JPWO2019117207A1 - Insulator and stator and motor equipped with it - Google Patents

Abstract

The insulator 5 is provided on the core segment 41 side of the coil winding portion 50 around which the coil 7 is wound, and has a first flange portion 51 having a coil introduction groove 53 for guiding the coil 7 to the coil winding portion 50, and a tooth. It is provided with a second flange portion 52 provided on the tip side of the 42. The coil holding portion 54 composed of a plurality of grooves 55 is provided on both side surfaces 50c and 50d in the circumferential direction of the coil winding portion 50, while the groove 55 is not provided on the axial end surface 50a of the coil winding portion 50. .. While the plurality of grooves 55 extend in the axial direction, the plurality of grooves 55 are composed of a plurality of protrusions 56 protruding in the circumferential direction, and the end portion 56a of the protrusions 56 is inclined so as to be lower in height toward the outer peripheral surface 50a.

Description

The present invention relates to an insulator around which a coil is wound, a stator provided with the insulator, and a motor.

In recent years, the demand for motors has been increasing in industrial and in-vehicle applications. Among them, improvement of motor efficiency and cost reduction are required.

As one of the methods for improving the efficiency of the motor, it is known to improve the space factor of the coil arranged in the slot of the stator. By improving the space factor of the coil, it is possible to suppress the loss caused by the current flowing through the coil when the motor is driven.

As a structure for improving the space factor of the coil, a so-called aligned winding coil in which the coil is aligned and wound around the teeth of the stator is generally known, and various types are used to realize this. The configuration has been proposed (see, for example, Patent Documents 1 to 4). For example, Patent Document 1 has a configuration in which an aligned winding coil is realized by providing a step or an inclination inside a flange portion provided at an end of a cylinder of an insulating coil bobbin around which the coil is wound or at both ends of the cylinder. Proposed. Further, in Patent Document 2, a coil formed of a plurality of grooves and wound on the upper surface of a split type insulator which is mounted on the upper end surface of the tooth in the axial direction and insulates the coil and the tooth. A configuration is disclosed in which a holding portion for holding the coil is provided to realize an aligned winding coil.

Japanese Unexamined Patent Publication No. 11-12285 Japanese Unexamined Patent Publication No. 2013-243835 U.S. Pat. No. 6,356,001 International Publication No. 2011/118357

By the way, in general, when a coil is wound around an insulator by passing a winding through an introduction groove formed in a flange of an insulator, the winding is bent at the outlet of the introduction groove, so that the coil has a predetermined angle in the radial direction. In the state, it is wound from the axial upper end surface of the insulator.

In such a case, if, for example, a conventional insulator as shown in Patent Document 2 is used as the insulator mounted on the upper end surface in the axial direction of the tooth and the insulator mounted on the lower end surface, the groove for holding the coil is inclined. Will be formed in each.

However, since the direction of inclination of the coil with respect to the insulator is reversed in the radial direction between the upper end surface and the lower end surface in the axial direction, it becomes necessary to separately manufacture two insulators mounted in the axial direction of the tooth, and the manufacturing cost of the insulator is high. There was a problem that it would rise.

The present invention has been made in view of this point, and an object of the present invention is to provide an insulator capable of aligning and winding wound coils and reducing costs.

In order to achieve the above object, in the insulator according to the present invention, the coil holding portion for positioning and fixing the coil is formed only on both side surfaces in the circumferential direction of the coil winding portion.

Specifically, the insulator according to the present invention covers a one end surface in the axial direction and a part of both side surfaces in the circumferential direction of the tooth protruding from the core segment, and has a coil winding portion around which a coil composed of windings is wound. The insulator is provided, and is composed of a plurality of grooves on both side surfaces in the circumferential direction of the coil winding portion, and is provided with a coil holding portion for positioning and fixing the coil, while the coil winding portion is provided in one axial direction. The end face is not provided with a groove, and a plurality of protrusions extending in the axial direction while extending in the circumferential direction are formed at predetermined intervals on each of both side surfaces of the coil winding portion in the circumferential direction. The groove is configured, and the axial end portion of the protrusion is inclined so as to be lowered in height toward the axial end surface of the coil winding portion.

According to this configuration, the coil is positioned and fixed by the coil holding portions provided on both sides in the circumferential direction of the coil winding portion, while the coil is not provided with a groove on the axial end surface of the coil winding portion. When wound diagonally, insulators of the same shape can be used for the axial upper end surface and lower end surface of the tooth regardless of the inclination angle. As a result, the insulators can be standardized and the cost can be reduced. Further, in the coil winding portion, when the coil is wound from the axial end surface to the circumferential side surface, it is possible to prevent the coil from bulging and winding at the corner portion of the coil winding portion.

It is preferable that the axial end portion of the protrusion is located at a position separated by a predetermined distance from the axial end surface of the coil winding portion.

According to this configuration, it is possible to more reliably prevent the coil from being swollen and wound at the corners of the coil winding portion.

