JP7347352B2 - stator - Google Patents

Description

The present invention relates to a stator for an inner rotor type rotating electric machine.

Conventionally, in the stator of an inner rotor type rotating electric machine as disclosed in Patent Document 1, when the winding is manufactured by nozzle winding in order to reduce costs, a jig is placed outside the outermost diameter of the stator core. Wrap the end of the wire around the wire before starting the winding operation. Therefore, the coil terminal for the contact point is arranged on the outer periphery of the stator, and the connection point between the coil terminal and the winding is located outside the outermost diameter of the stator core.

Patent No. 6520739

When the windings are manufactured by nozzle winding, the coil terminals are provided so as to protrude outward in the radial direction from the stator core, which increases the radial size of the stator. Therefore, it has been difficult to achieve both cost reduction and miniaturization.

The present invention has been made in view of the above points, and its purpose is to provide an inexpensive and compact stator.

The present invention provides a stator (31) for an inner rotor type rotating electric machine (30), which includes a stator core (32) having a plurality of teeth (56) and a plurality of coils (71) wound around the teeth. a winding (33), one end (72) or the other end (73) of the winding , or a plurality of winding holding parts (83) that hold both the one end and the other end; A plurality of coil terminals (81) having winding connection portions (84) connected to the coil terminals (81) are provided. The winding consists of one electric wire provided across two or more teeth, and has two or more coils between one end and the other end of the winding. The winding holding part is provided at a different position from the winding connection part, and the winding wire and the winding connection part are connected at least after the winding starts to be formed by intertwining the electric wires that are the material of the winding. It is possible to hold the electric wire until it is connected. If the direction perpendicular to the rotational axis of the rotating electric machine is defined as the radial direction, the winding holding section and the winding connecting section are arranged radially inward of the coil.

As a result, the winding holding part and the winding connecting part located on the inner circumference of the stator are used to perform nozzle winding in which the winding is continuously wound around two or more teeth from the start of winding to the end of winding. Can be implemented. Therefore, it is possible to avoid providing the coil terminal so as to protrude outward in the radial direction while employing a nozzle winding that can be manufactured at low cost. Therefore, an inexpensive and compact stator can be obtained.

FIG. 1 is a schematic diagram illustrating a shift-by-wire system to which a rotary actuator including a motor according to a first embodiment is applied. FIG. 2 is a cross-sectional view of the rotary actuator of FIG. 1; FIG. 3 is a diagram of the stator and control board of FIG. 2 viewed from the direction of arrow III. FIG. 3 is an enlarged view of the main parts of the stator in FIG. 2. FIG. 5 is a diagram of the stator in FIG. 4 viewed from the direction of arrow V. FIG. 4 is a diagram schematically showing the winding and coil terminal of FIG. 3; FIG. 3 is a view of the stator, motor terminal, and sensor terminal of FIG. 2 as viewed from the direction of arrow VII. FIG. 4 is a view of the stator of the second embodiment viewed from the axial direction, and corresponds to FIG. 3 of the first embodiment. FIG. 9 is a diagram schematically showing the winding and coil terminal of FIG. 8;

Hereinafter, a plurality of embodiments of the stator will be described based on the drawings. Substantially the same configurations in the embodiments are denoted by the same reference numerals, and description thereof will be omitted.

[First embodiment]
As shown in FIG. 1, a motor 30 as an inner rotor type rotating electrical machine of the first embodiment is included in a rotary actuator (hereinafter referred to as an actuator) 10. Actuator 10 is fixed to the outer wall of case 12 of vehicle transmission 11 and is used as a power source for shift-by-wire system 13 . In the shift-by-wire system 13, a control device 15 controls an actuator 10 in response to a command signal from a shift operation device 14, thereby operating a shift range switching mechanism 16 of a transmission 11 to switch the shift range.

(actuator)
First, the overall configuration of the actuator 10 will be described with reference to FIG. 2. The actuator 10 includes a housing 20, a motor 30, and a reduction gear 40.

The housing 20 has a cup-shaped front housing 21 and a rear housing 22. The front housing 21 and the rear housing 22 are fastened to each other by bolts 23 with their openings combined. A bottomed cylindrical metal plate 24 is inserted into the front housing 21 . The rear housing 22 has a cylindrical protrusion 28 that protrudes on the opposite side from the front housing 21 . A bracket 29 is fixed to the outer wall of the rear housing 22. The actuator 10 is fixed to the case 12 (see FIG. 1) of the transmission 11 using a bracket 29.

