JPH10290545A - Stator for electric rotating machine and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To miniaturize a motor while increasing torque by inflating a coil stepwise from the inner circumferential part toward the outer circumferential part thereof and utilizing the inside of slot effectively as a space being occupied by the coil. SOLUTION: Each coil 17 is inflated stepwise from the inner circumferential part toward the outer circumferential part thereof by winding the coil such that the number of turn of k-th layer will be [N-α(k-1)/2] and the number of turn of (k+1)th layer will be [N-α(k-1)/2-1], where N is the number of turn of reference layer, α is a natural number of 2 or above and k is a positive odd number. When the coil 17 is wound around a bobbin 15, the number of turn of a magnet wire 17a is set as specified and the coil 17 is inflated stepwise from the inner circumferential part toward the outer circumferential part thereof. According to the structure, the coil 17 especially in a three-phase six pole stator corresponds to the shape of inner surface of slot and the inside of slot is utilized effectively as a space being occupied by the coil 17.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a stator for a rotating electrical machine having a stator core having a plurality of magnetic pole teeth projecting from an inner peripheral portion of a yoke core, and a method of manufacturing the stator.

[0002]

For example, a stator of an inner rotor type DC brushless motor is shown in FIG.
As shown in (b), the coil 2 is wound around the magnetic pole teeth 1 in a bale shape, and as shown in (b), the coil 2 is wound in a single bale shape. However, in the case of this configuration, the coil 2 does not correspond to the inner surface shape of the slot 3 and a lot of dead space is generated in the slot 3, so that the inside of the slot 3 cannot be effectively used as the occupied space of the coil 2. Was.

[0003] The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a stator of a rotating electric machine and a method of manufacturing the same, which can effectively utilize the inside of a slot as a space occupied by a coil.

[0004]

According to a first aspect of the present invention, there is provided a method of manufacturing a stator for a rotating electric machine, comprising: a stator core having a plurality of magnetic pole teeth projecting from an inner peripheral portion of an annular yoke iron core; And a coil attached to the teeth, the number of turns of the k-th layer is “N−α (k−1) / 2”, and the number of turns of the k + 1-th layer is “N”.
−α (k−1) / 2-1 ”(where N is the number of turns of the reference layer, α is a natural number of 2 or more, and k is a positive odd number) from the inner periphery. It is characterized in that it bulges in a substantially stepped manner toward the outer peripheral portion. According to the above means, the coil swells substantially stepwise from the inner peripheral portion to the outer peripheral portion. For this reason, since the coil corresponds to the inner surface shape of the slot, the inside of the slot is effectively used as a space occupied by the coil.

According to a second aspect of the present invention, there is provided a stator for a rotating electric machine, wherein a plurality of magnetic pole teeth project from an inner peripheral portion of an annular yoke iron core, and a stator core is mounted on each of the magnetic pole teeth. A coil that expands in a substantially stepwise manner toward the outer peripheral portion, and the number of turns of the k-th layer of each coil is “N−α (k−1) / 2”, and the number of turns of the k + 1-th layer is “N
−α (k−1) / 2-1 ”(however, N
Is the number of turns of the reference layer, α is a natural number of 2 or more, and k is a positive odd number). According to the above means, the coil swells substantially stepwise from the inner peripheral portion to the outer peripheral portion.
For this reason, since the coil corresponds to the inner surface shape of the slot, the inside of the slot is effectively used as a space occupied by the coil.

According to a third aspect of the present invention, a bobbin on which a coil is wound is fitted on the outer surface of each magnetic pole tooth, and a pair of pin terminals is provided on an outer peripheral portion of each of the bobbins at an interval. It has a characteristic where it is. According to the above means, the terminal of the coil is connected to the pin terminal, and the crossover is connected between the pin terminals, so that the terminal of the heterophase coil is commonly connected or the terminal of the in-phase coil is connected in series. , The processing of the terminal unit becomes easy. Moreover, since the pair of pin terminals are arranged on the outer peripheral portion of the bobbin, the space is effectively used.

