US20130200742A1 - Stator, brushless motor, stator manufacturing method - Google Patents

Stator, brushless motor, stator manufacturing method Download PDF

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Publication number
US20130200742A1
US20130200742A1 US13/752,396 US201313752396A US2013200742A1 US 20130200742 A1 US20130200742 A1 US 20130200742A1 US 201313752396 A US201313752396 A US 201313752396A US 2013200742 A1 US2013200742 A1 US 2013200742A1
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US
United States
Prior art keywords
portions
stator
insulator
configuration
connection
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US13/752,396
Inventor
Akihiko Seki
Tetsuji Yoshikawa
Yoshihiro Adachi
Yukihide ISHINO
Isoshi SOGA
Yuji Takemura
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Asmo Co Ltd
Original Assignee
Asmo Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority to JP2012-025298 priority Critical
Priority to JP2012025297A priority patent/JP5502115B2/en
Priority to JP2012-025297 priority
Priority to JP2012025298A priority patent/JP2013162726A/en
Priority to JP2012040627A priority patent/JP5536123B2/en
Priority to JP2012-040627 priority
Priority to JP2012-095872 priority
Priority to JP2012095871 priority
Priority to JP2012-095870 priority
Priority to JP2012095872A priority patent/JP5502131B2/en
Priority to JP2012-095871 priority
Priority to JP2012095870A priority patent/JP5921309B2/en
Priority to JP2012-252190 priority
Priority to JP2012252190A priority patent/JP6046987B2/en
Application filed by Asmo Co Ltd filed Critical Asmo Co Ltd
Assigned to ASMO CO., LTD. reassignment ASMO CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ADACHI, YOSHIHIRO, ISHINO, YUKIHIDE, SEKI, AKIHIKO, SOGA, ISOSHI, TAKEMURA, YUJI, YOSHIKAWA, TETSUJI
Publication of US20130200742A1 publication Critical patent/US20130200742A1/en
Abandoned legal-status Critical Current

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    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K1/00Details of the magnetic circuit
    • H02K1/06Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/12Stationary parts of the magnetic circuit
    • H02K1/14Stator cores with salient poles
    • H02K1/146Stator cores with salient poles consisting of a generally annular yoke with salient poles
    • H02K1/148Sectional cores
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K15/00Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/02Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K15/00Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/02Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
    • H02K15/022Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies with salient poles or claw-shaped poles
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K15/00Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/08Forming windings by laying conductors into or around core parts
    • H02K15/095Forming windings by laying conductors into or around core parts by laying conductors around salient poles
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K15/00Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/10Applying solid insulation to windings, stators or rotors
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K3/00Details of windings
    • H02K3/04Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/18Windings for salient poles
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K3/00Details of windings
    • H02K3/04Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/28Layout of windings or of connections between windings
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K3/00Details of windings
    • H02K3/32Windings characterised by the shape, form or construction of the insulation
    • H02K3/34Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation
    • H02K3/345Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation between conductor and core, e.g. slot insulation
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K3/00Details of windings
    • H02K3/46Fastening of windings on the stator or rotor structure
    • H02K3/52Fastening salient pole windings or connections thereto
    • H02K3/521Fastening salient pole windings or connections thereto applicable to stators only
    • H02K3/522Fastening salient pole windings or connections thereto applicable to stators only for generally annular cores with salient poles
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K2203/00Specific aspects not provided for in the other groups of this subclass relating to the windings
    • H02K2203/06Machines characterised by the wiring leads, i.e. conducting wires for connecting the winding terminations
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K2203/00Specific aspects not provided for in the other groups of this subclass relating to the windings
    • H02K2203/12Machines characterised by the bobbins for supporting the windings
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49002Electrical device making
    • Y10T29/49009Dynamoelectric machine

Abstract

A stator includes: plural core configuration sections each including plural yoke configuration sections that configure a ring shaped yoke and are segmented in a yoke circumferential direction and plural teeth sections that project from the respective yoke configuration sections along a yoke radial direction, with the plural yoke configuration sections and the plural teeth sections integrated together; plural coil wires that are wound onto the respective teeth sections to configure plural winding portions; and plural insulators that each include plural insulator portions that are integrated to each of the respective core configuration sections and insulate between the teeth sections and the winding portions, and a connection portion that connects together the plural insulator portions.

Description

    CROSS-REFERENCE TO RELATED APPLICATIONS
  • This application is based on and claims priority under 35 USC 119 from Japanese Patent Application Nos. 2012-25297 filed on Feb. 8, 2012, 2012-25298 filed on Feb. 8, 2012, 2012-40627 filed on Feb. 27, 2012, 2012-95870 filed on Apr. 19, 2012, 2012-95871 filed on Apr. 19, 2012, 2012-95872 filed on Apr. 19, 2012, and 2012-252190 filed on Nov. 16, 2012, the disclosures of which are incorporated by reference herein.
  • BACKGROUND OF THE INVENTION
  • 1. Technical Field
  • The present invention relates to a stator, a brushless motor, and a stator manufacturing method.
  • 2. Related Art
  • Known stators employed in a brushless motor are for example disclosed in Japanese Patent Application Laid-Open (JP-A) No. 9-322441. JP-A No. 9-322441 discloses an armature with a yoke configured by plural ring shaped yoke configuration sections segmented along the axial direction. Each of the yoke configuration sections is integrally formed with plural tooth portions that project towards a radial direction outside of the yoke.
  • As disclosed in Japanese Patent No. 3816783, known stators include a stator core and a pair of insulators mounted to the stator core from both axial direction sides of the stator core.
  • SUMMARY
  • However, when the technology of JP-A No. 9-322441 is applied to an armature employed in an inner rotor type rotating machine armature, the plural tooth portions project towards a radial direction inside of each of the yoke configuration portions. It is accordingly difficult to wind a coil from the radial direction outside of each of the yoke configuration portions with the flyer of a flyer machine. The coils need to be wound from the radial direction inside of each of the yoke configuration portions with a nozzle of a nozzle machine. However in such cases, since it is necessary to secure space for passage of the nozzle, it is difficult to achieve a high dense arrangement of the coils, this being disadvantageous in terms of reducing the size of a rotating machine. Moreover, the coil winding speed when employing a nozzle machine is lower than when employing a flyer machine. This is disadvantageous to high-speed coil winding operations, and therefore also disadvantageous to reducing costs resulting by reducing the number of equipment units.
  • Note that a flyer machine is a device that moves the flyer to circle the periphery of a tooth portion while aligning and winding a coil over the tooth portion with a variable former. A nozzle machine is a device that winds a coil on a tooth portion by repeatedly alternating between a process in which the nozzle circles the periphery of the tooth portion and a process of sliding the nozzle in the axial direction.
  • Since a stator disclosed in Japanese Patent No. 3816783 is provided with a pair of insulators, the number of components required to assemble the stator is increased.
  • In consideration of the above circumstances, the present invention is directed towards achieving a more compact and lower cost stator to be employed in a brushless motor.
  • The present invention is also directed towards providing a stator manufacturing method that can reduce the number of components necessary to assemble the stator.
  • In order to address the above issues, a stator of a first aspect of the present invention includes: plural core configuration sections each including plural yoke configuration sections that configure a ring shaped yoke and are segmented in a yoke circumferential direction and plural teeth sections that project from the respective yoke configuration sections along a yoke radial direction, with the plural yoke configuration sections and the plural teeth sections integrated together; plural coil wires that are wound onto the respective teeth sections to configure plural winding portions; and plural insulators that each includes plural insulator portions that are integrated to each of the respective core configuration sections and insulate between the teeth sections and the winding portions, and a connection portion that connects together the plural insulator portions.
  • Due to the configuration described above, the stator is for example manufactured using the following processes. First, the core configuration sections are integrated to the insulator portions of each of the insulators to form sub-assemblies of plural groups. Next, a flyer machine is employed to wind the coil wires onto the respective teeth sections of each of the sub-assemblies from a radial direction outside, forming stator configuration sections for each of the groups. Then, the plural stator configuration sections are assembled together to form the stator. The stator is manufactured by these processes.
  • In the stator, the yoke is segmented in the yoke circumferential direction and configured from the plural yoke configuration sections. Therefore, even when the stator is employed in a brushless motor in which plural teeth sections project along the yoke radial direction, the sub-assemblies for each of the plural groups are formed as described above, and the coil wires can be wound using a flyer machine onto each of the teeth sections of each of the sub-assemblies from the radial direction outside. There is accordingly no need to secure space between the teeth sections, as is required when a nozzle machine is employed, enabling a higher dense arrangement of the coil wires to be achieved, and enabling a more compact stator to be realized.
  • Moreover, as described above, the yoke is segmented in the yoke circumferential direction into the plural yoke configuration sections, and so, for example, the stator can be made more compact in the yoke axial direction than in cases in which the yoke is segmented into plural yoke configuration sections in the yoke axial direction.
  • When a flyer machine is employed, since the winding speed of the coil wires is higher than when using a nozzle machine, the process of winding the coil wires can be speeded up, and accordingly a reduction in cost of the stator can be achieved due to reducing the number of equipment units.
  • As in a stator of a second aspect of the present invention, the stator of the first aspect is preferably configured wherein the plural coil wires configure plural phases.