The stator according to the present invention includes a stator segment in which an insulator is provided on each of the axial end faces of the tooth of the core segment, and a coil made of a winding is wound around the coil winding portion of the insulator. A plurality of stator segments are provided in a ring shape, and the tooth is projected inward in the radial direction of the ring.

According to this configuration, the coil space factor in the stator can be increased.

It is preferable that the insulator having the same shape is mounted on each of the axial end faces of the tooth.

According to this configuration, all the insulators mounted on the tooth of the stator can be shared, and the cost of the stator can be reduced.

The coil is wound around the coil winding portion so that the winding is inclined in the radial direction. Further, it is preferable that the coil is aligned and wound around the coil winding portion.

According to this configuration, when the coil is wound diagonally with respect to the coil winding portion, it is possible to realize a stator in which the coils are aligned and wound while reducing the cost.

The space between the tooth adjacent to each other in the circumferential direction is configured as a slot for accommodating the coil, and the core segment and the insulating paper that insulates the tooth from the coil cover the side surface of the tooth in the slot. Moreover, it is preferable that the insulator is arranged so as to partially overlap with the first and second flange portions in the axial direction.

According to this configuration, it is possible to reliably electrically insulate between the teeth adjacent to each other in the circumferential direction of the stator.

The motor of the present invention is characterized by including at least the above-mentioned stator and a rotor including a rotating shaft disposed inside the stator in the radial direction at a predetermined distance from the stator.

According to this configuration, the coil space factor in the stator can be increased, and the efficiency of the motor can be improved.

As described above, according to the present invention, the aligned winding coil can be realized, and the cost of the insulator can be reduced.

FIG. 1 is a top view of the motor according to the embodiment. FIG. 2 is an equivalent circuit diagram of the motor shown in FIG. FIG. 3 is a schematic schematic view of the stator. FIG. 4A is a perspective view showing a portion surrounded by a broken line shown in FIG. FIG. 4B is a side view of the structure shown in FIG. 4A as viewed from the radial direction. FIG. 4C is a side view of the structure shown in FIG. 4A as viewed from the circumferential direction. FIG. 5A is a perspective view showing a main part of the insulator according to the embodiment. FIG. 5B is a schematic cross-sectional view showing a portion surrounded by a broken line shown in FIG. 5A. FIG. 5C is a schematic cross-sectional view taken along the line VC-VC in FIG. 5A. FIG. 6 is a schematic view of the process in which the coils are aligned and wound around the insulator.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. The following description of preferred embodiments is merely exemplary and is not intended to limit the present invention, its applications or its uses.

(Embodiment)
[Composition of motor and stator]
FIG. 1 shows a top view showing a motor according to the present embodiment, FIG. 2 shows an equivalent circuit diagram of the motor shown in FIG. 1, FIG. 3 shows a schematic schematic diagram of a stator, and a stator 4 is a shaft 2. The figure seen from the axial direction is shown. For convenience of explanation, some components and their functions are not shown and described in FIGS. 1 and 3. For example, the frame, bus bar, etc. are not shown. Further, in FIG. 3, the insulator 5 is not shown. Further, the exterior body that houses the stator 4 is not shown. The shape of the exterior body is, for example, a cylinder made of metal, a substantially rectangular parallelepiped, a substantially rectangular parallelepiped, a polygonal columnar body, or the like, and is appropriately selected according to the specifications of the motor 1. Further, the illustrated components are also simplified. For example, the insulator 5 shown in FIG. 1 is partially different from the actual shape, and the coils U1 to W4 and their lead terminals 71 shown in FIG. 3 are actually formed. It is very different from the shape of. Further, in FIG. 2, reference numeral + indicates the winding start of the coil, and reference numeral − indicates the winding end of the coil.

In the following description, the longitudinal direction of the shaft 2 may be referred to as an axial direction, the radial direction of the stator 4 may be referred to as a radial direction, and the circumferential direction of the stator 4 may be referred to as a circumferential direction. Further, in the axial direction, the side where the lead terminals 71 of the coils U1 to W4 are provided is called "upper", and the opposite side is called "lower", and in the radial direction, the central side of the stator 4, that is, the shaft 2 and The side on which the rotor is provided may be referred to as "inside", and the opposite side, that is, the stator core 40 side may be referred to as "outside".

The direction in which the electromagnetic steel sheets, which will be described later, are laminated and the above-mentioned axial direction are the same direction and have the same meaning.

In the following description, the terms teeth (plural types of teeth) and teeth (tooth) will be used properly. The plurality of teeth protruding toward the center of the annular stator core are referred to as teeth (plural types of teeth). Further, one of the plurality of teeth of the stator core 40 is referred to as tooth 42. Similarly, a plurality of tooth portions in the core segment 41 described later will be referred to as teeth. Further, one tooth portion among the plurality of tooth portions in the core segment 41 is referred to as tooth 42. Incidentally, the above-mentioned Patent Documents 3 and 4 are publicly known documents describing the proper use of the terms teeth and tooth.