According to a fourth aspect of the present invention, in the stator for a rotating electric machine, one of the pin terminals is disposed in an extension area of the magnetic pole teeth, and a winding start end of each coil is connected to the one of the pin terminals. The present invention is characterized in that a concave wire insertion portion into which the start end is inserted is formed on the outer peripheral portion of each bobbin. According to the above means, the winding start end of the coil is disposed on the axial end face side of the bobbin, so that the coil crosses the layer on the axial end face side of the bobbin.

According to a fifth aspect of the present invention, the stator of the rotary electric machine is characterized in that an arcuate portion is formed on the inner peripheral surface of each bobbin so as to be concave toward the outer peripheral side. According to the above means, since the radial dimension of the bobbin can be set large, the number of turns of the coil increases.

According to a sixth aspect of the present invention, in the stator for a rotating electric machine, the bobbin around which the coil is wound is fitted to the outer surface of each magnetic pole tooth, and the interphase insulating paper is sandwiched between the bobbin and the stator core. Has features. According to the above means, since the interphase insulating paper is sandwiched between the existing bobbin and the stator core, it is not necessary to provide a dedicated member for holding the interphase insulating paper.

[0010]

FIG. 1 shows a first embodiment of the present invention.
This will be described with reference to FIG. In this embodiment, the present invention is applied to an inner rotor type three-phase DC brushless industrial motor. First, in FIG. 2, the stator core 11 includes a cylindrical yoke core 12 and a teeth core 13 press-fitted into the inner peripheral portion of the yoke core 12, and the teeth core 13 includes six teeth cores 13. The inner peripheral portion of the magnetic pole teeth 13a is connected by a thin cylindrical connecting portion 13b, and a substantially trapezoidal (fan-shaped) slot 14 is formed between the magnetic pole teeth 13a. The yoke core 12 and the teeth core 13 are formed by laminating a plurality of steel plates.

As shown in FIG. 3, a bobbin 15 is fitted on the outer surface of each magnetic pole tooth 13a. Each of these bobbins 15, as shown in FIG.
The frame-shaped flange portions 15b and 15c are integrally formed at both ends of the flange portion 15a. On the outer peripheral surface of each flange portion 15b, an arc portion 15d having substantially the same shape as the inner peripheral surface of the yoke core 12 is formed. As shown in FIG. 3, each arc portion 15d is
2 is in close contact with the inner peripheral surface. Each bobbin 15 is formed of a synthetic resin such as polypropylene, nylon, ABS and the like.

As shown in FIG. 1, a pin terminal 16a is attached to a central portion in the circumferential direction, and a pin terminal 16b is attached to one end in the circumferential direction. Is being worn. A coil 17 is wound around the body 15a of each bobbin 15. After winding the winding start end of the magnet wire 17a around the pin terminal 16a, each of the coils 17 is wound in a winding direction from the outer side to the inner side and from the inner side to the outer side as shown by arrows. The coil 17 is wound in a substantially stepped manner, and the winding end of each coil 17 is wound around the pin terminal 16b. The magnet wire 17a is equivalent to a strand and has a circular cross section.

Reference numerals 1 to n in FIG.
7a shows the winding order of the magnet wire 1a.
7a, the winding number of the odd layer (= k layer) and the even layer (= k +
The number of turns of (one layer) is set based on the following equations (1) and (2).

N-α (k-1) / 2 (1) N-α (k-1) / 2-1 (2) where k is a positive odd number and N is the first layer (reference The number of turns of the layer (N = 10 in FIG. 1) and α is a natural number of 2 or more (α = 3 in FIG. 1).

FIG. 4 shows a connection state of the six coils 17, and a winding start end of the six coils 17 is formed by winding a crossover (not shown) between the pin terminals 16a. Accordingly, they are commonly connected. The in-phase coil 17
Are connected in series as a crossover (not shown) is wound between the pin terminals 16b.

