure a space between the tooth portions as in the case of using the nozzle device, so that the space of the windings can be increased, and the stator can be reduced in size.

  Moreover, as described above, since the yoke is divided into a plurality of yoke components in the circumferential direction, for example, compared to a case where the yoke is divided into a plurality of yoke components in the axial direction. The stator can be downsized in the axial direction.

  In addition, when using a flyer device, the winding speed of the winding is higher than when using a nozzle device. Therefore, the cost of the stator can be reduced by increasing the speed of the winding winding process and reducing the number of equipment. Can be realized.

  Further, in each of the plurality of groups of stator constituent parts, a plurality of adjacent core constituent parts are arranged with at least one gap therebetween. Therefore, as described above, even when the winding is wound around each tooth portion of each sub-assembly from the outside in the radial direction by using the flyer device, the flyer device can be prevented from interfering with other core components. .

  Each of the plurality of windings has a connecting wire that is wired along the connecting portion and connects the plurality of winding portions, and is formed continuously from one end to the other end. Therefore, loosening of the winding part from the teeth part can be suppressed.

Further , according to the stator, at least one of the connecting wires connected to the winding start end of the winding portion and the connecting wire connected to the winding end end of the winding portion are connected to the connecting portion. Since it crosses in the vicinity of the connecting portion with the insulating portion, it is possible to more effectively suppress the loosening of the winding portion from the tooth portion.

Furthermore, according to the stator according to claim 1, the extending portion that connects the insulating main body portion and the connecting portion is formed with a radially extending portion that extends in the radial direction of the stator constituting portion. The crossing portion of the above-described crossover wires is disposed at a position overlapping the radially extending portion as viewed in the axial direction of the stator constituent portion. Therefore, since the above-mentioned connecting wire crosses in the space secured by the radially extending portion, it is possible to further suppress loosening of the winding portion from the tooth portion.

Similarly, according to the stator of the second aspect, the extending portion that connects the insulating main body portion and the connecting portion is formed with the axial extending portion that extends in the axial direction of the stator constituting portion. In addition, the crossing portion of the above-described crossover wires is disposed at a position overlapping the axially extending portion as viewed in the radial direction of the stator component. Therefore, since the above-mentioned connecting wire crosses in the space secured by this axially extending portion, it is possible to further suppress the loosening of the winding portion from the tooth portion.

A stator according to a third aspect is the stator according to the first or second aspect , wherein the teeth portion protrudes from the yoke component toward the radially inner side of the yoke. Yes.

  Thus, even if the teeth portion is protruded from the yoke component toward the inside in the radial direction of the yoke, the yoke is constituted by a plurality of yoke components divided in the circumferential direction. A winding can be wound around each tooth portion of each subassembly from the outside in the radial direction by using a flyer device.

Moreover, in order to solve the said subject, the brushless motor of Claim 4 is a rotor rotated by the rotating magnetic field which the stator as described in any one of Claims 1-3 and the said stator form. And.

According to this brushless motor, since the stator according to any one of claims 1 to 3 is provided, a reduction in size and cost can be realized.

Moreover, in order to solve the said subject, the manufacturing method of the stator of Claim 5 is a manufacturing method of the stator as described in any one of Claims 1-3 , Comprising: The said each insulator is the said A sub-assembly forming step of forming the sub-assembly for each of a plurality of groups by integrating the core constituent part into an insulating part, and using a flyer device that winds the winding from the radially outer side to each tooth part of each sub-assembly. A stator component forming step for forming the stator component for each of the plurality of groups, and a stator forming step for forming the stator by assembling the plurality of stator components together.

  According to this stator manufacturing method, sub-assemblies are formed for each of a plurality of groups, and the winding is wound around each tooth portion of each sub-assembly from the outside in the radial direction using a flyer device. There is no need to secure a space between the teeth as in the case of the case. Therefore, the space of the winding can be increased, and the stator can be reduced in size.

  In addition, since the flyer device is used, the winding speed of the winding is higher than when the nozzle device is used, so the speed of the winding process is increased, and the cost of the stator is reduced by reducing the number of equipment. Can be realized.

It is a perspective view of a stator concerning one embodiment of the present invention. FIG. 2 is a perspective view of a U-phase stator component shown in FIG. 1. FIG. 2 is a perspective view of a V-phase stator component shown in FIG. 1. FIG. 2 is a perspective view of a W-phase stator component shown in FIG. 1. It is a perspective view which shows the process in which the some stator structure part shown by FIG. 1 is mutually assembled | attached. It is a perspective view which shows the state which assembly | attachment advanced rather than FIG. 3A. It is sectional drawing which shows schematic structure of the brushless motor provided with the stator shown by FIG. It is a perspective view explaining a mode that winding is wound with a flyer device. It is a figure which shows the modification of the stator which concerns on one Embodiment of this invention. FIG. 7 is a perspective view of a first group of stator components shown in FIG. 6. FIG. 7 is a perspective view of a second group of stator components shown in FIG. 6. FIG. 7 is a perspective view of a third group of stator components shown in FIG. 6. It is a perspective view which shows the modification of the coil | winding shown by FIG.

  Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

  A stator 10 according to an embodiment of the present invention shown in FIG. 1 is used for an inner rotor type brushless motor. U-phase stator components 12U and V-phase stators shown in FIGS. 2A to 2C. It is comprised by the structure part 12V and the stator structure part 12W of W phase.

  As shown in FIG. 2A, the U-phase stator component 12U includes a plurality of core components 14U, a winding 16U, and an insulator 18U. The plurality of core components 14U constitute a core 20 (all of which are shown in FIG. 1) by a plurality of V-phase core components 14V described later and a plurality of W-phase core components 14W. The yoke component 22U and a plurality of teeth 24U are provided.

  The plurality of yoke components 22U constitute a ring-shaped yoke 40 (all of which are shown in FIG. 1) with a plurality of V-phase yoke components 22V described later and a plurality of W-phase yoke components 22W. Each is formed in an arc shape. Each of the plurality of tooth portions 24U is integrally formed with the yoke component 22U, and protrudes from the yoke component 22U toward the radially inner side of the yoke 40 (see FIG. 1).

  Winding 16U constitutes the U phase, and has a plurality of winding parts 26U and a plurality of crossovers 28U. The winding 16U is formed continuously from one end to the other end. The plurality of winding portions 26U are intensively wound around the tooth portion 24U via an insulating portion 32U (insulating main body portion 33U), which will be described later, and are connected to each other by a plurality of crossover wires 28U. The connecting wire 28U is wired (wrapped) along the outer peripheral surface of the connecting portion 34U formed in the insulator 18U described later. Further, the end portions 30U on both ends of the winding 16U are led out from the teeth portion 24U to one axial side of the stator 10 (arrow Z1 side).

  The insulator 18U is made of resin and integrally includes a plurality of insulating portions 32U and a connecting portion 34U. The plurality of insulating portions 32U are provided in the same number as the plurality of tooth portions 24U described above. The plurality of insulating portions 32U include an insulating main body portion 33U, an extending side wall portion 35U, and a radially extending portion 37U. The insulating main body 33U is integrated with the surfaces of the plurality of core constituent portions 14U described above by being integrally formed, fitted and fitted to each other, and the tooth portion 24U and the winding portion 26U formed in the core constituent portion 14U. And is insulated. The extending side wall portion 35U is located on the radially inner side of the stator constituting portion 12U with respect to the core constituting portion 14U (insulating main body portion 33U). The radially extending portion 37U extends from the coupling portion 34U to the radially outer side of the stator constituting portion 12U, and the extending side wall portion 35U extends from the extending end of the radially extending portion 37U to the other axial direction of the stator constituting portion 12U. It extends to the side (Z2 side) and connects the insulating main body 33U and the radially extending portion 37U. The extending side wall portion 35U and the radial direction extending portion 37U constitute an extending portion 39U that connects the insulating main body portion 33U and the connecting portion 34U.

  The connecting portion 34U is provided on one axial side (Z1 side) of the plurality of insulating portions 32U. The connecting portion 34U is formed in a ring shape, and connects the plurality of insulating portions 32U (more specifically, the base end portion of the radially extending portion 37U in the plurality of insulating portions 32U), and the core It is located radially inward from the component 14U. Between the plurality of insulating portions 32U on the outer peripheral surface of the connecting portion 34U, a plurality of protruding holding portions 36U protrude outward in the radial direction. The holding portion 36U holds the above-described connecting wire 28U from the other axial side (arrow Z2 side) of the connecting portion 34U.

  The V-phase stator component 12V shown in FIG. 2B has the same basic configuration as the U-phase stator component 12U. In other words, the V-phase stator component 12V includes a plurality of yoke components 22V, a plurality of teeth 24V, a winding 16V, and an insulator 18V. The plurality of yoke components 22V, the plurality of teeth 24V, the winding 16V, and the insulator 18V are the above-described plurality of yoke components 22U, the plurality of teeth 24U, the winding 16U, and the insulator 18U. (Both refer to FIG. 2A). In the V-phase stator constituting portion 12V, the connecting portion 34V is formed in a ring shape and has a smaller diameter than the above-described U-phase connecting portion 34U (see FIG. 2A). The holding portion 36V holds the connecting wire 28V from one axial side (arrow Z1 side) of the connecting portion 34V, and is positioned radially inward from the core constituting portion 14V.

