JP7019452B2 - Stator and rotary machine - Google Patents

Description

The present application relates to a stator used in a rotary electric machine and a rotary electric machine incorporating such a stator.

In the armature of a rotary electric machine, the coil is wound around each tooth portion of the core via an insulating bobbin covering the core. The winding start wire and winding end wire of each coil are connected to the winding start wire and winding end wire of other coils, and the crossover wire connecting the coils in this connection is arranged on the insulating bobbin. In an electric motor in which a coil is wound via an insulating bobbin, it is necessary to avoid contact between crossover wires having a particularly large potential difference. Therefore, in order to fix the arrangement in the axial direction and the circumferential direction of each crossover, the following stators provided with grooves and protrusions for fixing the crossover on the insulating bobbin are disclosed.
That is, in the third yoke coating portion, an inner wall extending along the split annular portion of the split core is formed to extend in one axial direction. Three guide grooves arranged in the axial direction are formed along the circumferential direction on the radial outer surface of the inner wall of the third yoke coating portion. The three crossover guide grooves are referred to as a first crossover guide groove, a second crossover guide groove, and a third crossover guide groove in the order of being farthest from the third yoke coating portion in the axial direction (for example, Prior Document 1). See).

Japanese Unexamined Patent Publication No. 2015-133808 (paragraphs [0050] to [0052], FIG. 3)

In the conventional stator as described above, a coating portion which is an insulating bobbin is formed along the shape of the core. Therefore, in a rotary electric machine that is required to be smaller and lighter in recent years, if the outer diameter of the core is made smaller, the outer diameter of the insulating bobbin becomes smaller accordingly.
It is difficult to provide a wall with a narrow groove in the insulating bobbin due to the molding process and the durability of the structure. When multiple crossovers are arranged on the insulating bobbin, it is necessary to secure a sufficient distance between the crossovers. Therefore, since it is necessary to secure a predetermined size for the insulating bobbin, there is a problem that it is difficult to reduce the size and weight of the core with the conventional stator.

The present application has been made to solve the above-mentioned problems, and an object of the present invention is to provide a stator capable of ensuring a sufficient distance between crossover wires connecting coils, and a rotary electric machine incorporating the stator.

The stator disclosed in the present application is
The core has a core having a back yoke portion and a plurality of teeth portions protruding radially inward from the back yoke portion at predetermined intervals in the circumferential direction, and a teeth insulating portion covering the teeth portions. It comprises a mounted insulating bobbin and a coil that is wound around each of the teeth portions of the core via the teeth insulation portion of the bobbin and is housed in a slot formed between the teeth portions. ,
At least one between the coils wound around the teeth portion is in a stator connected by a crossover.
The bobbin has an extension portion extending radially outward from the tooth insulation portion for each tooth insulation portion on one end side in the axial direction of the core.
At least one of the extension portions
It has a portion that is radially outside the outer peripheral surface of the core on the radial side, and a crossover portion that guides at least a part of the crossover is formed at the portion.
The core is composed of a plurality of divided cores divided in the circumferential direction in the back yoke portion so as to have at least one of the teeth portions.
The extending portions of the teeth portions adjacent to each other in the circumferential direction are formed with a gap in the circumferential direction between the extending portions.
The circumferential ends of the back yoke portion of the split core are connected to each other at the position of the gap between the extension portions.
The crossover that is routed between the extension portions and guided to the crossover portion is one end side in the axial direction of the connection position between the circumferential end portions of the back yoke portion at the position of the gap between the extension portions. Is not arranged in the above, but is arranged at a position outside the radial direction by the first dimension from the outer peripheral surface of the core.
It is something like that.
Further, the rotary electric machine disclosed in the present application is a rotary electric machine.
With the stator configured as above,
A rotor provided with a predetermined distance from the inner peripheral surface of the stator and concentrically arranged inside the stator in the radial direction is provided.
It is something like that.

According to the stator and rotary electric machine disclosed in the present application, a sufficient distance can be secured between the crossovers connecting the coils even when the outer diameter of the core is made small for miniaturization and weight reduction.

It is a figure which looked at the cross section of the rotary electric machine by Embodiment 1 from the one end side in the axial direction. It is a figure which looked at the cross section of the rotary electric machine by Embodiment 1 from the other end side in the axial direction. It is a figure which shows the dimensional relationship between a core and an insulating bobbin in the rotary electric machine according to Embodiment 1. FIG. It is sectional drawing of the rotary electric machine according to Embodiment 1. FIG. It is a figure which shows the connection relation of the coil of the stator according to Embodiment 1. FIG. It is a schematic diagram which shows the arrangement position of the crossover wire of a coil in the stator of the comparative example. It is a schematic diagram which shows the arrangement position of the crossover wire of a coil in the stator according to Embodiment 1. FIG. It is a figure which looked at the cross section of the rotary electric machine by Embodiment 1 from the one end side in the axial direction. It is a perspective view of the rotary electric machine according to Embodiment 1. FIG. It is sectional drawing of the rotary electric machine according to Embodiment 1. FIG. It is a schematic diagram which shows the arrangement relation of the bobbin for insulation and a crossover. In the rotary electric machine according to the first embodiment, it is a figure which clarified the space area between the extension portions adjacent in the circumferential direction. It is a schematic diagram which clarified the space area between the extension part adjacent to each other in the circumferential direction in the rotary electric machine by the comparative example. It is a perspective view which shows the whole structure of the rotary electric machine according to Embodiment 1. FIG. It is sectional drawing which shows the whole structure of the rotary electric machine by Embodiment 1. FIG. It is sectional drawing which shows the other structure of the rotary electric machine according to Embodiment 1. FIG.

