JPWO2019142693A1 - Insulator and stator and motor equipped with it - Google Patents

Abstract

The insulator 5 has a coil winding portion 50 around which the coil 7 is wound, and a coil introduction groove 53 provided on the core segment 41 side of the coil winding portion 50 and guiding the coil 7 to the coil winding portion 50. It includes one flange portion 51 and a second flange portion 52 provided on the tip end side of the tooth 42 of the coil winding portion 50. A protrusion 54 having a height H from the surface of the coil winding portion 50 is formed at a corner portion between the surface of the coil winding portion 50 and the inner surface 52a of the second flange portion 52. When the half value of the wire diameter of the coil 7 is r, the height H is in the range of 0.9r (1 + tan30 °) <H <1.1r (1 + tan30 °).

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 holding groove for holding the wound coil is provided on the side surface of the insulator which is attached to the teeth and insulates the coil and the teeth, and is wound in an aligned manner. The configuration that realizes the coil is disclosed.

Japanese Unexamined Patent Publication No. 11-12285 Japanese Unexamined Patent Publication No. 2006-115565 U.S. Pat. No. 6,356,001 International Publication No. 2011/118357

In the conventional configuration disclosed in Patent Documents 1 and 2, it was possible to adjust the winding state of the coil in the radial direction.

However, in order to make the multi-layered coil aligned, it is necessary to match the position of the coil winding in the same layer, that is, the height of the coil in the axial direction. In particular, in the second layer of the coil, if the height is significantly different, the coil may be disturbed and it may not be possible to realize aligned winding.

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 multi-layer winding and aligned winding of a coil.

In order to achieve the above object, the insulator according to the present invention is provided with a protrusion at a corner between the surface of the coil winding portion and the inner surface of the flange portion, and the height of the coil winding portion from the surface is provided. I tried to specify.

Specifically, the insulator according to the present invention covers a portion of the axial end surface of the tooth protruding from the core segment and at least a part of both side surfaces in the circumferential direction, and has a coil winding portion around which a coil composed of windings is wound. A first flange portion that is continuously provided on either the tooth base end side or the tooth tip side of the coil winding portion and has a coil introduction groove that guides the coil to the coil winding portion, and the coil winding portion. An insulator including a second flange portion continuously provided on the tooth base end side or the tooth tip end side of the portion, and the surface of the coil winding portion and the inner surface of the first flange portion or When a protrusion having a height from the surface of the coil winding portion H is formed at a corner portion between the inner surface of the second flange portion and the half value of the wire diameter of the coil is r. The height H is in the range of 0.9r (1 + tan30 °) <H <1.1r (1 + tan30 °).

According to this configuration, in the second layer of the coil, the windings around each circumference can be positioned at the same height from the surface of the coil winding portion. As a result, it is possible to suppress the winding disorder in the axial direction in the second layer of the coil, and to make the coil of multiple layers, particularly the coil of three or more layers, aligned.

The height H preferably satisfies the relationship of H = r (1 + tan 30 °).

According to this configuration, the multi-layer winding coil can be reliably aligned.

It is preferable that the radial width of the protrusion is the same as the half value r of the wire diameter of the coil.

According to this configuration, the first winding winding in the second layer of the coil can be reliably brought into contact with the inner surface of the first or second flange portion, and the position of the first winding winding can be fixed. This makes it possible to reliably align the multi-layer winding coils.

At least one of the tip surface and the side surface of the protrusion may be a flat surface or a curved surface. When at least one of the tip surface and the side surface of the protrusion is the curved surface, the radius of curvature R of the curved surface is preferably longer than the half value r of the wire diameter of the coil.

According to this configuration, the center of gravity of the first winding winding in the second layer of the coil can be reliably supported by the tip surface of the protrusion, and the first winding winding can be stably arranged on the tip surface. ..

The radial width of the protrusion varies in the axial direction, and the radial width of the tip surface of the protrusion may be at least half the wire diameter r of the coil.

According to this configuration, the center of gravity of the first winding winding in the second layer of the coil can be reliably supported by the tip surface of the protrusion, and the first winding winding can be stably arranged on the tip surface. ..

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. It is characterized in that a plurality of the stator segments are connected in an annular shape, and the tooth protrudes inward in the radial direction of the annular ring.

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

It is preferable that the coil is multi-layered and alignedly wound around the coil winding portion.