Motor 30 has a stator 31 and a rotor 34. The stator 31 includes a stator core 32 fixed to the metal plate 24 by, for example, press fitting, and a winding 33 provided on the stator core 32. The rotor 34 includes a rotating shaft 37 rotatably supported around the rotational axis AX1 by a motor-side bearing 35 and a reducer-side bearing 36, and a rotor core 38 fitted and fixed to the outside of the rotating shaft 37. . The motor side bearing 35 is provided on the metal plate 24. The reduction gear side bearing 36 is provided in an output member 44, which will be described later.

The speed reducer 40 includes an eccentric shaft 41, a ring gear 42, an eccentric gear 43, an output member 44, and a transmission mechanism 45. The eccentric shaft 41 is provided on an eccentric axis AX2 that is eccentric with respect to the rotation axis AX1, and is formed integrally with the rotation axis 37. The ring gear 42 is provided coaxially with the rotation axis AX1 and is fixed to the rear housing 22. The eccentric gear 43 has an external toothed portion 47 that meshes with the internal toothed portion 46 of the ring gear 42, and is supported by a bearing 48 provided on the eccentric shaft 41 so as to be capable of planetary movement. The planetary motion is a motion in which the object rotates around the eccentric axis AX2 and revolves around the rotation axis AX1. The rotational speed of the eccentric gear 43 during planetary motion is varied relative to the rotational speed of the rotating shaft 37.

The output member 44 is provided coaxially with the rotation axis AX1 and rotatably supported by a bearing 49 provided in the rear housing 22. The transmission mechanism 45 includes an engagement protrusion 51 formed on the eccentric gear 43 and an engagement hole 52 formed on the output member 44 into which the engagement protrusion 51 is inserted. The rotation around the output member 44 is transmitted to the output member 44 .

In the actuator 10, a rotating magnetic field is generated by switching the energized phase of the winding 33, and the rotor 34 rotates in response to magnetic attraction or repulsion generated by the rotating magnetic field. When the eccentric shaft 41 rotates together with the rotor 34 around the rotation axis AX1, the eccentric gear 43 makes a planetary motion, and the rotation of the eccentric gear 43 that is decelerated relative to the rotation of the rotor 34 is output from the output member 44.

(stator)
Next, the stator 31 and its wiring will be explained with reference to FIGS. 2 to 7. In the following description, the direction parallel to the rotation axis AX1 is simply referred to as the "axial direction", and the direction around the rotation axis AX1 is simply referred to as the "circumferential direction", and the direction perpendicular to the rotation axis AX1 is simply referred to as the "circumferential direction". The direction in which this occurs is simply referred to as the "radial direction." Further, a portion outside the constituent elements of the actuator 10 will be referred to as "external".

As shown in FIGS. 2 and 3, the stator 31 includes a stator core 32, a plurality of windings 33, an insulator 61 interposed between the stator core 32 and the windings 33, and a plurality of windings 33 connected to the stator core 32. A coil terminal 81 is provided.

The stator core 32 is composed of a plurality of metal plates laminated in the axial direction. The stator core 32 includes an annular yoke 55 fixed to the inner wall of the cylindrical portion 25 of the front housing 21 and a plurality of teeth 56 formed to protrude radially inward from the yoke 55.

As shown in FIGS. 3 to 5, the insulator 61 includes a yoke insulating portion 62 provided on both axial ends and the radially inner inner wall of the yoke 55, and a portion around the teeth 56 (that is, a portion other than the tip surface of the teeth 56). The stator core 32 has a tooth insulating part 63 provided in the stator core 32 and a flange part 64 provided in the tooth insulating part 63 so as to protrude from the tooth tip side in the axial direction and the circumferential direction. .

As shown in FIGS. 3 and 6, the plurality of windings 33 include U-phase windings 33u1, 33u2, V-phase windings 33v1, 33v2, and W-phase windings 33w1, 33w2. The U-phase winding 33u1, the V-phase winding 33v1, and the W-phase winding 33w1 constitute a first winding set, and the U-phase winding 33u2, the V-phase winding 33v2, and the W-phase winding 33w2 constitute a first winding set. A second system winding set is configured. The winding 33 is made redundant by providing two systems. Hereinafter, when each winding is not distinguished, it will simply be referred to as "winding 33."

The winding 33 includes a coil 71 wound around the teeth 56, that is, around the teeth insulating portion 63 of the insulator 61. One winding 33 is made of one electric wire, and has two coils 71 between one end 72 and the other end 73 thereof. A crossover wire 74 is provided between each coil 71. That is, one winding 33 is provided across two teeth 56.