Embodiment 1.
Hereinafter, the stator 10 and the rotary electric machine 100 according to the first embodiment of the present application will be described with reference to the drawings.
FIG. 1 is a view of a cross section of the rotary electric machine 100 according to the first embodiment as viewed from the axial end side G1 of FIG.
FIG. 2 is a view of a cross section of the rotary electric machine 100 according to the first embodiment as viewed from the other end side G2 in the axial direction of FIG.
FIG. 3 is a diagram showing the dimensional relationship between the core and the insulating bobbin in the rotary electric machine 100 shown in FIG.
FIG. 4 is a cross-sectional view taken along the axial direction in the rotary electric machine shown in FIG.
In addition, in FIGS. 1 to 4 above, the illustration of the crossover connecting the coils is omitted for convenience. Further, in FIG. 4, the illustration of the coil is also omitted.

In the following description, each direction in the stator 10 is referred to as a circumferential direction S, an axial direction G, an axial one end side G1, an axial other end side G2, a radial inner side K1, and a radial outer side K2, respectively. Is shown.

As shown in FIGS. 1 to 3, the rotary electric machine 100 includes a stator 10 and a rotor 13 rotatably supported by a shaft 11 as a rotation axis in the radial inner side K1 of the stator 10. The rotor 13 has a 4-pole permanent magnet 12 supported by the shaft 11.
The rotary electric machine 100 is a single-phase brushless motor having four slots 5 for a four-pole permanent magnet 12.

The stator 10 includes a core 1 formed by laminating electromagnetic steel sheets, an insulating bobbin 2 (2X, 2Y) as an insulating bobbin attached to the core 1, and the insulating bobbin 2X, 2Y. It is provided with a coil 3 (3a, 3b, 3c, 3d) wound around the core 1 by a centralized winding.
The core 1 has an annular back yoke portion 1a, a plurality of teeth portions 1b protruding radially inside K1 at a predetermined interval in the circumferential direction S from the back yoke portion 1a, and a radial inside of the teeth portions 1b. It has tip protrusions 1c protruding from the ends of K1 on both sides in the circumferential direction S.

The core 1 is composed of four divided cores 1X divided into four in the circumferential direction S in the back yoke portion 1a so as to have at least one tooth portion 1b.
A notch (not shown) having an uneven shape is provided at the end of the back yoke portion 1a of each divided core 1X in the circumferential direction S, and each divided core 1X can be connected to each other with high accuracy by this notch. .. In this embodiment, the shape of the notch is not limited.

In the slot 5 formed between the teeth portions 1b of the core 1, a pair of electromagnetically excitable coils 3 (3a, 3b, 3c, 3d) wound around the teeth portions 1b via an insulating bobbin 2 ) Is stored. The coil 3a and the coil 3b and the coil 3c and the coil 3d are connected by a crossover wire 30. The details of the connection relationship of each coil 3 by the crossover wire 30 will be described later.
The total number of windings of each coil 3 is determined by the electromagnetic requirements of the stator 10. Further, each coil 3 has the same winding direction in order to improve productivity.

Further, a hall sensor 15 as a sensor for detecting the position of the rotor 13 is arranged between the tip protruding portions 1c adjacent to each other in the circumferential direction of the core 1.

The insulating bobbin 2 serves to secure an insulating distance between the core 1 and the coil 3, and there are two types of insulating bobbins 2X and 2Y having different shapes. The insulating bobbin 2 provided with the terminals 20a and 20c is referred to as an insulating bobbin 2X, and the insulating bobbin 2 provided with the terminals 20b and 20d is referred to as an insulating bobbin 2Y.
As shown in the figure, it can be seen that the insulating bobbins 2X and 2Y project radially outward K2 from the outer peripheral surface of the core 1.
In the following description, when it is not necessary to distinguish between the insulating bobbins 2X and 2Y, the insulating bobbins 2X and 2Y are simply referred to as the insulating bobbins 2.

The insulating bobbin 2 has a teeth insulating portion 2b that covers the teeth portion 1b of the core 1, an extending portion 2a that extends radially outward K2 from the teeth insulating portion 2b, and a tip protruding portion 1c of the core 1, respectively. It has a tip insulating portion 2c protruding from the teeth insulating portion 2b on both sides in the circumferential direction S so as to cover it.

The tip insulating portion 2c of the insulating bobbin 2 covers the tip protruding portion 1c of the core 1 by a predetermined dimension, and the portion formed larger by the predetermined dimension is the tip protruding portion 1c of the core 1. It has a structure in which a part of the hall sensor 15 is cut out so as not to interfere with the hall sensor 15 arranged between them. Therefore, as shown in FIG. 1, the tip insulating portion 2c of the insulating bobbin 2 is formed so as to secure a predetermined distance from the Hall sensor 15.

As shown in FIG. 4, the extending portion 2a of the insulating bobbin 2 is provided on one end side of the core 1 in the axial direction G. Further, as shown in FIG. 2, the outer peripheral surface of the insulating bobbin on the other end side G2 in the axial direction is formed on the inner side K1 in the radial direction from the outer peripheral surface of the core 1, and each tooth insulating portion 2b has the same shape. is doing.
Further, the extending portion 2a of the insulating bobbin 2 is provided for each tooth insulating portion 2b. Further, the extending portion 2a adjacent to the circumferential direction S is formed in a shape so as to have a spatial region as a gap in which the extending portion 2a is not formed between the adjacent extending portions 2a.
Further, the end portions of the back yoke portion 1a of the split core 1X in the circumferential direction S are connected to each other at a position where there is a spatial region in which the extending portion 2a is not formed.

As shown in FIG. 3, the dimension L1 from the radial center point C of the core 1 to the outer peripheral surface of the insulating bobbin 2 and the dimension L2 from the center point C to the outer peripheral surface of the core 1 have a dimensional relationship L1>. L2 holds. That is, the extending portion 2a of the insulating bobbin 2 has a portion formed so as to be radially outer K2 with respect to the radial outer outer peripheral surface of the core 1. A crossover portion 2e (see FIGS. 8 and 9) for guiding the crossover line 30 is formed at this portion of the extension portion 2a, which is K2 radially outside the outer peripheral surface of the core 1.