  • A stator of a third aspect of the present invention is the stator of the first aspect or the second aspect wherein: each of the coil wires includes plural crossing wires that connect together the plural winding portions and are laid out at the connection portion; the plural connection portions are disposed with a gap between each other in one direction out of the yoke radial direction, the yoke axial direction, or in a direction that is a combination thereof; and a housing portion is formed to at least one connection portion out of the plural connection portions for housing a member.
  • According to this stator, the housing portion for housing a member is formed to at least one connection portion out of the plural connection portions that are disposed with a gap between each other in one direction out of the yoke radial direction, the yoke axial direction, or in a direction that is a combination thereof. Interference between the connection portion and the member can accordingly be avoided, enabling the stator to be realized with an even more compact size and lower cost.
  • A stator of a fourth aspect of the present invention is the stator of any one of the first aspect to the third aspect wherein: each of the coil wires includes plural crossing wires that connect together the plural winding portions and are laid out at at least one of the plural connection portions; and each of the connection portions includes a retaining portion that retains the plural crossing wires laid out at the connection portion.
  • According to this stator, each of the connection portions includes the retaining portion that retains the plural crossing wires that are laid out at the connection portion. Therefore, for example, the crossing wires can be retained at the connection portions by the retaining portions when forming the stator by assembling together the plural stator configuration sections as described above, and so efficient handling can be achieved when assembling together the plural stator configuration sections. Moreover, even after the stator has been incorporated in a brushless motor, the crossing wires are retained at the connection portions by the retaining portions, and therefore, flapping of the crossing wires can be suppressed, enabling noise and fault occurrence to be suppressed.
  • A stator of a fifth aspect of the present invention is the stator of any one of the first to the fourth aspects wherein: the plural connection portions are disposed with a gap between each other in the yoke radial direction; and at least one of the plural connection portions includes a spacer provided between the plural connection portions in the yoke radial direction and retaining the plural connection portions in a state separated from each other in the yoke radial direction.
  • According to this stator, the plural connection portions can be retained in a state separated from each other in the yoke radial direction by the spacer. Space for laying out the crossing wires between the plural connection portions in the yoke radial direction can accordingly be secured, and rattling of the plural connection portions can also be suppressed.
  • A stator of a sixth aspect of the present invention is the stator of any one of the first to the fourth aspects wherein: the plural connection portions are disposed with a gap between each other in the yoke axial direction; at least one of the plural connection portions includes a spacer provided between the plural connection portions in the yoke axial direction and retaining the plural connection portions in a state separated from each other in the yoke axial direction.
  • According to this stator, the plural connection portions can be retained in a state separated from each other in the yoke axial direction by the spacer. Space for laying out the crossing wires between the plural connection portions in the yoke axial direction can accordingly be secured, and rattling of the plural connection portions can also be suppressed.
  • A stator of a seventh aspect of the present invention is the stator of any one of the first to the sixth aspects wherein the plural connection portions are provided coaxially to the yoke.
  • According to this stator, the connection portions are provided coaxially to the yoke, enabling the structure to be simplified.
  • A stator of an eighth aspect of the present invention is the stator of the third aspect wherein the member is a crossing wire out of the plural crossing wires, the crossing wire is laid out at the different connection portion form the connection portion having the housing portion.
  • According to this stator, interference between the connection portions and the crossing wires can thereby be avoided, and so the length of the crossing wires can be suppressed from increasing. The stator can accordingly be made even more compact and at even lower cost.
  • A stator of a ninth aspect of the present invention is the stator of the fourth aspect wherein the retaining portion is formed in a projection shape.
  • According to this stator, the retaining portion is formed in a projection shape, enabling the structure to be simplified. Better handling can also be achieved when assembling the plural connection portions together than in cases in which the plural connection portions are fitted together around the entire circumference.
  • A stator of a tenth aspect of the present invention is the stator of the fifth aspect or the sixth aspect wherein the spacer is formed in a projection shape.
  • According to this stator, the spacer is formed in a projection shape, enabling the structure to be simplified. Better handling can also be achieved when assembling the plural connection portions together than in cases in which the plural connection portions are fitted together around the entire circumference.
  • A stator of an eleventh aspect of the present invention is the stator of any one of the first to the tenth aspects wherein the connection portion is positioned further to the yoke radial direction inside than the core configuration section.
  • According to this stator, the connection portion is positioned further to the yoke radial direction inside than the core configuration section. Interference between the flyer of a flyer machine and the connection portion can accordingly be suppressed when winding the coil wire on the teeth sections from the radial direction outside using the flyer machine.
  • A stator of a twelfth aspect of the present invention is the stator of any one of the first to the eleventh aspects wherein: the insulator portions of at least one of the plural insulators include insulator main body portions that are integrated to the respective core configuration sections and insulate between the teeth sections and the winding portions, and extending portions that are positioned further to the radial direction inside than the core configuration section and extend from the insulator main body portion in one direction out of the yoke axial direction, the yoke radial direction, or the yoke circumferential direction, or a direction that is a combination thereof; and the connection portion connects together the extending portions of the plural insulator portions.
  • According to this stator, the extending portions extend from the insulator main body portions that are integrated to the respective core configuration sections in one direction out of the yoke axial direction, the yoke radial direction, or the yoke circumferential direction, or a direction that is a combination thereof, and the extension end portions of the extending portions are connected together by the connection portion. The extending portion is positioned here further to the yoke radial direction inside than the core configuration section. Interference between the flyer of a flyer machine and the extending portion and/or the connection portion can accordingly be suppressed when winding the coil wire on the teeth sections from the radial direction outside using the flyer machine.
  • A stator of a thirteenth aspect of the present invention is the stator of any one of the first to the twelfth aspects wherein: the insulator portion includes a first insulator portion and a second insulator portion, the first insulator portion and the second insulator portion each including a teeth section insulator portion and a yoke configuration section insulator portion respectively covering the teeth section and the yoke configuration section.
  • A stator of a fourteenth aspect of the present invention is the stator of any one of the first to the thirteenth aspects further including a terminal station that is provided to each of the plural insulators and that connects to a terminal portion of each of the plural coil wires.
  • The terminal station is provided to each of the plural insulators, and each of the terminal portions of the plural coil wires is connected to the respective terminal station. Positioning of the terminal portions of the coil wires can accordingly be performed easily.
  • A stator of a fifteenth aspect of the present invention is the stator of the fourteenth aspect wherein: the connection portion is positioned at the yoke radial direction inside; and a projection portion is formed to an end portion of at least one insulator portion out of the plural insulator portions at an opposite side to a yoke side, the projection portion projecting out to the yoke side with respect to the connection portion; and the terminal station is provided at the projection portion.
  • According to this stator, the terminal station is provided at the projection portion that projects out to the yoke side with respect to the connection portion. Interference between the terminal station and the connection portion can accordingly be suppressed, and positioning of the terminal portions can accordingly be performed easily.
  • A stator of a sixteenth aspect of the present invention is the stator of the fifteenth aspect wherein: an insertion groove is formed to the projection portion so as to open towards the yoke axial direction; and the terminal station is inserted into the insertion groove.
  • According to this stator, the terminal station can be easily fixed to the projection portion by inserting the terminal station into the insertion groove formed to the projection portion.
  • A stator of a seventeenth aspect of the present invention is the stator of the fifteenth aspect or the sixteenth aspect wherein: the connection portion is disposed displaced in the yoke axial direction with respect to the plural insulator portions; and the terminal station makes contact with a surface on the yoke side of the connection portion.
  • According to this stator, the terminal station makes contact with a surface on the yoke side of the connection portion, and rattling of the terminal station can accordingly be suppressed.
  • A stator of an eighteenth aspect of the present invention is the stator of any one of the fourteenth to the seventeenth aspects wherein: each of the plural coil wires includes a crossing wire that connects together the plural winding portions and that is laid out displaced in the yoke axial direction with respect to the insulator portion; and the terminal station is provided on the yoke axial direction opposite side to the crossing wires.
  • According to this stator, the terminal station is provided on the yoke axial direction opposite side to the crossing wires, enabling the terminal station and a control circuit to be connected together easily at the opposite side to the crossing wires.
  • A stator of a nineteenth aspect of the present invention is the stator the fourteenth aspect further including a guide portion that is formed along the yoke axial direction at each of the plural insulators, wherein the terminal portion of each of the plural coil wires is guided by the guide portion. Positioning of the terminal portions of the coil wires can accordingly be performed easily.
  • A stator of a twentieth aspect of the present invention is the stator of the nineteenth aspect wherein the guide portion is provided to a side face of the projection portion.
  • According to this stator, the guide portion is provided at the projection portion projecting towards the yoke side with respect to the connection portion, thereby enabling interference between the terminal portions and the connection portion to be suppressed, and enabling the terminal portions to be positioned easily.
  • A stator of a twenty-first aspect of the present invention is the stator of the fourteenth aspect wherein: one of the plural yoke configuration sections is provided with a terminal station that connects to a terminal portion of each of the plural coil wires.
  • The terminal station is provided to one of the plural yoke configuration sections and the terminal portions of each of the plural coil wires are connected to the terminal station. Positioning of the terminal portions of the coil wires can accordingly be performed easily.