At the center in the circumferential direction of each flange portion 15b, as shown in FIG. 1, a concave wire storage portion 15e is formed corresponding to the pin terminal 16a. Each of these wire storage sections 15e
Is set substantially equal to the diameter of the magnet wire 17a, and the winding start end of each coil 17 is
It is housed in the wire housing 15e. Accordingly, since the winding start end of each coil 17 is disposed on the axial end face side of the bobbin 15, each coil 17 is wound so as to extend over the layer on the axial end face side.

As shown in FIG. 3, an interphase insulating paper 18 is interposed between the coils 17. Each of these interphase insulating papers 18 is bent in a substantially L-shape, and a flange portion 15 c located on the inner peripheral side of the bobbin 15 and the stator core 1 are formed.
With being sandwiched between the first connecting portions 13b, the coils 17 are fixed between the coils 17.

As shown in FIG. 1, a circular arc portion 15f is formed on the inner peripheral surface of the flange portion 15c of each bobbin 15. Each of the arc portions 15f is recessed toward the outer peripheral side, is set to have substantially the same R shape as the outer peripheral surface of the connecting portion 13b, and is in close contact with the outer peripheral surface of the connecting portion 13b as shown in FIG. The rotor 19 is housed in the inner peripheral portion of the stator core 11.
As close to the outer peripheral surface as possible. The rotor 19 is
A plurality of rotor magnets (permanent magnets) are mounted on a rotor core.

Next, the procedure for assembling the stator will be described with reference to FIG. The coil 17 is wound around the body 15a of the bobbin 15, and the winding start end and winding end of the coil 17 are wound around the pin terminals 16a and 16b. In this state, the bobbins 15 are fitted to the magnetic pole teeth 13a of the teeth core 13, and the interphase insulating paper 18 is sandwiched between the flange 15c of each bobbin 15 and the connecting portion 13b of the stator core 11, and then the yoke core 12 A tooth core 13 is press-fitted into the inner peripheral portion.

According to the above embodiment, when winding the coil 17 around the bobbin 15, the number of turns of the magnet wire 17a is set as in the above equations (1) and (2), and the coil 17 is moved from the inner peripheral portion. Inflated substantially stepwise toward the outer periphery. For this reason, especially in a three-phase six-pole stator,
Since the coil 17 corresponds to the inner surface shape of the slot 14, and the inside of the slot 14 is effectively used as a space occupied by the coil 17, the motor is downsized and the torque is increased.

Each bobbin 1 having a sufficient space
A pair of pin terminals 16a and 16b were attached to the outer peripheral portion of No. 5. For this reason, the winding start end and the winding end of each coil 15 are wound around the pin terminals 16a and 16b, and a connecting wire is connected between the pin terminals 16a. In addition, the terminal portion of the in-phase coil 17 can be connected in series with the connection or winding of the crossover wire between the pin terminals 16b, so that the terminal portion can be easily processed by effectively utilizing the space.

Further, one of the pin terminals 16a is disposed at the center of the magnetic pole teeth 13a in the circumferential direction, and the winding start end of the coil 17 is housed in the wire housing 15e.
Is disposed on the axial end surface side of the bobbin 15. For this reason, since the coil 17 crosses over the layer on the axial end surface side of the bobbin 15, the crossover portion of the coil 17 is prevented from expanding in the slot 14. Therefore, the slot 14 is effectively used from this point, and the slot 1
Since the coil 17 is filled in the coil 1 at a higher density, the size and torque of the motor are reduced.

Further, the arc portion 1 is attached to the flange portion 15c of the bobbin 15.
5f, unlike the case where the flange portion 15c is formed in a flat plate shape, the radial length of the body portion 15a
3b. For this reason, the number of windings of the coil 17 increases, and from this point as well, the motor can be reduced in size and increased in torque. In addition, existing bobbin 1
5 and the connecting portion 13b of the stator core 11 sandwich the interphase insulating paper 18. Therefore, there is no need to provide a dedicated member for holding the interphase insulating paper 18, so that the configuration is simplified.