Further, on the upper end surface of the axial end end side G1 of the extending portion 2a of the insulating bobbins 2X and 2Y, as a protruding portion extending to the axial end side G1 for connecting the control board 40 and the core 1 to be described later. The boss portions 21 (21a, 21b) of the above are formed respectively.
Further detailed structures of the insulating bobbins 2X and 2Y will be described in the connection procedure of the crossover wire 30 described later.

Here, the connection relationship and connection procedure of each coil 3 in the stator 10 of the first embodiment in which the insulating bobbin 2 and the core 1 satisfy the above dimensional relationship L1> L2 will be described with reference to FIGS. 5 to 11. do.
FIG. 5 is a wiring diagram showing the connection relationship of each coil 3 of the stator 10 according to the first embodiment.
FIG. 6 is a schematic view showing the arrangement position of the crossover line 30 of the coil 3 in the stator of the comparative example.
FIG. 7 is a schematic view showing the arrangement position of the crossover line 30 of the coil 3 in the stator 10 according to the first embodiment.
FIG. 8 is a view of a cross section of the rotary electric machine 100 according to the first embodiment as viewed from one end side G1 in the axial direction.
FIG. 9 is a perspective view of the rotary electric machine 100 shown in FIG. 8 when only the upper half of the figure is seen from the direction of the arrow 72 from the alternate long and short dash line 73.
FIG. 10 is a cross-sectional view of the rotary electric machine 100 shown in FIG. 8 cut along the alternate long and short dash line 73.
FIG. 11 is a schematic diagram showing the arrangement relationship between the insulating bobbin 2 and the crossover line 30.

In the following description of the connection relationship of the crossover line 30 and the connection procedure, in the four teeth portions 1b of the stator 10, one of the teeth portions 1b adjacent to the circumferential direction S is referred to as the first teeth portion 1b1 and the other is the second teeth portion. It is set to 1b2. Further, the slot 5 between the first teeth portion 1b1 and the second teeth portion 1b2 is designated as the first slot 5a, and the slot 5 on the side opposite to the first slot 5a of the first teeth portion 1b1 is designated as the second slot 5b. The slot 5 on the side opposite to the first slot 5a of the 2 teeth portion 1b2 is referred to as a third slot 5c.

Further, the crossover wire 30 extending from the first slot 5a of the coil 3a wound around the first teeth portion 1b1 is used as the first crossover wire, and the second crossover wire 30 of the coil 3a wound around the first teeth portion 1b1 is used as the first crossover wire. The crossover 30 extending from the slot 5b is referred to as a second crossover, and the crossover 30 extending from the first slot 5a of the coil 3b wound around the second teeth portion 1b2 is referred to as a third crossover. The crossover 30 extending from the third slot 5c of the coil 3b wound around the teeth portion 1b2 will be described as a fourth crossover.

First, the connection relationship between the coils 3 will be described with reference to FIG.
As shown in FIG. 5, the winding start wire 30a of the coil 3a (N1) as the first crossover wire and the winding end wire 30x of the coil 3b (S1) as the third crossover wire are connected to the terminal 20b. To. Similarly, the winding start wire 30b of the coil 3b (S1) as the fourth crossover wire and the winding end wire 30w of the coil 3a (N1) as the second crossover wire are connected to the terminal 20a.

Similarly, for the coil 3c (N2) and the coil 3d (S2), the winding start wire 30d as the first crossover wire of the coil 3c (N2) and the winding end wire as the third crossover wire of the coil 3d (S2). 30z is connected to the terminal 20d. Similarly, the winding start wire 30c of the coil 3d (S2) as the fourth crossover and the winding end wire 30y of the coil 3c (N2) as the second crossover are connected to the terminal 20c.
Then, the terminal 20a and the terminal 20d, and the terminal 20b and the terminal 20c are connected by a control board 40 described later.

Hereinafter, the arrangement position on the stator 10 of the connection relationship shown above will be described by comparing the stator in the comparative example of FIG. 6 with the stator 10 of the present embodiment of FIG.
In the case of making the connection as shown in FIG. 5, and when the terminals 20a, 20b, 20c, and 20d are provided on the insulating bobbins 2X and 2Y, respectively, normally, FIG. 6 shows. As shown in the arrangement position of the crossover wire 30 in the comparative example, it is possible to directly connect the winding start wire 30b of the coil 3b (S1) to the terminal 20a on the insulating bobbin 2X in terms of manufacturing and workability. good. However, since the Hall sensor 15 is inserted between the tip protruding portions 1c of the adjacent teeth portions 1b, when the winding start wire 30b of the coil 3b (S1) is connected straight to the terminal 20a in this way, FIG. As shown in the above, there is a possibility that the winding start wire 30b and the Hall sensor 15 interfere with each other. This also applies to the winding start wire 30c of the coil 3d (S2).

Therefore, as shown in the arrangement relationship of the crossover wire 30 of the present embodiment of FIG. 7, the winding start wire 30b of the coil 3b (S1) is routed further on the radial outer side K2 than the outer peripheral surface of the core 1. With such an arrangement, the winding start wire 30b does not interfere with the Hall sensor 15.

Hereinafter, the crossover wire 30 (winding start wire 30a, 30b, 30c, 30d, winding end wire 30w, 30x, 30y, 30z) is used as the actual rotary electric machine 100 so as to have the arrangement position as shown in FIG. The procedure of routing in the single-phase brushless motor of FIG. 8 to 11 will be described in order with reference to FIGS. 8 to 11.
In FIG. 8, the winding start wires 30a, 30b, 30c, 30d and the winding end wires 30v, 30w, 30x, 30y from each coil 3 (3a, 3b, 3c, 3d) are placed on the insulating bobbins 2X and 2Y. The state in which the terminals 20a, 20b, 20d, and 20c are connected to each of the terminals 20a, 20b, 20d, and 20c is shown.
Since the connection of each coil 3 is symmetrical up and down in the figure with the alternate long and short dash line 73 as a boundary, only the procedure for routing the crossover wire 30 between the coil 3a and the coil 3b in the upper half of the figure of FIG. 8 will be described. do.