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 arranged at a predetermined distance from the stator inside the stator in the radial direction.

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 with a simple configuration.

FIG. 1 is a top view of the motor according to the first embodiment of the present invention. 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 schematic cross-sectional view of a main part of the insulator around which the coil according to the first embodiment is wound. FIG. 5B is an enlarged view of a portion surrounded by a broken line in FIG. 5A. FIG. 6 is an enlarged cross-sectional view of a main part of an insulator in which a coil for comparison is wound. FIG. 7A is an enlarged cross-sectional view of a main part of the insulator in which the coil according to the modified example is wound. FIG. 7B is an enlarged cross-sectional view of a main part of another insulator in which the coil according to the modified example is wound.

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 invention, its applications or its uses.

(Embodiment 1)
[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 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 formed by punching an electromagnetic steel sheet containing silicon or the like as a core segment sheet having a substantially annular stator core sheet that forms a part thereof. 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 three phases of U, V, and W are star-connected. Further, three-phase currents of U, V, and W phases having a phase difference of 120 ° in electric 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, but in particular, this 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. 5A) 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 both end surfaces of the tooth 42 in the axial direction are in the axial direction of the tooth 42 from the first flange portion 51 to the second flange portion 52, respectively. It is formed by being monotonously inclined so that the height from the upper side surface or the lower side surface in the axial direction is high. By doing so, it becomes easy to align the coil 7 with respect to the coil winding portion 50. 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, respectively. In the following description, the outer peripheral surfaces 50a to 50d may be referred to as the surface of the coil winding portion 50. Further, "orthogonal" means "orthogonal" including the processing tolerance of the insulator 5 and 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, and faces the first flange portion 51 of the second flange portion 52. Similarly, the inner surface 52a (hereinafter referred to as the inner surface 52a of the second flange portion 52) is also a surface provided parallel to the axial upper end surface or the axial lower end surface of the tooth 42.

The insulator 5 is provided with a protrusion 54 at a corner between the surface of the coil winding portion 50 and the inner surface 52a of the second groove portion 52. The protrusion 54 is integrally formed with the insulator 5. The structure of the protrusion 54 will be described in detail later.

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 cross-sectional view of a main part of the insulator around which the coil according to the present embodiment is wound, FIG. 5B shows an enlarged view of a portion surrounded by a broken line in FIG. 5A, and FIG. 6 is a comparison. The enlarged sectional view of the main part of the insulator in which the coil for winding is shown. The insulators 5 shown in FIGS. 5A and 5B are the same as those shown in FIGS. 4A to 4C, but the structure of the insulators 5 is shown in a simplified manner for convenience of explanation. Further, in FIG. 5A, of the coil introduction groove 53 and the coil 7, the portion extending to the outside through the coil introduction groove 53 is not shown.

As shown in FIGS. 5A and 5B, a protrusion 54 is provided at a corner between the surface of the coil winding portion 50 and the inner surface 52a of the second flange portion 52. That is, the protrusion 54 is provided along the root of the second flange 52 from the outer peripheral surfaces 50a to 50d of the coil winding portion 50. Further, the protrusion 54 has a height W in the axial direction of the protrusion 54, that is, a height from the surface of the coil winding portion 50 so that the width W in the radial direction satisfies the relationship of the equation (1). Is configured to satisfy the relationship of equation (2).

W = r (r is half the wire diameter of the coil 7) ... (1)

H = r (1 + tan30 °) ・ ・ ・ (2)

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 wire diameter including the thickness of the insulating film. Therefore, the wire diameter of the coil 7 is a value obtained by adding twice the thickness of the insulating film to the wire diameter of the electric wire, and the half value r is a half value thereof.

By making the shape of the protrusion 54 satisfy the relationship of the above equations (1) and (2), the two layers of the coil 7 are diagonally above the winding 71L of the final circumference of the first layer of the coil 7. While the winding 721 of the first round of the eye abuts, the winding 721 abuts on the inner surface of the second flange portion and is wound around the coil winding portion 50, and the outer peripheral surface 50a of the coil winding portion 50 a. The virtual line connecting the center of the winding 71L and the center of the winding 721 is 60 ° with respect to the reference plane in the cross-sectional view in the axial direction. Is placed. Further, the protrusion 54 and the windings 71L, 721 are connected so that the line connecting the centers of the windings 721 and 71L and the side surface 54c of the protrusion 54 arranged so as to extend vertically from the outer peripheral surface 50a form 30 °. The placement relationship is defined.