Next, a second embodiment of the present invention will be described with reference to FIG. The same members as those in the first embodiment are denoted by the same reference numerals, and description thereof will be omitted. Hereinafter, only different members will be described. Interphase insulating paper 20 is interposed between the coils 17. Each of these interphase insulating papers 20
It is bent in a substantially T-shape, and is held between the flange 15c of the bobbin 15 and the connecting portion 13b of the stator core 11, and between the flange 15c of the adjacent bobbin 15 and the connecting portion 13b of the stator core 11. As a result, the coils 17 are fixed between the coils 17.

According to the above-described embodiment, the substantially T-shaped interphase insulating paper 20 is provided between the flange 15c of the bobbin 15 and the connecting portion 13b of the stator core 11, and between the flange 15c of the adjacent bobbin 15.
And the connecting portion 13b of the stator core 11, the interphase insulating paper 20 is difficult to remove.

In the first and second embodiments, the stator core 11 is formed by press-fitting the teeth core 13 into the inner periphery of the yoke core 12. However, the present invention is not limited to this. As shown in FIG. 7 showing a third embodiment of the present invention, a deployment core 21 in a form in which a plurality of unit cores 21A to 21F are connected by a connecting bar 21a is used.
After the bobbin 15 is fitted to the magnetic pole teeth 13a of each of the unit cores 21A to 21F, the unit core 21A and the unit core 2
The stator core 11 may be formed by welding between 1F.
Alternatively, as shown in FIG. 8 showing a fourth embodiment of the present invention, the bobbin 15 is connected to the magnetic pole teeth 13 of each of the unit cores 21A to 21F.
After fitting to a, the stator core 11 may be formed by welding between the six unit cores 21A to 21F.

In the case of the third and fourth embodiments, since the arcuate portion 15f on the inner peripheral side of each bobbin 15 escapes the outer peripheral surface of the rotor 19, the gap between the bobbin 15 and the rotor 19 is reduced to a minimum constant value. Can be set to Therefore, the length of the body 15a in the radial direction can be set particularly large, and the number of turns of the coil 17 is further increased, so that the motor can be further reduced in size and torque can be increased.

In the first to fourth embodiments,
The one pin terminal 16a is arranged at the center in the circumferential direction of the magnetic pole teeth 13a, but the present invention is not limited to this. The two-dot line α in FIG. 1 defines an extended area.

In the first to fourth embodiments,
Although the magnet wire 17a is wound directly on the bobbin 15, the present invention is not limited to this. For example, a conductive sheet may be wound. In this configuration, the magnet wire 17a may be connected in series to the conductive sheet, and the magnet wire 17a may be wound on the conductive sheet based on the formulas (1) and (2).

In the first to fourth embodiments,
Although the six coils 17 are Y-connected, the present invention is not limited to this. In addition, the first
In the fourth to fourth embodiments, α in equations (1) and (2) is set to “3”, but is not limited to this.
In short, if the length is set to “2” or more, preferably “3” or more, the coil 17 is wound in a beautiful step shape.

[0031]

As is apparent from the above description, the stator of the rotating electric machine and the method of manufacturing the stator according to the present invention have the following effects. According to the measures of claims 1 and 2,
The coil was expanded substantially stepwise from the inner periphery to the outer periphery. For this reason, the inside of the slot is effectively used as a space occupied by the coil, so that the motor is downsized and the torque is increased. According to the third aspect of the present invention, since the pair of pin terminals is provided on the outer peripheral portion of the bobbin having a sufficient space, the terminal portion of the coil can be easily processed by effectively utilizing the space.

According to the fourth aspect of the present invention, the wire storage portion is formed on the outer periphery of the bobbin. For this reason, the coil can be layered on the axial end surface side of the bobbin, and the coil is more densely filled in the slot. Claim 5
According to the described means, the arc portion is formed on the inner peripheral surface of the bobbin. For this reason, the bobbin can be set to have a large radial dimension, so that the number of turns of the coil increases. Claim 6
According to the described means, since the interphase insulating paper is sandwiched between the existing bobbin and the stator core, there is no need to provide a dedicated member for holding the interphase insulating paper, and the configuration is simplified.