The motor 1 includes a rotor 3 having a shaft 2 which is a rotation shaft of the motor 1, a stator 4, and coils U1 to W4 inside an exterior body (not shown).

The rotor 3 includes a shaft 2 and magnets 31 in which north poles and south poles are alternately arranged along the outer peripheral direction of the shaft 2 so as to face the stator 4. In the present embodiment, a neodymium magnet is used as the magnet 31 used in the rotor 3, but the material, shape, and material thereof can be appropriately changed according to the output of the motor and the like. Further, when viewed from the axial direction, the rotor 3 is arranged inside the stator 4 in the radial direction at regular intervals from the stator 4.

The stator 4 is a cylindrical body formed by connecting a plurality of stator segments 40a in an annular shape. In the stator segment 40a, insulators 5 are attached to the tooth 42 of the core segment 41 from each of the upper and lower end surfaces in the axial direction, and an insulator such as an insulating paper 6 is attached between the insulators 5 to form the insulator 5. A coil U1 is formed by winding a winding around the coil winding portion 50 and the insulating material arrangement portion (see FIGS. 4A to 4C) such as the insulating paper 6. The appearance of the stator segment 40a configured as described above is a columnar body having a substantially fan-shaped cross section.

The stator 4 and the stator segment 40a have a plurality of core segments 41 and a tooth 42 protruding inward in the radial direction from the inner circumference of each of the core segments 41. The core segment 41 is obtained by punching an electromagnetic steel sheet containing silicon or the like as a core segment sheet that forms a part of a substantially annular stator core sheet. It is a laminated body in which a plurality of layers of this plate body (core segment sheet) are laminated. The appearance of the core segment 41 configured as described above is a columnar body having a cross-sectional shape of an individual piece forming a part of a substantially annular stator core plate body (stator core sheet). The stacking direction of the plate body is the normal direction with respect to the plate surface of the plate body. The core segment 41 has a yoke portion 41c and a tooth 42 protruding from a substantially central portion of the yoke portion 41c.

The core segment 41 has a concave portion 41a formed on one side surface of the yoke portion 41c located in the circumferential direction and a convex portion 41b formed on the other side surface, and both the concave portion 41a and the convex portion 41b have shafts on each side surface. It is formed to extend in the entire direction. Focusing on one core segment 41, the convex portion 41b of the core segment 41 adjacent to the concave portion 41a in the circumferential direction is fitted into the concave portion 41a of the core segment 41, and the convex portion 41b of the core segment 41 is in the circumferential direction. On the other hand, they are fitted into the recesses 41a of the adjacent core segments 41 and connected to each other. By fitting and connecting the core segments 41 adjacent to each other in the circumferential direction in this way, the annular-shaped stator core 40 is formed.

As shown in FIGS. 1 and 3, the tooth 42s are arranged at equal intervals along the inner circumference of the stator core 40 by connecting the core segments 41 to form the annular stator core 40. Further, each distance between the tooth 42s adjacent to each other in the circumferential direction constitutes a slot 43.

Further, the stator 4 has 12 coils U1 to W4, and these coils are attached to each tooth 42 via an insulator 5 and an insulating paper 6 (see FIGS. 4A to 4C) and have a shaft. Seen from the direction, they are arranged in each slot 43. Although not shown, the coils U1 to W4 are wound with a circular cross section made of a metal material such as copper having an insulating film on the surface thereof, and are wound in an aligned manner and a multi-layer winding with respect to the insulator 5. Has been done. The multi-layer winding means a state in which the coil 7 is wound in a plurality of layers with respect to the insulator 5. Further, "circular" means "circular" including the processing tolerance of the winding and the deformation of the winding when wound around the tooth 42, and is the same in the following description. Further, in the following description, when the coils U1 to W4 are not specified and one is taken up to explain the structure and the like, the coil 7 is referred to.

As shown in FIG. 2, the coils U1 to U4, V1 to V4, and W1 to W4 are connected in series, and the three phases U, V, and W are star-connected. Further, three phases of U, V, and W having a phase difference of 120 ° in electrical angle from each other are supplied to and excited by the coils U1 to U4, V1 to V4, and W1 to W4, respectively, to generate a rotating magnetic field. .. Torque is generated in the rotor 3 by this rotating magnetic field, and the shaft 2 is supported by a bearing (not shown) and rotates.

In the present embodiment, the number of magnetic poles of the rotor 3 is 10 poles in total, 5 N poles and 5 S poles facing the stator 4, and the number of slots 43 is 12. It is not limited to, and can be applied to other combinations of the number of magnetic poles and the number of slots.

[Structure of main parts of stator segment]
4A to 4C show a perspective view of a portion surrounded by a broken line in FIG. 1 and a side view seen from the radial direction and the circumferential direction, respectively. For convenience of explanation, the coil 7 is not shown in FIGS. 4A to 4C. Further, the insulating paper 6 attached by being sandwiched between the insulator 5 and the core segment 41 and the tooth 42 is also shown, but shows the state before being bent so as to be accommodated in the slot 43.