Since the protrusion 54 and the windings 71L and 721 have the above-mentioned arrangement relationship, the center of the winding 721 and the center of the winding 722 on the second circumference of the second layer of the coil 7 are the above-mentioned reference planes ( It will be located at the same height from the outer peripheral surface 50a). Further, the winding 721 and the winding 722 are arranged so as to be in contact with each other in the radial direction.

[Effects, etc.]
As described above, the insulator 5 according to the present embodiment covers the axial end surface of the tooth 42 protruding from the core segment 41 and at least a part of both side surfaces in the circumferential direction, and a coil 7 composed of windings is wound around the insulator 5. A first flange portion having a coil winding portion 50 to be rotated and a coil introduction groove 53 provided continuously on the base end side of the tooth 42 in the coil winding portion 50 and guiding the coil 7 to the coil winding portion 50. It includes a 51 and a second flange portion 52 continuously provided on the tip end side of the tooth 42 in the coil winding portion 50.

Further, the insulator 5 has a protrusion 54 having a predetermined radial width W and an axial height H at a corner portion between the surface of the coil winding portion 50 and the inner surface 52a of the second flange portion 52. It is provided. Further, when the half value of the wire diameter of the coil 7 is r, the width W in the radial direction and the height H in the axial direction are defined so as to satisfy the relationship of the above equations (1) and (2). On the other hand, as shown in FIG. 6, when the protrusion 54 does not satisfy the relationship of the above equation (2), the first winding 721 and the second winding in the second layer of the coil 7 are wound. A step is generated in the axial direction with the wire 722. If there is such a step, for example, when winding the third layer of the coil 7, winding disorder may occur, and the coil 7 may not be aligned with the coil winding portion 50 and wound.

By providing the insulator 5 of the present embodiment with the above configuration, when the coil 7 is wound around the coil winding portion 50, in the second layer of the coil 7, the windings around each circumference are wound on the surface of the coil winding portion 50. Can be located at the same height. As a result, the winding disorder in the axial direction in the second layer of the coil 7 can be suppressed, and the multi-layer winding, particularly the coil 7 having three or more layers can be aligned and wound. 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.

Further, by setting the radial width W of the protrusion 54 to the same value as the half value r of the wire diameter of the coil 7, the first peripheral winding 721 in the second layer of the coil 7 is formed on the inner surface 52a of the second flange 52. The position can be fixed by abutting against. As a result, the multi-layer winding, particularly the coils 7 having three or more layers can be reliably wound in an aligned manner.

As is clear from the comparison between the configuration shown in FIG. 5B and the configuration shown in FIG. 6, in the second layer of the coil 7, the windings around each circumference are positioned at the same height from the surface of the coil winding portion 50. Therefore, the relationship of the equation (1) does not necessarily have to be established. Further, the relationship of the equation (2) is established including the processing tolerance of the protrusion 54 and the processing tolerance of the coil 7. That is, in the equation (2), the right side and the left side do not have to be exactly the same value. For example, as shown in the equation (3), the height H may be within a predetermined range.

0.9r (1 + tan30 °) <H <1.1r (1 + tan30 °) ・ ・ ・ (3)

As is clear from the equation (3), the range of the height H depends on the wire diameter 7 of the coil 7. However, as described above, the wire diameter of the coil 7 also includes the thickness of the insulating film. The metal material such as copper that constitutes the electric wire of the coil 7 is hard to be plastically deformed, but since the insulating film is made of nylon, acrylic, or the like, its thickness changes when pressure or the like is applied. Therefore, the thickness of the insulating film changes due to the force applied in the winding work of the coil 7 and the pressure when the coil 7 is laminated in multiple layers, and the wire diameter of the coil 7 changes accordingly. Since the thickness of the insulating coating is about 10% of the wire diameter of the coil 7, the allowable range of the wire diameter r of the coil 7 shown in the equation (3) is set in consideration of the amount of deformation.

Further, by setting the height H to the range shown in the equation (4), it is possible to more reliably align the windings on each circumference with the same height in the second layer of the coil 7.

0.95r (1 + tan30 °) <H <1.05r (1 + tan30 °) ... (4)

The relationship between the equations (3) and (4) can be modified by the wire diameter of the coil 7, the thickness of the insulating coating, the number of layers, and the like.

