JP7297102B2 - Stator for rotating electrical machine, rotating electrical machine, method for manufacturing stator for rotating electrical machine, and method for manufacturing rotating electrical machine - Google Patents

Description

The present application relates to a stator of a rotating electrical machine, a rotating electrical machine, a method of manufacturing a stator of a rotating electrical machine, and a method of manufacturing a rotating electrical machine.

2. Description of the Related Art Conventionally, a stator used in a rotating electric machine such as an electric motor or a generator is composed of a stator core and coils that are housed and mounted in slots formed between teeth of the stator core. A coil wire forming the coil is covered with an insulating coating, and the coil is electrically insulated from the stator core. However, in the stator of the rotary electric machine, in order to ensure sufficient insulation between the coil and the stator core, an insulating portion is further arranged at the portion where the stator core and the coil contact each other.

As a conventional stator, a technique has been proposed in which a coil wire is wound simultaneously on three consecutive teeth (see, for example, Patent Document 1).

JP-A-9-191588

Generally, in the manufacture of stators for rotary electric machines, it is important to prevent loose winding of coils by preventing loosening of connecting wires between coils and to make coils uniform in order to maintain product quality.

In the stator disclosed in Patent Document 1, three winding nozzles are used to simultaneously wind three teeth on a six-teeth stator core. First, a three-teeth coil is formed at the same time, two teeth are sandwiched between each tooth, and a connecting wire is formed between the teeth.

In this document, the winding end wires of the three coils wound at the same time are routed as they are to the next tooth to be wound as a connecting wire, and the three coils are wound continuously. Therefore, there is a problem that when the crossover wire is loosened, the coil that has already been wound or the coil that is being wound is broken.

The present application discloses a technique for solving the above-described problems. The purpose is to provide a method.

The stator of the rotary electric machine disclosed in the present application is
a stator core formed by annularly combining a plurality of core portions each having a yoke portion and tooth portions formed so as to protrude radially inward from a circumferential center portion of an inner peripheral surface of the yoke portion;
A rotating electrical machine comprising: a coil formed by winding a coil wire around each of the plurality of tooth portions; and an insulating portion disposed between the core portion and the coil to insulate the stator core and the coil. is the stator of
The first winding frame as the insulating portion includes a first tooth end surface covering portion covering one axial end surface of a portion of the tooth portion around which the coil is wound, and a radial direction of the first tooth end surface covering portion. a first outer flange that is connected to the outer end and that covers one axial end surface of the yoke portion and protrudes axially upward;
The first outer flange is formed in the axial direction and includes a first lead-out groove portion for leading the coil wire after winding the coil toward the radially outer side of the stator core and holding the coil wire,
The fourth winding frame as the insulating portion includes a second tooth end surface covering portion covering the other axial end surface of the portion of the tooth portion around which the coil is wound, and a radial direction of the second tooth end surface covering portion. a second outer flange connected to the outer end portion and projecting upward in the axial direction to cover the other axial end surface of the yoke portion;
The second outer flange protrudes axially upward from a central portion in the circumferential direction, and guides the coil wire after winding the coil radially outward of the stator core from the first lead-out groove portion. A winding part is provided in front for winding the winding end of each coil,
A plurality of the coils are formed by the continuous coil wire.
Further, the rotating electric machine disclosed in the present application is
a stator of the rotating electric machine;
A rotor is provided inside the stator and opposed to the stator with a gap therebetween.
Further, the manufacturing method of the stator of the rotary electric machine disclosed in the present application includes:
linearly deforming the yoke portions of the plurality of core portions;
a winding step of winding the coil wire around the teeth using a winding nozzle to form the coil;
a winding step of winding the coil wire around the winding portion;
and a locking step of fixing the coil wire between the binding portion and the locking portion.
Further, in the method for manufacturing a rotating electric machine disclosed in the present application, a rotor is disposed opposite to the inner side of the stator manufactured by the method for manufacturing a stator for a rotating electric machine with a gap therebetween.

According to the stator of the rotating electrical machine, the rotating electrical machine, the method of manufacturing the stator of the rotating electrical machine, and the method of manufacturing the rotating electrical machine disclosed in the present application,
It is possible to provide a stator for a rotating electrical machine, a rotating electrical machine, a method for manufacturing a stator for a rotating electrical machine, and a method for manufacturing a rotating electrical machine that can prevent winding collapse of each coil.

2 is a cross-sectional view perpendicular to the axial direction of the rotary electric machine according to Embodiment 1; FIG. 2 is a cross-sectional view of the rotary electric machine according to Embodiment 1 cut along a plane passing through the axis of the rotating shaft; FIG. FIG. 4 is a rear view showing a state in which the stator of the rotary electric machine according to Embodiment 1 is cut open and deformed linearly; 4 is a perspective view of the stator shown in FIG. 3, showing the back side of FIG. 3, ie the inside of the stator; FIG. FIG. 4 is a perspective view showing the configuration of two types of core piece groups that constitute the stator core of the stator shown in FIG. 3 ; 2 is a perspective view showing the configuration of a stator core according to Embodiment 1; FIG. 4 is a plan view of a core portion according to Embodiment 1. FIG. 4 is a perspective view showing the configuration of the first winding frame according to Embodiment 1. FIG. 4 is a perspective view showing the configuration of a fourth winding frame according to Embodiment 1; FIG. 4 is a perspective view showing a state in which a first winding frame and a fourth winding frame are attached to the core portion according to Embodiment 1. FIG. It is the figure which looked at the 1st core part in the arrow A direction of FIG. It is the figure which looked at the 1st core part in the arrow B direction of FIG. It is the figure which looked at the 1st core part in the arrow C direction of FIG. It is the figure which looked at the 1st core part in the arrow D direction of FIG. 4 is a perspective view of a second winding frame according to Embodiment 1. FIG. 4 is a view of the second core portion on which the second winding frame and the fourth winding frame according to Embodiment 1 are mounted, viewed from the outside X1 in the radial direction X; FIG. 4 is a perspective view of a third winding frame according to Embodiment 1; FIG. 4 is a view of the third core portion to which the third winding frame and the fourth winding frame according to Embodiment 1 are attached, viewed from the outside X1 in the radial direction X; FIG. 4 is a flow chart showing a manufacturing process of the rotating electric machine according to Embodiment 1; 4 is a flow chart showing the manufacturing process of the coil according to Embodiment 1. FIG. FIG. 4 is an exploded view of the stator in a coil forming process according to Embodiment 1; FIG. 4 is a diagram showing the movement of the winding nozzle of the winding machine according to Embodiment 1; 4 is a perspective view showing movement of each winding nozzle in the winding process according to Embodiment 1. FIG. 4 is a perspective view showing the state of the core portion at the end of the winding process according to Embodiment 1. FIG. 4 is a diagram showing movements of nozzles N1, N2, and N3 after forming coils of the first core portion, the second core portion, and the third core portion according to Embodiment 1. FIG. 4 is a conceptual diagram showing another winding method according to Embodiment 1. FIG. FIG. 8 is a perspective view showing a state in which a first winding frame, a second winding frame, a third winding frame, a fourth winding frame, and a film portion are attached to the stator core according to Embodiment 2; 27 is an exploded perspective view of each member in FIG. 26; FIG. FIG. 11 is a perspective view showing the configuration of a film portion according to Embodiment 2; FIG. 11 is a perspective view showing the configuration of a first winding frame according to Embodiment 2; 29B is a perspective view of the first winding frame shown in FIG. 29A as viewed from the opposite side in the axial direction Y; FIG. FIG. 11 is a perspective view showing the configuration of a fourth winding frame according to Embodiment 2; FIG. 11 is a perspective view of a stator core according to Embodiment 3; FIG. 11 is an enlarged plan view of a main portion of a stator core according to Embodiment 3; FIG. 11 is a perspective view of a core portion according to Embodiment 4; FIG. 11 is a perspective view showing a state after winding of a stator according to Embodiment 4;

Embodiment 1.
A stator for a rotating electrical machine, a rotating electrical machine, a method for manufacturing a stator for a rotating electrical machine, and a method for manufacturing a rotating electrical machine according to Embodiment 1 will be described below with reference to the drawings.
FIG. 1 is a cross-sectional view perpendicular to the axial direction of rotating electric machine 100 .
FIG. 2 is a cross-sectional view of the rotor 20 of the rotary electric machine 100 taken along a plane passing through the axis of the rotating shaft 21 .
The rotary electric machine 100 includes a cylindrical frame 101, brackets 103 closing openings at both ends of the frame 101 in the axial direction, a stator 10 fitted inside the frame 101, and two brackets 103 at their respective centers. and a rotor 20 which is rotatably supported via bearings (not shown) and arranged so that its outer peripheral surface faces the inner peripheral surface of the stator 10 . A gap 107 exists between the outer peripheral surface of the rotor 20 and the inner peripheral surface of the stator 10 .

Further, although the permanent magnets 105 are embedded in a V shape in the rotor core 22 fixed to the outer circumference of the rotating shaft 21, the permanent magnets may be arranged in a straight line or in another shape. Moreover, the permanent magnets may not be embedded, and may be attached to the outer peripheral surface of the rotor core 22 so as to face the inner peripheral surface of the stator 10 .

In the following description, the directions of the stator 10 of the rotary electric machine 100 are the circumferential direction Z, the axial direction Y, and the radial direction X, respectively, based on the state in which the yoke portions 11a of the plurality of core portions 60 are arranged and combined in a ring. , radially X outside X1 and radially X inside X2. Therefore, when the stator 10 is deformed by linearly rotating each yoke portion 11a of each core portion 60 of the stator 10, or when the direction in which each tooth portion 11b protrudes is reversed, that is, when the stator 10 is an annular stator Even if the yoke portion 11a of the stator 10 is rotated and deformed in a reverse warp shape in which the inside and outside of the stator 10 are reversed, each direction is set based on the direction in which the yoke portion 11a of the stator 10 is arranged in an annular shape, which is the product state. , are shown and described in each figure.

In addition, when referring to "upper" and "lower" without particular notice, the surface side perpendicular to the axial direction Y of the stator 10 and passing through the center of the stator 10 at a reference location is "lower", and the opposite is "upper". ”. When comparing the height, the distance from a plane perpendicular to the axial direction Y of the stator 10 and passing through the center of the stator 10 is used for comparison.

The stator 10 includes a plurality of core portions 60 each having a yoke portion 11a and teeth portions 11b formed so as to protrude inward X2 in the radial direction X from the central portion in the circumferential direction Z of the inner peripheral surface of the yoke portion 11a, A stator core 11A combined in an annular shape, coils 7 each formed by winding a coil wire around a plurality of tooth portions 11b, and each core portion 60 and the coil 7 are disposed between the core portion 60 and the coil 7. and an insulating portion that insulates the The stator core 11A is formed by connecting and combining nine core portions 60 .