  The plurality of insulating portions 32V include an insulating main body portion 33V, an extending sidewall portion 35V, and a radially extending portion 37V. The insulating main body 33V is integrated with the surface of the above-described plurality of core constituent parts 14V, for example, by being integrally formed or fitted and fitted, and the tooth part 24V and the winding part 26V formed in the core constituent part 14V. And is insulated. The extending side wall portion 35V is located on the radially inner side of the stator constituting portion 12V with respect to the core constituting portion 14V (insulating main body portion 33V). The radially extending portion 37V extends from the coupling portion 34V to the radially outer side of the stator constituting portion 12V, and the extending side wall portion 35V extends from the extending end of the radially extending portion 37V to the other axial direction of the stator constituting portion 12V. It extends to the side (Z2 side) and connects the insulating main body 33V and the radially extending portion 37V. The extended side wall portion 35V and the radially extending portion 37V constitute an extended portion 39V that connects the insulating main body portion 33V and the connecting portion 34V. The connecting portion 34V is provided on one axial side (Z1 side) of the plurality of insulating portions 32V. The connecting portion 34V is formed in a ring shape to connect the plurality of insulating portions 32V, and is located radially inward from the core constituting portion 14V.

  The basic configuration of the W-phase stator component 12W shown in FIG. 2C is the same as that of the U-phase stator component 12U. That is, the W-phase stator component 12W includes a plurality of yoke components 22W, a plurality of teeth 24W, a winding 16W, and an insulator 18W. The plurality of yoke components 22W, the plurality of teeth 24W, the windings 16W, and the insulator 18W include the above-described plurality of yoke components 22U, the plurality of teeth 24U, the windings 16U, and the insulator 18U. (Both refer to FIG. 2A). In the W-phase stator constituting portion 12W, the connecting portion 34W is formed in a ring shape and has a smaller diameter than the above-described V-phase connecting portion 34V (see FIG. 2B). Further, the holding portion 36W holds the crossover wire 28W from the one axial side (arrow Z1 side) of the connecting portion 34W, and is positioned radially inward from the core constituting portion 14W.

  The plurality of insulating portions 32W include an insulating main body portion 33W, an extending side wall portion 35W, and a radially extending portion 37W. The insulating main body 33W is integrated with the surface of each of the plurality of core constituent portions 14W by integral molding, mounting and fitting, and the like. The tooth portion 24W and the winding portion 26W formed in the core constituent portion 14W are integrated. And is insulated. The extending side wall portion 35W is located on the radially inner side of the stator constituting portion 12W with respect to the core constituting portion 14W (insulating main body portion 33W). The radially extending portion 37W extends from the connecting portion 34W to the radially outer side of the stator constituting portion 12W, and the extending side wall portion 35W extends from the extending end of the radially extending portion 37W to the other axial direction of the stator constituting portion 12W. It extends to the side (Z2 side) and connects the insulating main body 33W and the radially extending portion 37W. The extending side wall portion 35W and the radially extending portion 37W constitute an extending portion 39W that connects the insulating main body portion 33W and the connecting portion 34W. The connecting portion 34W is provided on one axial side (Z1 side) of the plurality of insulating portions 32W. The connecting portion 34W is formed in a ring shape and includes a plurality of insulating portions 32W (more specifically, extending end portions (end portions on the radially inner side) of the extending side wall portions 35W in the plurality of insulating portions 32W). Are connected and are located radially inward of the core component 14W.

  As shown in FIGS. 2A to 2C, a plurality of groups (independently formed from each other) are assembled by assembling a plurality of core components 14U, 14V, 14W to each of the plurality of insulators 18U, 18V, 18W. U-phase, V-phase, and W-phase) stator components 12U, 12V, and 12W are configured. In the U-phase stator constituent part 12U, a plurality of adjacent core constituent parts 14U are arranged with a gap corresponding to the core constituent parts 14V and 14W (two core constituent parts). Similarly, in the V-phase stator constituent portion 12V, a plurality of adjacent core constituent portions 14V are arranged with a gap corresponding to the core constituent portions 14U and 14W. Further, in the W-phase stator component 12W, a plurality of adjacent core components 14W are arranged with a gap corresponding to the core components 14U and 14V.

  As shown in FIG. 1, the plurality of stator constituent portions 12U, 12V, and 12W are assembled to each other to constitute the stator 10, as will be described in detail later. In a state where the plurality of groups of stator constituent portions 12U, 12V, and 12W are assembled to each other in this manner, the core constituent portions 14 of other groups are arranged in the gaps between the plurality of adjacent core constituent portions 14 described above. ing. In other words, the V-phase core component 14V and the W-phase core component 14W are arranged in the gap between the adjacent U-phase core components 14U. Similarly, a U-phase core component 14U and a W-phase core component 14W are arranged in a gap between adjacent V-phase core components 14V. Also, a U-phase core component 14U and a V-phase core component 14V are arranged in a gap between adjacent W-phase core components 14W.

  Further, in the stator 10, an annular yoke 40 is formed by a plurality of yoke components 22U, 22V, 22W. That is, in other words, the yoke 40 is divided into a plurality of yoke components 22U, 22V, 22W in the circumferential direction. The plurality of yoke components 22U, 22V, and 22W are fitted between a pair of yoke components adjacent to each other on both sides.