As shown in FIGS. 4A to 4C, insulators 5 having the same shape from each of the upper and lower end surfaces in the axial direction are attached to the tooth 42 protruding from one core segment 41, and the core segment 41 and The insulating paper 6 is sandwiched between the tooth 42 and the insulator 5. As described above, the insulator 5 is provided so as to cover both end faces in the axial direction of the tooth 42 and portions in the vicinity of both end faces.

The insulator 5 is an insulating member formed by molding an insulating resin material, and is a coil winding portion 50 around which a coil 7 (see FIG. 5C) is wound, and a first coil winding portion 50 formed at one end of the coil winding portion 50. It has a flange portion 51 and a second flange portion 52 formed at the other end. In the present embodiment, the first flange portion 51 is attached to the core segment 41 side, and the second flange portion 52 is attached to the tip of the tooth 42 located inside the stator 4 in the radial direction. Further, a coil introduction groove 53 is formed in the first flange portion 51, and when the coil is wound around the coil winding portion 50, the windings constituting the coil 7 are formed with the coil introduction groove 53. As a result, the winding start portion is in contact with the inner surface 51a of the first flange portion 51 facing the second flange portion 52 (hereinafter referred to as the inner surface 51a of the first flange portion 51) and is guided to the coil winding portion 50. In the present specification, the winding start portion of the coil 7 means the vicinity of the first circumference of the first layer coil wound around the coil winding portion 50 in the coil 7.

Of the outer peripheral surfaces of the coil winding portion 50, the outer peripheral surfaces 50a and 50b covering each of the axially upper end surfaces of the tooth 42 are smooth surfaces having no grooves or the like on their surfaces. However, even on these outer peripheral surfaces 50a and 50b, irregularities (not shown) that occur when the insulator 5 is molded by a mold or the like remain. The arithmetic mean roughness of the unevenness is, for example, about 3 μm to 6 μm. Further, among the outer peripheral surfaces of the coil winding portion 50, the surfaces 50c and 50d covering both end faces in the circumferential direction of the tooth 42 are formed so as to be orthogonal to the axial upper end surface of the tooth 42, and the coil 7 is formed. A coil holding portion 54 is formed to hold and fix the winding position thereof (see FIGS. 5A to 5C). The shapes of the outer peripheral surfaces 50a to 50d (hereinafter, may be referred to as the surface of the coil winding portion 50) of the insulator 5 including the coil holding portion 54 will be described later. In addition, "orthogonal" means "orthogonal" including the processing tolerance of the insulator 5, the processing tolerance of the tooth 42, and the assembly tolerance when the insulator 5 is mounted on the tooth 42, and "parallel" means the insulator 5. It means "parallel" including the processing tolerance of the above and the assembly tolerance when the insulator 5 is attached to the tooth 42, and the same applies to the following description.

The inner surface 51a of the first flange portion 51 is a surface provided parallel to a surface orthogonal to the axial upper end surface or the axial lower end surface of the tooth 42.

The insulator 5 has a function of electrically insulating the core segment 41 and the tooth 42 and the coil 7 together with the insulating paper 6. Further, the insulator 5 has a function of stably maintaining the aligned winding of the coil 7, which will be described later.

The insulating paper 6 is impregnated with, for example, insulating oil so as to cover both side surfaces in the circumferential direction of the tooth 42, and axially with the first and second flange portions 51 and 52 of the insulator 5, respectively. It is arranged so as to partially overlap. Further, although not shown, when assembling the motor 1, the insulating papers 6 are each bent and arranged so as to cover the inside of the slot 43. As a result, the core segment 41 and the tooth 42 can be electrically insulated from the coil 7, and the core segment 41 and the tooth 42 adjacent to each other in the circumferential direction can be electrically insulated from each other.

[Structure of the main part of the insulator]
FIG. 5A shows a schematic view of a main part of the insulator according to the present embodiment as viewed from the axial direction, FIG. 5B shows a schematic cross-sectional view of a portion surrounded by a broken line shown in FIG. 5A, and FIG. 5C is a diagram. A schematic cross-sectional view taken along the VC-VC line at 5A is shown. Further, FIG. 6 shows a schematic diagram of the process in which the coils are aligned and wound around the insulator. The insulators 5 shown in FIGS. 5A to 5C are the same as those shown in FIGS. 4A to 4C, but for convenience of explanation, the structure of the insulators 5 is shown in a simplified manner in FIGS. 5A to 5C. Further, in FIGS. 5B and 5C, a part of the coil 7 is shown.