U-phase winding 33u1 has coils 71u1 and 71u4, and U-phase winding 33u2 has coils 71u2 and 71u3. V-phase winding 33v1 has coils 71v1 and 71v4, and V-phase winding 33v2 has coils 71v2 and 71v3. W-phase winding 33w1 has coils 71w1 and 71w4, and W-phase winding 33w2 has coils 71w2 and 71w3. In the first embodiment, twelve teeth 56 are provided, and one coil 71 is provided for each tooth 56. One winding 33 has a coil 71 for one phase.

As shown in FIGS. 2 to 4, the yoke insulating portion 62 has a protruding locking portion 65 that projects toward the bottom portion 26 of the front housing 21. As shown in FIGS. The locking portion 65 locks the crossover wire 74. In the first embodiment, the locking portion 65 is provided integrally with the insulator 61.

As shown in FIGS. 2 and 3, the actuator 10 includes a magnet 57 provided in the rotor core 38, a magnetic sensor 58 which is an element that detects the rotational position of the rotor 34, and which detects the magnetism of the magnet 57, and a magnetic sensor 58 that detects the magnetism of the magnet 57. A control board 59 on which a sensor 58 is mounted is provided.

As shown in FIG. 2, the front housing 21 includes a bottom portion 26, a cylindrical portion 25, and a connector portion 27, which constitute a main body portion made of resin. The connector portion 27 is formed on the outside of the cylindrical portion 25. The external connector 17 is detachably connected to the connector portion 27 . External connector 17 holds power supply terminal 18 and signal terminal 19.

As shown in FIGS. 2, 4, 5, and 7, the front housing 21 includes a plurality of motor terminals 91 as external connection terminals connected to the coil terminal 81 and directly connectable to the external power terminal 18. It is connected to the control board 59 and has a plurality of sensor terminals 95 connectable to external signal terminals 19. The motor terminal 91 and the sensor terminal 95 are inserted into the main body portion of the front housing 21 and extend from the bottom portion 26 through the cylindrical portion 25 to the connector portion 27. In the first embodiment, the motor terminal 91 and the sensor terminal 95 are inserted into the front housing 21 while being held by the primary molded body 99.

As shown in FIGS. 2 to 5, a terminal holding portion 67 for holding a coil terminal 81 is provided on the flange portion 64 on the bottom portion 26 side of the front housing 21. As shown in FIGS. In the first embodiment, the terminal holding portion 67 is provided integrally with the insulator 61.

The coil terminal 81 is electrically connected to a held portion 82 held by a terminal holding portion 67 , a winding holding portion 83 holding one end 72 or the other end 73 of the winding 33 , and the winding 33 . It has a winding connection portion 84 and a contact portion 85 that abuts and is electrically connected to the motor terminal 91. In the first embodiment, the winding holding portion 83 is provided integrally with the coil terminal 81.

One coil terminal 81 is provided for each tooth 56. Among the 12 coil terminals 81, six coil terminals 81 are connected to one end portion 72, and the other six coil terminals 81 are connected to the other end portion 73.

The coil terminals 81 are provided at both ends of the winding 33, and two coil terminals are provided for each phase of the winding. One end portion 72, which is a winding start portion of the winding 33, extends from the winding holding portion 83 through the winding connecting portion 84 to the teeth 56. The other end 73 of the winding 33 extends from the teeth 56 to the winding holding portion 83 through the winding connecting portion 84 .

The motor terminal 91 has an abutted part 92 that extends in a direction perpendicular to the axial direction and abuts the abutting part 85 of the coil terminal 81 in the axial direction. The coil terminal 81 is directly connected to the motor terminal 91 without using a connecting component such as a bus bar. In the first embodiment, the abutting portion 85 and the abutted portion 92 are coupled by welding. Hereinafter, the joint portion between the contact portion 85 and the abutted portion 92 will be appropriately referred to as a “welded portion”.

The winding holding portion 83 and the winding connecting portion 84 are arranged radially inward than the coil 71, and the welded portion is arranged radially inner than the teeth tips of the stator core 32. Specifically, as shown in FIGS. 4 and 5, the winding holding portion 83 and the winding connecting portion 84 are formed to extend from the held portion 82 toward the bottom portion 26 in the axial direction. The contact portion 85 is formed to extend radially inward from the tip of the winding holding portion 83 . In the first embodiment, the winding holding portion 83 and the winding connecting portion 84 are provided separately from the held portion 82 .