  Further, the plurality of connecting portions 34U, 34V, 34W are arranged inside the yoke 40 in the radial direction. The plurality of connecting portions 34U, 34V, 34W are arranged with a gap in the radial direction and the axial direction of the yoke 40, and are provided coaxially with the yoke 40. The V-phase holding portion 36V is fitted to the inner peripheral surface of the U-phase connecting portion 34U, and the W-phase holding portion 36W is fitted to the inner peripheral surface of the V-phase connecting portion 34V. Yes. Thus, the plurality of connecting portions 34U, 34V, 34W are held in a state of being separated from each other in the radial direction. That is, the holding portions 36U, 36V, and 36W are provided between the plurality of connecting portions 34U, 34V, and 34W in the radial direction and hold the plurality of connecting portions 34U, 34V, and 34W in a state of being radially separated from each other. It also serves as a spacer.

  Moreover, as shown in FIG. 2A, the connecting wire 28U1 connected to the winding start end of any winding portion 26U among the above-described connecting wires 28U and the winding of any one of the winding portions 26U. The connecting wire 28U2 connected to the end of the end intersects on the radially extending portion 37U between the connecting portion 34U and the insulating portion 32U. The radially extending portion 37U is an example of the vicinity of the connecting portion between the connecting portion 34U and the insulating portion 32U. That is, in this embodiment, as an example, the connecting wire 28U1 connected to the winding start end of one of the winding portions 26U and the winding end end of any of the winding portions 26U are connected. The intersecting portion 29U with the crossover wire 28U2 is disposed at a position overlapping with the radially extending portion 37U as viewed in the axial direction of the stator constituting portion 12U.

  Further, as shown in FIGS. 2B and 2C, the connecting lines 28V and W are the same as the above connecting line 28U. That is, as shown in FIG. 2B, the connecting wire 28V1 connected to the winding start end of any winding portion 26V of the V phase and the winding end end of any winding portion 26V The intersecting portion 29V with the connected connecting wire 28V2 is disposed at a position overlapping the radially extending portion 37V when viewed in the axial direction of the stator constituting portion 12V. Further, as shown in FIG. 2C, the connecting wire 28W1 connected to the winding start end of any winding portion 26W of the W phase and the winding end end of any winding portion 26W The intersecting portion 29W with the connected jumper wire 28W2 is disposed at a position overlapping the radially extending portion 37W as viewed in the axial direction of the stator constituting portion 12W.

  2A, the terminal portion 30U is connected to two winding portions 26U of the four winding portions 26U, and the remaining two winding portions 26U are crossed. Line 28U is connected. Of the two winding portions 26U to which the connecting wire 28U is connected, the connecting wire 28U2 connected to the end of the winding end of one winding portion 26U is at the end of the winding start of the other winding 16U. It is connected. The connecting wire 28U1 connected to the winding start end of the one winding portion 26U is the end of winding of one winding portion 26U out of the two winding portions 26U to which the terminal portion 30U is connected. The connecting wire 28U2 connected to the end and connected to the end of the winding end of the other winding portion 26U is the other winding portion of the two winding portions 26U to which the terminal portion 30U is connected. It is connected to the end of the winding start of 26U. The same applies to the windings 16V and 16W shown in FIGS. 2B and 2C.

  And the stator 10 which consists of the said structure comprises the inner rotor type brushless motor 60 with the rotor 50 and the housing 70, as FIG. 4 shows. The brushless motor 60 is configured to rotate the rotor 50 when a rotating magnetic field is formed by the stator 10. The brushless motor 60 has, for example, 8 poles and 12 slots.

  Next, a method for manufacturing the stator 10 having the above configuration will be described.

  First, as shown in FIG. 2A, the core component 14U is integrated with the insulating portion 32U of the insulator 18U to form a U-phase subassembly 42U including the insulator 18U and a plurality of core components 14U. Similarly, as shown in FIG. 2B, the core constituent part 14V is integrated with the insulating part 32V of the insulator 18V to form a V-phase subassembly 42V composed of the insulator 18V and the plurality of core constituent parts 14V. 2C, the core component 14W is integrated with the insulating portion 32W of the insulator 18W to form a W-phase subassembly 42W including the insulator 18U and the plurality of core components 14V. In this way, the subassemblies 42U, 42V, and 42W are formed for each of the U phase, the V phase, and the W phase (subassembly forming step).

  Subsequently, as shown in FIG. 2A, the winding 16U is wound around each tooth portion 24U of the U-phase subassembly 42U from the outside in the radial direction using the flyer device 100 (see FIG. 5), and the subassembly 42U is wound. A U-phase stator constituting portion 12U having a plurality of winding portions 26U is formed. As shown in FIG. 5, the flyer device 100 includes a flyer 101 that circularly moves around the teeth portion 24 to wind the winding 16, and a winding wound around the teeth portion 24. 16 includes a variable former 102 that aligns 16 and a drive circuit 103 that controls them.

