JP5859369B2 - Stator - Google Patents

Description

  The present invention relates to 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

  Such a stator is generally required to be reduced in size and cost.

  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 constituent portions integrally including a plurality of teeth portions protruding radially inward of the yoke; a plurality of windings each including a plurality of winding portions wound around the teeth portions; A plurality of insulating portions that are integrated with a core constituent portion and insulate the teeth portion and the winding portion, and a connecting portion that connects the plurality of insulating portions on the radially outer side of the yoke than the teeth portion. having provided a plurality of insulators, and by the fact that a plurality of core components are assembled to each of the plurality of insulators are composed stator components of a plurality of groups which are formed independently of one another, wherein In each of the plurality of groups of stator component parts, the plurality of core component parts are arranged with at least one gap therebetween, and the plurality of groups of stator component parts are assembled with each other when the plurality of groups of stator component parts are assembled to each other. The core constituent parts of other groups are arranged in FIG .

  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, the winding is wound around each tooth portion from the inside in the radial direction of each subassembly by using a winding 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 radially inward of the yoke, as described above, a subassembly is formed for each of a plurality of groups. Windings can be wound around each tooth portion from the radially inner side of the assembly. Therefore, since it is not necessary to secure a space between the teeth portions, the stator can be reduced in size.

Moreover, in each insulator, a plurality of insulating portions are connected by a connecting portion, and this connecting portion is located on the radially outer side of the yoke than the teeth portion. Therefore, as described above, even when the winding is wound around the teeth portion from the radially inner side of the subassembly by the winding winding device, it is possible to avoid the winding winding device from interfering with the connecting portion. it can. As a result, the cost of the stator can be reduced by increasing the speed of the winding process, and by reducing the number of facilities.
Further, according to this stator, in each of the plurality of groups of stator constituent portions, the plurality of core constituent portions are arranged with at least one gap therebetween. Therefore, as described above, even when the winding is wound around each tooth portion from the radially inner side of each subassembly by the winding winding device, the winding winding device is prevented from interfering with other core components. can do.

  As in the stator according to claim 2, in the stator according to claim 1, it is preferable that the plurality of windings constitute a plurality of phases.

  A stator according to a third aspect is the stator according to the first or second aspect, wherein the connecting portion is formed integrally with the plurality of insulating portions.

  According to this stator, since the connecting portion is formed integrally with the plurality of insulating portions, an increase in the number of parts can be suppressed, and as a result, the cost of the stator can be further reduced.

  The stator according to claim 4 is the stator according to any one of claims 1 to 3, wherein the connecting portion is disposed on a radially outer side of the yoke than the yoke component. It is configured.

  According to this stator, the connection part is arrange | positioned in the radial direction outer side of a yoke rather than the yoke structure part. Thereby, interference with a connection part and a yoke structure part can be suppressed, and the structure of an insulator can be simplified.

A stator according to a fifth aspect is the stator according to any one of the first to fourth aspects, wherein the adjacent yoke components are fitted to each other.

  According to this stator, since the adjacent yoke components are fitted to each other, the rigidity of the yoke can be increased.

Moreover, in order to solve the said subject, the brushless motor of Claim 6 is a rotor rotated by the stator as described in any one of Claims 1-5 , and the rotating magnetic field which the said stator forms. And.

According to this brushless motor, since the stator according to any one of claims 1 to 5 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 7 is a manufacturing method of the stator as described in any one of Claims 1-5 , 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 component with the insulating portion, and winding the windings from the radially inner side of the sub-assemblies to the teeth portions. 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 windings are wound around the teeth portions from the radially inner side of the sub-assemblies by the winding winding device. Therefore, since it is not necessary to secure a space between the teeth portions, the stator can be reduced in size.

  In addition, sub-assemblies are formed for each group, and windings are wound around each tooth portion from the inside in the radial direction of each sub-assembly, thus speeding up the winding process and thus reducing the number of equipment. Thus, the cost of the stator can be reduced.

It is a top view of the stator which concerns on one Embodiment of this invention. FIG. 2 is an exploded perspective view of the stator shown in FIG. 1. It is a figure explaining a mode that a coil | winding is wound around the teeth part shown by FIG. It is sectional drawing which shows schematic structure of the brushless motor provided with the stator 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, and includes a U-phase stator component 12U, a V-phase stator component 12V, and a W-phase stator. It is comprised by the structure part 12W.

  In the following description, when the U phase, the V phase, and the W phase are distinguished, U, V, and W are added to the end of the reference numeral, and the U phase, the V phase, and the W phase are not distinguished. Omits U, V, and W from the end of the code.

  As shown in FIGS. 1 and 2, 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). An arcuate umbrella portion 25U is formed at the tip of the tooth portion 24.