The winding 33 is manufactured by nozzle winding. Specifically, the electric wire is wound around the winding holding part 83 and passed through the winding connection part 84, and then wound around the first tooth insulating part 63. Subsequently, the electric wire pulled out from the first tooth insulating part 63 is locked in the locking part 65, and then wound around the second tooth insulating part 63. Finally, the electric wire pulled out from the second tooth insulation part 63 is passed through a winding connection part 84 different from the first one, and then tied around the winding holding part 83. The winding connection portion 84 and the winding 33 are connected, for example, by fusing or the like.

As described above, the winding operation is performed across a plurality of slots. When using the locking part 65 disposed on the outer circumference of the stator 31 and the winding holding part 83 and the winding connection part 84 disposed on the inner circumference, the number of winding layers of the electric wire on the tooth insulating part 63 is limited. By using an odd number, perfectly aligned winding can be achieved. The first and third layers of the winding 33 are wound from the inside in the radial direction to the outside, and the second layer is wound from the outside in the radial direction to the inside.

(effect)
As described above, in the first embodiment, the stator 31 includes a stator core 32 having a plurality of teeth 56, a plurality of windings 33 having a coil 71 wound around the teeth 56, and one end of the winding 33. It includes a plurality of winding holding parts 83 that hold the part 72 or the other end part 73, and a plurality of coil terminals 81 having a winding connection part 84 connected to the winding 33. The winding 33 has two or more coils 71 between one end 72 and the other end 73. The winding holding portion 83 and the winding connecting portion 84 are arranged radially inside the coil 71.

As a result, the winding 33 is continuously wound around two or more teeth 56 from the start of winding to the end of winding, using the winding holding part 83 and the winding connection part 84 located on the inner circumference of the stator 31. Can perform nozzle winding. Therefore, it is possible to avoid providing the coil terminal 81 so as to protrude outward in the radial direction while employing a nozzle winding that can be manufactured at low cost. Therefore, an inexpensive and compact stator 31 can be obtained.

Further, in the first embodiment, the one end portion 72 extends from the winding holding portion 83 to the teeth 56 through the winding connecting portion 84 . The other end portion 73 extends from the teeth 56 through the winding connection portion 84 to the winding holding portion 83 . Therefore, by passing the electric wire through the winding connection part 84 in the process of winding the winding 33, it becomes unnecessary to operate the winding 33 in the process of connecting the winding connection part 84 and the winding 33, and only crimping is performed. This simplifies the connection process.

Further, in the first embodiment, the winding holding portion 83 is provided integrally with the coil terminal 81. This makes it easy to ensure the strength of the winding holding portion 83.

[Second embodiment]
In the second embodiment, as shown in FIGS. 8 and 9, the winding 33 has four coils 71 between one end 72 and the other end 73. The U-phase winding 33u has coils 71u11, 71u12, 71u21, 71u22, the V-phase winding 33v has coils 71v11, 71v12, 71v21, 71v22, and the W-phase winding 33w has coils 71w11, 71w12, 71w21, 71w22. has. In the U-phase winding 33u, the coils 71u11 and 71u12 from one end 72 to the middle part 74c and the coils 71u21 and 71u22 from the middle part 74c to the other end 73 are arranged in parallel. Similarly, in the V-phase winding 33v and the W-phase winding 33w, the first coil group and the second coil group are arranged in parallel.

The plurality of coil terminals include a first coil terminal 811 having a first winding connection part 841 connected to one end 72 and the other end 73, and an intermediate part between two coils 71 included in one winding 33. and a second coil terminal 812 having a second winding connection 842 connected to 74c. The shapes of the first coil terminal 811 and the second coil terminal 812 are similar to the shape of the coil terminal 81 in the first embodiment. The first winding connection portion 841 of the first coil terminal 811 and the second winding connection portion 842 of the second coil terminal 812 are arranged radially inward of the coil 71. One end portion 72 and the other end portion 73 included in one winding 33 are connected to the same first winding connection portion 841.

The winding 33 is manufactured by nozzle winding. Specifically, the electric wire is wound around the first winding holding part 831 and passed through the first winding connection part 841, and then wound around the first tooth insulating part 63. Subsequently, the electric wire pulled out from the first tooth insulating part 63 is locked in the locking part 65, and then wound around the second tooth insulating part 63. Subsequently, the electric wire pulled out from the second tooth insulating section 63 is passed through the second winding connection section 842, locked by the locking section 65, and then wound around the third tooth insulating section 63. Subsequently, the electric wire pulled out from the third tooth insulating part 63 is locked in the locking part 65, and then wound around the fourth tooth insulating part 63. Finally, the electric wire pulled out from the fourth tooth insulating section 63 is passed through the first first winding connection section 841, and then tied to the first first winding holding section 831. The first winding connection portion 841 and the one end portion 72 and the other end portion 73 are connected by, for example, fusing or the like. The second winding connection portion 842 and the intermediate portion 74c are similarly connected, for example, by fusing or the like.