FIG. 3 is a rear view showing a state in which the stator 10 of the rotary electric machine 100, which is originally annular, is cut open and deformed into a straight line, and is a view of the stator 10 seen from the outer peripheral side.
In the following description, the respective core portions 60 are denoted by reference numerals 61 to 69 and described as the first core portion 61 to the ninth core portion 69. As shown in FIG.
4 is a perspective view of the stator 10 shown in FIG. 3, showing the back side of FIG. 3, that is, the inside of the stator 10. FIG.
FIG. 5 is a perspective view showing the configuration of two types of core piece groups 11k1 and 11k2 that constitute the stator core 11A of the stator 10 shown in FIG.
FIG. 6 is a perspective view showing the configuration of a stator core 11A formed by alternately laminating a plurality of groups of the two types of core piece groups 11k1 and 11k2 shown in FIG.
FIG. 7 is a plan view of the core portion 60. FIG.

As shown in FIGS. 3 and 4, the stator 10 includes a stator core 11A made up of a plurality of core portions 60, a coil 7, and an insulating portion arranged to insulate the stator core 11A and the coil 7. It has a first reel 51, a second reel 52, a third reel 53, and a fourth reel 54 on the lower side of the page. As shown in FIG. 6 , the core portions 60 arranged in the circumferential direction Z are divided into a first core portion 61 , a second core portion 62 , a third core portion 63 and a fourth core from the winding start side of the first coil wire 71 . A portion 64 , a fifth core portion 65 , a sixth core portion 66 , a seventh core portion 67 , an eighth core portion 68 and a ninth core portion 69 . The first winding frame 51 is used for the first core portion 61, the fourth core portion 64, and the seventh core portion 67, that is, for the core portion 60 that constitutes the U phase. The second winding frame 52 is used for the second core portion 62, the fifth core portion 65, and the eighth core portion 68, that is, for the core portion 60 that constitutes the V phase. The third winding frame 53 is used for the third core portion 63, the sixth core portion 66, and the ninth core portion 69, that is, for the core portion 60 that constitutes the W phase, but the details of the difference will be described later. .

The stator core 11A comprises a plurality of core piece groups 11k1 and 11k2 shown in FIG. It is formed by lamination. Thus, the stator core 11A is formed by connecting the yoke portions 11a of the first core portion 61 to the ninth core portion 69 with the connecting portions 111 provided at the ends in the circumferential direction Z. As shown in FIG. In FIG. 6 , the stator core 11A is configured by linearly connecting nine first core portions 61 to ninth core portions 61 to 69 at connecting portions 111 .

In this connecting portion 111, the yoke portions 11a of the adjacent core portions 60 are freely rotatable. As a result, the stator core 11A can rotate in a straight line or in a reverse warp in which the radial direction X of the teeth 11b is reversed.

The stator coil is composed of three phases, U phase, V phase, and W phase, and has a star connection structure in which different phases are arranged for each core portion 60 connected in the circumferential direction Z. The first core portion 61 is the U phase (U1), the second core portion 62 is the V phase (V1), the third core portion 63 is the W phase (W1), the fourth core portion 64 is the U phase (U2), The fifth core portion 65 is the V phase (V2), the sixth core portion 66 is the W phase (W2), the seventh core portion 67 is the U phase (U3), the eighth core portion 68 is the V phase (V3), the ninth A W-phase (W3) coil 7 is wound around the core portion 69 .

Note that the first core portion 61 to the ninth core portion 69 will be collectively described as the core portion 60 when the explanation of the order is not required. Each core portion 60 is provided with a coil 7 and an upper first winding frame 51, a second winding frame 52, a third winding frame 53, and a fourth winding frame 54 as insulating portions. However, the first core portion 61 to the ninth core portion 69 include, in each core portion 60, the coil 7, the insulating portion shown in FIG. This description is adopted regardless of whether the frame 53 and the fourth winding frame 54 on the lower side of the page are installed or not installed.

Next, the configuration of each part of the core part 60 will be described with reference to FIG. A yoke outer peripheral surface 113 is defined as a surface along the axial direction Y on the outer side X1 in the radial direction X of the yoke portion 11a. A first concave portion 114 extending in the axial direction Y is formed in the center portion in the circumferential direction Z of the yoke outer peripheral surface 113 . The first concave portion 114 is used for positioning when the stator core 11A is attached to the winding machine that forms the coil 7 . Further, the teeth 11b are provided with shoe portions 11c protruding in the circumferential direction Z from the tips of the inner sides X2 in the radial direction X. As shown in FIG. A yoke inner peripheral surface 112 is defined as a surface along the axial direction Y on the inner side X2 in the radial direction X of the yoke portion 11a.

Both sides along the axial direction Y of both ends of the tooth portion 11b in the circumferential direction Z are called the tooth portion side surfaces 121, and a surface along the axial direction Y of the tip of the inner side X2 of the tooth portion 11b in the radial direction X is called the tooth portion inner peripheral surface 122. do. A surface along the axial direction Y on the outer side X1 in the radial direction X of the shoe portion 11 c is defined as a shoe portion outer peripheral surface 131 . A region surrounded by the yoke inner peripheral surface 112, the tooth portion side surface 121, and the shoe portion outer peripheral surface 131 serves as the slot 14 around which the coil wire 70 is wound and the coil 7 is formed.

Next, the first winding frame 51, the second winding frame 52, the third winding frame 53, and the fourth winding frame 54 on the lower side of FIG. 4 will be described as insulating portions.
The first winding frame 51 is a winding frame attached to the first core portion 61 , the fourth core portion 64 and the seventh core portion 67 . The first winding frame 51 is attached to the teeth portion 11b and the yoke portion 11a.
The second winding frame 52 is a winding frame attached to the second core portion 62 , the fifth core portion 65 and the eighth core portion 68 . The second winding frame 52 is attached to the teeth portion 11b and the yoke portion 11a.
The third winding frame 53 is a winding frame attached to the third core portion 63 , the sixth core portion 66 and the ninth core portion 69 . The third winding frame 53 is attached to the teeth portion 11b and the yoke portion 11a.
FIG. 8 is a perspective view showing the configuration of the first winding frame 51 used in the stator 10 shown in FIGS.

The first winding frame 51 includes a tooth end surface covering portion 51c (first tooth end surface covering portion), an outer flange 51a (first outer flange), an inner flange 51b (first inner flange), and a slot side surface covering portion 51d ( and a first slot side covering portion), which are integrally formed.
The tooth end surface covering portion 51c covers one end surface in the axial direction Y of the portion of the tooth portion 11b around which the coil 7 is wound. The outer collar 51a is connected to an outer X1 end portion in the radial direction X of the tooth end surface covering portion 51c, covers one end surface in the axial direction Y of the yoke portion 11a, and protrudes upward in the axial direction Y. As shown in FIG.

The inner flange 51b is connected to an inner X2 end portion in the radial direction X of the tooth end surface covering portion 51c, and covers an inner tip portion of one end surface in the axial direction Y of the tooth portion 11b and one end surface in the axial direction Y of the shoe portion 11c. cover and protrude upwards in the axial direction Y;

The slot side surface covering portion 51d covers the tooth portion side surface 121 of the tooth portion 11b, the yoke inner peripheral surface 112 of the yoke portion 11a, and the shoe portion outer peripheral surface 131 of the shoe portion 11c. The slot side covering portion 51d protrudes downward from the tooth end surface covering portion 51c, the outer flange 51a, and the inner flange 51b. Actually, the slot side surface covering portion 51d covers half of each surface forming the slot 14 in the axial direction Y. As shown in FIG.

FIG. 9 is a perspective view showing the configuration of the fourth winding frame 54 used in the stator 10 shown in FIGS. 3 and 4. FIG. The fourth winding frame 54 is an insulating member on the lower side of the paper surface of the stator 10 shown in FIG.

The fourth winding frame 54 includes a tooth end surface covering portion 54c (second tooth end surface covering portion), an outer flange 54a (second outer flange), an inner flange 54b (second inner flange), and a slot side surface covering portion 54d ( second slot end surface covering portion), which are integrally formed.
The tooth end surface covering portion 54c covers the other end surface in the axial direction Y of the portion of the tooth portion 11b around which the coil 7 is wound. The outer flange 54a is connected to the outer X1 end in the radial direction X of the tooth end surface covering portion 54c, covers the other end surface in the axial direction Y of the yoke portion 11a, and protrudes upward in the axial direction Y. As shown in FIG.

The inner flange 54b is connected to the inner X2 end in the radial direction X of the tooth end surface covering portion 54c, and covers the inner tip portion of the other end surface in the axial direction Y of the tooth portion 11b and the other end surface in the axial direction Y of the shoe portion 11c. cover and protrude upwards in the axial direction Y; Further, as shown in FIGS. 11 and 13, the outer collar 54a has a binding portion 54k that protrudes upward in the axial direction Y from the central portion in the circumferential direction Z. As shown in FIGS. Projections 54t protrude toward both sides in the circumferential direction Z from the upper end in the axial direction Y of the binding portion 54k.
In addition, the outer flange 54a protrudes outward X1 in the radial direction X from the upper end in the axial direction Y of the outer peripheral surface 54aout and the central portion in the circumferential direction, and extends upward in the axial direction Y in parallel with the binding portion 54k. It has a hook-shaped locking portion 54f extending to. The width in the radial direction X of the gap 54r between the binding portion 54k and the locking portion 54f is slightly smaller than the wire diameter of the coil wire 70 .

The winding portion 54k is used for winding and fixing the coil wire 70, which is the winding end portion, after winding each coil 7 and before routing a connecting wire, which will be described later. Further, the projecting portion 54t is provided to prevent the coil wire 70 from coming off from the binding portion 54k during the binding operation to the binding portion 54k. The locking portion 54f is used to hold the coil wire 70 between itself and the binding portion 54k.

The slot side surface covering portion 54d covers the tooth portion side surface 121 of the tooth portion 11b, the yoke inner peripheral surface 112 of the yoke portion 11a, and the shoe portion outer peripheral surface 131 of the shoe portion 11c. The slot side covering portion 54d protrudes downward from the tooth end surface covering portion 54c, the outer flange 54a, and the inner flange 54b. Actually, the slot side surface covering portion 54d covers half of each surface forming the slot 14 in the axial direction Y. As shown in FIG. Therefore, the entire surface of each side surface of the slot 14 can be covered by the slot side covering portion 51d of the first winding frame and the slot side covering portion 54d of the fourth winding frame 54 described above.

The first winding frame 51 and the fourth winding frame 54 are attached to each core portion 60 from both sides in the axial direction so as to fit into the inner peripheral surface of the slot 14 . The first winding frame 51 and the fourth winding frame 54 electrically insulate the coil 7 and each core portion 60 . The first winding frame 51 and the fourth winding frame 54 are formed, for example, by injection molding of insulating resin.

In the first embodiment, the slot side covering portion 51d of the first winding frame 51 and the slot side covering portion 54d of the fourth winding frame 54 are formed to have substantially the same length in the axial direction Y. However, it is not limited to this, and the length of each in the axial direction Y can be changed as appropriate as long as it can cover all of the side surfaces forming the slot 14 .

