JP6869092B2 - Stator used for rotary electric machine, rotary electric machine, and manufacturing method of stator - Google Patents

Description

The present invention relates to a stator used in a rotary electric machine, a rotary electric machine, and a method for manufacturing the stator.

Patent Document 1 (Japanese Unexamined Patent Publication No. 2006-6777) is provided as a background technique in the present technical field. In this publication, the insulator bobbin around which the coil is wound is provided with a guide groove for guiding the coil. It is stated that it can be wound smoothly by preventing it from collapsing.

However, the insulator bobbin can guide the coil only in the first stage, and depending on the winding specifications, the coil may have two stages, three stages, or four stages. As the number of stages increases, the coil is more likely to be unwound, and the effect of the guide groove as in Patent Document 1 can no longer be expected.

In particular, when the coil is stepped up from the first stage to the second stage, the second stage to the third stage, or the like, winding collapse occurs when the coil cannot be dropped into a predetermined position. When the step-up is always dropped to the coil position close to each other, the winding collapse is unlikely to occur, but the space factor of the coil cannot be increased accordingly.
In order to increase the space factor of the coil, it is necessary to drop the step-up to a distant coil position, and it is necessary to step up at a steep angle. Therefore, the risk of coil unwinding increases.

Japanese Unexamined Patent Publication No. 2006-6777

An object of the present invention is to provide a compact, high-output rotary electric machine in which a coil is wound at a high space factor while suppressing unwinding of the coil.

The stator of a rotary electric machine that solves the above problems is a rotary electric machine having a rotating shaft including a core in which a tooth portion is formed and a coil that is wound around the tooth portion by centralized winding via an insulating bobbin. A stator, the coil extends in the direction of rotation axis and is arranged on both side surfaces of the teeth portion, and the first coil portion forming a plurality of stages and the coil extending in the circumferential direction of the stator and extending in the axial direction of the teeth portion. It is composed of a second coil portion arranged on the end side, and the second coil portion is composed of a coil that connects the first coil portions of the same stage and a coil that goes up to the next stage. On the side of both side surfaces where the coil lead wire is arranged, the coil constituting the winding end of the even-stage stage is separated from the coil constituting the winding start of the next-stage winding of the even-stage stage in the first coil portion. .. Further, when viewed from the rotation axis direction, in at least one of the plurality of stages, a plurality of coils connecting the first coil portions of the same stage overlap in the axial direction.

According to the present invention, it is possible to wind the coil at a high space factor while suppressing the unwinding of the coil in a physical space where the winding nozzles do not interfere with each other. Can provide electric appliances.

It is sectional drawing of the rotary electric machine 100 in this embodiment. It is a front view of the stator core 7 seen from the rotation axis direction of a shaft 2. It is an enlarged view of the part where the coil 9 is wound around the insulator bobbin 8 in the stator 101. As a comparative example, it is a front view in which the coil 9 is arranged to the maximum in a physical space where the winding nozzle 23 does not interfere, and is viewed from the direction of the rotation axis. It is explanatory drawing of the winding order of the coil 9 in the nozzle concentrated winding of this embodiment. It is the figure which wound the coil 9 which concerns on this embodiment from the 1st stage 9a to the 2nd stage 9b. It is a figure from the coil 9 which concerns on this embodiment step up from the 2nd step 9b to the 3rd step 9c, and is wound around the 3rd step 9c. It is the figure which wound the coil 9 which concerns on this embodiment to the 3rd stage 9c. It is the figure which wound the coil 9 which concerns on this embodiment to the 4th stage 9d. It is explanatory drawing of the winding order of a coil 9 in a normal nozzle concentrated winding. As a comparative example, it is a figure from the coil 9 stepping up from the 1st step 9a to the 2nd step 9b. As a comparative example, it is a figure until the coil 9 winds the 2nd stage 9b. As a comparative example, it is a figure from the coil 9 stepping up from the 2nd step 9b to the 3rd step 9c. As a comparative example, it is a figure from winding the coil to the third stage 9c and stepping up from the third stage 9c to the fourth stage 9d.