  • A stator of a twenty-second aspect of the present invention is the stator of any one of the first to the twenty-first aspects further including a second connection portion that is separated in a stator core axial direction from the connection portion, that is formed to at least one insulator out of the plural insulators, and that connects together the plural insulator portions of the at least one insulator.
  • According to this stator, the second connection portion is formed to at least one insulator out of the plural insulators, and connects together the plural insulator portions of the at least one insulator. The second connection portion accordingly enables the rigidity between the plural insulator portions, and therefore the rigidity of the stator overall after assembly, to be secured.
  • The second connection portion is separated in the stator core axial direction from the connection portion. The rigidity of the overall stator after assembly can accordingly be secured with good balance.
  • A stator of a twenty-third aspect of the present invention is the stator of the twenty-second aspect wherein: the connection portion is disposed at a first side in the stator core axial direction; and the second connection portion is formed at the insulator positioned furthest to a second side in the stator core axial direction out of the plural insulators when the plural insulators are in a pre-assembly state arranged along the stator core axial direction.
  • According to this stator, the second connection portion is formed to the insulator positioned furthest to the stator core axial direction second side out of the plural insulators when the plural insulators are in a pre-assembly state arranged along the stator core axial direction. Accordingly interference of the insulator portions formed to the other insulators with the second connection portion can be avoided when the plural insulators are being assembled along the stator core axial direction.
  • A stator of a twenty-fourth aspect of the present invention is the stator of the twenty-second aspect wherein: the plural connection portions are disposed coaxially to each other and have different external diameters to each other; and the second connection portion is formed to the insulator with the connection portion of the smallest external diameter out of the plural insulators.
  • According to this stator, the second connection portion is formed to the insulator with the connection portion of the smallest external diameter out of the plural insulators. Accordingly interference of the insulator portions formed to the other insulators with the second connection portion can be avoided when the other insulators are being assembled from a first stator core axial direction side to the insulator with the first connection portion of the smallest external diameter.
  • A stator of a twenty-fifth aspect of the present invention is the stator of any one of the twenty-second to the twenty-fourth aspects wherein: the second connection portion connects together the plural extending portions of one of the insulators.
  • According to this stator, the second connection portion connects together the plural extending portions of one of the insulators. The rigidity between the plural insulator portions can accordingly secured even when each of the insulator portions includes the extending portions extending from the first connection portion.
  • A stator of a twenty-sixth aspect of the present invention is the stator of any one of the twenty-second to the twenty-fifth aspects wherein the plural insulators have an interlocking structure for positioning with respect to each other, the interlocking structure including: a fitting portion formed at the second connection portion; and a fitted-to portion that fits together with the fitting portion and is formed to an insulator portion positioned between a pair of insulator portions connected by the second connection portion out of the plural insulator portions.
  • According to this stator, the fitting portion is formed to the second connection portion, and the fitted-to portion is formed to the insulator portion positioned between a pair of insulator portions connected by the second connection portion out of the plural insulator portions. Fitting together of the fitting portion and the fitted-to portion can accordingly be performed easily.
  • A stator of a twenty-seventh aspect of the present invention is the stator of any one of the twenty-second to the twenty-sixth aspects wherein: the insulator portion includes a first insulator portion and a second insulator portion segmented in the stator core axial direction; the connection portion connects together the plural first insulator portions of each of the insulators; and the second connection portion connects together the plural first insulator portions in one of the insulators.
  • According to this stator, the plural first insulator portions are connected together by the second connection portion as well as the connection portion in at least one of the plural insulators. The rigidity between the plural first insulator portions, and hence the rigidity of the overall stator after assembly, can accordingly be secured by the second connection portion.
  • A stator of a twenty-eighth aspect of the present invention is the stator of any one of the twenty-second to the twenty-sixth aspects wherein: the insulator portion includes a first insulator portion and a second insulator portion segmented in the stator core axial direction; the connection portion connects together the plural first insulator portions of each of the insulators; and the second connection portion connects together the plural second insulator portions in one of the insulators.
  • According to this stator, the plural first insulator portions are connected by the connection portion and the plural second insulator portions are connected by the second connection portion in at least one of the plural insulators. The rigidity between the plural first insulator portions and the rigidity between the plural second insulator portions can accordingly be increased with good balance, and hence the rigidity of the overall stator after assembly can be secured by the connection portion and the second connection portion.
  • A stator of a twenty-ninth aspect of the present invention is the stator of any one of the first to the twenty-first aspect wherein: the plural insulators have an interlocking structure for positioning with respect to each other; the core configuration portion includes a teeth section extending along the stator core radial direction and a yoke configuration section formed to a leading end portion of the teeth section; the insulator portions each includes a yoke configuration section insulator portion that covers the yoke configuration section; and the interlocking structure includes a fitting portion formed to a first of adjacent of the yoke configuration section insulator portions, and a fitted-to portion that fits together with the fitting portion and is formed to a second of the adjacent yoke configuration section insulator portions.
  • According to this stator, the fitting portion is formed at the first of the adjacent yoke configuration section insulator portions, and the fitted-to portion is formed to the second of the adjacent yoke configuration section insulator portion. Fitting together of the fitting portions and the fitted-to portions can accordingly be performed easily.
  • A stator of a thirtieth aspect of the present invention is the stator of any one of the first to the twenty-first aspects further including an interlocking structure that fixes the plural connection portions together.
  • This stator includes the interlocking structure that fixes the plural connection portions together. The rigidity between the plural connection portions, and hence the rigidity of the overall stator after assembly, can accordingly be secured by fixing together the plural connection portions with the interlocking structure.
  • A stator of a thirty-first aspect of the present invention is the stator of any one of the first to the thirtieth aspect wherein: plural independently formed groups of stator configuration sections are configured by assembling the plural core configuration sections to the respective plural insulators; in each of the plural stator configuration section groups, the plural core configuration sections are disposed so as to form a gap corresponding to at least one core configuration section between adjacent core configuration sections; the plural stator configuration section groups are disposed such that in a mutually assembled state a core configuration section of another group is disposed in the gap; and each of the plural coil wires is formed continuously from end-to-end and includes a crossing wire that connects together the plural winding portions.
  • This stator in the configuration described above is for example manufactured using the following processes. Namely, first the core configuration sections are integrated to the insulator portions of each of the insulators, forming a sub-assembly for each of the plural groups. Next, the coil wire is wound on each of the teeth sections of each of the sub-assemblies from the radial direction outside using a flyer machine, forming a stator configuration section for each of the plural groups. Then, the plural stator configuration sections are assembled together to form the stator. The stator is manufactured by the above processes.
  • In each of the plural stator configuration section groups, the plural core configuration sections are disposed such that a gap corresponding to at least one core configuration section is present between adjacent core configuration sections. Accordingly, as described above, the flyer machine can be suppressed from interfering with the other core configuration sections when winding the coil wire on each of the teeth sections of each of the sub-assemblies from the radial direction outside using a flyer machine.
  • Moreover, each of the plural coil wires is formed continuously from end-to-end and includes the crossing wire that connects together the plural winding portions laid out along the connection portion. Slackening of the winding portion from the teeth section can accordingly be suppressed.
  • A stator of a thirty-second aspect of the present invention is the stator of the thirty-first aspect wherein: out of the crossing wires, at least one of the crossing wires connected to a winding start end portion of the winding portion and one of the crossing wires connected to a winding finish end portion of the winding portion cross over at a connection vicinity between the connection portion and the insulator portion.
  • According to this stator, at least one of the crossing wires connected to the winding start end portion of the winding portion and one of the crossing wires connected to the winding finish end portion of the winding portion cross over at the connection vicinity between the connection portion and the insulator portion. Accordingly, slackening of the winding portion from the teeth section can be even more effectively suppressed.
  • A stator of a thirty-third aspect of the present invention is the stator of the thirty-second aspect wherein: each of the insulator portions includes an insulator main body portion that is integrated to the core configuration section and insulates between the teeth section and the winding portion, and an extending portion that connects together the insulator main body portion and the connection portion; and a radial direction extension portion is formed to the extending portion so as to extend in a radial direction of the stator configuration section from the connection portion; and an intersection portion between the crossing wire connected to the winding start end portion of the winding portion and the crossing wire connected to the winding finish end portion of the winding portion is disposed at a position that overlaps with the radial direction extension portion as viewed along the stator configuration section axial direction.
  • According to this stator, the radial direction extending portion that extends in the radial direction of the stator configuration section is formed to the extending portion that connects together the insulator main body portion and the connection portion, and the intersection portion mentioned above is disposed at the position that overlaps with the radial direction extension portion as viewed along the stator configuration section axial direction. Slackening of the winding portion from the teeth section can accordingly be even better suppressed due to the crossing wires mentioned above intersecting in a space secured by the radial direction extension portion.
  • A stator of a thirty-fourth aspect of the present invention is the stator of the thirty-second aspect wherein: each of the insulator portions includes an insulator main body portion that is integrated to the core configuration section and insulates between the teeth section and the winding portion, and an extending portion that connects together the insulator main body portion and the connection portion; and an axial direction extension portion is formed to the extending portion so as to extend in an axial direction of the stator configuration section from the connection portion; and an intersection portion between the crossing wire connected to the winding start end portion of the winding portion and the crossing wire connected to the winding finish end portion of the winding portion is disposed at a position that overlaps with the axial direction extension portion as viewed along the stator configuration section radial direction.