First, the winding end wire 30w of the coil 3a is connected to the terminal 20a of the insulating bobbin 2X.
Next, the winding start wire 30a of the coil 3a is connected to the terminal 20b of the insulating bobbin 2Y.

Next, the winding end wire 30x of the coil 3b is passed through the boss portion 21b so as to be guided along the outer peripheral surface of the boss portion 21b, and then connected to the terminal 20b of the insulating bobbin 2Y.
As described above, the reason why the winding end wire 30x passes through the boss portion 21b is that when the winding end wire 30x extending from the first slot 5a is directly connected to the terminal 20b, it becomes the winding start wire 30a of the coil 3a. The distance is getting closer. In this case, the winding end wire 30x and the winding start wire 30a may come into contact with each other due to vibration by the motor on which the stator 10 is mounted, work variation, etc., so that the winding end wire 30x passes through the boss portion 21b in this way. It is configured to be.

Next, the flow of connecting the winding start wire 30b of the remaining coil 3b to the terminal 20a of the insulating bobbin 2X will be described. Further, in this description, the detailed configuration of the insulating bobbins 2X and 2Y will also be described.
As shown in FIGS. 9 and 10, each of the crossover portions 2e formed on the outer peripheral surface of the radial outer side K2 of the insulating bobbins 2X and 2Y is recessed in the radial inner side K1 and extends in the circumferential direction S. The setting portion 2e1 is formed. The recessed portion 2e1 is formed at the second dimension X2 and the other end side G2 in the axial direction with respect to the axial position of the upper end surface of the axial end side G1 of the insulating bobbins 2X and 2Y.

Then, the winding start wire 30b of the coil 3b extending from the third slot 5c is guided in the circumferential direction S along the inner wall of the recessed portion 2e1 of the insulating bobbin 2Y and is pulled out toward the insulating bobbin 2X. It is pulled out from the position P. At this time, as shown in FIG. 10, the winding start wire 30b extending from the first slot 5c was pulled out toward the recessed portion 2e1 formed on the second dimension X2 dividing axis and the other end side G2 in the direction. It becomes a state. The winding start wire 30b drawn out in this way is in a state of being supported from the axial end side G1 by the inner wall of the axial end side G1 of the recessed portion 2e1, so that even if the stator 10 vibrates, the shaft The axial position is fixed without shifting to G1 on one end side in the direction.

As described above, the recessed portion 2e1 is provided to determine the position of the crossover line 30 crossing the space between the insulating bobbins 2X and 2Y adjacent to each other in the circumferential direction S in the axial direction G.
The dimension of the recessed portion 2e1 in the axial direction G is larger than the wire diameter of the winding start wire 30b so that the winding start wire 30b can be firmly held.

Further, as shown in FIG. 10, the winding end line 30x of the coil 3b is routed on the upper end surface of the axial end end side G1 of the insulating bobbin 2Y. As a result, the winding end wire 30x of the coil 3b and the winding start wire 30b of the coil 3b are arranged so as to secure a distance of the second dimension X2 in the axial direction G.

Further, as shown in FIG. 9, the extending portion 2a of the insulating bobbin 2Y draws the winding start wire 30b routed in the space between the insulating bobbins 2X and 2Y adjacent to each other in the circumferential direction S in the axial direction and the like. A protrusion 22 is provided as a support portion that supports from the end side G2. The radial position of the protrusion 22 needs to be located on the radial outer side K2 of the outer peripheral surface of the core 1 of the stator 10. Further, the position of the protrusion 22 in the axial direction G is not the same as the position of the recessed portion 2e1 in the axial direction G. That is, the distance between the upper end surface of the axial end side G1 of the protrusion 22 and the inner wall of the axial end side G1 of the recessed portion 2e1 is formed so as to be equal to or less than the diameter of the crossover line 30. There is. As a result, as shown in FIG. 9, the winding start wire 30b is vertically sandwiched between the protrusion 22 and the inner wall of the recessed portion 2e1.

In FIG. 11, the crossover line 30 is shown so that there is a gap between the end surface of the axial end side G1 of the protrusion 22 and the inner wall of the axial end side G1 of the recessed portion 2e1. , This is for convenience, to clarify the drawing, and such a gap does not occur in the actual product.

By providing the recessed portion 2e1 and the protrusion 22 in this way, the crossover line 30 routed in the space between the insulating bobbins 2X and 2Y adjacent to each other in the circumferential direction S moves in the axial direction G. Can be prevented. Further, as shown in FIG. 8, the crossover line 30 passes through the crossover portion 2e provided on the radial outer side K2 of the outer peripheral surface of the core 1 so as to be routed between the extension portions 2a. Is configured such that the radial position is arranged at the position of the first dimension X1 and the radial outer side K2 from the outer peripheral surface of the core 1.

The winding start wire 30b drawn in this way is pulled up to the upper end surface of the axial end side G1 of the insulating bobbin 2Y and connected to the terminal 20a after passing through the recessed portion 2e1 and the protrusion 22.

Further, as shown in FIG. 8, the crossover portion 2e is formed at the lead-out position P where the crossover line 30 is drawn from the insulating bobbin 2Y toward the insulating bobbin 2X. That is, the position of the radial direction K when the crossover wire 30 is pulled out from the insulating bobbin 2Y is the radial outer side K2 with respect to the outer peripheral surface of the core 1. Therefore, the crossover line 30 between the adjacent extension portions 2a can be reliably arranged on the radial outer side K2 of the core 1.
Further, the length of the crossover portion 2e formed on the insulating bobbin 2X in the circumferential direction S is shorter than the length of the crossover portion 2e formed on the insulating bobbin 2Y in the circumferential direction S. With such a configuration, the coil 3b can be connected to the terminal 20a at the shortest distance.