  Similarly, as shown in FIG. 2B, a winding 16V is wound around each tooth portion 24V of the V-phase subassembly 42V from the outside in the radial direction using the above-described flyer device 100, and a plurality of windings are wound around the subassembly 42V. A V-phase stator constituting portion 12V in which the turning portion 26V is formed is formed. Further, as shown in FIG. 2C, a winding 16W is wound around each tooth portion 24W of the W-phase subassembly 42W from the outside in the radial direction using the above-described flyer device 100, and a plurality of windings are wound around the subassembly 42W. The W-phase stator component 12W is formed with the portion 26W.

  At this time, as shown in FIG. 2A, the plurality of connecting wires 28U are wired along the outer peripheral surface of the connecting portion 34U. Further, the plurality of connecting wires 28U are held from the other axial side (arrow Z2 side) of the connecting portion 34U by the protruding holding portion 36U. Furthermore, the connecting wire 28U1 connected to the winding start end of any winding part 26U and the connecting wire 28U2 connected to the winding end end of any winding part 26U are connected to each other. It is made to cross | intersect on the radial direction extension part 37U of 34U and the insulation part 32U. At this time, the connecting wire 28U1 and the connecting wire 28U2 are firmly crossed so that the winding portion 26U does not loosen.

  Similarly, as shown in FIG. 2B, the plurality of connecting wires 28V are wired along the outer peripheral surface of the connecting portion 34V. Further, the plurality of connecting wires 28V are held from one side (arrow Z1 side) in the axial direction of the connecting portion 34V by the protruding holding portion 36V. Furthermore, the connecting wire 28V1 connected to the winding start end of any winding part 26V and the connecting wire 28V2 connected to the winding end end of any winding part 26V are connected to each other. 34V and the insulating part 32V are crossed on the radially extending part 37V.

  Further, as shown in FIG. 2C, the plurality of crossover wires 28W are wired along the outer peripheral surface of the connecting portion 34W. Further, the plurality of connecting wires 28W are held from one axial side (arrow Z1 side) of the connecting portion 34W by the protruding holding portion 36W. Furthermore, the connecting wire 28W1 connected to the winding start end of any winding portion 26W and the connecting wire 28W2 connected to the winding end end of any winding portion 26W are connected to each other. It is made to cross | intersect on the radial direction extension part 37W of 34W and the insulation part 32W.

  Further, as shown in FIG. 2A, the terminal portions 30U on both ends of the winding 16U are led out from the teeth portion 24U to one axial side of the stator 10 (arrow Z1 side). Similarly, as shown in FIG. 2B, the terminal portions 30V on both ends of the winding 16V are led out from the teeth portion 24V to one side in the axial direction of the stator 10. Further, as shown in FIG. 2C, the end portions 30 </ b> W on both ends of the winding 16 </ b> W are led out from the teeth portion 24 </ b> W to one side in the axial direction of the stator 10. In this way, the stator components 12U, 12V, and 12W are formed for each of the U phase, V phase, and W phase (stator component forming step).

  Next, as shown in FIGS. 3A and 3B, the V-phase stator component 12V is shifted in the circumferential direction by a predetermined angle with respect to the W-phase stator component 12W. Is assembled to the W-phase stator constituting portion 12W from one axial side (arrow Z1 side). In addition, with the U-phase stator component 12U shifted from the V-phase stator component 12V by a predetermined angle in the circumferential direction, the U-phase stator component 12U is moved from one axial side (arrow Z1 side) to the V-phase stator component 12U. It is assembled to the stator component 12V of the phase and the stator component 12W of the W phase.

  At this time, the plurality of yoke components 22U, 22V, and 22W are fitted between a pair of yoke components adjacent to each other on both sides. The V-phase holding portion 36V is fitted to the inner peripheral surface of the U-phase connecting portion 34U, and the W-phase holding portion 36W is fitted to the inner peripheral surface of the V-phase connecting portion 34V. In this way, the plurality of connecting portions 34U, 34V, 34W are held in a state of being radially separated from each other by the protruding holding portions 36U, 36V, 36W.

  In this manner, the stator 10 is formed by assembling a plurality of stator constituent portions 12U, 12V, and 12W (stator forming step). The terminal units 30U, 30V, and 30W are connected by a bus bar (not shown). The stator 10 is manufactured by the above procedure.

  Next, the operation and effect of one embodiment of the present invention will be described.

  In the following description, when the U phase, the V phase, and the W phase are not distinguished, the U, V, and W are omitted from the end of the reference for convenience.

  According to one embodiment of the present invention, the yoke 40 is constituted by a plurality of yoke components 22 divided in the circumferential direction. For this reason, even if it is a stator used for what is called an inner rotor type brushless motor by which a plurality of teeth parts 24 projected toward the diameter direction inner side of yoke 40, as mentioned above, U phase, V phase, W A subassembly 42 is formed for each phase, and the winding 16 can be wound around each tooth portion 24 of each subassembly 42 from the outside in the radial direction using the flyer device 100 (see FIG. 5). Accordingly, since it is not necessary to secure a space between the tooth portions 24 as in the case of using a nozzle device, the space of the winding 16 can be increased and the stator 10 can be reduced in size.