  • According to this stator, the axial direction extending portion that extends in the stator configuration section axial direction is formed to the extending portion that connects together the insulator main body portion and the connection portion, and the intersection portion mentioned above is disposed at the position that overlaps with the axial direction extension portion as viewed along the stator configuration section radial direction. Slackening of the winding portion from the teeth section can accordingly be even better suppressed due to the crossing wires mentioned above intersecting in a space secured by the axial direction extension portion.
  • A stator of a thirty-fifth aspect of the present invention is the stator of any one of the first to the thirty-fourth aspects wherein the teeth section projects from the yoke configuration section towards the yoke radial direction inside.
  • Accordingly, even when the teeth section projects from the yoke configuration section towards the yoke radial direction inside, the coil wire can be wound on each of the teeth sections of each of the sub-assemblies from the radial direction outside using a coil wire winding machine due to the yoke being configured by the plural yoke configuration sections segmented in the yoke circumferential direction.
  • A stator of a thirty-sixth aspect of the present invention is the stator of any one of the first to the thirty-fifth aspects wherein: the insulator portion includes an extension side wall portion that extends along an axial direction of the stator configuration section; and in each of the plural stator configuration section groups, with respect to an imaginary line extending in a tangential direction to the stator configuration section so as to pass through the extension side wall portion, an end in the circumferential direction of the yoke configuration section of a first core configuration section is positioned so as to be on the opposite side to a second core configuration section disposed adjacent to the first core configuration section with the imaginary line being disposed between the first and second core configuration sections.
  • According to this stator, in each of the plural stator configuration section groups, with respect to the imaginary line extending in a tangential direction to the stator configuration section so as to pass through the extension side wall portion, the end in the circumferential direction of the yoke configuration section of the first core configuration section is positioned so as to be on the opposite side to the second core configuration section adjacent to the first core configuration section with the imaginary line being disposed between the first and the second core configuration sections. Accordingly, as described above, even when a coil wire winding machine is employed to wind the coil wire on each of the teeth sections of each of the sub-assemblies from the radial direction outside, the coil wire winding machine can be suppressed from interfering with other core configuration sections, and in particular, with the yoke configuration section circumferential direction ends thereof.
  • A stator of a thirty-seventh aspect of the present invention is the stator of any one of the first to the thirty-fourth aspects, wherein the plural teeth sections project from the yoke configuration section towards the yoke radial direction outside.
  • Accordingly, since the interval between leading end portions of the adjacent e teeth sections can be secured when the teeth sections project from the yoke configuration section towards the yoke radial direction outside, a coil wire winding machine can be employed to wind the coil wire on each of the teeth sections from the radial direction outside.
  • A stator of a thirty-eighth aspect of the present invention is the stator of the thirty-seventh aspect, wherein adjacent yoke configuration sections are fitted together with recess and protrusion shaped fitting portions.
  • The rigidity of the yoke can accordingly be raised when the adjacent yoke configuration sections are fitted together with recess and protrusion shaped fitting portions.
  • A stator of a thirty-ninth aspect of the present invention is the stator of any one of the thirty-fifth to the thirty-eighth aspects, wherein the winding portions are compression deformed by pressing.
  • According to this stator, the winding portions are compression deformed by pressing. Bulging of the winding portions can accordingly be suppressed, and high dense arrangement of the coil wires can be achieved, and space for pressing operation by a press can be secured.
  • A stator of a fortieth aspect of the present invention is the stator of any one of the thirty-fifth to the thirty-ninth aspects wherein: each of the plural stator configuration section groups is configured by a combination of mutually different phases; in each of the stator configuration sections the plural teeth sections are disposed at even intervals from each other; and out of the plural winding portions, a pair of winding portions that face each other across a stator configuration section axis are formed from the same coil wire and are formed by winding in reverse directions to each other.
  • According to this stator, in each of the stator configuration sections, the plural teeth sections are disposed at even intervals from each other, so the intervals between the plural teeth sections can be respectively secured. The coil wire can accordingly be easily wound on the teeth sections.
  • A stator of a forty-first aspect of the present invention is the stator of the fortieth aspect wherein: a winding portion wound in a loosening direction on the teeth section out of the pair of winding portions and a crossing wire between the pair of winding portions are connected together by a lead portion that is led out from the teeth section; a protrusion portion to which the lead portion is anchored is formed to the insulator; and the winding portion wound in a loosening direction on the teeth section out of the pair of winding portions is restricted from slackening by the lead portion being anchored to the protrusion portion.
  • According to this stator, the winding portion wound in the loosening direction on the teeth section is restricted from slackening by the lead portion anchoring to the protrusion portion. Accordingly, slackening of the winding portion wound on the teeth section in the loosening direction can be suppressed.
  • A brushless motor of a forty-second aspect of the present invention includes the stator according to any one of the first to the forty-first aspects and a rotor that rotates in a rotational magnetic field generated by the stator.
  • According to this brushless motor, a compact size and low cost can be realized by employing the stator of any one of the first to the forty-first aspects
  • A forty-third aspect of the present invention is a manufacturing method of the stator of any one of the first to the fortieth aspects including: a sub-assembly forming process in which the core configuration sections are integrated to the insulator portions of each of the insulators to form a sub-assembly for each of plural groups; a stator configuration section forming process in which the stator configuration sections are formed for each of the plural groups by winding the coil wire on each of the teeth sections of each of the sub-assemblies from a radial direction outside of the stator configuration section using a coil wire winding machine; and a stator forming process that forms a stator by assembling the plural stator configuration sections together.
  • According to this stator manufacturing method, the sub-assemblies are formed for each of the plural groups, and the coil wire is wound on each of the teeth sections of each of the sub-assemblies from the radial direction outside of the stator configuration section using the coil wire winding machine. There is accordingly no need to secure space between the teeth sections, as would be required when employing a nozzle machine. High dense arrangement of the coil wire is accordingly possible, and a compact size can be achieved for the stator.
  • Moreover, the sub-assemblies are formed for each of the plural groups, and the coil wire is wound on each of the teeth sections of each of the sub-assemblies from a radial direction outside. An increased speed in the coil wire winding process is accordingly realized, and therefore a reduction in cost of the stator can be realized due to a reduction in the number of equipment units.
  • A stator manufacturing method of a forty-fourth aspect of the present invention is the stator manufacturing method of the forty-third aspect further including: between the stator configuration section forming process and the stator forming process, a compression process that presses and compression deforms the winding portions in each of the plural stator configuration section groups.
  • According to this stator manufacturing method, the winding portions are pressed and compression deformed in the compression process. Bulging of the winding portions can accordingly be suppressed, and high dense arrangement of the coil wires can be achieved, and space for the pressing operation by a press can be secured.
  • A stator manufacturing method of a forty-fifth aspect of the present invention is the stator manufacturing method of the forty-fourth aspect, wherein in the compression process the winding portions are pressed from a direction orthogonal to a teeth section axial direction.
  • According to this stator manufacturing method, in the compression process the winding portions are pressed from a direction orthogonal to the teeth section axial direction. Bulging of the winding portions can accordingly be further suppressed, and high dense arrangement of the coil wires can be achieved.
  • A stator manufacturing method of a forty-sixth aspect of the present invention is the stator manufacturing method of the forty-fourth aspect or the forty-fifth aspect, wherein in the compression process the winding portions are pressed from both sides of the direction orthogonal to the teeth section axial direction.
  • According to this stator manufacturing method, in the compression process, the winding portions are pressed from both sides of the direction orthogonal to the teeth section axial direction. The winding portions can accordingly be further compression deformed.
  • A stator manufacturing method of a forty-seventh aspect of the present invention is the stator manufacturing method of the forty-fourth aspect, wherein in the compression process the winding portions are pressed such that the pressing direction on the winding portions is a tangential direction to the respective stator configuration sections.
  • According to this stator manufacturing method, in the compression process the winding portions are pressed such that the pressing direction on the winding portions is a tangential direction to the respective stator configuration sections. In each of the plural stator configuration section groups here, the plural core configuration sections are disposed such that at least a gap corresponding to one stator configuration section is present between adjacent of the plural core configuration sections. The winding portions can accordingly be pressed whilst still suppressing interference between the press and the core configuration sections.
  • A stator manufacturing method of a forty-eighth aspect of the present invention includes: an installation and cutoff process that employs an insulator in which plural first insulator portions, second insulator portions, and bridging sections have been integrated together and each of the bridging sections connect together the first insulator portions and the second insulator portions, that installs a core configuration section for forming a stator core to one portion out of the first insulator portion and the second insulator portion, and that cuts off the bridging section; a positional alignment process that performs positional alignment between the other portion out of the first insulator portion and the second insulator portion and the core configuration section by moving at least one portion out of the first insulator portion and the second insulator portion with respect to the other portion; an installation process that installs the other portion out of the first insulator portion and the second insulator portion to the core configuration section; and a coil wire winding process that forms a coil wire winding portion with a coil wire on the core configuration section by winding the coil wire on the core configuration section with the first insulator portion and the second insulator portion interposed therebetween.