Hereinafter, examples will be described with reference to FIGS. 1 to 8. First, a schematic configuration of a rotary electric machine as an example of the present invention will be described.

FIG. 1 is a cross-sectional view of the rotary electric machine 100 according to the present embodiment.

In the rotary electric machine 100, the stator 101 is fixed to the inner circumference of the bottomed cylindrical housing 1 by press fitting or the like. The rotor 102 is inherited and supported by a bearing 15 on the inner diameter side of the stator 101 via a gap.

The rotor 102 includes a shaft 2 and a rotor core 3 fixed to the shaft 2 by press fitting or the like. Further, on the outer peripheral surface of the rotor core 3, the magnet 4, the end plate 5 for positioning the magnet 4 in the axial direction, and the magnet 4 are protected from external impacts and the magnet 4 is scattered by centrifugal force due to rotation. A cylindrical protective cover 6 is provided to prevent the above.

The stator 101 is wound around an annular stator core 7 in which a plurality of thin magnetic steel plates punched by a press are laminated, an insulator bobbin 8 formed of nylon or the like on the stator core 7 and having an insulating function, and an insulator bobbin 8. It is composed of a coil 9 that is rotated.

The terminal block 10 is formed by resin-molding a plurality of bus bars 11 for connecting the coil 9 to a power source to the outside, and is inserted into the housing 1. The plurality of bus bars 11 form a connecting portion 13 for electrically connecting to the lead wire 12 of the coil 9, and electrically connects the plurality of bus bars 11 and the coil 9 by fusing or the like. Further, the connector housing 14 is also integrally molded with the terminal block 10, and the shape is a disk shape except for the protruding portion of the connector housing 14.

The inner ring side of the two bearings 15 is fixed to the shaft 2 of the rotor 102 and is rotatably supported. The outer ring of the bearing 15 is housed in the bearing box 17 of the housing 1 and the cover 16, respectively. The outer ring end of the bearing 15 on the cover 16 side is pressed and fixed to the cover 16 by a plate 19 screwed with bolts 18, and has a configuration in which the axial movement of the rotor 102 is restricted.

FIG. 2 is a front view of the stator core 7 as viewed from the rotation axis direction of the shaft 2.

The stator core 7 is composed of a fixing portion 7a fixed by press fitting or the like, and a plurality of teeth 7b on the inner diameter side of the stator core 7 protruding at predetermined intervals. The stator core 7 shown in FIG. 2 is an example, and is a 12-slot stator core composed of 12 teeth 7b.

The teeth 7b has a teeth tip portion 7c formed on the inner diameter side, and has a shape that expands toward the inner diameter side. Further, it has an opening width 20 at a distance between adjacent tooth tip portions 7c.

FIG. 3 is an enlarged view of a portion of the stator 101 in which the coil 9 is wound around the insulator bobbin 8.

An insulator bobbin 8 for insulating the stator core 7 and the coil 9 is configured around the stator core 7. The insulator bobbin 8 is made of a resin such as nylon, and is formed by resin molding or the like in which the stator core 7 is inserted.

The insulator bobbin 8 forms a teeth 8a and a winding portion 8b around which the coil 9 of the teeth 8a is wound. A winding wall portion 8c is formed on the inner and outer diameter sides of the winding portion 8b so that the coil 9 does not protrude from the winding portion 8b. A groove 8d for allowing the winding start wire 12a of the coil 9 to escape is formed in a part of the winding wall portion 8c on the outer diameter side. Further, a side wall 8e is formed on the outer diameter side excluding the winding portion 8b.

Starting from the outer diameter side of the teeth 8a, the coil 9 is wound around the teeth 8a by the winding nozzle 23 while moving from the outer diameter side to the inner diameter side, and a plurality of coils 9 are wound while sequentially forming step-up portions. It is a coil composed of stages.

Next, the arrangement of the coils 9 will be described below based on an example composed of four stages.

FIG. 4 is a front view in which the coil 9 is arranged to the maximum in a physical space where the winding nozzle 23 does not interfere, and is viewed from the direction of the rotation axis.