<Modification example>
FIG. 7A shows an enlarged cross-sectional view of a main part of an insulator in which a coil is wound according to the present modification, and FIG. 7B shows an enlarged cross-sectional view of a main part of another insulator in which a coil is wound.

As shown in FIG. 7A, the tip surface 54b of the protrusion 54 may be a curved surface that curves downward. Also in this case, by setting the height in the axial direction of the portion where the protrusion 54 supports the winding 721 to the above-mentioned height H, the windings around each circumference can be formed in the second layer of the coil 7. Multi-layer winding, particularly three or more layers of coils 7, can be aligned and wound by being positioned at the same height from the surface of the coil winding portion 50. By making the radius of curvature R1 of the tip surface 54b larger than the half value r of the wire diameter of the coil 7, the winding 721 is supported radially outside the center, that is, on the side farther from the second flange portion 52. Therefore, the center of gravity of the winding 721 can be reliably supported by the tip surface 54b of the protrusion 54. As a result, the winding 721 can be stably arranged on the tip surface 54b of the protrusion 54.

Further, as shown in FIG. 7B, the side surface 54c of the protrusion 54 may be a curved surface that curves inward in the radial direction. Also in this case, by setting the height in the axial direction of the portion where the protrusion 54 supports the winding 721 to the above-mentioned height H, the windings around each circumference can be formed in the second layer of the coil 7. Multi-layer winding, particularly three or more layers of coils 7, can be aligned and wound by being positioned at the same height from the surface of the coil winding portion 50. By making the radius of curvature R2 of the side surface 54c larger than the half value r of the wire diameter of the coil 7, the winding 71L can be brought into contact with the side surface 54c, and the winding 71L can be positioned. Further, by setting the radial width A of the tip surface 54b of the protrusion 54 to be equal to or greater than the half value r of the wire diameter of the coil 7, the winding 721 is more than the second flange 52 as shown in FIG. 7A. Supporting on the distant side, the winding 721 can be stably arranged on the tip surface 54b of the protrusion 54. Further, in this case, by setting the radial width B at the bottom of the protrusion 54 to be equal to or less than the radial width A of the tip surface 54b, it is possible to prevent the protrusion 54 from expanding more than necessary in the radial direction, and the coil. It is possible to suppress a decrease in the winding region of the coil 7 in the winding portion 50.

Further, as is clear from the above description, the shape of the protrusion 54, particularly the width W in the radial direction and the height H in the axial direction may vary within a predetermined range. The fluctuation range for the height H in the axial direction is as shown in the equations (3) and (4). Further, regarding the width W in the radial direction, the minimum value is a value in consideration of the processing tolerance of the protrusion 54 and the processing tolerance of the coil 7, and the maximum value is preferably less than the wire diameter of the coil 7, mainly. In the case of a motor used in which the wire diameter of the coil 7 used is 0.3 mm to 2.3 mm, the above width W is allowed in the range of 0.15 mm to 1.15 mm.

In the embodiment including the modification, the protrusion 54 is provided at the corner between the surface of the coil winding portion 50 and the inner surface 52a of the second flange portion 52, but the surface of the coil winding portion 50 and the first A protrusion 54 may be provided at a corner of the flange 51 with the inner surface 51a.

(Other embodiments)
In the above embodiment including the modification, the example in which the coil 7 starts to be wound 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. The winding may be started from the second flange portion 52 located on the tip end side of the tooth 42. In this case, the coil introduction groove 53 will be provided in the second flange portion 52. Further, the example in which the coil 7 is composed of windings having a circular cross section has been described, but the present invention is not particularly limited to this, and for example, the coil 7 may be composed of windings having a quadrangular cross section. 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.

Further, the insulator 5 is a so-called split type insulator, and an example is shown in which the tooth 42 is mounted from the vertical direction in the axial direction, but the present invention is not particularly limited to this, and the coil winding portion 50 has a tubular shape. It may be an integral structure that covers the entire outer peripheral surface of the tooth 42. For example, when the stator 4 has a structure in which the tooth 42 is attached to the core segment 41 later, the insulator 5 having this integrated structure may be used. Further, the insulators 5 mounted on one tooth from above and below do not have to have the same shape. By using the same shape as the insulator 5 mounted on one tooth from above and below, the number of types of the insulator 5 can be reduced, and the manufacturing cost and the like can be reduced.