  • According to this stator manufacturing method, an insulator is employed in which the plural first insulator portions, second insulator portions, and bridging sections have been integrated together and the bridging sections connect together the first insulator portions and the second insulator portions. A reduction in the number of components required for stator assembly can hence be achieved in comparison to cases in which an insulator is employed wherein the first insulator portions and the second insulator portions are formed separately.
  • A stator manufacturing method of a forty-ninth aspect of the present invention is the stator manufacturing method of the forty-eighth aspect, wherein in the installation and cutoff process, the bridging section is cut off after the core configuration section has been installed to the one portion out of the first insulator portion and the second insulator portion.
  • According to this stator manufacturing method, in the installation and cutoff process, the bridging section is cut off after the core configuration section has been installed to the one portion out of the first insulator portion and the second insulator portion. Accordingly, for example when installing the core configuration section to the one portion out of the first insulator portion and the second insulator portion, the entire insulator including the first insulator portion and the second insulator portion can be set in a jig in one operation when the insulator is set in a jig. A reduction in the number of processes for setting the insulator in the jig can accordingly be achieved in comparison to cases in which the bridging portion is cut off before the core configuration section has been installed to the one portion out of the first insulator portion and the second insulator portion.
  • A stator manufacturing method of a fiftieth aspect of the present invention is the stator manufacturing method of the forty-eighth aspect or the forty-ninth aspect wherein, as the insulator, the first insulator portion and the second insulator portion each respectively include a teeth section insulator portion and a yoke configuration section insulator portion that respectively cover a teeth section and a yoke configuration section formed to the core configuration section, and the bridging section connects together the yoke configuration section insulator portions of the first insulator portion and the second insulator portion.
  • The teeth section of the core configuration section is a location at which the coil wire is wound to form a coil wire winding portion. Moreover, for example a guide portion that guides the terminal portion of the coil wire is formed at a base end side of the teeth section of the core configuration section.
  • With regards to this point, according to this stator manufacturing method, the bridging section is employed in the insulator to connect together the yoke configuration section insulator portions of the first insulator portions and the second insulator portions. Accordingly, it is possible to suppress the bridging section provided to cause adverse influence to for example the coil wire winding portion and the guide portion.
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • Embodiments of the present invention will be described in detail based on the following figures, wherein:
  • FIG. 1 is a perspective view illustrating a stator according to a first exemplary embodiment of the present invention;
  • FIG. 2A is a perspective view illustrating a U-phase stator configuration section illustrated in FIG. 1;
  • FIG. 2B is a perspective view illustrating a V-phase stator configuration section illustrated in FIG. 1;
  • FIG. 2C is a perspective view illustrating a W-phase stator configuration section illustrated in FIG. 1;
  • FIG. 3A is a perspective view illustrating a process in which the plural stator configuration sections illustrated in FIG. 1 are being assembled together;
  • FIG. 3B is a perspective view illustrating a state in which assembly has progressed further than in FIG. 3A;
  • FIG. 4 is a cross-section illustrating a schematic configuration of a brushless motor provided with the stator illustrated in FIG. 1;
  • FIG. 5 is a drawing to explain winding of a coil wire by a flyer machine;
  • FIG. 6 is a drawing to explain plural connection patterns of coil wires applicable to a stator according to the first exemplary embodiment of the present invention;
  • FIG. 7 is a perspective view illustrating a stator according to a second exemplary embodiment of the present invention;
  • FIG. 8 is a perspective view illustrating a U-phase stator configuration section illustrated in FIG. 7;
  • FIG. 9 is a perspective view illustrating an assembled state of a control circuit section to the stator illustrated in FIG. 7;
  • FIG. 10 is a perspective view illustrating a first modified example of the stator illustrated in FIG. 7;
  • FIG. 11 is an enlarged perspective view illustrating relevant portions of a second modified example of the stator illustrated in FIG. 7;
  • FIG. 12 is an enlarged perspective view illustrating relevant portions of a third modified example of the stator illustrated in FIG. 7;
  • FIG. 13 is an enlarged perspective view illustrating relevant portions of a fourth modified example of the stator illustrated in FIG. 7;
  • FIG. 14 is a perspective view illustrating a fifth modified example of the stator illustrated in FIG. 7;
  • FIG. 15 is a drawing illustrating a first modified example of a stator according to the first exemplary embodiment;
  • FIG. 16 is a drawing illustrating a second modified example of a stator according to the first exemplary embodiment;
  • FIG. 17 is a drawing illustrating a third modified example of a stator according to the first exemplary embodiment;
  • FIG. 18A is a plan view illustrating a first group of the stator configuration sections illustrated in FIG. 17;
  • FIG. 18B is a plan view illustrating a second group of the stator configuration sections illustrated in FIG. 17;
  • FIG. 18C is a plan view illustrating a third group of the stator configuration sections illustrated in FIG. 17;
  • FIG. 19 is a side-on cross-section of a motor pump applied with a brushless motor according to the second exemplary embodiment of the present invention;
  • FIG. 20A is a side-on cross-section of plural connection portions illustrated in FIG. 1;
  • FIG. 20B is a side-on cross-section of a first modified example of plural connection portions illustrated in FIG. 20A;
  • FIG. 20C is a side-on cross-section of a second modified example of plural connection portions illustrated in FIG. 20A;
  • FIG. 21 is a perspective view illustrating a stator according to a third exemplary embodiment of the present invention;
  • FIG. 22A is an exploded perspective view illustrating a U-phase stator configuration section illustrated in FIG. 21;
  • FIG. 22B is an exploded perspective view illustrating a V-phase stator configuration section illustrated in FIG. 21;
  • FIG. 22C is an exploded perspective view illustrating a W-phase stator configuration section illustrated in FIG. 21;
  • FIG. 23A is a plan view illustrating the insulator illustrated in FIG. 22A;
  • FIG. 23B is a plan view illustrating the insulator illustrated in FIG. 22B;
  • FIG. 23C is a plan view illustrating the insulator illustrated in FIG. 22C;
  • FIG. 24A is a drawing illustrating the insulator illustrated in FIG. 22A set in a jig and plural core configuration sections in a mounted state to second insulator portions;
  • FIG. 24B is a drawing illustrating cut off of bridging section in the insulators illustrated in FIG. 24A;
  • FIG. 24C is a drawing illustrating the insulators illustrated in FIG. 24B with portions other than the second insulator portions having been raised, and the second insulator portions having been slid;
  • FIG. 24D is a drawing illustrating the insulators illustrated in FIG. 24C in a state with portions other than the second insulation sections having been lowered, and first insulator portions in a mounted state to core configuration sections;
  • FIG. 24E is a drawing illustrating coil wires being wound onto the core configuration sections illustrated in FIG. 24D;
  • FIG. 25 is a drawing illustrating a modified example of insulators of the third exemplary embodiment;
  • FIG. 26A is a drawing illustrating the insulators illustrated in FIG. 25 set in a jig and plural core configuration sections in an installed state to second insulator portions;
  • FIG. 26B is a drawing illustrating cut off of bridging sections in the insulators illustrated in FIG. 26A;
  • FIG. 26C is a drawing illustrating the insulators illustrated in FIG. 26B with portions other than the second insulator portions having been raised, and the second insulator portions having been slid;
  • FIG. 26D is a drawing illustrating the insulators illustrated in FIG. 26C in a state with portions other than the second insulator portions having been lowered, and first insulator portions in an installed state to core configuration sections;
  • FIG. 27 is a perspective view illustrating a stator according to a fourth exemplary embodiment of the present invention;
  • FIG. 28A is an exploded perspective view illustrating a U-phase stator configuration section illustrated in FIG. 27;
  • FIG. 28B is an exploded perspective view illustrating a V-phase stator configuration section illustrated in FIG. 27;
  • FIG. 28C is an exploded perspective view illustrating a W-phase stator configuration section illustrated in FIG. 27;
  • FIG. 29 is a perspective view illustrating an interlocking structure of the fourth exemplary embodiment of the present invention;
  • FIG. 30 is a perspective view illustrating a process of assembling together plural stator configuration sections illustrated in FIG. 27;
  • FIG. 31 is a perspective view illustrating a modified example of an insulator of the fourth exemplary embodiment of the present invention;
  • FIG. 32 is a perspective view illustrating a modified example of insulators of the fourth exemplary embodiment of the present invention;
  • FIG. 33 is a perspective view illustrating a modified example of insulators of the fourth exemplary embodiment of the present invention;
  • FIG. 34 is a drawing illustrating an interlocking structure of a fifth exemplary embodiment of the present invention;
  • FIG. 35 is a drawing illustrating a modified example of an interlocking structure of the fifth exemplary embodiment of the present invention;
  • FIG. 36 is a drawing illustrating a modified example of an interlocking structure of the fifth exemplary embodiment of the present invention;
  • FIG. 37 is a drawing illustrating a modified example of an interlocking structure of the fifth exemplary embodiment of the present invention;
  • FIG. 38 is a drawing illustrating an interlocking structure of a sixth exemplary embodiment of the present invention;
  • FIG. 39 is a perspective view illustrating a stator according to a seventh exemplary embodiment of the present invention;
  • FIG. 40A is a perspective view illustrating a U-phase stator configuration section illustrated in FIG. 39;
  • FIG. 40B is a perspective view illustrating a V-phase stator configuration section illustrated in FIG. 39;
  • FIG. 40C is a perspective view illustrating a W-phase stator configuration section illustrated in FIG. 39;
  • FIG. 41A is a perspective view illustrating a process in which plural stator configuration sections illustrated in FIG. 39 are being assembled together;
  • FIG. 41B is a perspective view illustrating a state in which assembly has progressed further than in FIG. 41A;
  • FIG. 42 is a cross-section illustrating a schematic configuration of a brushless motor provided with the stator illustrated in FIG. 39;
  • FIG. 43 is a perspective view illustrating a modified example of a coil wire illustrated in FIG. 39;
  • FIG. 44 is a perspective view illustrating a stator according to an eighth exemplary embodiment of the present invention;
  • FIG. 45A is a perspective view illustrating a U-phase stator configuration section illustrated in FIG. 44;
  • FIG. 45B is a perspective view illustrating a V-phase stator configuration section illustrated in FIG. 44;
  • FIG. 45C is a perspective view illustrating a W-phase stator configuration section illustrated in FIG. 44;
  • FIG. 46A is a perspective view illustrating a process in which plural stator configuration sections illustrated in FIG. 44 are being assembled together;
  • FIG. 46B is a perspective view illustrating a state in which assembly has progressed further than in FIG. 46A;
  • FIG. 47 is a cross-section illustrating a schematic configuration of a brushless motor provided with the stator illustrated in FIG. 44;
  • FIG. 48 is a plan view to explain winding of a coil wire using a flyer machine;
  • FIG. 49 is a plan view to explain a manner in which a coil wire is pressed using a press;
  • FIG. 50 is an expanded area drawing to explain a manner in which a winding portion is pressed;
  • FIG. 51 is an exploded perspective view illustrating a stator according to a ninth exemplary embodiment of the present invention;
  • FIG. 52 is a plan view illustrating an assembled state of the stator illustrated in FIG. 51;
  • FIG. 53 is a plan view illustrating a brushless motor provided with a stator according to a tenth exemplary embodiment of the present invention;
  • FIG. 54A is a plan view illustrating a first group stator configuration section illustrated in FIG. 53;
  • FIG. 54B is a plan view illustrating a second group stator configuration section illustrated in FIG. 53;
  • FIG. 54C is a plan view illustrating a third group stator configuration section illustrated in FIG. 53;
  • FIG. 55 is an enlarged plan view of relevant portions of the stator illustrated in FIG. 53; and
  • FIG. 56 is a drawing to explain winding a coil wire in a stator according to a comparative example.