The coil 9 is composed of four stages, from the first stage 9a to the fourth stage 9d, from the teeth 8a side. The number of turns of the coil 9 in each stage is 1st stage × 5 windings, 2nd stage × 5 windings, 3rd stage × 4 windings, and 4th stage × 1 winding, for a total of 15 windings.

The number of stages and the number of turns of the coil 9 are determined by the required characteristics of the rotary electric machine 100 and the nozzle width 23a. The nozzle width 23a is determined by the wire diameter of the coil 9 and the strength of the winding nozzle required to wind the coil 9.

In order to reduce the size and increase the output of the rotary electric machine 100, it is necessary to wind the coil 9 as many times as possible to increase the space factor.

First, in the case of normal nozzle concentrated winding, FIGS. 7 and 8 will be described. The coil numbers in the coils 9 shown in FIGS. 7 and 8 indicate the order in which the coils 9 are wound.

First, FIG. 7 is an explanatory diagram of the winding order of the coil 9 in the normal nozzle concentrated winding. The coil 9 is wound 15 times in the order of coil number 1 to coil number 15.

The winding start wire 12a, which is the winding start, is wound from the coil number 1 on the outer diameter side of the winding portion 8b. The winding end lead wire 12b, which is the end of winding, is arranged at the coil number 15 on the outer diameter side of the winding portion 8b in order to cross the next teeth 8a or to connect with the bus bar 11 of FIG.

As shown in FIG. 7, it is difficult to wind the coil 9 to the end in the case of normal nozzle concentrated winding. The reason for this will be described in the order of winding in FIGS. 8 (a) to 8 (d).

FIG. 8A is a view from the coil 9 stepping up from the first step 9a to the second step 9b.

The first stage 9a of the coil 9 is wound from coil number 1 to coil number 5 from the outer diameter side to the inner diameter side of the winding portion 8b. Next, the coil number 5 forms a step-up portion 21a from the first step 9a to the second step 9b. The step-up portion 21a is dropped into the coil number 6 between the coil number 5 and the winding wall portion 8c that are close to each other, and is folded back so that the second step 9b is turned from the inner diameter side to the outer diameter side of the winding portion 8b. It is wound around.

Next, FIG. 8B is a diagram in which the coil 9 winds the second stage 9b.

The second stage 9b is wound from coil number 6 to coil number 10. Here, when winding the coil number 10 from the coil number 9, it passes over the coil number 1, but the winding start lead wire 12a avoids interference by the groove portion 8d of the insulator bobbin 8.

Next, FIG. 8C is a diagram from the coil 9 stepping up from the second step 9b to the third step 9c.

The coil number 10 forms a step-up portion 21b of the second step 9b to the third step 9c. The step-up portion 21b is dropped into the coil number 11 between the coil number 10 and the winding wall portion 8c that are close to each other, and is folded back so that the third step 9c and the winding portion 8b are directed from the outer diameter side to the inner diameter side. It is wound.

However, when the step-up portion 21b is formed, there is a risk of winding collapse due to the interference portion 22 that interferes with the mouth-out portion 12a at the beginning of winding.

Similar to the coil number 10 in FIG. 8B, it can be avoided by the groove 8d of the insulator bobbin 8, but for that purpose, it is necessary to set the groove depth of the groove 8d wide (one coil or more). Due to the structure of the insulator bobbin 8, it may not be possible due to the layout. Even if the depth of the groove 8d can be secured, the winding start wire 12a cannot be dropped to the depth of the groove 8d at the time of winding, and as a result, there is a risk of winding collapse. In addition, the unwinding of the step-up portion 21b also leads to the unwinding of the entire third-stage 9c.

Finally, FIG. 8D is a diagram in which the coil is wound up to the third stage 9c and stepped up from the third stage 9c to the fourth stage 9d.

The third stage 9c is wound from coil number 11 to coil number 14. The coil number 14 forms a step-up portion 21c of the third step 9c to the fourth step 9d. The step-up portion 21c needs to be dropped into the coil number 15 between the coil number 11 and the coil number 12 separated by two coils from the coil number 13, not between the coil number 13 and the coil number 14 which are close to each other. The rising portion 21c must be wound at a steep angle θ2.