  Moreover, as described above, the yoke 40 is divided into the plurality of yoke components 22 in the circumferential direction. For example, when the yoke 40 is divided into the plurality of yoke components in the axial direction. In comparison, the stator 10 can be reduced in size in the axial direction.

  Further, when the flyer device 100 is used, the winding speed of the winding 16 is higher than when the nozzle device is used. Therefore, the speed of the winding process of the winding 16 is increased, and as a result, the number of facilities is reduced. A cost reduction of 10 can be realized.

  Furthermore, in each of the plurality of groups (U-phase, V-phase, W-phase) stator constituent parts 12, a plurality of adjacent core constituent parts 14 are arranged with a gap corresponding to two core constituent parts. Therefore, as described above, even when the winding 16 is wound around each tooth portion 24 of each subassembly from the outside in the radial direction using the flyer device 100, the flyer device 100 interferes with the other core components 14. Can be suppressed.

  The plurality of windings 16U have crossover wires 28U that are wired along the connecting portions 34U and connect the plurality of winding portions 26U, and are formed continuously from one end to the other end. Therefore, loosening of the winding part 26U from the teeth part 24U can be suppressed.

  Further, the connecting wire 28U1 connected to the winding start end of any winding part 26U and the connecting wire 28U2 connected to the winding end end of any winding part 26U are connected portions. It intersects in the vicinity of the connecting portion between 34U and insulating portion 32U. Therefore, loosening of the winding part 26U from the teeth part 24U can be more effectively suppressed.

  In particular, the extending portion 39U that connects the insulating main body portion 33U and the connecting portion 34U is formed with a radially extending portion 37U that extends in the radial direction of the stator constituting portion 12U. The intersecting portion 29U of 28U2 is disposed at a position overlapping with the radially extending portion 37U as viewed in the axial direction of the stator constituting portion 12U. Accordingly, since the above-described connecting wires 28U1 and 28U2 intersect each other in the space secured by the radially extending portion 37U, the loosening of the winding portion 26U from the tooth portion 24U can be further suppressed.

  Further, since the V-phase connecting wires 28V1, 28V2 and the W-phase connecting wires 28W1, 28W2 are also intersected in the same manner as the U-phase connecting wires 28U1, U2, the winding portions 26V from the tooth portions 24V, 24W , 26 W can be suppressed.

  Moreover, even if the teeth part 24 protrudes toward the radial direction inner side of the yoke 40 from the yoke structure part 22, it is comprised by the several yoke structure part 22 by which the yoke 40 was divided | segmented into the circumferential direction. Therefore, the winding 16 can be wound around each tooth portion 24 of each subassembly from the outside in the radial direction using the flyer device 100.

  Further, in each stator component 12, the connecting portion 34 is located on the radially inner side of the core component 14. Therefore, when the winding 16 is wound around the teeth portion 24 from the outside in the radial direction by using the flyer device 100, interference between the flyer of the flyer device 100 and the connecting portion 34 can be suppressed.

  Moreover, since the several yoke structure part 22 is integrally formed in the teeth part 24, for example, the some tooth part to which the front-end | tip part was mutually connected by the thin-walled bridge part, and the base end of this teeth part Compared with a two-part type core having a yoke connecting the parts as an independent member, magnetic loss at each connecting part can be suppressed. That is, in the two-divided type core, magnetic loss occurs at three locations: the bridging portion between the tip ends of a pair of adjacent teeth portions, the base end portion of the pair of teeth portions, and the connecting portion of the yoke. On the other hand, in the stator 10 of the present embodiment, the magnetic loss only occurs at one place of the connecting portion between the pair of adjacent yoke components 22, so that the magnetic loss can be reduced. This makes it possible to further reduce the size and weight.

  Next, a modification of one embodiment of the present invention will be described.

  In one embodiment of the present invention, the brushless motor is, for example, 8 poles and 12 slots, but the number of magnetic poles and the number of slots may be other combinations.

  Moreover, the connection method of the plurality of windings 16U, 16V, and 16W may be a star connection or a delta connection both in series and in parallel.

  In addition, the holding portion 36 has a function as a holding portion that holds the crossover 28 and a function as a protruding spacer that holds the plurality of connecting portions 34 in a state of being separated from each other in the radial direction. The holding part 36 and the spacer may be provided independently of each other.

  Further, the holding portions 36 are formed in all the connecting portions 34, but instead of the holding portions 36U and 36W being omitted from the U-phase connecting portion 34U and the W-phase connecting portion 34W, the V-phase connecting portion 34V. In addition to the holding portion 36, spacers that are fitted to the inner peripheral surface of the U-phase connecting portion 34 </ b> U and the outer peripheral surface of the W-phase connecting portion 34 </ b> W may be formed on the outer peripheral surface and the inner peripheral surface.