Next, the configuration of the rightmost first core portion 61 in FIG. 3, which is one of the core portions 60, will be described with reference to the drawings. A first winding frame 51 is attached to the upper side of the paper surface of the first core portion 61 , and a fourth winding frame 54 is attached to the lower side of the paper surface.
10 is a perspective view showing a state in which the first winding frame 51 and the fourth winding frame 54 are attached to the first core portion 61. FIG.
11 is a diagram of the first core portion 61 to which the first winding frame 51 and the fourth winding frame 54 shown in FIG. It is the figure seen in the direction of the arrow A.
12 is a view of the first core portion 61 to which the first winding frame 51 and the fourth winding frame 54 shown in FIG. 10 are attached, viewed from the inner side X2 in the radial direction X. It is the figure seen in the arrow B direction.
13A is a view of the first core portion 61 to which the first winding frame 51 and the fourth winding frame 54 shown in FIG. It is a diagram seen in
13B is a view of the first core portion 61 to which the first winding frame 51 and the fourth winding frame 54 shown in FIG. It is a diagram seen in

As shown in FIGS. 10, 11, and 13A, a plurality of grooves M extending in the circumferential direction Z are formed in the axial direction Y on the outer peripheral surface of the outer collar 51a on the outer side X1 in the radial direction X. . Here, the groove portion M is formed in three stages, ie, a first groove portion M1, a second groove portion M2, and a third groove portion M3 from the upper side away from the core portion 60 in the axial direction Y. As shown in FIG. That is, the first groove portion M1, the second groove portion M2, and the third groove portion M3 are formed parallel to the circumferential direction Z and aligned in the axial direction Y with different heights. The first groove portion M1 is formed between a first guide G1 and a second guide G2 provided in the circumferential direction Z on the outer circumferential surface of the outer collar 51a. Similarly, the second groove portion M2 is formed between the second guide G2 and the third guide G3 provided in the circumferential direction Z on the outer circumferential surface of the outer collar 51a. The third groove portion M3 is formed between a third guide G3 and a fourth guide G4 provided in the circumferential direction Z on the outer circumferential surface of the outer collar 51a. Therefore, the first guide G1 to the fourth guide G4 are also formed parallel to the circumferential direction Z and aligned in the axial direction Y with different heights. As shown in FIG. 11, the first guide G1 is actually provided on both sides in the circumferential direction Z of the derivation groove portion 51out (first derivation groove portion) described later and in the circumferential direction of the introduction groove portion 51in (first introduction groove portion) described later. Since it is provided only in the vicinity of one edge of Z, the first groove portion M1 is formed only in the vicinity of one edge in the circumferential direction Z of both sides of the lead-out groove portion 51out in the circumferential direction Z and of the introduction groove portion 51in. Become. The second groove portion M2 and the third groove portion M3 continue in the circumferential direction Z intermittently.

The first groove portion M1, the second groove portion M2, and the third groove portion M3 are used to hold a plurality of connecting wires 70J connecting the coils 7 of different tooth portions 11b in parallel in the circumferential direction. This crossover wire 70J is a continuous line between the coils 7 . The introduction groove portion 51in formed in the outer flange 51a in the axial direction Y extends the coil wire 70 from the outer side X1 in the radial direction X of the stator core 11A to the inner side X2 in the radial direction X in order to wind the coil 7 around the tooth portion 11b. It is the entrance to introduce to

The lead-out groove portion 51out formed in the outer flange 51a in the axial direction Y extends the coil wire 70, which has been wound around the teeth portion 11b to form the coil 7, in the radial direction X from the inner side X2 in the radial direction X of the stator core 11A. It is an outlet leading to the outside X1. The lead-out groove portion 51out is inclined such that the lower end portion of the side surface of the connecting wire 70J on the connecting direction side is positioned closer to the connecting direction side of the connecting wire 70J than the upper end portion thereof.

Then, as shown in FIG. 11, the lead-out groove portion 51out formed in the outer flange 51a of the first winding frame 51 has a lower portion connected to the first groove portion M1 provided on the left side of the lead-out groove portion 51out in the circumferential direction Z. , and the height of the lower portion of the lead-out groove portion 51out and the height of the upper surface of the second guide G2 constituting the lower surface of the first groove portion M1 are set to be the same height. That is, the lower part of the lead-out groove part 51out and the upper surface of the second guide G2 are flush with each other.

14 is a perspective view of the second bobbin 52. FIG.
FIG. 15 is a view of the second core portion 62 with the second reel 52 and the fourth reel 54 mounted thereon, viewed from the radial direction X outside X1.
Since the basic configuration of the second reel 52 is the same as that of the first reel 51, only different parts will be described.
First, on the outer collar 52a of the second winding frame 52, the second guides G2 intermittently provided in the circumferential direction Z on the outer collar 51a of the first winding frame 51 are arranged in the circumferential direction Z of the outer collar 52a. It is provided only in the central portion, and is not provided at both end portions in the circumferential direction Z. Therefore, the second guide G2 does not exist on both sides of the lead-out groove portion 52out (second lead-out groove portion) in the circumferential direction Z, and the first groove portion M1 and the second groove portion M2 of the first winding frame 51 are integrated. . The same applies to the outer side in the circumferential direction Z of the introduction groove portion 52in (second introduction groove portion). Therefore, the third groove portion M3 and the second groove portion M2 at the center in the circumferential direction Z are groove portions that can fix the crossover wire 70J in the axial direction.

Further, as shown in FIG. 15, the lead-out groove portion 52out formed in the outer flange 52a of the second winding frame 52 is set to be at the same height as the upper surface of the third guide G3. In other words, the lower portion of the lead-out groove portion 52out and the upper surface of the third guide G3 are flush with each other.

16 is a perspective view of the third winding frame 53. FIG.
FIG. 17 is a view of the third core portion 63 with the third reel 53 and the fourth reel 54 mounted thereon, viewed from the outside X1 in the radial direction X. As shown in FIG.
Since the basic configuration of the third reel 53 is the same as that of the first reel 51, only different parts will be described.
First, on the outer collar 53a of the third winding frame 53, the second guide G2 and the third guide G3 intermittently provided in the circumferential direction Z on the outer collar 51a of the first winding frame 51 are attached to the outer collar 52a. The guides are provided only at the central portion in the circumferential direction Z, and the end portions in the circumferential direction Z are not provided with these guides. Therefore, the second groove portion M2 and the third groove portion M3 do not exist on both sides of the lead-out groove portion 53out (the third lead-out groove portion) in the circumferential direction Z, and the first groove portion M1, the second groove portion M2, and the third groove portion M2 in the first winding frame 51 do not exist. The three grooves M3 are integrated. The same applies to the outer side in the circumferential direction Z of the introduction groove portion 53in (third introduction groove portion).

Further, as shown in FIG. 17, the lead-out groove portion 53out formed in the outer flange 53a of the third winding frame 53 is set so that the lower portion thereof is at the same height as the upper surface of the fourth guide G4. In other words, the lower portion of the lead-out groove portion 53out and the upper surface of the fourth guide G4 are flush with each other.

Next, the coil wire 70 will be described with reference to FIGS. 3 and 4. FIG. A coil wire 70 is a wire for forming the coil 7 . Here, three coil wires 70 of a first coil wire 71, a second coil wire 72 and a third coil wire 73 are used. In the first coil wire 71 , the second coil wire 72 , and the third coil wire 73 , the portions where the winding of the coil 7 starts are the first winding start wire 711 , the second winding start wire 721 , and the third winding start wire 731 . be.

When the first winding starting wire 711, the second winding starting wire 721, and the third winding starting wire 731 are moved from the outer side X1 to the inner side X2 in the radial direction X of the stator core 11A and used as a power supply line, each part are the first power line 713 , the second power line 723 , and the third power line 733 .

In the first coil wire 71, the second coil wire 72, and the third coil wire 73, the portions pulled out after the winding of the coil 7 is finished are the first winding end wire 712, the second winding end wire 722, and the third winding wire. It is the end line 732 . First winding end 712 , second winding end 722 , and third winding end 732 are connected to form neutral point 700 . Each of the first coil wire 71, the second coil wire 72, and the third coil wire 73 is one continuous wire. In addition, when it is not necessary to use the name of each part of the coil wire 70 for description, the coil wire 70 will be generically described.

Next, the connecting wire 70J will be described with reference to FIG. The crossover wire 70J is formed as part of the coil wire 70 . The connecting wires 70J include a first connecting wire 70J1, a second connecting wire 70J2, a third connecting wire 70J3, a fourth connecting wire 70J4, a fifth connecting wire 70J5, and a sixth connecting wire 70J6. The first connecting wire 70J1 connects the coil 7 of the first core portion 61 and the coils 7 of the fourth core portion 64 separated by three in the circumferential direction Z. As shown in FIG. The second connecting wire 70J2 connects the coil 7 of the second core portion 62 and the coils 7 of the fifth core portion 65 separated by three in the circumferential direction Z. As shown in FIG. The third connecting wire 70J3 connects the coil 7 of the third core portion 63 and the coils 7 of the sixth core portion 66 that are three coils apart in the circumferential direction Z. As shown in FIG.

The fourth connecting wire 70J4 connects the coil 7 of the fourth core portion 64 and the coils 7 of the seventh core portion 67 separated by three in the circumferential direction Z. The fifth connecting wire 70J5 connects the coil 7 of the fifth core portion 65 and the coils 7 of the eighth core portion 68 separated by three in the circumferential direction Z. The sixth connecting wire 70J6 connects the coil 7 of the sixth core portion 66 and the coils 7 of the ninth core portion 69 separated by three in the circumferential direction Z.

Incidentally, when it is not necessary to distinguish between the first connecting wire 70J1 to the sixth connecting wire 70J6, they will be collectively described as the connecting wire 70J.

Next, a manufacturing process of the rotating electrical machine 100 will be described.
FIG. 18 is a flow chart showing a manufacturing process of rotating electric machine 100 .
FIG. 19 is a flow chart showing the manufacturing process of the coil 7. As shown in FIG.
FIG. 20 is an exploded view of the stator 10 in the coil forming process. FIG. 4 is a rear view showing a state in which the stator 10 is linearly rotated (deformed), and is a view of the stator 10 as seen from the outer peripheral side.
FIG. 21 is a diagram showing the movement of the winding nozzle of the winding machine.
First, two types of core piece groups 11k1 and 11k2 are alternately punched out from a magnetic steel plate, and a plurality of groups are laminated in the axial direction Y, and adjacent core portions 60 are connected by the connecting portion 111 of the yoke portion 11a. , the stator core 11A is formed (ST1: stator core manufacturing step).