After the wiring is made in this way, the terminals 20a and 20d, and the terminals 20b and 20c are connected to the control board 40, which will be described later, respectively. Then, as shown in FIG. 5 showing the connection relationship of the coil 3, the coil 3a (N1) and the coil 3b (S1) are connected to the paired coil 3c (N2) and the coil 3d (S2) on the control board 40. Will be done.
The terminals 20a, 20b, 20c, 20d and each crossover wire 30 are electrically connected by soldering, but the electrical connection method is not limited.

Hereinafter, the ends of the back yoke portion 1a of the split core 1X in the circumferential direction S are connected to each other at the position of the spatial region between the adjacent extension portions 2a, and are routed between the extension portions 2a. The advantage of having the crossover line 30 arranged at the position of the outer K2 in the radial direction with respect to the outer peripheral surface of the core will be described with reference to the drawings.

FIG. 12 is a diagram showing a space region 25 between the extension portions 2a adjacent to the circumferential direction S in the rotary electric machine 100 shown in FIG.
FIG. 13 is based on a comparative example in which the dimensional relationship between the dimension L1 from the center point C of the core 1 to the outer peripheral surface of the insulating bobbin 2 and the dimension L2 from the center point C to the outer peripheral surface of the core 1 is L1 <L2. It is a figure which showed the space area 25 in the rotary electric machine.

The connection relationship in the rotary electric machine in the comparative example of FIG. 13 is the same as that shown in FIG. In such a rotary electric machine in which the dimensional relationship is L1 <L2, that is, the extending portion 2a of the insulating bobbin 2 is located radially inside K1 from the outer peripheral surface of the core 1, the winding start wire 30b of the coil 3b is a hole. When the crossover is arranged so as to pass through the outer peripheral surface of the insulating bobbin 2 so as to avoid the sensor 15, the winding start wire 30b is arranged in the space region 25 on the back yoke portion 1a of the core 1.

When a plurality of split cores 1X are connected to form the core 1, the connection portion of the end portion of the back yoke portion 1a in the circumferential direction S is cured in order to prevent the positional deviation of the adjacent split cores 1X in the axial direction G. It is necessary to align the position by pressing it in the axial direction G with a tool or the like. Therefore, this spatial region 25 can be used as a pressurizing region for aligning the axial heights of the divided cores 1. If the winding start wire 30b is routed around the space region 25, the winding start wire 30b may interfere with the jig or the like to pressurize. If a jig or the like is inserted from the side of the core 1 in order to prevent interference with the winding start wire 30b, manufacturing becomes complicated.

Therefore, like the rotary electric machine 100 of the present embodiment shown in FIG. 12, the extending portion 2a adjacent to the circumferential direction S is configured to have a space region 25 in the circumferential direction S between the extending portions 2a. The end portions of the back yoke portion 1a of the split core 1X in the circumferential direction S are configured to be connected to each other at the position of the space region 25, and the crossover line 30 routed between the extension portions is further formed. By configuring it so that it is arranged at the position of the first dimension X1 and the radial outer side K2 from the outer peripheral surface of the core 1, the divided core is divided in the space region 25 while avoiding the interference between the pressurizing jig and the crossover. It is possible to align the axial direction G of 1.

Hereinafter, the overall configuration of the rotary electric machine 100 including the control board 40 for controlling the rotary electric machine 100 will be described with reference to the drawings.
FIG. 14 is a perspective view showing the overall configuration of the rotary electric machine 100 including the control board 40.
FIG. 15 is a vertical cross-sectional view of the rotary electric machine 100 shown in FIG.

The rotary electric machine 100 includes a frame 50 that supports the outer peripheral surface of the core 1 from the radial outer side K2. The upper end surface of the axial end side G1 of the frame 50 is configured to be at the position of the axial other end side G2 with respect to the lower end surface of the axial other end side G2 of the extending portion 2a. Further, the frame 50 rotatably supports the shaft 11 only at the other end side G2 in the axial direction from the lower end surface of the other end side G2 in the axial direction of the core 1 via the bearing 51. The frame and the core 1 are fixed by, for example, shrink fitting.

Further, the rotary electric machine 100 includes a control board 40 having a wiring pattern connected to the crossover line 30 and an electronic component 41. The control board 40 is supported from the other end side G2 in the axial direction by the boss portions 21a and 21b provided on the bobbins 2X and 2Y for insulation, and is arranged on the one end side G1 in the axial direction of the core 1. Then, the control board 40 and the core 1 are screwed together at the boss portions 21a and 21b.

The terminals 20a, 20b, 20c, and 20d provided on the insulating bobbins 2X and 2Y are connected to the control board 40 arranged directly above the insulating bobbins 2X and 2Y in this way. The hall sensor 15 is also connected to the control board 40. In this way, the coils 3a, 3b, 3c, and 3d are connected to the control board 40 via the terminals 20a, 20b, 20c, and 20d and are electromagnetically excited.

As described above, since the control board 40 is provided on one end side G1 in the axial direction of the core 1, the shaft 11 has a cantilever structure supported only on the other end side G2 in the axial direction of the core 1. Due to the cantilever structure as described above, the frame 50 does not extend to the axial end side G1 of the core 1. That is, the frame 50 is not arranged on the radial outer side K2 of the insulating bobbin 2 mounted on the core 1.