  As shown in FIG. 1, the winding 16U forms a U-phase, and has a plurality of winding portions 26U and a plurality of crossovers (not shown). 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 insulating portions 32U described later, and are connected to each other by a plurality of crossover wires.

  The insulator 18U is made of resin and integrally includes a plurality of insulating portions 32U and a connecting portion 34U as shown in FIG. 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 are integrated with the surfaces of the plurality of core constituent portions 14U described above by integral molding, fitting and the like, respectively, and a tooth portion 24U and a winding portion 26U (see FIG. 1). Is insulated.

  The connecting portion 34U is formed in a ring shape, and is arranged so as to be shifted to one side (Z1 side) from the axial center portion of the yoke 40. The connecting portion 34U connects the plurality of insulating portions 32U on the radially outer side of the yoke 40 than the tooth portion 24U (more specifically, on the radially outer side of the yoke 40 than the yoke constituting portion 22U). Yes. Further, the connecting portion 34U is formed integrally with the plurality of insulating portions 32U.

  The basic configuration of the V-phase stator component 12V is the same as that of 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. It is equivalent to. The connecting portion 34 </ b> V formed in the insulator 18 </ b> V is disposed at the central portion in the axial direction of the yoke 40.

  The basic configuration of the W-phase stator component 12W is the same as the U-phase stator component 12U and the V-phase stator component 12V. 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 winding 16W, the insulator 18W, the insulating portion 32W, and the connecting portion 34W include the above-described plurality of yoke components 22U and the plurality of teeth. This corresponds to 24U, winding 16U, insulator 18U, insulating portion 32U, and connecting portion 34U. The connecting portion 34W formed on the insulator 18W is arranged so as to be shifted to the other side (Z2 side) from the axial center portion of the yoke 40.

  Then, as shown in FIG. 2, a plurality of groups (U-phase, U-phase, 14U, 14W) are formed independently of each other by assembling a plurality of core components 14U, 14V, 14W to each of the plurality of insulators 18U, 18V, 18W. The stator constituent portions 12U, 12V, and 12W of the V phase and W phase groups are configured. In the U-phase stator component 12U, a plurality of core components 14U are arranged with a gap corresponding to the core components 14V and 14W (two core components). Similarly, in the V-phase stator constituent portion 12V, a plurality of core constituent portions 14V are arranged with a gap corresponding to the core constituent portions 14U and 14W. In the W-phase stator component 12W, a plurality of 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 core constituent portions 14 described above. . In other words, the V-phase core component 14V and the W-phase core component 14W are arranged in the gap between the U-phase core component 14U. Similarly, a U-phase core component 14U and a W-phase core component 14W are arranged in the gap between the V-phase core components 14V. Also, a U-phase core component 14U and a V-phase core component 14V are arranged in the gap between the 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.

  Moreover, the some connection part 34U, 34V, 34W is arrange | positioned in the radial direction outer side of the yoke 40 rather than the yoke structure part 22U, 22V, 22W. The plurality of connecting portions 34U, 34V, 34W are provided coaxially with the yoke 40.

  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.

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

  First, as shown in FIG. 2, 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, the core component 14V is integrated with the insulating portion 32V of the insulator 18V to form a V-phase subassembly 42V including the insulator 18V and the plurality of core components 14V. Further, 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. 3, the winding 16U is wound around each tooth portion 24U from the radially inner side of the U-phase subassembly 42U by a winding winding device 100 (for example, a nozzle device), and then the subassembly. A U-phase stator constituting portion 12U having a plurality of winding portions 26U formed in 42U is formed.

  Similarly, the winding 16V is wound around each tooth portion 24V from the inside in the radial direction of the V-phase subassembly 42V by the above-described winding winding device, and a plurality of winding portions 26V are formed in the subassembly 42V. A phase stator component 12V is formed. In addition, a W phase in which a plurality of winding portions 26W are formed in the subassembly 42W by winding the winding 16W around each tooth portion 24W from the radially inner side of the W phase subassembly 42W by the above-described winding winding device. The stator constituent part 12W is formed (stator constituent part forming step).

  Next, as shown in FIG. 2, the V-phase stator component 12V is axially moved in a state where the V-phase stator component 12V is shifted by a predetermined angle in the circumferential direction with respect to the W-phase stator component 12W. It is assembled from the one side (arrow Z1 side) to the W-phase stator component 12W. 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. In this manner, the stator 10 is formed by assembling a plurality of stator constituent portions 12U, 12V, and 12W (stator forming step).

  In addition, about the terminal part of each coil | winding 16U, 16V, 16W, it connects with the bus bar etc. which are not shown in figure. The stator 10 is manufactured by the above procedure.

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

  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 by the winding winding device 100 from the radially inner side of each subassembly 42. Accordingly, it is not necessary to secure a space for passing the nozzles between the teeth portions 24, so that the stator 10 can be reduced in size.