Next, in the slots 14 on both sides in the circumferential direction Z of the first core portion 61, the fourth core portion 64, and the seventh core portion 67, from one end side in the axial direction Y, the slot side covering portion 51d of the first winding frame 51 is inserted. , and the slot side covering portion 54d of the fourth winding frame 54 is fitted and mounted from the other end side. Similarly, the second core portion 62, the fifth core portion 65 and the eighth core portion 68 are provided with the second winding frame 52 and the fourth winding frame 54, and the third core portion 63, the sixth core portion 66 and the ninth core portion 63 The third winding frame 53 and the fourth winding frame 54 are mounted on the core portion 69 (ST2: winding frame mounting step). In this manner, three types of winding frames are attached to one end of the nine core portions 60, and the same fourth winding frame 54 is attached to the other end.

Next, the coil forming step (ST3) for forming the coil 7 will be described with reference to FIGS. 19, 20, 21, 11, 15 and 17. FIG.
First, the first coil wire 71 is introduced from the outside X1 to the inside X2 in the radial direction X using the introduction groove portion 51in of the first core portion 61 . At this time, at the same time, the second coil wire 72 and the third coil wire 73 are similarly pulled from the outside X1 in the radial direction X using the introduction groove portions 52in and 53in of the second core portion 62 and the third core portion 63, respectively. It is introduced into the inside X2 (FIG. 19, ST31: introduction step).

Then, as shown in FIG. 21, the first core portion 61, the A first coil wire 71, a second coil wire 72, and a third coil wire 73 are simultaneously wound around the tooth portions 11b of the second core portion 62 and the third core portion 63, respectively, as indicated by arrows N11, N21, and N31. (FIG. 19, ST32: Winding step).

FIG. 22 is a perspective view showing movement of each winding nozzle in the winding process. The first winding nozzle N1, the second winding nozzle N2 and the third winding nozzle N3 all perform the same operation at the same time.
FIG. 23 is a perspective view showing the state of the core portion 60 at the end of the winding process.
After the coil 7 is wound around the teeth portion 11b of each of the first core portion 61, the second core portion 62 and the third core portion 63, the first winding nozzle N1, the second winding nozzle N2, the third winding By moving the nozzle N3 from position P1 to position P5 in FIG. The wire 73 is simultaneously entwined around the entwining portions 54k of the fourth winding frames 54 of the first core portion 61, the second core portion 62, and the third core portion 63 (FIG. 19, ST32B: entwining step), To prevent loosening of each coil 7 wound immediately before. At this time, by moving the first winding nozzle N1, the second winding nozzle N2, and the third winding nozzle N3 from the position P3 to the position P4, the first coil wire 71, the second coil wire 72, the third coil wire The coil wire 73 is guided to the gap 54r between the engaging portion 54f and the binding portion 54k, and is fixed to the bottom of the gap 54r by moving to the position P5 (ST32C: locking step).

As shown in FIG. 23, when the winding process is completed, the coil wire 70 is wound around the winding portion 54k once, and the coil wire 70 crosses inside the winding portion 54k. A locking effect can be exhibited at the portion where 70 overlaps. In addition, the protrusion 54t can prevent the coil wire 70 from coming off the winding portion 54k during the winding process.

FIG. 24 shows the first winding nozzle after the first to third coil wires 71 to 73 of the first core portion 61, the second core portion 62, and the third core portion 63 are bound around the respective binding portions 54k. FIG. 10 is a diagram showing movements of N1, a second winding nozzle N2, and a third winding nozzle N3;
After forming the coils 7 on the teeth portions 11b of the first core portion 61, the second core portion 62, and the third core portion 63 as described above, the first coil wire 71, the second coil wire 72, and the third coil The wire 73 is wrapped around the binding portions 54k of the first core portion 61, the second core portion 62, and the third core portion 63, and sandwiched and fixed between the binding portions 54k and the engaging portions 54f to form a coil. Looseness of the wire 70 is prevented, and furthermore, the lead-out grooves 51out, 52out, and 53out hold the wire 70 so as to prevent loosening, and lead out from the inner side X2 in the radial direction X to the outer side X1 (see FIG. 20). Then, in order to perform the next winding process (step ST33-NO), the first winding nozzle N1, the second winding nozzle N2, and the third winding nozzle N3 are moved in the direction of arrow E, respectively. While feeding the wire 71, the second coil wire 72, and the third coil wire 73, the first winding nozzle N1 reaches the position of the fourth core portion 64, and the second winding nozzle N2 reaches the position of the fifth core portion 65. , the third winding nozzle N3 is moved by three teeth to the position of the sixth core portion 66 (FIG. 19, ST34: nozzle moving step).

At this time, the first connecting wire 70J1 that connects the coil 7 of the first core portion 61 and the coil 7 of the fourth core portion 64 is arranged so that the lower end portion of the side surface in the connecting direction is closer than the upper end portion of the first connecting wire 70J1. 11 and 20 of the first core portion 61 from the bottom portion of the lead-out groove portion 51out inclined so as to be located on the crossing direction side, is held in the first groove portion M1 provided on the left side in the circumferential direction of the lead-out groove portion 51out in FIGS. Further, along the upper surface of the second guide G2 and the lower surface of the first guide G1 of the third core portion 63, which is held in the first groove portion M1 of the second core portion 62 connected in the circumferential direction Z and further connected in the circumferential direction Z 11 and 20 of the fourth core portion 64 connected in the circumferential direction Z and held in the first groove portion M1 provided on the right side in the circumferential direction of the introduction groove portion 51in. It is introduced from the outside X1 to the inside X2 in the radial direction X of the portion 64 .

In addition, the second connecting wire 70J2 that connects the coil 7 of the second core portion 62 and the coil 7 of the fifth core portion 65 has a lower end portion of the side surface in the connecting direction that is closer to the second connecting wire 70J2 than the upper end portion. A third core portion 63 is connected in the circumferential direction Z along the upper surface of the third guide G3 of the second core portion 62 shown in FIG. , held in the second groove portion M2 of the fourth core portion 64 connected in the circumferential direction Z, and further held in the second groove portion M2 of the fifth core portion 65 connected in the circumferential direction Z, on the upper surface of the third guide G3 of the fifth core portion 65 Along the way, it is introduced from the outside X1 to the inside X2 in the radial direction X of the fifth core portion 65 from the introduction groove portion 52in.

Similarly, in the third connecting wire 70J3 that connects the coil 7 of the third core portion 63 and the coil 7 of the sixth core portion 66, the lower end portion of the side surface in the connecting direction is closer to the third connecting wire 70J3 than the upper end portion. 17 along the upper surface of the fourth guide G4 of the third core portion 63 shown in FIG. 17, the fourth core portion connected in the circumferential direction Z 64, held in the third groove portion M3 of the fifth core portion 65 connected in the circumferential direction Z, and further connected in the circumferential direction Z, the fourth guide G4 of the sixth core portion 66 is introduced from the outer side X1 to the inner side X2 in the radial direction X of the sixth core portion 66 from the introduction groove portion 53in.

Then, similarly to the first core portion 61 to the third core portion 63, the first winding nozzle N1, the second winding nozzle N2, and the third winding nozzle N3 are used to form the fourth core portion 64 and the fifth core portion. A first coil wire 71, a second coil wire 72, and a third coil wire 73 are simultaneously wound around the tooth portions 11b of the portion 65 and the sixth core portion 66, respectively, as indicated by arrows N11, N21, and N31.

After the coil 7 is wound around the teeth portion 11b of each of the fourth core portion 64, the fifth core portion 65, and the sixth core portion 66, the first winding nozzle N1, the second winding nozzle N2, the third winding By moving the nozzle N3 from position P1 to position P5 in FIG. The wire 73 is simultaneously bound around the binding portions 54k of the fourth winding frames 54 of the fourth core portion 64, the fifth core portion 65, and the sixth core portion 66 (FIG. 19, ST32B: binding step), To prevent loosening of each coil 7 wound immediately before. At this time, by moving the first winding nozzle N1, the second winding nozzle N2, and the third winding nozzle N3 from the position P3 to the position P4, the first coil wire 71, the second coil wire 72, the third coil wire The coil wire 73 is guided to the gap 54r between the engaging portion 54f and the binding portion 54k, and is fixed to the bottom of the gap 54r by moving to the position P5 (ST32C: locking step).

After forming the coils 7 on the teeth portions 11b of the fourth core portion 64, the fifth core portion 65, and the sixth core portion 66 in this way, the first coil wire 71, the second coil wire 72, and the third coil The wire 73 is bound around the binding portions 54k of the fourth core portion 64, the fifth core portion 65, and the sixth core portion 66, and is sandwiched between the binding portions 54k and the locking portions 54f to form a coil. The wire 70 is prevented from being loosened, and is further held so as to be prevented from being loosened by each lead-out groove portion 51out, and is led out from the inner side X2 in the radial direction X to the outer side X1 (see FIG. 20). Then, in order to perform the next winding process, the first winding nozzle N1, the second winding nozzle N2, and the third winding nozzle N3 are moved in the direction of arrow E, respectively, the first coil wire 71 and the second coil wire. While paying out the wire 72 and the third coil wire 73, the first winding nozzle N1 reaches the position of the seventh core portion 67, the second winding nozzle N2 reaches the position of the eighth core portion 68, and the third winding The nozzle N3 is moved to the position of the ninth core portion 69 .

At this time, the fourth connecting wire 70J4 that connects the coil 7 of the fourth core portion 64 and the coil 7 of the seventh core portion 67 is arranged so that the lower end portion of the side surface on the connecting direction side is closer to the upper end portion than the upper end portion of the fourth connecting wire 70J4. 11 and 20 of the fourth core portion 64 from the bottom portion of the lead-out groove portion 51out inclined so as to be located on the crossing direction side, is held in the first groove portion M1 provided on the left side in the circumferential direction of the lead-out groove portion 51out in FIGS. Further, along the upper surface of the second guide G2 and the lower surface of the first guide G1 of the sixth core portion 66, which is held in the first groove portion M1 of the fifth core portion 65 connected in the circumferential direction Z and further connected in the circumferential direction Z 11 and 20 of the seventh core portion 67 connected in the circumferential direction Z and held in the first groove portion M1 provided on the right side in the circumferential direction of the introduction groove portion 51in. It is introduced from the outside X1 to the inside X2 in the radial direction X of the portion 67 .

In addition, the fifth connecting wire 70J5 that connects the coil 7 of the fifth core portion 65 and the coil 7 of the eighth core portion 68 has a lower end portion of the side surface in the connecting direction that is closer to the fifth connecting wire 70J5 than the upper end portion. A sixth core portion 66 is connected in the circumferential direction Z from the bottom of the lead-out groove portion 52out inclined so as to be positioned on the transfer direction side along the upper surface of the third guide G3 of the fifth core portion 65 shown in FIG. held in the second groove portion M2 of, further held in the second groove portion M2 of the seventh core portion 67 connected in the circumferential direction Z, and further connected in the circumferential direction Z on the upper surface of the third guide G3 of the eighth core portion 68 Along the way, it is introduced from the outside X1 to the inside X2 in the radial direction X of the eighth core portion 68 from the introduction groove portion 52in.