As shown in FIGS. 5A to 5C, of the surface of the coil winding portion 50 of the insulator 5, the outer peripheral surfaces 50c and 50d corresponding to the peripheral side surfaces are provided with the coil holding portion 54 composed of a plurality of grooves 55. The coil holding portion 54 is provided over the entire radial direction of the outer peripheral surfaces 50c and 50d, and each of the plurality of grooves 55 is formed so as to extend in the axial direction. Further, the radial width of the groove 55 is formed so as to match the wire diameter of the coil 7 to be wound. In addition, "matching" means "matching" including the machining tolerance of the wire diameter of the coil 7 and the machining tolerance of the groove 55, and the same applies to the following description. Further, the windings constituting the coil 7 are generally formed by forming an insulating film on the surface of an electric wire made of copper or the like. Therefore, the wire diameter of the coil 7 means the value obtained by adding twice the thickness of the insulating film to the wire diameter of the electric wire.

The plurality of grooves 55 extend in the axial direction on the outer peripheral surfaces 50c and 50d of the coil winding portion 50, while the plurality of protrusions 56 protruding in the circumferential direction are formed at a pitch corresponding to the wire diameter of the coil 7. It is configured. The space between the adjacent protrusions 56 corresponds to one groove 55. Further, as shown in FIGS. 5C and 6, the winding of the coil 7 is fitted into each of the plurality of grooves 55, and the coil 7 is positioned and fixed with respect to the coil winding portion 50. Further, as shown in FIG. 6, the winding of the coil 7 is wound so as to be inclined obliquely in the radial direction with respect to the coil winding portion 50. As shown in FIGS. 5C and 6, the protrusion 56 may have a substantially triangular shape in a cross-sectional view in the radial direction, or may have another shape. For example, the cross-sectional shape may be substantially quadrangular or substantially circular. The shape of the protrusion 56 can be appropriately changed according to the cross-sectional shape of the coil 7 to be wound. Further, the protrusions 56 are integrally formed when the insulator 5 is formed.

Further, as shown in FIG. 5B, the axial upper end portion 56a (hereinafter, simply referred to as the end portion 56a) of the protrusion 56 is located at a position separated from the outer peripheral surface 50a by a predetermined distance L in the axial direction. Further, the end portion 56a is inclined so that the height of the protrusion 56 is lowered toward the outer peripheral surface 50a, and the protrusion 56 is formed so that the inclination angle θ is 45 °. Although not shown, in the insulator 5 mounted on the axial lower end surface of the tooth 42, the axial lower end portion of the protrusion 56 is located at a position separated from the outer peripheral surface 50b by a predetermined distance L in the axial direction. Further, the protrusion 56 is inclined so as to be lowered toward the outer peripheral surface 50b, and the protrusion 56 is formed so that the inclination angle θ is 45 °. The inclination angle θ is not particularly limited to this value, and can be appropriately changed depending on the dimensions of the coil winding portion 50, the wire diameter of the winding of the coil 7, the flexural rigidity, and the like.

[Effects, etc.]
As described above, the insulator 5 according to the present embodiment covers one end surface in the axial direction and a part of both side surfaces in the circumferential direction of the tooth 42 protruding from the core segment 41, and a coil 7 composed of windings is wound around the insulator 5. The coil winding portion 50 is provided. A coil holding portion 54 composed of a plurality of grooves 55 is provided on the outer peripheral surfaces 50c and 50d which are both peripheral surfaces of the coil winding portion 50 in the circumferential direction, while the outer peripheral surfaces 50a and 50b which are the axial end surfaces of the coil winding portion are grooves. Is not provided.

With such a configuration of the insulator 5, the coil 7 is positioned and fixed with respect to the coil winding portion 50 by the coil holding portion 54. Further, since the outer peripheral surfaces 50a and 50b located on the upper end surface or the lower end surface in the axial direction of the tooth 42 are smooth surfaces without grooves, the winding of the coil 7 is oblique with respect to the coil winding portion 50. Even when the coil is wound, it is not necessary to change the shapes of the outer peripheral surfaces 50a and 50b. Therefore, the extending direction of the groove 55 in the coil holding portion 54 can be the same for the insulator 5 mounted on the axial upper end surface of the tooth 42 and the insulator 5 mounted on the axial lower end surface. As a result, the same insulator 5 can be used for the axial upper end surface and the lower end surface of the tooth 42, the insulators can be standardized, and the manufacturing cost of the insulator 5 can be reduced.

Further, when the winding of the coil 7 is bent and wound at the corner portion of the coil winding portion 50, the curvature thereof changes according to the bending rigidity and the wire diameter of the winding of the coil 7. When the end portion 56a of the protrusion 56 extends to the position of the outer peripheral surface 50a at a predetermined height, the coil 7 protrudes from the groove 55 depending on the curvature of the winding and bulges at the corner portion of the coil winding portion 50. It may end up. When the coil 7 is wound in multiple layers, the coil 7 wound on the bulge may be disturbed, and the coil 7 may not be wound in an aligned manner as a whole.

As shown in the present embodiment, the coil 7 is formed by inclining the end portion 56a of the protrusion 56 forming the groove 55 toward the outer peripheral surface 50a of the coil winding portion 50 so that the height becomes lower. It is possible to prevent the coil 7 from swelling at the corners of the coil winding portion 50 when the coil is wound from the 50a to the outer peripheral surface 50c or 50d.