  Moreover, although the connection part 34 was provided only in the axial direction one side (Z1 side) of the some insulation part 32U, only the axial direction other side (Z2 side) of the some insulation part 32U, or several It may be provided on both sides in the axial direction of the insulating portion 32U.

  Moreover, although the connection part 34 was provided coaxially with the yoke 40, it does not need to be provided coaxially with the yoke 40. Moreover, although the connection part 34 was formed in ring shape, for example, it may be formed in polygonal shape, and may be made into other shapes, such as C shape with a part notch. good.

  Moreover, although the holding | maintenance part 36 was formed in protrusion shape, it may extend in circular arc shape along the circumferential direction of the stator 10, for example, and may be made into another shape.

  In addition, the stator 10 is used for a so-called inner rotor type brushless motor in which a plurality of teeth portions 24 protrude toward the radially inner side of the yoke 40, but a plurality of stators 10 are disposed toward the radially outer side of the yoke 40. The teeth portion 24 may be used for a so-called outer rotor type brushless motor.

  Moreover, although the stator 10 was divided | segmented into the stator structure part 12U, 12V, 12W comprised for every some phase as an example of a some group, as FIG. 6, FIG. 7A-FIG. It may be divided into stator constituent parts 12A, 12B, 12C configured for each group in which the phases are mixed.

  As an example, in the example shown in FIGS. 6 and 7A to 7C, the stator constituting portion 12A constituting the first group includes a + U-phase tooth portion 24U and a −W-phase tooth portion 24W. The stator constituting portion 12B constituting the second group includes a + V-phase tooth portion 24V and a -U-phase tooth portion 24U. The stator constituting portion 12C constituting the third group includes a + W-phase tooth portion 24W and a -V-phase tooth portion 24V. The brushless motor in this example is a 10-pole 12-slot or 14-pole 12-slot motor. In addition, a winding is wound around the teeth portion of the −U phase, the −V phase, and the −W phase by reverse winding.

  Although not particularly illustrated, as another combination, for example, the stator constituting portion 12A constituting the first group includes a U-phase tooth portion and a -V-phase tooth portion, and constitutes the second group. The stator component 12B includes a + V-phase tooth portion and a -U-phase tooth portion, and the stator component portion 12C constituting the third group includes a + W-phase tooth portion and a -W-phase tooth portion. You may have.

  The stator constituting portion 12A constituting the first group has a U-phase tooth portion and a -U-phase tooth portion, and the stator constituting portion 12B constituting the second group is a + V-phase tooth portion. The stator constituting portion 12C, which has a −V phase tooth portion and constitutes the third group, may have a + W phase tooth portion and a −W phase tooth portion.

  Furthermore, the stator constituting portion 12A constituting the first group has a U-phase tooth portion and a -U-phase tooth portion, and the stator constituting portion 12B constituting the second group is constituted by a + V-phase tooth portion. The stator constituent portion 12C having the -W phase tooth portion and constituting the third group may have a + W phase tooth portion and a -V phase tooth portion.

  In addition to the above, the stator constituent parts constituting each group may have a plurality of phase tooth parts composed of other combinations.

  Further, as in the example shown in FIGS. 6 and 7A to 7C, in each of the plurality of groups of stator constituting portions 12A, 12B, and 12C, the plurality of adjacent core constituting portions 14 have at least one gap. It may be arranged with a gap.

  In the embodiment of the present invention, in each stator component 12, all the crossover wires 28 intersect each other in the vicinity of the connecting portion between the connecting portion 18 and the insulating portion 32, but as shown in FIG. At least one of the crossover lines 28 may not be crossed. That is, if the case where the crossover wires 28 intersect as shown in FIGS. 2A to 2C is a tight winding, as shown in FIG. 8, any of the crossover wires 28 is an unwrapped winding. Also good.

  Further, in one embodiment of the present invention, the extending portion 39 is formed with a radially extending portion 37 extending in the radial direction of the stator constituting portion 12, and the crossing portion 29 of the crossover wire 28 described above is configured as a stator structure. The portion 12 was disposed at a position overlapping the radially extending portion 37 when viewed in the axial direction. However, the extending portion 39 is formed with an axially extending portion that extends in the axial direction of the stator constituting portion 12, and the crossing portion 29 of the above-described connecting wire 28 is as viewed in the radial direction of the stator constituting portion 12. You may arrange | position in the position which overlaps with this axial direction extension part. Even if comprised in this way, the loosening of the winding part 26 from the teeth part 24 can be suppressed.

  In addition, the crossover 28 is wired along the connecting portion 34, but may alternatively be of a straight extension type in which tension is applied without being along the connecting portion 34.

  Although one embodiment of the present invention has been described above, the present invention is not limited to the above, and other various modifications can be made without departing from the spirit of the present invention. It is.