Similarly, in the sixth connecting wire 70J6 connecting the coil 7 of the sixth core portion 66 and the coil 7 of the ninth core portion 69, the lower end portion of the side surface on the connecting direction side is located higher than the upper end portion of the sixth connecting wire 70J6. From the bottom of the lead-out groove portion 53out inclined so as to be located on the transition direction side, along the upper surface of the fourth guide G4 of the sixth core portion 66 shown in FIG. The upper surface of the fourth guide G4 of the ninth core portion 69, which is held in the third groove portion M3 of 67, is held in the third groove portion M3 of the eighth core portion 68 connected in the circumferential direction Z, and is further connected in the circumferential direction Z. is introduced from the outer side X1 to the inner side X2 in the radial direction X of the ninth core portion 69 from the introduction groove portion 53in.

Then, similarly to the fourth core portion 64 to the sixth core portion 66, the first winding nozzle N1, the second winding nozzle N2 and the third winding nozzle N3 are used to form the seventh core portion 67 and the eighth core portion. A first coil wire 71, a second coil wire 72, and a third coil wire 73 are simultaneously wound around the tooth portions 11b of the portion 68 and the ninth core portion 69, respectively, as indicated by arrows N11, N21, and N31.

After winding the coil 7 around each of the tooth portions 11b of the seventh core portion 67, the eighth core portion 68 and the ninth core portion 69, the first winding nozzle N1, the second winding nozzle N2, the third winding By moving the nozzle N3 from position P1 to position P5 in FIG. The wire 73 is simultaneously bound around the binding portions 54k of the fourth winding frames 54 of the seventh core portion 67, the eighth core portion 68, and the ninth core portion 69 (FIG. 19, ST32B: binding step), To prevent loosening of each coil 7 wound immediately before. At this time, by moving the first winding nozzle N1, the second winding nozzle N2, and the third winding nozzle N3 from the position P3 to the position P4, the first coil wire 71, the second coil wire 72, the third coil wire The coil wire 73 is guided to the gap 54r between the engaging portion 54f and the binding portion 54k, and is fixed to the bottom of the gap 54r by moving to the position P5 (ST32C: locking step).

After the coils 7 are formed on the teeth portions 11b of the seventh core portion 67, the eighth core portion 68, and the ninth core portion 69, the first coil wire 71, the second coil wire 72, and the third coil wire 73 are formed. to form a first winding end 712, a second winding end 722, and a third winding end 732. Then, the first winding end wire 712, the second winding end wire 722, and the third winding end wire 732 are crimped together to form the neutral point 700 of the star connection (see FIG. 3). As a method of assembling, a connection process such as crimping, brazing or soldering with a terminal may be used (FIG. 19, ST33-YES, ST35: connection and wiring process).

In this way, the lower portion of the lead-out groove portion 51out of the first winding frame 51 is flush with the upper surface of the second guide G2, and the lower portion of the lead-out groove portion 52out of the second winding frame 52 is flush with the upper surface of the third guide G3. The lower part of the lead-out groove portion 53out of the third winding frame 53 is connected flush with the upper surface of the fourth guide G4. Each of the side surfaces is inclined so that the lower end thereof is positioned closer to the crossing direction of the connecting wire 70J than the upper end thereof. While being fixed to the lower portions of 51out to 53out, the connecting wires 70J constituting each phase are held in the first to third groove portions M1 to M3 at different heights in the axial direction.

As shown in FIG. 3, the first coil wire 71 formed in this manner is not cut in the middle, but is formed as a continuous wire by forming a first winding start wire 711, a coil 7 of the first core portion 61, and a first connecting wire. 70J1, the coil 7 of the fourth core portion 64, the fourth connecting wire 70J4, the coil 7 of the seventh core portion 67, and the end wire 712 of the first winding. Similarly, the second coil wire 72 is formed as a continuous wire without being cut in the middle, the second winding start wire 721, the coil 7 of the second core portion 62, the second connecting wire 70J2, and the coil 7 of the fifth core portion 65. , the fifth connecting wire 70J5, the coil 7 of the eighth core portion 68, and the second winding end wire 722. Similarly, the third coil wire 73 is formed as a continuous wire without being cut in the middle. , the sixth connecting wire 70J6, the coil 7 of the ninth core portion 69, and the third winding end wire 732.

Next, a process of using the first winding starting wire 711, the second winding starting wire 721, and the third winding starting wire 731 as power supply lines is performed. These three first winding starting wires 711, second winding starting wires 721, and third winding starting wires 731 need to be arranged inside X2 in the radial direction X of the stator 10 when the stator 10 is formed into an annular shape. However, when the winding of the coil 7 is finished, the first winding starting wire 711, the second winding starting wire 721, and the third winding starting wire 731 are arranged in the radial direction of the stator 10 as shown by solid lines in FIG. It is on the outside X1 side of X.

By the way, even if all the coils 7 are formed, the second groove portion M2 and the third groove portion M3 of the first core portion 61 and the third groove portion M3 of the second core portion 62 are not used to hold the connecting wire 70J.

1, the first winding start wire 711, the second winding start wire 721, and the third winding start wire 731 are folded back as shown by the broken lines in FIG. M2 is passed through the third groove portion M3, and is arranged inside X2 in the radial direction X of the stator 10 through a notch K that is continuously cut in the circumferential direction Z of the introduction groove portion 51in of the first core portion 61 . The first power line 713, the second power line 723, and the third power line 733 are wired inside X2 in the radial direction X by covering them with insulating tubes to maintain insulation (FIG. 19, ST35: wire connection and wiring process). .

Next, each core portion 60 is circularly rotated and deformed, and the ends of the stator core 11A are fixed together by welding or the like to form the stator 10 (FIG. 18, ST4: stator forming step). Next, the outer peripheral surface of the stator 10 is fixed to the inner peripheral surface of the frame 101 (FIG. 18, ST5: stator fixing step). Next, the rotor 20 is rotatably supported on the bracket 103 by bearings (not shown), and the rotor 20 is arranged to face the stator 10 with a gap therebetween (FIG. 18, ST6: rotor placement step). Rotating electric machine 100 is formed by these processes.

In the description so far, the method of forming the coil 7 by linearly rotating the plurality of yoke portions 11a of the stator core 11A and winding the coil wire 70 around the tooth portions 11b has been shown, but the method is not limited to this. . As another method, a method of forming a coil is performed by rotating a plurality of yoke portions 11a of the stator core 11A using connecting portions so that the direction in which the tooth portions protrude in the radial direction X is reversed to the product state. explain.

FIG. 25 is a conceptual diagram showing another winding method. The manufactured stator 10 is the same except that the winding machine is different. The winding machine 400 has a hexagonal chuck mechanism 40 . The chuck mechanism 40 has chucks 41 , 42 , 43 , 44 , 45 and 46 .

A first winding nozzle NB1, a second winding nozzle NB2, and a third winding nozzle NB3 for winding the coil wire 70 are installed at positions facing the chucks 41, 42, and 43 in FIG. The first winding nozzle NB1, the second winding nozzle NB2, and the third winding nozzle NB3 are rotated around the rotation axis RB1, the rotation axis RB2, and the rotation axis RB3, and the coil wire 70 is wound around each tooth portion 11b. do. However, unlike the case of FIG. 3, FIG. 25 shows the axial direction Y reversed. That is, FIG. 25 is a diagram showing a state in which the fourth winding frame 54 of each core portion 60 is visible. Since the chuck mechanism 40 rotates in the direction of the arrow R, the positions of the chucks 41 to 46 change.

First, as shown in FIG. 25, the first core portion 61, the second core portion 62 and the third core portion 63 are fixed to the chucks 41, 42 and 43, respectively. Then, the first winding nozzle NB1, the second winding nozzle NB2, and the third winding nozzle NB3 are rotated around the rotation axes RB1, RB2, and RB3, and the coil wire 70 is wound around each tooth portion 11b to form the coil 7. to form

After the coil 7 is wound around each of the tooth portions 11b of the first core portion 61, the second core portion 62 and the third core portion 63, the first winding nozzle NB1, the second winding nozzle NB2, the third winding nozzle By moving the nozzle NB3 from position P1 to position P5 in FIG. The wire 73 is simultaneously bound around the binding portion 54k of the fourth winding frame 54 of each of the first core portion 61, the second core portion 62, and the third core portion 63 (FIG. 19, ST32B binding step). It is fixed between the locking portion 54f and the binding portion 54k to prevent loosening of the coils 7 wound immediately before (ST32C locking step).

After the first winding process is completed, the first winding nozzle NB1, the second winding nozzle NB2, and the third winding nozzle NB3 are moved back and forth and up and down, and the chuck mechanism 40 is rotated. Then, the crossover wire 70J is made to extend between predetermined core portions 60 in the same manner as described above.

At this time, the chuck mechanism 40 rotates three times at a pitch of 60°. That is, until the fourth core portion 64 shown in FIG. 25 comes to the position where the first core portion 61 was fixed in the first coil winding process (moved by three core portions 60), the Repeat the rotation 3 times. At this time, all other core portions 60 are also moved at the same time (a core portion moving step that replaces the nozzle moving step). 25, the core portion 60 is sequentially ejected from the position of the chuck 46 shown in FIG. 25, so the stator core 11A is not fixed to the chuck mechanism 40 at the position of the chuck 45 shown in FIG.

According to this method, the coil 7 can be formed by winding the coil wire 70 around the tooth portions 11b while securing a wide space between the tooth portions 11b adjacent to each other in the circumferential direction Z. That is, as shown in FIG. 25, the rotating shafts of the first winding nozzle NB1, the second winding nozzle NB2, and the third winding nozzle NB3 can always be directed toward the teeth portion 11b. Therefore, the coil wire 70 can be wound at high speed around the tooth portion 11b, and the cycle time for winding the coil wire 70 can be shortened.

The method for manufacturing the stator of the rotary electric machine shown in the first embodiment can be similarly performed in the following embodiments, and therefore the description thereof will be omitted as appropriate.

Further, in Embodiment 1, three types of winding frames, ie, the first winding frame 51, the second winding frame 52, and the third winding frame 53 are used on one end side of each core portion 60, but the first winding frame 51 alone may be used.
Further, in the present embodiment, the first groove portion M1 to the third groove portion M3 are provided parallel to the circumferential direction Z, but the first groove portion M1 to the third groove portion M3 may be provided obliquely.

Moreover, in the first embodiment, an example in which the insulating portion is composed of a plurality of members has been shown, but the insulating portion may be formed integrally with each core portion 60 . For example, after laminating each core portion 60, an insulating portion having a shape in which the first winding frame 51 and the fourth winding frame 54 are combined with the core portions 60 may be integrally resin-molded.

Moreover, even if a stator core without the shoe portion 11c is used, it is sufficient if the stator core is provided with a winding frame capable of forming the coil 7 on the insulator.