Generally, when the frame is fixed to the core by shrink fitting or the like, the insulating bobbin is formed so as to have a predetermined gap from the frame 50 in order to avoid the influence of heat by the frame.
In the stator 10 of the present embodiment, it is not necessary to form the outer diameter dimensions of the insulating bobbins 2X and 2Y in accordance with the outer diameter dimensions of the frame 50. Therefore, even when the outer diameter of the core 1 is made small, the extending portions 2a of the insulating bobbins 2X and 2Y are formed so as to be K2 radially outside the outer peripheral surface of the core 1, and the crossover wire is formed. A sufficient wiring area of 30 can be secured.

Hereinafter, the rotary electric machine 100a having a configuration different from the above will be described.
FIG. 16 is a view of a cross section of the rotary electric machine 100a according to the first embodiment as viewed from one end side G1 in the axial direction.
The rotary electric machine 100a has a mold portion 42 that covers the core 1, the coil 3, and the insulating bobbin 2 with an insulating resin. As the insulating resin, for example, oximethylene such as POM or polyoxymethylene, or PPS may be used. This is advantageous for fixing and cooling the crossover wire 30 and the coil 3.

According to the stator of the present embodiment configured as described above and the rotary electric machine incorporating the stator, the extending portion of the insulating bobbin is radially outside the outer peripheral surface of the core on the radial outside. At this point, a crossover portion for guiding the crossover line connecting the coils is formed. As a result, the area outside the radial direction of the core can be used as the wiring area for the crossover. Therefore, even if the outer diameter of the core is made small for the purpose of miniaturization and weight reduction, a sufficient distance between the crossovers connecting the coils can be secured. In this way, contact between the crossovers can be avoided, and damage to the insulating coating can be prevented. Further, since a sufficient work space can be secured for the connection work of the crossover, workability can be improved, wiring mistakes and the like can be prevented, and reliability can be improved.

Further, since the insulating bobbin itself can secure a predetermined size, it is not necessary to perform complicated processing such as a thin groove on the insulating bobbin, and the structure of the insulating bobbin can be simplified. Therefore, the productivity of the insulating bobbin is improved and the manufacturing cost can be suppressed. That is, it is possible to reduce the size and weight of the heavy stator core while maintaining the quality of the core and the rotary electric machine using the core, and it is possible to reduce the size and weight of the motor and reduce the manufacturing cost.
In this way, since it is not necessary to form an insulating bobbin having a complicated shape, it is not necessary to insert a slide core into the molding die, and the manufacturing cost can be reduced.

Further, even when an electronic component such as a sensor is arranged between the tip protruding portions of the teeth portions adjacent to each other in the circumferential direction, it is possible to prevent the electronic component from interfering with the crossover.

Further, between the extension portions attached to the teeth portions adjacent to the circumferential direction S, the crossover is routed between the extension portions with the crossover portion of one of the extension portions as a pull-out position. As described above, the drawing position for drawing the crossover from the insulating bobbin is K2 radially outside the outer peripheral surface of the core 1. Therefore, the crossover line routed between the adjacent extension portions can be reliably arranged radially outside the outer peripheral surface of the core.

Further, the crossover portion of the insulating bobbin may be formed on the outer side in the radial direction by the diameter of the crossover wire or more from the outer peripheral surface of the core. As a result, for example, even when a crossover with a large diameter is used, the crossover can be more reliably arranged radially outside the outer peripheral surface of the core, and a sufficient distance between the crossovers can be reliably secured.

Further, the crossover line routed between the extending portions adjacent to each other in the circumferential direction may be arranged at a position outside the radial direction by a predetermined first dimension from the outer peripheral surface of the core. In this case, by setting the first dimension to a dimension including an error in the connection work, it is possible to surely secure the distance between the crossovers regardless of the variation in the manufacturing process.

Further, the core may be composed of a plurality of divided cores. The shape of the divided core has the advantage that the manufacturing cost of the core mold can be suppressed.
Further, when the divided core is used in this way, the extending portions adjacent to each other in the circumferential direction are shaped so that a spatial region not covered by the insulating bobbin is formed between the extending portions. Then, the circumferential ends of the back yoke portion of the split core are connected to each other at the position of this spatial region. In this way, the connection position of the split core is arranged in the spatial region, and the crossover is not arranged on the split core, so that the spatial region can be used as a pressurizing region for axially positioning the split core. In this way, positioning can be performed with a simple manufacturing device, and the manufacturing method can be simplified, which is advantageous in manufacturing.

When two crossovers are routed on one extension, one crossover is routed to the recessed portion of the crossover and the other crossover is routed to one end side of the extension in the axial direction. Route it on the upper end surface of G1. Then, by forming this recessed portion on the second dimension X2 and the other end side G2 in the axial direction from the upper end surface of the one end side G1 in the axial direction of the extending portion, two crossover lines in the axial direction G are formed. A sufficient distance can be secured between them.

Further, at least one of the extending portions adjacent to each other in the circumferential direction includes a supporting portion that supports the crossover line drawn between the adjacent extending portions from the other end side G2 in the axial direction. As a result, it is possible to prevent the crossover from moving toward the other end in the axial direction due to vibration of the motor or the like, and it is possible to improve reliability.
Further, by configuring the extending portion of the insulating bobbin attached to all the teeth insulating portions to include the crossover portion, the crossover wire can be more reliably arranged radially outside the outer peripheral surface of the core.
Further, by setting the distance between the end face on the one end side in the axial direction of the support portion and the inner wall on the one end side in the axial direction of the recessed portion to be equal to or less than the diameter of the crossover wire, the crossover wire is sandwiched in the axial direction. It can be prevented from moving to.

Further, the upper end surface of the axial end side G1 of the frame supporting the outer peripheral surface of the core is positioned at the axial end side G2 of the lower end surface of the axial other end side G2 of the extending portion of the insulating bobbin. It is possible to prevent the upper end surface of the frame from interfering with the crossover between the adjacent extension portions. This makes it possible to further improve the reliability.