(effect)
According to the stator 31 of the second embodiment, between the first coil terminal 811 and the second coil terminal 812, the coil 71 from the one end 72 of one winding 33 to the intermediate portion 74c and the coil 71 from the intermediate portion 74c The coils 71 up to the other end 73 are arranged in parallel. Therefore, in the same way as when winding wires are wound in series, nozzle winding is performed in which winding wire 33 is continuously wound around two or more teeth 56 from the start to the end of winding, and at the same time, By passing the winding 33 through the second coil terminal 812, a parallel circuit can be constructed. In addition, unlike the conventional configuration in which coil terminals are provided at both ends of two windings wound in series, the two coil terminals can be replaced with one second coil terminal 812, and the winding 33 terminal processing can be reduced. Therefore, the number of parts and manufacturing man-hours can be reduced.

Further, in the second embodiment, one end portion 72 and the other end portion 73 included in one winding 33 are connected to the same first winding connection portion 841. As a result, two coil terminals can be replaced with one first coil terminal 811 not only on the intermediate portion 74c side but also on the end portion side, and the number of terminal treatments of the winding 33 can be reduced. Therefore, the number of parts and manufacturing man-hours can be further reduced.

Further, in the second embodiment, the first winding connection portion 841 and the second winding connection portion 842 are arranged radially inside the coil 71. Therefore, similarly to the first embodiment, the winding connection parts 841 and 842 located on the inner circumference of the stator 31 are used to connect two or more teeth 56 between the winding start and the winding end of the winding 33. Continuous nozzle winding can be performed. Therefore, it is possible to avoid providing the coil terminals 811 and 812 so as to protrude outward in the radial direction while employing a nozzle winding that can be manufactured at low cost. Therefore, an inexpensive and compact stator 31 can be obtained.

[Other embodiments]
In other embodiments, the winding holding portion is not limited to a part of the coil terminal, but may be, for example, a part of an insulator or other member. Further, the extending direction of the winding holding portion is not limited to the axial direction, but may be the radial direction, the circumferential direction, or any other direction.

In other embodiments, the coil terminal and the motor terminal are joined by not only welding but also other methods such as pressure welding or soldering. In other embodiments, the connector portion of the front housing may be divided into two or more parts.

In other embodiments, the number of teeth is not limited to 12, and may be any other number. In other embodiments, the number of winding phases is not limited to three, and may be any other number of phases. In other embodiments, the stator is not limited to a motor, but may be applied to a generator.

The present invention is not limited to the embodiments described above, and can be implemented in various forms without departing from the spirit of the invention.

30 motor (inner rotor type rotating electric machine), 31 stator, 32 stator core,
33 winding, 56 teeth, 71 coil, 72 one end, 73 other end,
81 Coil terminal, 83 Winding holding part, 84 Winding connection part, AX1 Rotation axis center.

Claims (3)

A stator (31) of an inner rotor type rotating electric machine (30),
a stator core (32) having a plurality of teeth (56);
a plurality of windings (33) having coils (71) wound around the teeth;
one end (72) or the other end (73) of the winding , or a plurality of winding holding parts (83) that hold both the one end and the other end ;
a plurality of coil terminals (81) having winding connections (84) connected to the windings;
Equipped with
The winding consists of one electric wire provided across two or more of the teeth, and has two or more of the coils between the one end and the other end,
The winding holding part is provided at a different position from the winding connecting part, and the winding wire is connected to the winding wire at least after the winding is formed by intertwining the electric wire that is the material of the winding wire. The electric wire can be held until the wire is connected to the winding connection part,
If the direction perpendicular to the rotation axis (AX1) of the rotating electric machine is defined as the radial direction,
The stator, wherein the winding holding part and the winding connecting part are arranged radially inside the coil. The one end portion extends from the winding holding portion through the winding connecting portion to the teeth,
The stator according to claim 1, wherein the other end extends from the teeth to the winding holding part through the winding connection part. The stator according to claim 1 or 2, wherein the winding holding section is provided integrally with the coil terminal.

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