According to the stator of the rotary electric machine of Embodiment 1 configured as described above,
a stator core formed by annularly combining a plurality of core portions each having a yoke portion and tooth portions formed so as to protrude radially inward from a circumferential center portion of an inner peripheral surface of the yoke portion;
A rotating electrical machine comprising: a coil formed by winding a coil wire around each of the plurality of tooth portions; and an insulating portion disposed between the core portion and the coil to insulate the stator core and the coil. is the stator of
The first winding frame as the insulating portion includes a first tooth end surface covering portion covering one axial end surface of a portion of the tooth portion around which the coil is wound, and a radial direction of the first tooth end surface covering portion. a first outer flange that is connected to the outer end and that covers one axial end surface of the yoke portion and protrudes axially upward;
The fourth winding frame as the insulating portion includes a second tooth end surface covering portion covering the other axial end surface of the portion of the tooth portion around which the coil is wound, and a radial direction of the second tooth end surface covering portion. a second outer flange connected to the outer end portion and projecting upward in the axial direction to cover the other axial end surface of the yoke portion;
The second outer collar protrudes upward in the axial direction from a central portion in the circumferential direction, and includes a binding portion that binds the winding end portions of the coils,
Since the plurality of coils are formed by the continuous coil wire,
It is possible to prevent winding collapse of each coil.
In addition, it is possible to prevent the interference of the stator crossover wire, make the number of turns of the tooth coil the same, and make the direction of the winding start wire and the winding end wire common, so that electrical problems such as pulsation and vibration can be reduced. We can provide stators for rotating electric machines. Moreover, the number of connection members can be reduced, and the manufacturing time can be shortened to improve productivity.

In addition, since the binding portion has protrusions projecting from the upper end in the axial direction to both sides in the circumferential direction, it is possible to prevent the coil wire from coming off the binding portion during the binding process.

Further, the second outer brim protrudes radially outward from the axially upper end portion of the outer peripheral surface and the circumferentially central portion, and extends axially upwardly in parallel with the binding portion. A hook-shaped locking portion is provided, and the width in the radial direction of the gap between the binding portion and the locking portion is smaller than the wire diameter of the coil wire. The wire coil can be fixed between the binding part and the locking part, and the collapse of the winding of the coil and the loosening of the connecting wire can be prevented.

In addition, the first outer collar includes a plurality of guides extending in the circumferential direction and arranged in the axial direction, each of which forms a plurality of grooves each holding a plurality of connecting wires connecting the coils of the different teeth. Therefore, it is possible to prevent interference between crossover wires of multiple phases.

Further, since the yoke portion of the core portion is formed so that the yoke portion of each of the plurality of core portions can be linearly deformed,
linearly deforming the yoke portion of the stator core;
a winding step of winding the coil wire around the teeth using a winding nozzle to form the coil;
a winding step of winding the coil wire around the winding portion;
A coil is formed by winding the coil wire around the teeth using a method for manufacturing a stator for a rotating electric machine, which includes a locking step of fixing the coil wire between the binding portion and the locking portion. Then, the winding end line can be tied around the binding portion and then fixed between the binding portion and the engaging portion. As a result, it is possible to prevent the winding collapse of the coil and the loosening of the connecting wire.

Further, since the yoke portion is formed so as to be deformable in a reverse warp shape that reverses the direction in which the plurality of teeth portions protrude in the radial direction,
deforming the yoke portion of the stator core into a reverse warp;
a winding step of winding the coil wire around the teeth using a winding nozzle to form the coil;
a winding step of winding the coil wire around the winding portion;
A coil is formed by winding the coil wire around the teeth using a method for manufacturing a stator for a rotating electric machine, which includes a locking step of fixing the coil wire between the binding portion and the locking portion. Then, the winding end line can be tied around the binding portion and then fixed between the binding portion and the engaging portion. As a result, it is possible to prevent the winding collapse of the coil and the loosening of the connecting wire.

Embodiment 2.
Hereinafter, a stator of a rotating electrical machine, a rotating electrical machine, a method of manufacturing a stator of a rotating electrical machine, and a method of manufacturing a rotating electrical machine according to a second embodiment will be described with reference to drawings, focusing on portions different from the first embodiment.
26 is a perspective view showing a state in which the first winding frame 251, the second winding frame 252, the third winding frame 253, the fourth winding frame 254, and the film portion 230 are attached to each core portion 60. FIG. The yoke portion 11a of each core portion 60 is linearly deformed, and the first winding frame 251, the second winding frame 252, the third winding frame 253 on the upper side of the paper surface as an insulating portion, the fourth winding frame 254 on the lower side of the paper surface and A state in which the film portion 230 is attached to each slot 14 is shown.

27 is an exploded perspective view of each member in FIG. 26. FIG.
FIG. 28 is a perspective view showing the configuration of the film portion 230 shown in FIG. 26. As shown in FIG.
29A is a perspective view showing the configuration of the first winding frame 251 shown in FIG. 27. FIG.
29B is a perspective view of the first winding frame 251 shown in FIG. 29A as seen from the opposite side in the axial direction Y. FIG.
FIG. 30 is a perspective view showing the configuration of the fourth winding frame 254. As shown in FIG.

As shown in each figure, the stator 10 according to the second embodiment includes a first winding frame 251, a second winding frame 252, and a third winding frame 253 as insulating portions for insulating each of the plurality of core portions 60 and the coils 7. And the configuration of the fourth winding frame 254 is different from each winding frame of the first embodiment. In the second embodiment, in order to insulate the plurality of core portions 60 and the coils 7, the insulating portion covers the side surfaces of these four types of winding frames and the slot 14, and has an electrically insulating film portion 230 (slot side covering portion).

The first reel 251, the second reel 252, the third reel 253, and the fourth reel 254 do not have the slot side covering portions that the reels in the first embodiment have. That is, as shown in FIG. 29A, the first winding frame 251 includes a tooth end surface covering portion 251c, an outer flange 251a, and an inner flange 251b, which are integrally formed. The tooth end surface covering portion 251c covers one end surface in the axial direction Y of the portion of the tooth portion 11b around which the coil 7 is wound. The outer flange 251a is connected to an outer X1 end in the radial direction X of the tooth end surface covering portion 251c, covers one end surface in the axial direction Y of the yoke portion 11a, and protrudes upward in the axial direction Y. As shown in FIG.

The inner flange 251b is connected to an inner X2 end in the radial direction X of the tooth end surface covering portion 251c, covers an inner tip portion of one end surface of the tooth portion 11b and one end surface of the shoe portion 11c, and extends upward in the axial direction Y. protrude.

Since the first winding frame 251, the second winding frame 252, and the third winding frame 253 have the same configuration of the winding frames to be described below, the first winding frame 251 is used in the description.
The first winding frame 251 includes claw portions bt1, bt2, and at1 for fixing the film portion 230, which will be described later. Among the three claw portions, claw portions bt1 and bt2 are provided on the outer side X1 in the radial direction X of both end portions in the circumferential direction Z of the inner collar 251b. The remaining claw portion at1 is provided on the side surface in the circumferential direction Z of the end portion of the tooth end surface covering portion 251c on the outer collar 251a side, on the side where the lead-out groove portion 251out exists. Each of the claw portions bt1, bt2, and at1 protrudes downward in the axial direction Y. As shown in FIG. No claw portion is provided on the opposite side in the circumferential direction Z from the side where the claw portion at1 is provided. Since the lead-in groove portion 251in for the coil wire 70 is provided on the outside X1 side in the radial direction X of the relevant portion, interference with the lead-in wire is avoided.

As shown in FIG. 30, the fourth winding frame 254 has four claw portions bt3, bt4, at3, and at4. Since the fourth winding frame 254 does not interfere with the lead-in wire, a claw portion at4 is provided at a portion corresponding to the omitted portion of the first winding frame 251 .

Further, as shown in FIG. 29B, the lower surface of the first winding frame 251 is provided with a convex portion 251e that protrudes downward in the axial direction Y. As shown in FIG. Further, as shown in FIG. 30, a convex portion 254e that protrudes downward in the axial direction Y is provided on the lower surface of the fourth winding frame 254. As shown in FIG. The convex portion 251e and the convex portion 254e are used to position the first winding frame 251 and the fourth winding frame 254 on both end surfaces of the core portion 60 in the axial direction Y, respectively. The convex portion 251e is fitted into the second concave portion 11r provided on one end surface of the core portion 60 in the axial direction Y, and the convex portion 254e is engaged with the second concave portion 11r provided on the other end surface of the core portion 60 in the axial direction Y. to be accepted.

The film part 230 is formed of a thin insulating film material, and for example, a film material having a thickness of 0.125 mm may be used. Then, the film material is formed with a plurality of creases in a shape as shown in FIG. With this crease, the film portion 230 forms a first yoke inner peripheral surface covering portion that covers a yoke inner peripheral surface 112 that is one side surface in the axial direction Y of the inner side X2 in the radial direction X of the yoke portion 11a of the first core portion 61. 231, a first side surface covering portion 232 covering one side surface of the tooth portion 11b in the circumferential direction Z and the outer peripheral surface of one shoe portion 11c, and an inner side X2 of the tooth portion 11b of the first core portion 61 in the radial direction X. , the continuous portion 233 continuing to the second side surface covering portion 232b covering the outer peripheral surface of the other shoe portion 11c and the side surface of the other tooth portion 11b, the second side surface covering portion 232b, and the first core portion The other yoke inner peripheral surface 112 of the second core portion 62 and the second yoke inner peripheral surface covering portion 231b that continuously covers the one yoke inner peripheral surface 112 of the second core portion 62 are continuous. It is formed to cover up to 69.

The film portion 230 includes claw portions bt1, bt2, and at1 provided on each core portion 60 and the first reel frame 251, the second reel frame 252, the third reel frame 253, and the fourth reel frame 254 described above. , bt1 to bt4, each core portion 60 and the coil 7 can be completely insulated. Note that the continuous portion 233 and the second yoke inner peripheral surface covering portion are cut after the coil 7 is wound.

According to the stator of the rotating electrical machine, the rotating electrical machine, the method of manufacturing the stator of the rotating electrical machine, and the method of manufacturing the rotating electrical machine according to the second embodiment,
a stator core formed by annularly combining a plurality of core portions each having a yoke portion and tooth portions formed so as to protrude radially inward from a circumferential center portion of an inner peripheral surface of the yoke portion;
A rotating electrical machine comprising: a coil formed by winding a coil wire around each of the plurality of tooth portions; and an insulating portion disposed between the core portion and the coil to insulate the stator core and the coil. is the stator of
The first winding frame as the insulating portion includes a first tooth end surface covering portion covering one axial end surface of a portion of the tooth portion around which the coil is wound, and a radial direction of the first tooth end surface covering portion. a first outer flange that is connected to the outer end and that covers one axial end surface of the yoke portion and protrudes axially upward;
The fourth winding frame as the insulating portion includes a second tooth end surface covering portion covering the other axial end surface of the portion of the tooth portion around which the coil is wound, and a radial direction of the second tooth end surface covering portion. a second outer flange connected to the outer end portion and projecting upward in the axial direction to cover the other axial end surface of the yoke portion;
The second outer collar protrudes upward in the axial direction from a central portion in the circumferential direction, and includes a binding portion that binds the winding end portions of the coils,
Since the plurality of coils are formed by the continuous coil wire,
It is possible to prevent winding collapse of each coil.
In addition, it is possible to prevent the interference of the stator crossover wire, make the number of turns of the tooth coil the same, and make the direction of the winding start wire and the winding end wire common, so that electrical problems such as pulsation and vibration can be reduced. We can provide stators for rotating electric machines. Moreover, the number of connection members can be reduced, and the manufacturing time can be shortened to improve productivity.