Further, by locating the end portion 56a of the protrusion 56 at a predetermined distance L from the outer peripheral surface 50a of the coil winding portion 50, the coil 7 also bulges at the corner portion of the coil winding portion 50. Can be prevented. The above limitation may be applied to only one of the shapes and positions of the end portion 56a of the protrusion 56. For example, the end portion 56a may be positioned at a predetermined distance L from the outer peripheral surface 50a without being inclined.

Further, the insulator 5 according to the present embodiment can handle the case where the winding direction of the coil 5 is clockwise or counterclockwise. In the motor 1 shown in FIG. 1, depending on the specifications, for example, the U-phase coils U1 and U2 are wound with the same winding, the coil U1 is wound in the clockwise direction, and the coil U2 is wound in the counterclockwise direction. In some cases. According to the present embodiment, even when the coils U1 and U2 are wound around the insulator 5 having the same structure, both coils can be similarly wound in an aligned manner.

The insulator 5 according to the present embodiment covers a one end surface in the axial direction and a part of both side surfaces in the circumferential direction of the tooth 42 protruding from the core segment 41, and a coil winding formed by winding the coil 7 is wound around the coil winding. A first flange portion 51 having a portion 50, a first flange portion 51 which is continuously provided on the base end side of the tooth 42 in the coil winding portion 50 and has a coil introduction groove 53 for guiding the coil 7 to the coil winding portion 50, and a coil winding portion. It is provided with a second flange portion 52 continuously provided on the tip end side of the tooth 42 in the portion 50. A coil holding portion 54 composed of a plurality of grooves 55 is provided on the outer peripheral surfaces 50c and 50d which are both peripheral surfaces of the coil winding portion 50 in the circumferential direction, while the outer peripheral surfaces 50a and 50b which are the axial end surfaces of the coil winding portion are grooves. Is not provided. Further, a plurality of grooves 55 are formed on each of both side surfaces of the coil winding portion 50 in the circumferential direction by forming a plurality of protrusions 56 extending in the axial direction and protruding in the circumferential direction at predetermined intervals. The axial end portion 56a of the protrusion 56 is inclined so as to be lower in height toward the outer peripheral surface 50a which is the axial end surface of the coil winding portion 50.

Further, by applying the insulator 5 according to the present embodiment to, for example, the stator 4 of the motor 1 shown in FIG. 1, the coils 7 can be wound in a aligned manner, and the dead space in which the coil 7 in the coil winding portion 50 is not wound. Can be reduced. As a result, the space factor of the coil 7 in the slot 43 can be increased, and the efficiency of the motor 1 can be improved.

(Other embodiments)
In the above embodiment, an example in which the coil 7 is started from the first flange portion 51 located on the core segment 41 side, which is the base end side of the tooth 42, has been described, but the present invention is not particularly limited to this, and the coil 7 is on the tip side of the tooth 42. The winding may be started from the second flange portion 52 located. In this case, the coil introduction groove 53 will be provided in the second flange portion 52. The winding method of the coil 7 is not particularly limited, and a general nozzle winding method, fryer winding method, or the like can be used.

The outer peripheral surfaces 50a and 50b of the coil winding portion 50 may be provided substantially parallel to the axial upper end surface of the tooth 42, respectively. Further, the inner surface 51a of the first flange portion 51 may be provided so as to be inclined outward in the radial direction with a surface orthogonal to the axial upper end surface or the axial lower end surface of the tooth 42 as a reference surface.

Needless to say, the insulator 5 in the above embodiment can be applied even when the coil 7 is wound in one layer or in multiple layers.

Further, in the above embodiment, the embodiment in which the insulator 5 is mounted on the tooth 42 of the core segment 41 and the coil 7 is wound around the coil winding portion 50 to form the stator segment 40a has been described, but the insulator 5 is annular. The coil 7 may be wound around the coil winding portion 50 by being attached to each of the tooth 42s of the stator core. The annular stator core referred to here is formed by laminating a plate body obtained by punching an electromagnetic steel plate in an annular shape. Further, the annular stator core has a plurality of tooth portions (so-called teeth).

Further, in the above embodiment, the embodiment in which one tooth portion (so-called tooth) is provided for each core segment 41 has been described, but a plurality of tooth portions (so-called teeth) for each core segment 41 have been described. You may adopt the aspect which has.

The motor 1 in the above embodiment will be described when it is used for an inner rotor type motor, but it goes without saying that the insulator 5 of the present embodiment can be applied to another type of motor.

Further, as shown in FIG. 3, the tip of the tooth 42 (the end portion on the inner side in the radial direction) is provided with two concave grooves. This concave groove is also referred to as a supplementary groove in US Pat. No. 6,104,117, JP-A-10-42531, and the like. The effect of this auxiliary groove suppresses cogging torque and torque ripple in the rotational operation of the rotor 3 of the motor 1, and contributes to low vibration and low noise in the characteristics of the motor.