Further, since the winding nozzle 23 has the side wall 8e of the insulator bobbin 8, it cannot be inserted all the way, and the moving range is limited.

Therefore, in the dotted line portion B in FIG. 8D, when the step-up portion 21c is dropped into the coil number 15, the winding collapse occurs in the direction of the coil number 13 (the collapse direction 24 in FIG. 8D). ..

As a result, in the process of winding the coil 9, there is a possibility that the coil 9 at the unwinding portion and the winding nozzle 23 interfere with each other and the coil 9 cannot be wound. This is because the occurrence of the unwinding of the third stage 9c described above in FIG. 8C makes the occurrence of the unwinding of the fourth stage 9d more likely.

Next, in the arrangement of the coil 9 shown in FIG. 4, an embodiment in which the nozzles are centrally wound according to the present embodiment will be described with reference to FIGS. 5 and 6. The coil numbers in the coils 9 in FIGS. 5 and 6 indicate the order in which the coils 9 are wound.

FIG. 5 is an explanatory diagram of the winding order of the coil 9 in the concentrated nozzle winding of the present embodiment. The coil 9 is wound 15 times in the order of coil number 1 to coil number 15.

The winding start wire 12a, which is the winding start, is wound from the coil number 1 on the outer diameter side of the winding portion 8b. The winding end lead wire 12b, which is the end of winding, is arranged at the coil number 15 on the outer diameter side of the winding portion 8b in order to cross the next teeth 8a or to connect with the bus bar 11 of FIG.

In the present embodiment, by devising the winding order of the coil numbers 11 to 14, the coil 9 is not unwound and can be wound at a high space factor, so that it is reliable, compact and has a high output. The rotary electric machine 100 can be provided.

Next, the present embodiment will be specifically described in the order of winding with reference to FIGS. 6 (a) to 6 (d).

FIG. 6A is a diagram in which the coil 9 according to the present embodiment is wound from the first stage 9a to the second stage 9b. The first stage 9a and the second stage 9b are the same as the normal nozzle concentrated winding described in FIGS. 8A and 8B, and thus the description thereof will be omitted.

Next, FIG. 6B is a diagram in which the coil 9 according to the present embodiment is stepped up from the second step 9b to the third step 9c and is wound around the third step 9c. The coil number 10 forms a step-up portion 21b of the second step 9b to the third step 9c. The step-up portion 21b is folded back and dropped into the coil number 11 between the coil number 9 and the coil number 8 in which one coil 9 is separated from the adjacent coil number 9 and the coil number 10, and the third step. 9c is wound up to coil number 12. At this point, a coil space 25 in which the coil 9 is not wound is formed on the outer diameter side of the winding portion 8b.

Further, in the dotted line portion A of FIG. 6B, by arranging the step-up portion 21b at a position away from the adjacent coil 9, interference between the step-up portion 21b and the lead wire 12a at the beginning of winding is avoided. be able to.

Next, FIG. 6C is a diagram in which the coil 9 according to the present embodiment is wound up to the third stage 9c.

The third stage 9c of the coil 9 is wound up to the coil number 12, then folded back, dropped into the coil number 13 in the coil space 25 of FIG. 6B, and wound up to the coil number 14. At this time, the coil number 11 also has an effect as a wall that can physically prevent the unwinding when the coil number 13 is dropped.

Finally, FIG. 6D is a diagram in which the coil 9 according to the present embodiment is wound up to the fourth stage 9d.

The coil number 14 forms a step-up portion 21c of the third step 9c to the fourth step 9d. The step-up portion 21c can be wound at a gentle angle θ1 with respect to the steep angle θ2 in FIG. 8D, and is dropped into the coil number 15 between the coil numbers 13 and the coil numbers 14 that are close to each other. , It is wound.

In this way, when stepping up from the second step 9b to the third step 9c in FIGS. 6 (b) and 6 (c), the step up portion 21b is formed at a position away from the adjacent coil 9. Then, the step-up portion 21c of the third step 9c to the fourth step 9d can be dropped into the position of the coil number 15 in FIG. 6 (d). As a result, it is possible to prevent the coil 9 from unwinding.