Further, by forming a protruding portion extending to the axial end side G1 on the upper end surface of the axial end side G1 of the bobbin extending portion and arranging the control board on the protruding portion, each coil 3 and the control board are arranged. The wiring distance with and can be shortened. As a result, it is possible to suppress an unintended voltage drop or the like and improve the operating performance of the rotary electric machine.

Further, between the teeth portions adjacent to each other in the circumferential direction, the winding direction of the coil is set to the same direction, and then the first crossover wire of one coil and the third crossover wire are connected. Then, at least a part of the fourth crossover is guided along the crossover portion of the extension portion of the second teeth portion and connected to the second crossover line. Then, by providing a terminal connected to the control board at the connection position between the first crossover line and the third crossover line and the connection position between the fourth crossover line and the second crossover line, a potential difference is generated. A sufficient distance between the crossover line and the first crossover line can be secured. In this way, it is possible to further improve the reliability.
Further, one of the first crossover line and the third crossover line is guided along the outer peripheral surface of the protruding portion of the extension portion of the second tooth portion, so that the first crossover line and the third crossover line can be used. Can secure the distance.

Further, the tip insulating portion of the insulating bobbin is formed so as to secure a predetermined distance from the sensor arranged between the tip protruding portions of the teeth portion. In this way, it is possible to prevent the sensor and the bobbin from interfering with each other.
Further, between the extending portions of the teeth portions adjacent to each other in the circumferential direction, the circumferential length of the crossover portion of one tooth portion and the circumferential length of the crossover portion of the other teeth portion are formed so as to be different from each other. By doing so, the crossover can be connected in the shortest distance.
Further, by providing a mold portion for covering the core, the coil, and the bobbin for insulation with an insulating resin, it is advantageous to fix and cool the crossover wire and the coil.

Although the single-phase rotary electric machine 100 has been described above, the present invention is not limited to this. The above configuration is similarly applicable to a rotary electric machine in which the coil 3 has a three-phase configuration of U-phase, V-phase, and W-phase.
Further, the present invention is not limited to the brushless motor, and can be similarly applied to rotary electric machines having other configurations.
Further, the core 1 is not limited to the one configured by the divided core 1X, and the integrated core 1 which is not divided in the back yoke portion 1a may be used.
Further, the divided core 1X is not limited to one having one teeth portion 1b each, and each divided core 1X may have a plurality of teeth portions 1b.

Further, although the insulating bobbin 2 has been shown to use two types of insulating bobbins 2X and 2Y, for example, a configuration using only the insulating bobbin 2Y may be used. Similarly, in this case as well, the same effect as described above can be obtained by guiding the crossover wire 30 along the crossover portion 2e of the insulating bobbin 2Y.
Further, if the crossover line 30 can be arranged on the radial outer side K2 of the outer peripheral surface of the core 1, it is not necessary that all the extending portions 2a of the insulating bobbin have the crossover portion 2e.

Further, although an example in which the space region 25 is formed between the insulating bobbins 2 adjacent to each other in the circumferential direction S is shown, the present invention is not limited to this. The configuration may not have a space region 25 such that the end face of the insulating bobbin 2 in the circumferential direction S comes into contact with the end face of the adjacent insulating bobbin 2 in the circumferential direction S. It can be arranged on the radial outer side K2 of 1, and the distance between the crossovers 30 can be secured.
Further, the crossover portion 2e has been shown to be provided on the outer peripheral surface of the radial outer side K2 of the extension portion 2a, but the present invention is not limited to this. For example, the crossover portion 2e may be provided on the upper end surface of the axial end end side G1 of the extension portion 2a. Even in this case, the crossover line 30 can be arranged on the radial outer side K2 of the core 1, and the distance between the crossover lines 30 can be secured.

Further, the protrusion 22 provided on the extending portion 2a shows a configuration in which the insulating bobbins 2X and 2Y adjacent to each other in the circumferential direction are provided only on the insulating bobbin 2Y, but the present invention is not limited thereto. It may be provided only on the insulating bobbin 2X, or may be provided on both the insulating bobbins 2X and 2Y.

Further, although the crossover portion 2e provided in the insulating bobbins 2X and 2Y respectively shows a configuration in which only a part of the crossover line 30 extending from each slot 5 is guided, the total length of the crossover line 30 is guided. The configuration may be as follows.

Further, as the insulating bobbins 2X and 2Y, bobbins having a configuration vertically divided in the axial direction G may be used. In this case, the insulating bobbins are attached from the upper end side in the axial direction and the lower end side in the axial direction of the divided core 1, and the work of attaching each to the divided core 1 tends to be complicated. In this case, it is also conceivable to integrally mold the insulating bobbins mounted on both ends of the core 1 in the axial direction G together with the core 1. As a result, workability can be expected to improve.
Further, an insulating sheet may be used as the tooth insulating portion 2b of the insulating bobbin 2.

Further, although an example in which the hall sensor 15 is arranged between the tip protruding portions 1c of the core 1 is shown, parts such as other electronic parts may be arranged due to the design.

It is possible to freely combine the embodiments and to modify or omit the embodiments as appropriate.

1 core, 1X split core, 2 insulation bobbins, 3 coils, 30 crossovers,
2e crossover, 22 protrusions, 15 sensors, 40 control boards, 50 frames,
10 stator, 13 rotor, 42 mold part, 100, 100a rotary electric machine.