In addition, since the binding portion has protrusions projecting from the upper end in the axial direction to both sides in the circumferential direction, it is possible to prevent the coil wire from coming off the binding portion during the binding process.

Further, the second outer brim protrudes radially outward from the axially upper end portion of the outer peripheral surface and the circumferentially central portion, and extends axially upwardly in parallel with the binding portion. A hook-shaped locking portion is provided, and the width in the radial direction of the gap between the binding portion and the locking portion is smaller than the wire diameter of the coil wire. The wire coil can be fixed between the binding part and the locking part, and the collapse of the winding of the coil and the loosening of the connecting wire can be prevented.

In addition, the first outer collar includes a plurality of guides extending in the circumferential direction and arranged in the axial direction, each of which forms a plurality of grooves each holding a plurality of connecting wires connecting the coils of the different teeth. Therefore, it is possible to prevent interference between crossover wires of multiple phases.

Further, since the yoke portion of the core portion is formed so that the yoke portion of each of the plurality of core portions can be linearly deformed,
linearly deforming the yoke portion of the stator core;
a winding step of winding the coil wire around the teeth using a winding nozzle to form the coil;
a winding step of winding the coil wire around the winding portion;
A coil is formed by winding the coil wire around the teeth using a method for manufacturing a stator for a rotating electric machine, which includes a locking step of fixing the coil wire between the binding portion and the locking portion. Then, the winding end line can be tied around the binding portion and then fixed between the binding portion and the engaging portion. As a result, it is possible to prevent the winding collapse of the coil and the loosening of the connecting wire.

Further, since the yoke portion is formed so as to be deformable in a reverse warp shape that reverses the direction in which the plurality of teeth portions protrude in the radial direction,
deforming the yoke portion of the stator core into a reverse warp;
a winding step of winding the coil wire around the teeth using a winding nozzle to form the coil;
a winding step of winding the coil wire around the winding portion;
A coil is formed by winding the coil wire around the teeth using a method for manufacturing a stator for a rotating electric machine, which includes a locking step of fixing the coil wire between the binding portion and the locking portion. Then, the winding end line can be tied around the binding portion and then fixed between the binding portion and the engaging portion. As a result, it is possible to prevent the winding collapse of the coil and the loosening of the connecting wire.

Embodiment 3.
Hereinafter, a stator of a rotating electrical machine, a rotating electrical machine, a method of manufacturing a stator of a rotating electrical machine, and a method of manufacturing a rotating electrical machine according to a third embodiment will be described with reference to drawings, focusing on portions different from the first embodiment.
The stator of the present embodiment is the same as the stator 10 of the first embodiment, except that the stator core 311A used in the stator has a different configuration.

FIG. 31 is a perspective view of stator core 311A.
FIG. 32 is an enlarged plan view of the main part of stator core 311A.
The difference between the stator core 11A of the first embodiment and the stator core 311A of the present third embodiment is that the adjacent core portions 60 constituting the stator core 11A of the first embodiment are located at the ends of the yoke portion 11a in the circumferential direction Z. While the rotatable connecting portions 111 are formed to be connected, the adjacent core portions 360 constituting the stator core 311A of the third embodiment are formed at the ends of the yoke portion 311a in the circumferential direction Z. are connected by a folded bendable connecting portion 111B.

In the stator core 11A of the first embodiment, the coupling portion 111 is formed by alternately stacking two types of core piece groups 11k1 and 11k2 formed by punching thin magnetic steel plates in the axial direction Y. , in the third embodiment, a plurality of core plates 311k of one type formed by punching a thin magnetic steel plate are laminated in the axial direction Y. FIG.

The core plate 311k is formed such that the portions that are laminated to form the yoke portions 311a are arranged in a straight line, that is, the portions that become the teeth portions 311b are arranged so as to be arranged in parallel, forming the adjacent yoke portions 311a. The parts are not physically separated but thinly connected. Therefore, by simply stacking a plurality of core plates 311k of one type in the axial direction Y, thin connecting portions 111B can be formed between adjacent core portions 360. FIG.

When a plurality of core plates 311k are stacked in the axial direction Y, the yoke portions 311a of the respective core portions 360 are kept aligned in a straight line. The stator of the third embodiment also includes the same insulating member as the insulating member used in the first or second embodiment.
After completion of winding on each tooth portion 311b, the connecting portion 111B is plastically deformed and bent so that the yoke portions 311a are arranged in an annular shape. At this time, the positional relationship between each yoke portion 311a and each tooth portion 311b is the same as the positional relationship between each yoke portion 11a and each tooth portion 11b in the first embodiment.

The stator according to the present embodiment also has the same configuration as the stator according to the first embodiment except for the stator core connecting portion.
a stator core formed by annularly combining a plurality of core portions each having a yoke portion and tooth portions formed so as to protrude radially inward from a circumferential center portion of an inner peripheral surface of the yoke portion;
A rotating electrical machine comprising: a coil formed by winding a coil wire around each of the plurality of tooth portions; and an insulating portion disposed between the core portion and the coil to insulate the stator core and the coil. is the stator of
The first winding frame as the insulating portion includes a first tooth end surface covering portion covering one axial end surface of a portion of the tooth portion around which the coil is wound, and a radial direction of the first tooth end surface covering portion. a first outer flange that is connected to the outer end and that covers one axial end surface of the yoke portion and protrudes axially upward;
The fourth winding frame as the insulating portion includes a second tooth end surface covering portion covering the other axial end surface of the portion of the tooth portion around which the coil is wound, and a radial direction of the second tooth end surface covering portion. a second outer flange connected to the outer end portion and projecting upward in the axial direction to cover the other axial end surface of the yoke portion;
The second outer collar protrudes upward in the axial direction from a central portion in the circumferential direction, and includes a binding portion that binds the winding end portions of the coils,
Since the plurality of coils are formed by the continuous coil wire,
It is possible to prevent winding collapse of each coil.
In addition, it is possible to prevent the interference of the stator crossover wire, make the number of turns of the tooth coil the same, and make the direction of the winding start wire and the winding end wire common, so that electrical problems such as pulsation and vibration can be reduced. We can provide stators for rotating electric machines. Moreover, the number of connection members can be reduced, and the manufacturing time can be shortened to improve productivity.

In addition, since the binding portion has protrusions projecting from the upper end in the axial direction to both sides in the circumferential direction, it is possible to prevent the coil wire from coming off the binding portion during the binding process.

Further, the second outer brim protrudes radially outward from the axially upper end portion of the outer peripheral surface and the circumferentially central portion, and extends axially upwardly in parallel with the binding portion. A hook-shaped locking portion is provided, and the width in the radial direction of the gap between the binding portion and the locking portion is smaller than the wire diameter of the coil wire. The wire coil can be fixed between the binding part and the locking part, and the collapse of the winding of the coil and the loosening of the connecting wire can be prevented.

In addition, the first outer collar includes a plurality of guides extending in the circumferential direction and arranged in the axial direction, each of which forms a plurality of grooves each holding a plurality of connecting wires connecting the coils of the different teeth. Therefore, it is possible to prevent interference between crossover wires of multiple phases.

Further, since the yoke portion of each of the core portions is formed in a straight line,
linearly deforming the yoke portion of the stator core;
a winding step of winding the coil wire around the teeth using a winding nozzle to form the coil;
a winding step of winding the coil wire around the winding portion;
A coil is formed by winding the coil wire around the teeth using a method for manufacturing a stator for a rotating electric machine, which includes a locking step of fixing the coil wire between the binding portion and the locking portion. Then, the winding end line can be tied around the binding portion and then fixed between the binding portion and the engaging portion. As a result, it is possible to prevent the winding collapse of the coil and the loosening of the connecting wire. In addition, since each yoke portion is held straight by the rigidity of the thin connecting portion without using a jig, the fixing jig for winding can be simplified.

Embodiment 4.
A stator for a rotating electrical machine, a rotating electrical machine, a method for manufacturing a stator for a rotating electrical machine, and a method for manufacturing a rotating electrical machine according to a fourth embodiment will be described below with reference to the drawings, focusing on differences from the first embodiment.
The stator of the present embodiment is the same as the stator 10 of the first embodiment, except for the configuration of the stator core used in the stator.

33 is a perspective view of the core portion 460. FIG.
Core portion 460 includes yoke portion 411a and tooth portion 411b similar to core portion 60 of the first embodiment.
FIG. 34 is a perspective view showing the state of stator 410 after winding.
The difference between the stator core 11A of the first embodiment and the stator core 411A of the fourth embodiment is that the adjacent core portions 60 constituting the stator core 11A of the first embodiment are located at the ends of the yoke portions 11a in the circumferential direction Z. While they are connected by the formed rotatable connecting portion 111, the adjacent core portions 460 constituting the stator core 411A of the fourth embodiment do not have any connecting portion and are independently connected to each other. This is the point.

The core portion 460 is also formed by laminating in the axial direction Y a plurality of core pieces 411k formed by punching a thin magnetic steel plate.

In the stator core 11A of the first embodiment, the coupling portion 111 is formed by alternately stacking two types of core piece groups 11k1 and 11k2 formed by punching thin magnetic steel plates in the axial direction Y. In the fourth embodiment, the core portion 460 is formed by stacking a plurality of core pieces 411k of one type formed by punching a thin magnetic steel plate in the axial direction Y. As shown in FIG. Thus, stator 410 of the fourth embodiment is composed of nine independent core portions 460 . Stator 410 of the fourth embodiment also includes the same insulating member as the insulating member used in the first or second embodiment.

In order to wind each core portion 460, all the core portions 460 are arranged and held by the core portion fixing jig 80 so that the respective yoke portions 411a are aligned in a straight line, and the same winding as in the first embodiment is performed. continuously. After that, the core portion fixing jig 80 is removed, and the core portions 460 are combined so that the yoke portions 411a of the respective core portions 460 form an annular shape. The fixing method is welding, shrink fitting, or the like.