According to this embodiment, it is possible to wind the coil as much as possible in a physical space where the winding nozzles do not interfere with each other, and it is possible to provide a compact and high-output rotary electric machine.

1 ... housing, 2 ... shaft, 3 ... rotor core, 4 ... magnet, 5 ... end plate, 6 ... protective cover, 7 ... stator core, 7a ... fixed part, 7b ... teeth, 7c ... teeth tip, 8 ... insulator bobbin, 8a ... Teeth, 8b ... Winding part, 8c ... Winding wall part, 8d ... Groove part, 8e ... Side wall, 9 ... Coil, 9a ... 1st stage, 9b ... 2nd stage, 9c ... 3rd stage, 9d ... 4 Steps, 10 ... Terminal block, 11 ... Bus bar, 12 ... Mouth wire, 12a ... Mouth part at the beginning of winding, 12b ... Mouth part at the end of winding, 13 ... Connection part, 14 ... Connector housing, 15 ... Bearing, 16 ... Cover , 17 ... Bearing box, 18 ... Bolt, 19 ... Plate, 20 ... Opening width, 21a ... 1st to 2nd step rising part, 21b ... 2nd to 3rd step rising part, 21c ... 3 Step-up part from the 4th stage to the 4th stage, 22 ... Interference part, 23 ... Winding nozzle, 23a ... Nozzle width, 24 ... Collapse direction, 25 ... Coil space, 100 ... Rotor, 101 ... Stator, 102 ... Rotation Child, θ1 ... gentle angle, θ2 ... steep angle

Claims (6)

The core on which the teeth part is formed and
A stator of a rotating electric machine having a rotating shaft including a coil wound around the teeth portion by centralized winding via an insulating bobbin.
The coil extends in the direction of the rotation axis and is arranged on both side surfaces of the teeth portion to form a plurality of stages, and an axial end portion of the teeth portion extending in the circumferential direction of the stator. It is composed of a second coil part arranged on the side.
The second coil portion is composed of a coil that connects the first coil portions of the same stage and a coil that goes up to the next stage.
On both sides of the tooth, on the side where the lead wire of the coil is arranged
Of the first coil portion, the coil constituting the even-numbered winding end is separated from the coil constituting the even-numbered next-stage winding start .
When viewed from the direction of the rotation axis
A stator of a rotary electric machine in which coils connecting a plurality of the first coil portions of the same stage are vertically overlapped in at least one of the plurality of stages. The stator of the rotary electric machine according to claim 1.
The coil forming the winding end of the even-numbered stage is a stator of a rotary electric machine arranged between the lead wire of the coil and the coil forming the winding start of the next stage. The stator of the rotary electric machine according to claim 1.
A stator of a rotary electric machine in which another first coil portion is arranged between the lead wire of the coil and the coil constituting the winding start of the next stage. A rotary electric machine provided with the stator according to any one of claims 1 to 3.
A rotary electric machine including a rotor that faces the stator via a gap. The core on which the teeth part is formed and
A stator of a rotating electric machine having a rotating shaft including a coil wound around the teeth portion by centralized winding via an insulating bobbin.
The coil extends in the direction of the rotation axis and is arranged on both side surfaces of the teeth portion to form a plurality of stages, and an axial end portion of the teeth portion extending in the circumferential direction of the stator. It is composed of a second coil part arranged on the side.
The second coil portion is composed of a coil that connects the first coil portions of the same stage and a coil that goes up to the next stage, and in at least one of the plurality of stages, the plurality of the same This is a method for manufacturing a stator of a rotary electric machine in which the coils connecting the first coil portions of one stage are overlapped in the axial direction.
On both sides of the tooth, on the side where the lead wire of the coil is arranged
A method for manufacturing a stator of a rotary electric machine, which comprises a step of separating a coil constituting an even-numbered winding end from a coil constituting an even-numbered next-stage winding start in the first coil portion.

The method for manufacturing a stator of a rotary electric machine according to claim 5.
A stator of a rotary electric machine including a step of arranging another first coil portion between the lead wire of the coil and the coil constituting the winding start of the next stage.

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