[Brief description of the drawings]

FIG. 1 is a diagram showing a first embodiment of the present invention (a is a diagram showing an initial state of coil winding, and b is a cross-sectional view showing a completed state of coil winding).

FIG. 2 is a plan view showing a stator core.

FIG. 3 is a plan view showing the entire configuration.

FIG. 4 is a diagram showing a connection state of a coil;

FIG. 5 is an exploded perspective view showing a yoke core, a teeth core, and a bobbin.

FIG. 6 is a view corresponding to FIG. 3, showing a second embodiment of the present invention.

FIG. 7 is a plan view showing a third embodiment of the present invention.

FIG. 8 is a view corresponding to FIG. 7, showing a fourth embodiment of the present invention;

FIG. 9 shows a conventional example.

[Explanation of symbols]

11 is a stator core, 12 is a yoke iron core, 13a is a magnetic pole tooth, 14 is a slot, 15 is a bobbin, 15e is a wire insertion part, 15f is an arc part, 16a and 16b are pin terminals, 17 is a coil, and 18 is an interphase insulating paper. , 19 are rotors, 20 is interphase insulating paper, and 21A to 21F are unit cores.

 ──────────────────────────────────────────────────続 き Continuing from the front page (72) Inventor Naoki Mizutani 2121 Asahi-cho, Mie-gun, Mie Prefecture 2121, Nagoya, Toshiba Corporation (72) Inventor Kingo Miyaoka 2121, Asahi-machi, Mie-gun, Mie Prefecture Address Co., Ltd.Toshiba Mie Plant

Claims (6)

[Claims] 1. A method for manufacturing a stator for a rotating electric machine, comprising: a stator core having a plurality of magnetic pole teeth projecting from an inner peripheral portion of an annular yoke iron core; and a coil mounted on each of the magnetic pole teeth. The number of turns of the k-th layer of each coil is “N−α (k−1)
/ 2 ”, the number of turns of the (k + 1) th layer is“ N−α (k−1) / 2 ”.
-1 "(where N is the number of turns of the reference layer, α is a natural number of 2 or more, and k is a positive odd number)
A method for manufacturing a stator of a rotating electric machine, wherein the stator is swelled substantially stepwise from an inner peripheral portion toward an outer peripheral portion. A stator core having a plurality of magnetic pole teeth projecting from an inner peripheral portion of an annular yoke iron core; a stator core mounted on each of the magnetic pole teeth; and having a substantially stepped shape from the inner peripheral portion to the outer peripheral portion. A coil that expands, and the number of turns of the k-th layer is “N−α (k−
1) / 2 ", the number of turns of the (k + 1) th layer is" N-α (k-1)
/ 2-1 "(where N is the number of turns of the reference layer, α is a natural number of 2 or more, and k is a positive odd number). 3. A bobbin on which a coil is wound is fitted on the outer surface of each magnetic pole tooth, and a pair of pin terminals are provided on the outer peripheral portion of each bobbin at intervals. The stator of a rotary electric machine according to claim 2, wherein 4. One of the pin terminals is disposed in an extension area of the magnetic pole teeth, a winding start end of each coil is connected to one of the pin terminals, and an outer peripheral portion of each bobbin is provided with a coil winding. The stator of a rotating electric machine according to claim 3, wherein a concave wire insertion portion into which the rotation start end is inserted is formed. 5. The stator for a rotating electric machine according to claim 2, wherein an arcuate portion is formed on an inner peripheral surface of each bobbin so as to be concave toward an outer peripheral side. 6. A bobbin on which a coil is wound is fitted on an outer surface of each magnetic pole tooth, and an interphase insulating paper is sandwiched between the bobbin and the stator core. 3. The stator of the rotating electric machine according to 2.