The stator according to the present embodiment also has the same configuration as the stator according to the first embodiment, except that the stator core does not have a connecting portion.
a stator core formed by annularly combining a plurality of core portions each having a yoke portion and tooth portions formed so as to protrude radially inward from a circumferential center portion of an inner peripheral surface of the yoke portion;
A rotating electrical machine comprising: a coil formed by winding a coil wire around each of the plurality of tooth portions; and an insulating portion disposed between the core portion and the coil to insulate the stator core and the coil. is the stator of
The first winding frame as the insulating portion includes a first tooth end surface covering portion covering one axial end surface of a portion of the tooth portion around which the coil is wound, and a radial direction of the first tooth end surface covering portion. a first outer flange that is connected to the outer end and that covers one axial end surface of the yoke portion and protrudes axially upward;
The fourth winding frame as the insulating portion includes a second tooth end surface covering portion covering the other axial end surface of the portion of the tooth portion around which the coil is wound, and a radial direction of the second tooth end surface covering portion. a second outer flange connected to the outer end portion and projecting upward in the axial direction to cover the other axial end surface of the yoke portion;
The second outer collar protrudes upward in the axial direction from a central portion in the circumferential direction, and includes a binding portion that binds the winding end portions of the coils,
Since the plurality of coils are formed by the continuous coil wire,
It is possible to prevent winding collapse of each coil.
In addition, it is possible to prevent the interference of the stator crossover wire, make the number of turns of the tooth coil the same, and make the direction of the winding start wire and the winding end wire common, so that electrical problems such as pulsation and vibration can be reduced. We can provide stators for rotating electric machines. Moreover, the number of connection members can be reduced, and the manufacturing time can be shortened to improve productivity.

In addition, since the binding portion has protrusions projecting from the upper end in the axial direction to both sides in the circumferential direction, it is possible to prevent the coil wire from coming off the binding portion during the binding process.

Further, the second outer brim protrudes radially outward from the axially upper end portion of the outer peripheral surface and the circumferentially central portion, and extends axially upwardly in parallel with the binding portion. A hook-shaped locking portion is provided, and the width in the radial direction of the gap between the binding portion and the locking portion is smaller than the wire diameter of the coil wire. The wire coil can be fixed between the binding part and the locking part, and the collapse of the winding of the coil and the loosening of the connecting wire can be prevented.

In addition, the first outer collar includes a plurality of guides extending in the circumferential direction and arranged in the axial direction, each of which forms a plurality of grooves each holding a plurality of connecting wires connecting the coils of the different teeth. Therefore, it is possible to prevent interference between crossover wires of multiple phases.

In addition, since the yoke portion of the core portion can hold the yoke portion of each of the plurality of core portions in a straight line,
a winding step of winding the coil wire around the teeth using a winding nozzle to form the coil;
a winding step of winding the coil wire around the winding portion;
A coil is formed by winding the coil wire around the teeth using a method for manufacturing a stator for a rotating electric machine, which includes a locking step of fixing the coil wire between the binding portion and the locking portion. Then, the winding end line can be tied around the binding portion and then fixed between the binding portion and the engaging portion. As a result, it is possible to prevent the winding collapse of the coil and the loosening of the connecting wire. In addition, since the core portion has no connection portion, the mold for the core piece that constitutes the core portion can be miniaturized.

The number of magnetic poles generated by the permanent magnets of the rotor is not limited to six poles, and may be the number corresponding to the number of tooth portions of the stator 10,410. For example, in the present invention (UVWUVW...) in which a connecting wire is required to a tooth portion straddling two teeth, if the number of tooth portions is 3N (N is an integer of 2 or more), the number of magnetic poles is (( 3±1)·N) may be used. In addition, in the method of winding 3 teeth continuously to adjacent teeth (UU'UVV'VWW'W...), when winding the 2nd tooth, the winding of the 1st tooth, the 3rd tooth, and the reverse rotation is required, and when the number of teeth is 9·N (N is an integer equal to or greater than 1), the number of magnetic poles may be ((9±1)·N). In addition, in a method (UU'VV'WW' . may be ((6±1)·N).

When the number of magnetic poles is ((9±1)·N), if N is 2 or more, it is necessary to wind 3 teeth in succession and then wind to the next tooth 6 teeth apart. Therefore, it is necessary to route the crossover wire at a distance of 6 teeth. When the number of magnetic poles is ((6±1)·N), if N is 2 or more, it is necessary to wind two teeth in succession and then to the next tooth that is four teeth apart. Therefore, it is necessary to route the crossover wire at a distance of 4 teeth.

While this application describes various exemplary embodiments and examples, various features, aspects, and functions described in one or more embodiments may not apply to particular embodiments. can be applied to the embodiments singly or in various combinations.
Therefore, countless modifications not illustrated are envisioned within the scope of the technology disclosed in the present application. For example, modification, addition or omission of at least one component, extraction of at least one component, and combination with components of other embodiments shall be included.

REFERENCE SIGNS LIST 100 rotary electric machine 10, 410 stator 11A, 311A, 411A stator core 11a, 311a, 411a yoke portion 11b, 311b, 411b tooth portion 11c shoe portion 11r second concave portion 11k1, 11k2 core piece group 311k core Plate 411k Core piece 14 Slot 20 Rotor 21 Rotating shaft 22 Rotor core 51, 251 First winding frame 51a, 52a, 53a, 54a, 251a Outer collar 51b, 54b, 251b Inner collar 51c, 54c , 251c tooth end surface covering portion 51d, 54d slot side surface covering portion 51in, 52in, 53in, 251in introduction groove portion 51out, 52out, 53out, 251out lead-out groove portion 52, 252 second winding frame 53, 253 third winding frame , 54,254 fourth winding frame, 54k binding portion, 54t protrusion, 54f locking portion, 54r gap, 60,360,460 core portion, 61 first core portion, 62 second core portion, 63 third core 64 fourth core portion 65 fifth core portion 66 sixth core portion 67 seventh core portion 68 eighth core portion 69 ninth core portion 70 coil wire 71 first coil wire 72 second Second coil wire 73 Third coil wire 70J Crossover wire 70J1 First crossover wire 70J2 Second crossover wire 70J3 Third crossover wire 70J4 Fourth crossover wire 70J5 Fifth crossover wire 70J6 Sixth crossover wire G1 first guide, G2 second guide, G3 third guide, G4 fourth guide, M1 first groove, M2 second groove, M3 third groove, N1 first winding nozzle, N2 second winding nozzle, N3 Third Winding Nozzle 80 Core Part Fixing Jig 101 Frame 103 Bracket 105 Permanent Magnet 107 Air Gap 111, 111B Connecting Part 112 Yoke Inner Peripheral Surface 113 Yoke Outer Peripheral Surface 114 First Concave Part 121 Teeth Part side surface 122 Teeth inner peripheral surface 131 Shoe outer peripheral surface 230 Film portion 231 First yoke inner peripheral surface covering portion 231b Second yoke inner peripheral surface covering portion 232 First side surface covering portion 232b Second side surface Coating part 233 Continuous part 251e, 254e Convex part 400 Winding machine 40 Chuck mechanism 41 to 46 Chuck 700 Neutral point 711 First winding start line 712 First winding end line 713 First power supply Line 721 Second winding start wire 722 Second winding end wire 723 Second power supply wire 731 Third winding start wire 732 Third winding end wire 733 Third power supply wire NB1 First winding nozzle NB2 Second winding nozzle, NB3 Third winding nozzle, RB1, RB2, RB3 Rotating shaft, at1, at4, bt1, bt3 Claw portion.

Claims (12)

a stator core formed by annularly combining a plurality of core portions each having a yoke portion and tooth portions formed so as to protrude radially inward from a circumferential center portion of an inner peripheral surface of the yoke portion;
A rotating electrical machine comprising: a coil formed by winding a coil wire around each of the plurality of tooth portions; and an insulating portion disposed between the core portion and the coil to insulate the stator core and the coil. is the stator of
The first winding frame as the insulating portion includes a first tooth end surface covering portion covering one axial end surface of a portion of the tooth portion around which the coil is wound, and a radial direction of the first tooth end surface covering portion. a first outer flange that is connected to the outer end and that covers one axial end surface of the yoke portion and protrudes axially upward;
The first outer flange is formed in the axial direction and includes a first lead-out groove portion for leading the coil wire after winding the coil toward the radially outer side of the stator core and holding the coil wire,
The fourth winding frame as the insulating portion includes a second tooth end surface covering portion covering the other axial end surface of the portion of the tooth portion around which the coil is wound, and a radial direction of the second tooth end surface covering portion. a second outer flange connected to the outer end portion and projecting upward in the axial direction to cover the other axial end surface of the yoke portion;
The second outer flange protrudes axially upward from a central portion in the circumferential direction, and guides the coil wire after winding the coil radially outward of the stator core from the first lead-out groove portion. A winding part is provided in front for winding the winding end of each coil,
A stator for a rotary electric machine, wherein a plurality of said coils are formed by said continuous coil wire. 2. The stator for a rotary electric machine according to claim 1, wherein the coil wire is wound around the winding portion once and crosses the winding portion radially inwardly of the winding portion. The first outer collar is formed in the axial direction and includes an introduction groove for introducing the coil wire around which the coil is wound,
The first outer brim has a notch that is continuously cut in the circumferential direction of the introduction groove so that one end of the coil wire introduced into the introduction groove passes radially inward. The stator for a rotary electric machine according to claim 1 or 2. The stator for a rotary electric machine according to any one of claims 1 to 3, wherein the entwined portion includes protrusions that protrude from an axially upper end to both sides in the circumferential direction. The second outer brim protrudes radially outward from the axially upper end of the outer peripheral surface and the circumferentially central portion, and extends axially upward in a hook shape parallel to the binding portion. and a radial width of a gap between the binding portion and the locking portion is smaller than the wire diameter of the coil wire. A stator of the described rotating electric machine. The yoke portion of the core portion is rotatable so that the yoke portion of each of the plurality of core portions is straight, or in a reverse warp shape that reverses the direction in which the plurality of tooth portions protrude in the radial direction. The stator for a rotary electric machine according to claim 5, comprising a connecting portion. 6. The stator for a rotary electric machine according to claim 5, wherein the yoke portions are thinly connected at circumferential ends of adjacent yoke portions. The first outer collar includes a plurality of guides extending in the circumferential direction and arranged in the axial direction, each of which forms a plurality of grooves for holding a plurality of connecting wires connecting coils of different teeth. The stator for a rotary electric machine according to any one of claims 1 to 7. a stator for a rotary electric machine according to any one of claims 1 to 8;
A rotating electric machine comprising a rotor arranged opposite to the stator inside the stator with a gap interposed therebetween. A method for manufacturing a stator for a rotary electric machine according to claim 6,
linearly deforming the yoke portions of the plurality of core portions;
a winding step of winding the coil wire around the teeth using a winding nozzle to form the coil;
a winding step of winding the coil wire around the winding portion;
A method of manufacturing a stator for a rotating electric machine, comprising a locking step of fixing the coil wire between the winding portion and the locking portion. A method for manufacturing a stator for a rotary electric machine according to claim 6,
deforming the yoke portions of the plurality of core portions into a reverse warp;
a winding step of winding the coil wire around the teeth using a winding nozzle to form the coil;
a winding step of winding the coil wire around the winding portion;
A method of manufacturing a stator for a rotating electric machine, comprising a locking step of fixing the coil wire between the winding portion and the locking portion. 12. A method of manufacturing a rotating electric machine, comprising: disposing a rotor inside the stator manufactured by the method of manufacturing a stator for a rotating electric machine according to claim 10 or claim 11 so as to face the rotor with a gap therebetween.

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