Further, the winding of the coil 7 in the above embodiment is also referred to as a winding electric wire and is commercially available. The conductor portion of the winding or winding wire contains copper or aluminum containing unavoidable impurities. Here, the unavoidable impurity means a trace amount of impurity element that is unavoidably mixed with copper and aluminum during the manufacturing process. In the case of copper, the unavoidable impurities are As, Bi, Sb, Pb, Fe, S, oxygen and the like. In the case of aluminum, the unavoidable impurities are Si, Mn, Ti, V, Zr, Fe, Cu and the like. The conductor portion of the winding is covered with an insulating layer made of an insulating resin. As the insulating resin, for example, polyimide, polyamideimide, polyesterimide, polyesteramideimide, polyamide, polyhydrantin, polyurethane, polyacetal, epoxy resin and the like are appropriately selected according to the specifications of the motor 1. The cross-sectional shape of the winding is various, such as a substantially square shape and a substantially rectangular shape, in addition to the circular shape in the present embodiment.

Further, the material component of the magnet 31 in the above embodiment contains at least one of Sc, Y and a lanthanoid element, Fe or Fe and Co, and B. Specifically, the magnet 31 is a rare earth sintered magnet, and is called a so-called neodymium sintered magnet or neodymium sintered magnet. The surface layer of this rare earth sintered magnet is provided with a rust preventive film (rust preventive layer) for rust prevention.

The insulator according to the present invention can realize an aligned winding coil corresponding to the wire diameters of coils having different wire diameters, and is therefore useful for application to motors and the like that require high efficiency.

1 Motor 2 Shaft 3 Rotor 4 Stator 5 Insulator 6 Insulation paper 7 Coil 31 Magnet 40 Stator core 40a Stator segment 41 Core segment 41c Yoke part 42 Tooth
43 Slot 50 Coil winding portion 51 First flange portion 51a Inner surface of first flange portion 51 Second flange portion 53 Coil introduction groove 54 Coil holding portion 55 Groove 56 Protrusion 56a Axial end of protrusion 56 U1 to W4 Coil

In the following description, the terms teeth (plural types of teeth) and teeth (tooth) will be used properly. The plurality of teeth protruding toward the center of the annular stator core 40 are referred to as teeth 42 (plural types of teeth). Further, one of the plurality of teeth of the stator core 40 is referred to as tooth 42. Similarly, the plurality of teeth in the core segment 41 described later are referred to as teeth. Further, one of the plurality of teeth in the core segment 41 is referred to as tooth 42. By the way, the above-mentioned Patent Documents 3 and 4 are publicly known documents that describe the proper use of the terms teeth and tooth.

[Effects, etc.]
As described above, the insulator 5 according to the present embodiment covers one end surface in the axial direction and a part of both side surfaces in the circumferential direction of the tooth 42 protruding from the core segment 41, and a coil 7 composed of windings is wound around the insulator 5. The coil winding portion 50 is provided. The coil holding portions 54 composed of a plurality of grooves 55 are provided on the outer peripheral surfaces 50c and 50d which are both peripheral surfaces of the coil winding portion 50 in the circumferential direction, while the outer peripheral surfaces 50a and 50b which are the axial end surfaces of the coil winding portion 50 are provided. There is no groove.

Further, the insulator 5 according to the present embodiment can handle the case where the winding direction of the coil 7 is clockwise or counterclockwise. In the motor 1 shown in FIG. 1, depending on the specifications, for example, the U-phase coils U1 and U2 are wound with the same winding, the coil U1 is wound in the clockwise direction, and the coil U2 is wound in the counterclockwise direction. In some cases. According to the present embodiment, even when the coils U1 and U2 are wound around the insulator 5 having the same structure, both coils can be similarly wound in an aligned manner.

The insulator 5 according to the present embodiment covers a one end surface in the axial direction and a part of both side surfaces in the circumferential direction of the tooth 42 protruding from the core segment 41, and a coil winding formed by winding the coil 7 is wound around the coil winding. A first flange portion 51 having a portion 50, a first flange portion 51 which is continuously provided on the base end side of the tooth 42 in the coil winding portion 50 and has a coil introduction groove 53 for guiding the coil 7 to the coil winding portion 50, and a coil winding portion. It is provided with a second flange portion 52 continuously provided on the tip end side of the tooth 42 in the portion 50. The coil holding portions 54 composed of a plurality of grooves 55 are provided on the outer peripheral surfaces 50c and 50d which are both peripheral surfaces of the coil winding portion 50 in the circumferential direction, while the outer peripheral surfaces 50a and 50b which are the axial end surfaces of the coil winding portion 50 are provided. There is no groove. Further, a plurality of grooves 55 are formed on each of both side surfaces of the coil winding portion 50 in the circumferential direction by forming a plurality of protrusions 56 extending in the axial direction and protruding in the circumferential direction at predetermined intervals. The axial end portion 56a of the protrusion 56 is inclined so as to be lower in height toward the outer peripheral surface 50a which is the axial end surface of the coil winding portion 50.