  In addition, in each insulator 18, the plurality of insulating portions 32 are connected by the connecting portion 34, and the connecting portion 34 is located on the radially outer side of the yoke 40 than the tooth portion 24. Therefore, as described above, even when the winding 16 is wound around the teeth portion 24 from the radially inner side of the subassembly 42 by the winding winding device 100, the winding winding device 100 interferes with the connecting portion 34. You can avoid that. As a result, the cost of the stator 10 can be reduced by increasing the speed of the process of winding the windings 16 and by reducing the number of facilities.

  In particular, the connecting portion 34 is disposed on the radially outer side of the yoke 40 with respect to the yoke component 22. Thereby, interference with the connection part 34 and the yoke structure part 22 can be suppressed, and the structure of the insulator 18 can be simplified.

  Moreover, since the connection part 34 is integrally formed with the some insulating part 32, the increase in a number of parts can be suppressed and the cost of the stator 10 can be reduced further by extension.

  Furthermore, in each of a plurality of groups (U-phase, V-phase, W-phase) stator constituent parts 12, a plurality of 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 from the inside in the radial direction of each subassembly by the winding winding device 100, the winding winding device 100 is connected to the other core components 14. Interference can be suppressed.

  Moreover, since the adjacent yoke structure part 22 is mutually fitted, the rigidity of the yoke 40 can be improved.

  Further, as described above, after the winding 16 is wound around the tooth portion 24, the plurality of stator constituent portions 12 are assembled, so that the portion that is a dead space compared to the case where the core is integrally formed (that is, The winding 16 can be wound up to the interval provided between the tooth portions 24 for passing through the nozzle.

  Further, since the winding 16 is wound around each tooth portion 24 from the radially inner side of the sub assembly 42, the winding start of the winding 16 is the radially inner side of the sub assembly 42 (the tip side of the tooth portion 24). Sixteen terminal portions are radially outward of the subassembly 42. Therefore, it is advantageous when it is desired to dispose the terminal portion of the winding 16 on the radially outer side of the subassembly 42.

  Further, in this way, in addition to the connecting portion 34, when the terminal portion of the winding 16 is positioned on the radially outer side of the subassembly 42, it is effective for a product having no space on the inner peripheral side of the core 20. .

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

  In the embodiment of the present invention, the connecting portion 34 is provided coaxially with the yoke 40, but may not 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 stator 10 was divided | segmented into the stator structure part 12U, 12V, and 12W comprised for every some phase as an example of a some group, the stator structure part comprised for every group in which several phases were mixed It may be divided into two. In this case, in each of the plurality of groups of stator constituent portions, the plurality of core constituent portions may be arranged with at least one gap therebetween.

  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, 12, 12U, 12V, 12W ... Stator component, 14, 14U, 14V, 14W ... Core component, 16, 16U, 16V, 16W ... Winding, 18, 18U , 18V, 18W ... insulator, 20 ... core, 22, 22U, 22V, 22W ... yoke component, 24, 24U, 24V, 24W ... teeth, 25, 25U, 25V, 25W Umbrella part, 26, 26U, 26V, 26W ... winding part, 32, 32U, 32V, 32W ... insulation part, 34, 34U, 34V, 34W ... connection part, 40 ... yoke, 42, 42U, 42V, 42W ... subassembly, 50 ... rotor, 60 ... brushless motor, 70 ... housing

Claims (7)

A plurality of yoke components that constitute an annular yoke and divided in the circumferential direction of the yoke, and a plurality of teeth portions that protrude from the yoke components to the inside in the radial direction of the yoke, respectively. A plurality of core components integrally having;
A plurality of windings each having a plurality of winding portions wound around the teeth portion;
A plurality of insulating portions that are integrated with each core constituent portion and insulate the teeth portion and the winding portion, and that connect the plurality of insulating portions on the radially outer side of the yoke than the teeth portion. A plurality of insulators having a section;
Equipped with a,
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 core constituent parts are arranged with at least one gap therebetween,
In a state where the plurality of groups of stator constituent parts are assembled to each other, the core constituent parts of other groups are arranged in the gap.
Stator. The plurality of windings constitute a plurality of phases,
The stator according to claim 1. The connecting portion is formed integrally with the plurality of insulating portions.
The stator according to claim 1 or 2. The connecting part is arranged on the outer side in the radial direction of the yoke than the yoke component part.
The stator according to any one of claims 1 to 3. The adjacent yoke components are fitted to each other,
The stator according to any one of claims 1 to 4 . The stator according to any one of claims 1 to 5,
  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 5,
  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 for forming the stator component for each of the plurality of groups by winding the winding around the teeth from the radially inner side of each sub-assembly by a winding winding 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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