Claims (18)

The core has a core having a back yoke portion and a plurality of teeth portions protruding radially inward from the back yoke portion at predetermined intervals in the circumferential direction, and a teeth insulating portion covering the teeth portions. It comprises a mounted insulating bobbin and a coil that is wound around each of the teeth portions of the core via the teeth insulation portion of the bobbin and is housed in a slot formed between the teeth portions. ,
At least one between the coils wound around the teeth portion is in a stator connected by a crossover.
The bobbin has an extension portion extending radially outward from the tooth insulation portion for each tooth insulation portion on one end side in the axial direction of the core.
At least one of the extension portions
It has a portion that is radially outside the outer peripheral surface of the core on the radial side, and a crossover portion that guides at least a part of the crossover is formed at the portion.
The core is composed of a plurality of divided cores divided in the circumferential direction in the back yoke portion so as to have at least one of the teeth portions.
The extending portions of the teeth portions adjacent to each other in the circumferential direction are formed with a gap in the circumferential direction between the extending portions.
The circumferential ends of the back yoke portion of the split core are connected to each other at the position of the gap between the extension portions.
The crossover that is routed between the extension portions and guided to the crossover portion is one end side in the axial direction of the connection position between the circumferential end portions of the back yoke portion at the position of the gap between the extension portions. Is not arranged in the above, but is arranged at a position outside the radial direction by the first dimension from the outer peripheral surface of the core.
Stator. The crossover line drawn between the extending portions of the teeth portions adjacent to each other in the circumferential direction is
The crossover portion of one of the extension portions is set as a drawer position, and the extension portion is routed between the extension portions toward the other extension portion.
The stator according to claim 1. The crossover is
It is formed radially outside the outer peripheral surface of the core by an amount equal to or larger than the radial dimension of the crossover.
The stator according to claim 1 or 2. In a configuration in which the two crossovers are routed on the predetermined extension.
The crossover portion of the predetermined extension portion is formed on the outer peripheral surface of the radial outer side of the extension portion, and has a concave portion recessed inward in the radial direction.
One of the crossovers is routed to the recessed portion of the crossover, and the other crossover is routed over the end face of the extension on one end side in the axial direction.
The recessed portion is formed on the other end side in the axial direction by a second dimension from the axial position of the end surface on one end side in the axial direction of the extension portion.
The stator according to any one of claims 1 to 3 . At least one of the extending portions of the teeth portion adjacent in the circumferential direction is
A support portion for supporting the crossover line routed between the adjacent extension portions from the other end side in the axial direction is provided.
The stator according to any one of claims 1 to 4 . At least one of the extending portions of the teeth portion adjacent in the circumferential direction is
A support portion for supporting the crossover line routed between the adjacent extension portions from the other end side in the axial direction is provided.
The distance between the end face on the axial end side of the support portion and the inner wall on the axial end side of the recessed portion is configured to be equal to or less than the diameter of the crossover.
The stator according to claim 4 . The extension of all the teeth insulations comprises the crossover.
The stator according to any one of claims 1 to 6 . A frame that supports the outer peripheral surface of the core from the outside in the radial direction is provided.
The end face on the one end side in the axial direction of the frame is configured at a position on the other end side in the axial direction with respect to the end face on the other end side in the axial direction of the extension portion.
The stator according to any one of claims 1 to 7 . A control board having a wiring pattern connected to the crossover is provided.
The extension portion of the bobbin has a protrusion extending toward one end surface in the axial direction on the end surface on one end side in the axial direction.
The control board is supported from the other end side in the axial direction by the protrusion and is arranged on one end side in the axial direction of the core.
The stator according to any one of claims 1 to 8 . One of the teeth portions adjacent to each other in the circumferential direction is used as the first teeth portion, and the other is designated as the second teeth portion.
The slot between the first teeth portion and the second teeth portion is referred to as a first slot.
The slot on the side opposite to the first slot of the first teeth portion is referred to as a second slot.
The slot on the side opposite to the first slot of the second teeth portion is referred to as a third slot.
The crossover wire extending from the first slot of the coil wound around the first teeth portion is referred to as a first crossover wire.
The crossover wire extending from the second slot of the coil wound around the first teeth portion is referred to as a second crossover wire.
The crossover wire extending from the first slot of the coil wound around the second teeth portion is referred to as a third crossover wire.
The crossover wire extending from the third slot of the coil wound around the second teeth portion is defined as a fourth crossover wire.
The first crossover and the third crossover are connected,
At least a part of the fourth crossover is guided along the crossover portion of the extension portion of the second tooth portion and connected to the second crossover.
The stator according to any one of claims 1 to 9 . The extension portion of the bobbin has a protrusion extending toward one end surface in the axial direction on the end surface on one end side in the axial direction.
One of the first crossover and the third crossover is guided along the outer peripheral surface of the protrusion of the extension of the second tooth portion, and the first crossover and the third crossover are guided. Is connected,
The stator according to claim 10 . The tooth portion has a tip protruding portion protruding from the inner end in the radial direction to both sides in the circumferential direction.
Electronic components are arranged between the tip protrusions of the teeth portions adjacent to each other in the circumferential direction.
The bobbin has a tip insulating portion formed so as to cover the tip protrusion and secure a predetermined distance from the electronic component.
The stator according to any one of claims 1 to 11 . The electronic component is a sensor that detects the position of a rotor arranged radially inside the core.
12. The stator according to claim 12 . In a configuration in which the extending portions of the teeth portions adjacent to each other in the circumferential direction each have the crossover portion.
The circumferential length of the crossover portion of one of the teeth portions and the circumferential length of the crossover portion of the other teeth portion are formed to be different from each other.
The stator according to any one of claims 1 to 13 . A mold portion for covering the core, the coil, and the bobbin with an insulating resin is provided.
The stator according to any one of claims 1 to 14 . The stator according to any one of claims 1 to 15 ,
A rotor provided with a predetermined distance from the inner peripheral surface of the stator and concentrically arranged inside the stator in the radial direction is provided.
Rotating machine. A frame that supports the outer peripheral surface of the core from the outside in the radial direction is provided.
The frame rotatably supports a rotation shaft that supports a rotor disposed inside the core in the radial direction only on the other end side in the axial direction of the core.
The rotary electric machine according to claim 16 . A sensor for detecting the position of the rotor is provided.
Single-phase brushless motor or three-phase brushless motor,
The rotary electric machine according to claim 16 or 17.

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