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.

Further, when the coil 7 is wound in one layer or two layers, the insulator 5 in this embodiment may be applied.

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. However, the insulator 5 of the present invention has been described. May be attached to each of the tooth 42s of the annular stator core, 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 sheet 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) are provided for each core segment 41. 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 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 impurities mean a trace amount of impurity elements that cannot be avoided from being 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, which 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 and multi-layer winding coil with a simple configuration, and is therefore useful for application to a motor or the like that requires high efficiency.

1 Motor 2 Shaft 3 Rotor 4 Stator 5 Insulator 6 Insulating 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 1st flange portion 51a Inner surface of 1st flange portion 51 2nd flange portion 53 Coil introduction groove 54 Protrusions 54a, 54b Tip surface of protrusion 54 54c Side surface of protrusion 54 71L Coil 7 1st layer final winding 721 Coil 7 2nd layer 1st winding 722 Coil 7 2nd layer 2nd winding H Axial height of protrusion 54 r Coil 7 wire Half-value of diameter R1 Radius of curvature of tip surface 54b R2 Radius of curvature of side surface 54c W Width of protrusion 54 in direction 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 tooth portions in the core segment 41 described later will be referred to as teeth 42 . 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.

As is clear from the equation (3), the range of the height H depends on the wire diameter of the coil 7. However, as described above, the wire diameter of the coil 7 also includes the thickness of the insulating film. The metal material such as copper constituting the electric wire of the coil 7 is hard to be plastically deformed, but since the insulating film is made of nylon, acrylic or the like, its thickness changes when pressure or the like is applied. Therefore, the thickness of the insulating film changes due to the force applied in the winding operation of the coil 7, the pressure when the coil 7 is laminated in multiple layers, and the like, and the wire diameter of the coil 7 changes accordingly. Since the thickness of the insulating coating is about 10% of the wire diameter of the coil 7, the allowable range of half the wire diameter r of the coil 7 shown in the equation (3) is set in consideration of the amount of deformation. ..

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. However, the insulator 5 of the present invention has been described. May be attached to each of the tooth 42s of the annular 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 sheet in an annular shape. Further, the annular stator core has a plurality of tooth portions (so-called teeth).

Claims (11)

A coil winding portion that covers an axial end surface of the tooth protruding from the core segment and at least a part of both side surfaces in the circumferential direction and in which a coil composed of windings is wound, and a tooth base end side of the coil winding portion or A first flange portion that is continuously provided on one of the tooth tip sides and has a coil introduction groove that guides the coil to the coil winding portion, and the tooth base end side or the tooth tip side of the coil winding portion. It is an insulator provided with a second flange portion continuously provided on the other side of the coil.
A protrusion having a height from the surface of the coil winding portion is provided at a corner portion between the surface of the coil winding portion and the inner surface of the first flange portion or the inner surface of the second flange portion. Has been
When the half value of the wire diameter of the coil is r, the height H is
An insulator characterized in that it is in the range of 0.9r (1 + tan30 °) <H <1.1r (1 + tan30 °). In the insulator according to claim 1,
The height H is an insulator characterized by satisfying the relationship of H = r (1 + tan 30 °). In the insulator according to claim 1,
An insulator characterized in that the radial width of the protrusion is the same as half the wire diameter of the coil. In the insulator according to claim 1,
An insulator characterized in that at least one of a front end surface and a side surface of the protrusion is a flat surface. In the insulator according to claim 1,
An insulator characterized in that at least one of a tip surface and a side surface of the protrusion is a curved surface. In the insulator according to claim 1,
At least one of the tip surface and the side surface of the protrusion includes a curved surface.
An insulator characterized in that the radius of curvature of the curved surface is longer than half the wire diameter of the coil. In the insulator according to claim 1,
At least one of the tip surface and the side surface of the protrusion includes a curved surface.
The radius of curvature of the curved surface is longer than half the wire diameter of the coil.
An insulator characterized in that the radial width of the protrusion varies in the axial direction, and the radial width of the tip surface of the protrusion is at least half the wire diameter of the coil. 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.
A configuration is included 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 stator is characterized in that the coil is multi-layered and alignedly 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 and 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 partially overlapped with the first and second flanges of the insulator so as to cover the side surface of the tooth. A stator characterized by being arranged in such a manner. 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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