  • DESCRIPTION First Exemplary Embodiment of the Present Invention
  • Explanation first follows regarding a first exemplary embodiment of the present invention, with reference to FIG. 1 to FIG. 4.
  • A stator 10 according to the first exemplary embodiment illustrated in FIG. 1 is a stator employed in an inner rotor type brushless motor, and is configured including a U-phase stator configuration section 12U, a V-phase stator configuration section 12V and a W-phase stator configuration section 12W, as illustrated in FIG. 2A to FIG. 2C.
  • As illustrated in FIG. 2A, the U-phase stator configuration section 12U is configured with plural core configuration sections 14U, a coil wire 16U, and an insulator 18U. The plural core configuration sections 14U configure a core 20, together with plural V-phase core configuration sections 14V and plural W-phase core configuration sections 14W, described later (see FIG. 1 for each). The core configuration sections 14U respectively include plural yoke configuration sections 22U and plural teeth sections 24U.
  • The plural yoke configuration sections 22U configure a ring shaped yoke 40, together with V-phase yoke configuration sections 22V and W-phase yoke configuration sections 22W, described later (see FIG. 1 for each), and are respectively circular arc shaped. The plural teeth sections 24U are integrally formed to the respective yoke configuration sections 22U, and project from the yoke configuration sections 22U towards a radial direction inside from the yoke 40 (see FIG. 1).
  • The coil wire 16U configures the U-phase and includes plural winding portions 26U and plural crossing wires 28U. The plural winding portions 26U are wound concentrically on the teeth sections 24U, with insulator portions 32U, described later, disposed therebetween. The winding portions 26U are mutually connected to each other by the plural crossing wires 28U. The crossing wires 28U are connected to the plural winding portions 26U and are laid (wound) around the outer peripheral face of a connection portion 34U formed to the insulator 18U, described later. Terminal portions 30U at both end sides of the coil wire 16U lead out from the teeth sections 24U to a first axial direction side (the arrow Z1 side) of the stator 10. The crossing wires 28U are positioned on the same side in a first axial direction as the terminal portions 30U.
  • The insulator 18U is made from a resin, and includes integral plural insulator portions 32U and the connection portion 34U. The number of plural insulator portions 32U provided is the same as the number of the plural teeth sections 24U mentioned above. The plural insulator portions 32U project out on a yoke configuration sections 22U side (a yoke 40 side in FIG. 1) with respect to the connection portion 34U, described later. Each of the plural insulator portions 32U includes an insulator main body portion 32U1 and an extending portion 32U2. The insulator main body portions 32U1 are integrated to respective surfaces of the plural core configuration sections 14U mentioned above, for example by integral molding or interlock mounting. The insulator main body portions 32U1 insulate between the teeth sections 24U formed to the core configuration sections 14U and the winding portions 26U. The extending portions 32U2 are positioned further to the radial direction inside than the core configuration sections 14U, and extend from the insulator main body portion 32U1 to the first axial direction side (the arrow Z1 side) of the yoke 40.
  • The connection portion 34U is disposed displaced with respect to the plural insulator portions 32U at the yoke 40 first axial direction side (the arrow Z1 side) and is formed in a ring shape. The connection portion 34U connects together the plural insulator portions 32U (or more specifically, extension end portions (end portions on the Z1 side) of the extending portions 32U2 in the plural insulator portions 32U), and is positioned further to the yoke 40 radial direction inside (the radial direction inside of the yoke 40 illustrated in FIG. 1) than the core configuration sections 14U. Plural projection shaped retaining portions 36U project out towards a radial direction outside from between the plural insulator portions 32U on the outer peripheral face of the connection portion 34U. The retaining portions 36U retain the crossing wires 28U mentioned above from a second axial direction side (arrow Z2 side) of the connection portion 34U. Plural notches 38U opening towards the second axial direction side (arrow Z2 side) are formed to the connection portion 34U between the plural insulator portions 32U.
  • The V-phase stator configuration section 12V illustrated in FIG. 2B has basically the same configuration as the U-phase stator configuration section 12U mentioned above. Namely, the V-phase stator configuration section 12V is configured including the plural V-phase yoke configuration sections 22V, plural teeth sections 24V, a coil wire 16V and an insulator 18V. The plural yoke configuration sections 22V, the plural teeth sections 24V, the coil wire 16V and the insulator 18V correspond to the above mentioned plural yoke configuration sections 22U, the plural teeth sections 24U, the coil wire 16U and the insulator 18U (see FIG. 2A for each). Note that in the V-phase stator configuration section 12V, a connection portion 34V is formed in a ring shape, and formed with a smaller diameter than the U-phase connection portion 34U mentioned above (see FIG. 2A). Moreover, retaining portions 36V retain the crossing wires 28V from the first axial direction side (the arrow Z1 side) of the connection portion 34V, and are positioned further to the radial direction inside than the core configuration sections 14V.
  • Moreover, each of the plural insulator portions 32V includes an insulator main body portion 32V1 and an extending portion 32V2. The insulator main body portions 32V1 are integrated to respective surfaces of the plural core configuration sections 14V mentioned above, for example by integral molding or interlock mounting. The insulator main body portions 32V1 insulate between the teeth sections 24V formed to the core configuration sections 14V and the winding portions 26V. The extending portions 32V2 are positioned further to the radial direction inside than the core configuration sections 14V, and extend along a yoke 40 circumferential direction from the insulator main body portions 32V1. The connection portion 34V is provided at the first axial direction side (the arrow Z1 side) of the plural insulator portions 32V. The connection portion 34V is formed in a ring shape, connects together the plural insulator portions 32V, and is positioned further to the radial direction inside than the core configuration sections 14V.
  • The W-phase stator configuration section 12W illustrated in FIG. 2C has basically the same configuration as the U-phase stator configuration section 12U mentioned above. Namely, the W-phase stator configuration section 12W is configured including the plural W-phase yoke configuration sections 22W, plural teeth sections 24W, a coil wire 16W and an insulator 18W. The plural yoke configuration sections 22W, the plural teeth sections 24W, the coil wire 16W and the insulator 18W correspond to the above mentioned plural yoke configuration sections 22U, the plural teeth sections 24U, the coil wire 16U and the insulator 18U (see FIG. 2A for each). Note that in the W-phase stator configuration section 12W, a connection portion 34W is formed in a ring shape, and formed with a smaller diameter than the V-phase connection portion 34V mentioned above (see FIG. 2B). The above mentioned notches (see the notches 38U in FIG. 2A) are omitted from the connection portion 34W. Moreover, retaining portions 36W retain the crossing wires 28W from the first axial direction side (the arrow Z1 side) of the connection portion 34W, and are positioned further to the radial direction inside than the core configuration sections 14W.