Further, in the above embodiment, the embodiment in which the insulator 5 is mounted on the tooth 42 of the core segment 41 and the coil 7 is wound around the coil winding portion 50 to form the stator segment 40a has been described, but the insulator 5 is annular. It may be attached to each of the tooth 42s of the stator core 40 and the coil 7 may be wound around the coil winding portion 50. The annular stator core referred to here is formed by laminating a plate body obtained by punching an electromagnetic steel plate in an annular shape. Further, the annular stator core has a plurality of tooth portions (so-called teeth).

Claims (10)

An insulator that covers one end surface of the tooth in the axial direction and a part of both side surfaces in the circumferential direction protruding from the core segment, and has a coil winding portion around which a coil composed of windings is wound.
A coil holding portion is provided on both sides of the coil winding portion in the circumferential direction to position and fix the coil, while a groove is provided on one end surface in the axial direction of the coil winding portion. Not
The plurality of grooves are formed on each of both side surfaces of the coil winding portion in the circumferential direction by forming a plurality of protrusions extending in the axial direction and projecting in the circumferential direction at predetermined intervals.
An insulator characterized in that one end portion in the axial direction of the protrusion is inclined so as to be lowered in height toward one end surface in the axial direction of the coil winding portion. In the insulator according to claim 1,
An insulator characterized in that the axial end portion of the protrusion is located at a position separated by a predetermined distance from the axial end surface of the coil winding portion. The insulator according to claim 1 is provided on each of the axial end faces of the tooth of the core segment, and a plurality of stator segments in which the coil is wound are provided on the coil winding portion of the insulator.
A stator characterized in that a plurality of the stator segments are connected in an annular shape so that the tooth projects inward in the radial direction of the annulus. The insulator according to claim 1 is provided on each of the axial end faces of the tooth of the core segment, and a plurality of stator segments in which the coil is wound are provided on the coil winding portion of the insulator. Includes a configuration in which the stator segments are connected in an annular shape and the tooth projects inward in the radial direction of the annulus.
The stator is characterized by including an insulator having a configuration in which one end portion in the axial direction of the protrusion is located at a position separated by a predetermined distance from the one end surface in the axial direction of the coil winding portion. The insulator according to claim 1 is provided on each of the axial end faces of the tooth of the core segment, and a plurality of stator segments in which the coil is wound are provided on the coil winding portion of the insulator.
A configuration is included in which a plurality of the stator segments are connected in an annular shape so that the tooth projects inward in the radial direction of the annulus.
A stator characterized in that the insulator having the same shape is mounted on each of the axial end faces of the tooth. The insulator according to claim 1 is provided on each of the axial end faces of the tooth of the core segment, and a plurality of stator segments in which the coil is wound are provided on the coil winding portion of the insulator.
Includes a configuration in which a plurality of the stator segments are connected in an annular shape and the tooth projects inward in the radial direction of the annulus.
The insulator includes an insulator having a configuration in which one end in the axial direction of the protrusion is located at a predetermined distance from the one end surface in the axial direction of the coil winding portion.
A stator characterized in that the insulator having the same shape is mounted on each of the axial end faces of the tooth. The insulator according to claim 1 is provided on each of the axial end faces of the tooth of the core segment, and a plurality of stator segments in which the coil is wound are provided on the coil winding portion of the insulator.
A configuration is included in which a plurality of the stator segments are connected in an annular shape so that the tooth projects inward in the radial direction of the annulus.
The stator is characterized in that the coil is wound around the coil winding portion so that the winding is inclined in the radial direction. The insulator according to claim 1 is provided on each of the axial end faces of the tooth of the core segment, and a plurality of stator segments in which the coil is wound are provided on the coil winding portion of the insulator.
A configuration is included in which a plurality of the stator segments are connected in an annular shape so that the tooth projects inward in the radial direction of the annulus.
The stator is characterized in that the coil is aligned and wound around the coil winding portion. The insulator according to claim 1 is provided on each of the axial end faces of the tooth of the core segment, and a plurality of stator segments in which the coil is wound are provided on the coil winding portion of the insulator.
A configuration is included in which a plurality of the stator segments are connected in an annular shape so that the tooth projects inward in the radial direction of the annulus.
The space between the teeth adjacent to each other in the circumferential direction is configured as a slot for accommodating the coil.
In the slot, an insulating paper that insulates the core segment and the tooth from the coil is axially one with the first and second flanges provided on the insulator so as to cover the side surface of the tooth. A stator characterized in that it is arranged so as to overlap. The insulator according to claim 1 is provided on each of the axial end faces of the tooth of the core segment, and a plurality of stator segments in which the coil is wound are provided on the coil winding portion of the insulator. A stator including a configuration in which the tooth is projected inward in the radial direction of the ring by connecting the stator segments in an annular shape.
A motor comprising at least a rotor including a rotating shaft arranged at a predetermined distance from the stator on the inside in the radial direction of the stator.

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