10 ... Stator, 12U, 12V, 12W ... Stator component, 14U, 14V, 14W ... Core component, 16U, 16V, 16U ... Winding, 18U, 18V, 18W ... Insulator , 20 ... core, 22U, 22V, 22W ... yoke component, 24U, 24V, 24W ... teeth part, 26U, 26V, 26W ... winding part, 28U, 28V, 28W ... · Crossover, 29U, 29V, 29W ... intersection, 30U, 30V, 30W ... terminal, 32U, 32V, 32W ... insulation, 33U, 33V, 33W ... insulation body, 34U , 34V, 34W ... connecting portion, 35U, 35V, 35W ... extended side wall portion, 36U, 36V, 36W ... holding portion, 37U, 37V, 37W ... radially extending portion, 39U, 39V 39W ... extension part, 40 ... yoke, 42U, 42V, 42W ... subassembly, 50 ... rotor, 60 ... brushless motor, 100 ... flyer device, 104 ... Pressing machine

Claims (5)

A plurality of yoke components that constitute an annular yoke and are divided in the circumferential direction of the yoke, and a plurality of teeth portions that protrude from the yoke component in the radial direction of the yoke, respectively. A plurality of core components having
A plurality of windings each having a plurality of winding portions wound around the teeth portion;
A plurality of insulators that are integrated with each of the core constituent parts and insulate the teeth part and the winding part, and that have a connecting part that connects the plurality of insulating parts;
With
By assembling the plurality of core components to each of the plurality of insulators, a plurality of groups of stator components formed independently of each other are configured,
In each of the plurality of groups of stator constituent parts, the plurality of adjacent core constituent parts are arranged with at least one gap therebetween,
In a state where the stator constituent parts of the plurality of groups are assembled to each other, the core constituent parts of another group are arranged in the gap,
Each of the plurality of windings has a connecting wire connecting the plurality of winding portions, is formed continuously from one end to the other end ,
Among the connecting wires, at least one of the connecting wires connected to the winding start end of the winding portion and the connecting wire connected to the winding end end of the winding portion are the connecting portion and Crossed in the vicinity of the connecting portion with the insulating portion,
The insulating portion includes an insulating main body portion that is integrated with the core constituent portion and insulates the teeth portion and the winding portion, and an extending portion that connects the insulating main body portion and the connecting portion,
The extending portion is formed with a radially extending portion that extends from the connecting portion in the radial direction of the stator component,
An intersection of the connecting wire connected to the winding start end of the winding part and the connecting end connected to the winding end end of the winding part is an axial view of the stator component. Is disposed at a position overlapping the radially extending portion at
Stator. A plurality of yoke components that constitute an annular yoke and are divided in the circumferential direction of the yoke, and a plurality of teeth portions that protrude from the yoke component in the radial direction of the yoke, respectively. A plurality of core components having
A plurality of windings each having a plurality of winding portions wound around the teeth portion;
A plurality of insulators that are integrated with each of the core constituent parts and insulate the teeth part and the winding part, and that have a connecting part that connects the plurality of insulating parts;
With
By assembling the plurality of core components to each of the plurality of insulators, a plurality of groups of stator components formed independently of each other are configured,
In each of the plurality of groups of stator constituent parts, the plurality of adjacent core constituent parts are arranged with at least one gap therebetween,
In a state where the stator constituent parts of the plurality of groups are assembled to each other, the core constituent parts of another group are arranged in the gap,
Each of the plurality of windings has a connecting wire connecting the plurality of winding portions, is formed continuously from one end to the other end,
Among the connecting wires, at least one of the connecting wires connected to the winding start end of the winding portion and the connecting wire connected to the winding end end of the winding portion are the connecting portion and Crossed in the vicinity of the connecting portion with the insulating portion,
The insulating portion includes an insulating main body portion that is integrated with the core constituent portion and insulates the teeth portion and the winding portion, and an extending portion that connects the insulating main body portion and the connecting portion,
The extension portion is formed with an axial extension portion extending in the axial direction of the stator constituent portion from the connection portion,
An intersection of the connecting wire connected to the winding start end of the winding part and the connecting end connected to the winding end end of the winding part is a radial view of the stator component part. Arranged at a position overlapping the axially extending portion at
Stator. The teeth portion protrudes from the yoke component toward the radially inner side of the yoke,
The stator according to claim 1 or 2 . The stator according to any one of claims 1 to 3,
  A rotor rotated by a rotating magnetic field formed by the stator;
  Brushless motor with It is a manufacturing method of the stator according to any one of claims 1 to 3,
  A subassembly forming step of forming the subassembly for each of a plurality of groups by integrating the core component with the insulating portion of each insulator;
  A stator component forming step of forming the stator component for each of the plurality of groups by winding the winding from the radially outer side to each of the teeth of each sub-assembly using a flyer device;
  A stator forming step of forming the stator by assembling the plurality of stator constituent parts with each other;
  A method for manufacturing a stator comprising:

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