  • Moreover, each of the plural insulator portions 32W includes an insulator main body portion 32W1 and an extending portion 32W2. The insulator main body portions 32W1 are integrated to respective surfaces of the plural core configuration sections 14W mentioned above, for example by integral molding or interlock mounting. The insulator main body portions 32W1 insulate between the teeth sections 24W formed to the core configuration sections 14W and the winding portions 26W. The extending portions 32W2 are positioned further to the radial direction inside than the core configuration sections 14W, and extend from the insulator main body portions 32W1 towards a radial direction inside of the yoke 40. The connection portion 34W is provided at the first axial direction side (the arrow Z1 side) of the plural insulator portions 32W. The connection portion 34W is formed in a ring shape, connects together the plural insulator portions 32W (or more specifically, extension end portions (end portions on the radial direction inside) of the extending portions 32W2 in the plural insulator portions 32W), and is positioned further to the radial direction inside than the core configuration sections 14W.
  • As illustrated in FIG. 1, the plural stator configuration sections 12U, 12V, 12W are, as explained in detail later, assembled together to configure the stator 10. Moreover, in the stator 10, the ring shaped yoke 40 is configured by the plural yoke configuration sections 22U, 22V, 22W. In other words, the yoke 40 is segmented in the circumferential direction into the plural yoke configuration sections 22U, 22V, 22W. Each of the plural yoke configuration sections 22U, 22V, 22W is fitted between a respective pair of yoke configuration sections adjacent on both sides.
  • The plural connection portions 34U, 34V, 34W are disposed at the radial direction inside of the yoke 40. The plural connection portions 34U, 34V, 34W are disposed such that there are gaps present therebetween in the yoke 40 radial direction and axial direction, and are provided coaxially to the yoke 40. The V-phase retaining portions 36V are fitted against an inner peripheral face of the U-phase connection portion 34U, and the W-phase retaining portions 36W are fitted against an inner peripheral face of the V-phase connection portion 34V. The plural connection portions 34U, 34V, 34W are thus retained in a state separated from each other in the radial direction. Namely, the retaining portions 36U, 36V, 36W are provided between the plural connection portions 34U, 34V, 34W in the radial direction, and serve as projection shaped spacers to retain the plural connection portions 34U, 34V, 34W in a state separated from each other in the radial direction.
  • Moreover, as mentioned above, in the state in which the plural connection portions 34U, 34V, 34W are disposed such that gaps are present therebetween in the yoke 40 radial direction, the V-phase crossing wires 28V pass through inside the notches 38U formed at the U-phase connection portion 34U (are housed inside the notches 38U), and the W-phase crossing wires 28W pass through inside the notches 38U formed at the U-phase connection portion 34U and inside the notches 38V formed at the V-phase connection portion 34V (are housed inside the notches 38U and the notches 38V (see FIG. 3B)). The notches 38U, 38V are examples of a housing portion of the present invention.
  • As illustrated in FIG. 4, the stator 10 configured as described above configures an inner rotor type brushless motor 60, together with a rotor 50 and a housing 70. Configuration in the brushless motor 60 is such that a rotational magnetic field is formed by the stator 10, and the rotor 50 is rotated thereby. Note that the brushless motor 60 is for example an 8-pole 12 slot motor.
  • Explanation follows regarding a manufacturing method of the stator 10 configured as described above.
  • First, as illustrated in FIG. 2A, the core configuration sections 14U are integrated to the insulator portions 32U of the insulator 18U to form a U-phase sub-assembly 42U configured from the insulator 18U and the plural core configuration sections 14U. Similarly, as illustrated in FIG. 2B, the core configuration sections 14V are integrated to the insulator portions 32V of the insulator 18V to form a V-phase sub-assembly 42V configured from the insulator 18V and the plural core configuration sections 14V. Moreover, as illustrated in FIG. 2C, the core configuration sections 14W are integrated to the insulator portions 32W of the insulator 18W to form a W-phase sub-assembly 42W configured from the insulator 18W and the plural core configuration sections 14W. The sub-assemblies 42U, 42V, 42W are thus formed for each of the U-phase, the V-phase and the W-phase (the sub-assembly forming process).
  • Next, as illustrated in FIG. 2A, a flyer machine 100 (see FIG. 5) is employed to wind the coil wire 16U on each of the teeth sections 24U of the U-phase sub-assembly 42U from the radial direction outside, forming the U-phase stator configuration section 12U with plural winding portions 26U formed at the sub-assembly 42U. Note that the flyer machine 100 is, as illustrated in FIG. 5, configured including a flyer 101 that winds the coil wires 16 in a circular motion so as to circle the periphery of each of the teeth sections 24, a variable former 102 that aligns the coil wires 16 wound onto the teeth sections 24, and a drive circuit 103 that controls the flyer 101 and the variable former 102.
  • Similarly, as illustrated in FIG. 2B, the flyer machine 100 mentioned above is employed to wind the coil wire 16V on each of the teeth sections 24V of the V-phase sub-assembly 42V from the radial direction outside, forming the V-phase stator configuration section 12V with plural winding portions 26V formed at the sub-assembly 42V. Moreover, as illustrated in FIG. 2C, the flyer machine 100 mentioned above is employed to wind the coil wire 16W on each of the teeth sections 24W of the W-phase sub-assembly 42W from the radial direction outside, forming the W-phase stator configuration section 12W with plural winding portions 26W formed on the sub-assembly 42W.
  • When this is performed, as illustrated in FIG. 2A, the plural crossing wires 28U are laid out along the outer peripheral face of the connection portion 34U. The plural crossing wires 28U are also retained from the second axial direction side (arrow Z2 side) of the connection portion 34U by the projection shaped retaining portions 36U. Similarly, as illustrated in FIG. 2B, the plural crossing wires 28V are laid out along the outer peripheral face of the connection portion 34V. The plural crossing wires 28V are also retained from the first axial direction side (the arrow Z1 side) of the connection portion 34V by the projection shaped retaining portions 36V. Moreover, as illustrated in FIG. 2C, the plural crossing wires 28W are laid out along the outer peripheral face of the connection portion 34W. The plural crossing wires 28W are also retained from the connection portion 34W from the first axial direction side (the arrow Z1 side) by the projection shaped retaining portions 36W.
  • Moreover, as illustrated in FIG. 2A, the terminal portions 30U at the two end sides of the coil wire 16U are led out from the teeth sections 24U to the first axial direction side (the arrow Z1 side) of the stator 10. Similarly, as illustrated in FIG. 2B, the terminal portions 30V at the two end sides of the coil wire 16V are led out from the teeth sections 24V towards the first axial direction side of the stator 10. Moreover, as illustrated in FIG. 2C, the terminal portions 30W at the two end sides of the coil wire 16W are led out from the teeth sections 24W towards the first axial direction side of the stator 10. The stator configuration sections 12U, 12V, 12W are thus formed for each of the U-phase, the V-phase and the W-phase (the stator configuration section forming process).
  • Then, as illustrated in FIG. 3A and FIG. 3B, in a state in which the V-phase stator configuration section 12V is displaced by a specific angle in a circumferential direction with respect to the W-phase stator configuration section 12W, the V-phase stator configuration section 12V is assembled to the W-phase stator configuration section 12W from the first axial direction side (the arrow Z1 side). Then, in a state in which the U-phase stator configuration section 12U is displaced by a specific angle in a circumferential direction with respect to the V-phase stator configuration section 12V, the U-phase stator configuration section 12U is assembled to the V-phase stator configuration section 12V and the W-phase stator configuration section 12W from the first axial direction side (the arrow Z1 side).
  • When this is performed, each of the plural yoke configuration sections 22U, 22V, 22W is fitted between a pair of yoke configuration sections respectively adjacent on both sides. Moreover, the V-phase retaining portions 36V are fitted against the inner peripheral face of the U-phase connection portion 34U, and the W-phase retaining portions 36W are fitted against the inner peripheral face of the V-phase connection portion 34V. The plural connection portions 34U, 34V, 34W are thus retained in a state separated from each other in the radial direction by the projection shaped retaining portions 36U, 36V, 36W.
  • Moreover, when this is performed, the V-phase crossing wires 28V pass through inside the notches 38U formed at the U-phase connection portion 34U, and the W-phase crossing wires 28W pass through inside the notches 38U formed at the U-phase connection portion 34U and through inside the notches 38V formed at the V-phase connection portion 34V. The plural stator configuration sections 12U, 12V, 12W are thus assembled together to form the stator 10 (stator forming process). Note that the terminal portions 30U, 30V, 30W are connected by a buzz bar or the like, not shown in the drawings. The stator 10 is accordingly manufactured by the above processes.
  • Explanation follows regarding operation and advantageous effects of the first exemplary embodiment.
  • Note that in the following explanation, for convenience the letters U, V, W are omitted as suffixes to the labels of each member and each portion when no discrimination is made between the U-phase, the V-phase and the W-phase.
  • According to the stator 10 of the first exemplary embodiment, the yoke 40 is configured by the plural yoke configuration sections 22 segmented in the circumferential direction. Therefore, even in a stator employed in a so-called inner rotor type brushless motor in which plural teeth sections 24 project towards radial direction inside of the yoke 40, the sub-assemblies 42 for each of the U-phase, V-phase and W-phase are formed as described above, and the coil wires 16 can be wound using the flyer machine 100 (see FIG. 5) onto each of the teeth sections 24 of the sub-assemblies 42 from the radial direction outside. There is accordingly no need to secure space between the teeth sections 24, as would be required when a nozzle machine is employed, enabling a higher dense arrangement of the coil wires 16 to be achieved, and enabling a more compact stator 10 to be realized.
  • Moreover, as described above, the yoke 40 is segmented in the circumferential direction into the plural yoke configuration sections 22, and so, for example, the stator 10 can be made more compact in the axial direction in comparison to cases in which the yoke 40 is segmented into plural yoke configuration sections in the axial direction.
  • Moreover, when the flyer machine 100 is employed, since the winding speed of the coil wires 16 is higher than when using a nozzle machine, the process of winding the coil wires 16 can be speeded up, and accordingly a reduction in cost of the stator 10 can be achieved due to reducing the number of equipment units.
  • Moreover, the notches 38U, 38V are formed in the U-phase connection portion 34U and the V-phase connection portion 34V, for the crossing wires 28V, 28W to pass through inside. Interference between the connection portions 34U, 34V and the crossing wires 28V, 28W can thereby be avoided, and the length of the crossing wires 28V, 28W can be suppressed from increasing. The stator 10 can accordingly be made even more compact and at even lower cost.
  • Moreover, in the U-phase stator configuration section 12U, the extending portions 32U2 are positioned further to the radial direction inside than the core configuration sections 14U. Interference between the flyer of the flyer machine and the extending portions 32U2 and the connection portion 34U can accordingly be suppressed when winding the coil wire 16U on the teeth sections 24U from the radial direction outside using the flyer machine.
  • Moreover, in the V-phase stator configuration section 12V and in the W-phase stator configuration section 12W, the connection portions 34V, 34W are respectively positioned further to the radial direction inside than the core configuration sections 14V, 14W. Interference between the flyer of the flyer machine and the connection portion 34V, 34W can accordingly be suppressed during winding the coil wires on the respective teeth sections 24V, 24W from the radial direction outside using the flyer machine.
  • Each of the connection portions 34 includes the retaining portions 36 that retain the respective crossing wires 28 laid on the respective connection portion itself. Therefore, for example as stated above, the crossing wires 28 can be retained at the connection portions 34 by means of the retaining portions 36 when forming the stator 10 by assembling together the plural stator configuration sections 12, and so efficient operation can be achieved when assembling together the plural stator configuration sections 12. Moreover, even after the stator 10 has been incorporated into the brushless motor, the crossing wires 28 are retained at the connection portions 34 by means of the retaining portions 36, and so flapping of the crossing wires 28 can be suppressed, enabling noise and fault occurrence to be suppressed.
  • The plural connection portions 34 can also be retained in a state separated from each other in the radial direction by the projection shaped retaining portions 36. Space for laying out the crossing wires 28 between the plural connection portions 34 can accordingly be secured in the radial direction, and rattling of the plural connection portions 34 can also be suppressed. Better operating efficiency can also be achieved when assembling the plural connection portions 34 together than in cases in which the plural connection portions 34 are fitted together around the whole circumference.
  • Moreover, the plural yoke configuration sections 22 are integrally formed to the teeth sections 24. Magnetic loss at each of the connection portions can accordingly be suppressed compared with, for example, a two-part type core including independent members of plural teeth sections with leading end portions connected together with thinned bridging sections and a yoke that connects together base end portions of the teeth sections. Namely, magnetic loss occurs at three locations in a two-part type core, namely at the bridging sections between the leading end portions of adjacent pairs of teeth sections, at the base end portions of pairs of teeth sections, and at connection portions of the yoke. In contrast thereto, in the stator 10 of the present exemplary embodiment, magnetic loss only occurs at one location, the connection portion between adjacent pairs of the yoke configuration sections 22, enabling magnetic loss to be reduced. It is accordingly possible to achieve even greater compactness and reduction in weight.
  • Moreover, a buzz bar to connect the plural winding portions 26 is not required since the plural winding portions 26 are connected together by the crossing wires 28. A reduction in the number of components can accordingly be made, thereby also enabling a reduction in cost.
  • Moreover, the crossing wires 28 can be wound onto each of the connection portions 34, and so the winding speed of the coil wires 16 can be raised, and a process to align the crossing wires 28 after winding the coil wires 16 can be dispensed with. A decrease in cost can also be achieved as a result.
  • Moreover, the brushless motor according to the first exemplary embodiment is equipped with the stator 10 as described above, and so greater compactness and a decrease in cost can also be achieved.
  • Moreover, in the stator manufacturing method according to the first exemplary embodiment, the sub-assemblies 42 are formed for each of the U-phase, V-phase and W-phase, and the coil wires 16 are wound on each of the teeth sections 24 of the sub-assemblies 42 from the radial direction outside using the flyer machine 100. There is accordingly no need to secure space between the teeth sections 24, as would be required when a nozzle machine is employed. A higher dense arrangement of the coil wires 16 is thereby enabled, and a more compact stator 10 can be realized.
  • Moreover, due to employing the flyer machine 100, the winding speed of the coil wires 16 is higher than when a nozzle machine is employed, and so the process of winding the coil wires 16 can be speeded up, and thereby a reduction in cost of the stator 10 can be achieved due to reducing the number of equipment units.
  • The connection portions 34 are provided coaxially to the yoke 40, enabling the structure to be simplified. The retaining portions 36 are also formed in projection shapes, thereby also enabling the structure to be simplified.
  • Explanation follows regarding modified examples of the first exemplary embodiment.
  • In the first exemplary embodiment, the brushless motor is configured as an example by an 8-pole 12 slot motor, however configuration may be made with a motor having another combination of numbers of poles and numbers of slots.
  • The connection method of the plural coil wires 16U, 16V, 16W may be configured in a star connection pattern or a delta connection pattern, both in series or in parallel, as illustrated in FIG. 6.
  • The retaining portions 36 function for retaining the crossing wires 28 and also function as projection shaped spacers for retaining the plural connection portions 34 in a state separated from each other in the radial direction. However, retaining portions 36 and spacers may be independently provided.
  • Moreover, the retaining portions 36 are formed at all of the connection portions 34. However, the retaining portions 36U, 36W may be omitted from the U-phase connection portion 34U and the W-phase connection portion 34W. In their place, spacers formed separately at the retaining portions 36 may be provided at the outer peripheral face and the inner peripheral face of the V-phase connection portion 34V, to fit against the inner peripheral face of the U-phase connection portion 34U and the outer peripheral face of the W-phase connection portion 34W.
  • The connection portions 34 are only provided at the first axial direction side (Z1 side) of the plural insulator portions 32U, however connection portions may be provided only on the second axial direction side (Z2 side) of the plural insulator portions 32U or on both axial direction sides of the plural insulator portions 32U.
  • Moreover, the connection portions 34 are provided coaxially to the yoke 40, however connection portions may be provided so as not to be coaxial to the yoke 40. The connection portions 34 are also formed in ring shapes, however connection portions may be formed in another shape, such as a polygonal shape or for example a shape with a portion missing such as a C-shape.
  • The crossing wires 28V, 28W, serving as an example of a member of the present invention, are housed in the notches 38U, 38V, however different member may be housed.
  • The retaining portions 36 are formed in projection shapes, however the retaining portions 36 may be formed in a circular arc shape extending around the circumferential direction of the stator 10, or in another shape.
  • The extending portions 32U2 are only formed to the U-phase insulator 18U, however similar extending portions to the extending portions 32U2 may be formed to the V-phase insulator 18V and to the W-phase insulator 18W.
  • The connection portion 34U is positioned further to the radial direction inside than the core configuration sections 14U. However, as schematically illustrated in FIG. 15, as long as the insulator 18U has extending portions 32U2 positioned further to the radial direction inside than the core configuration sections 14U, the connection portion 34U may be positioned further to the radial direction outside than the core configuration sections 14U. Moreover, as long as the extending portions 32U2 are positioned further to the radial direction inside than the core configuration sections 14U, the extending portions 32U2 may extend in one direction of axial direction, radial direction, or a direction that is a combination thereof of the yoke 40. Although the connection portion 34U is provided on the first axial direction side (Z1 side) of the insulator portions 32U and connects together the extension end portions of the extending portions 32U2 extending in the yoke 40 axial direction, configuration may be made, for example as illustrated in FIG. 16, with the extending portions 32U2 extending in the yoke 40 circumferential direction, and the connection portion 34U extending in the yoke 40 circumferential direction and connecting the extension end portions of the extending portions 32U2. Moreover, in cases in which the extending portions 32U2 extend in one direction of the yoke 40 axial direction, radial direction, or a direction that is a combination thereof, the connection portion 34U may connect the extension end portions of the extending portions 32U2, and may also connect other locations of the extending portions 32U2 other than the extension end portions. The above also similarly applies to cases in which extending portions and a connection portion are formed to the V-phase insulator 18V and the W-phase insulator 18W.
  • Moreover, as illustrated in FIG. 20A, the plural connection portions 34U, 34V, 34W are disposed such that there are gaps present between each other in the yoke 40 radial direction and axial direction. However, configuration may be made with the connection portions 34U, 34V, 34W disposed such that there are gaps present between each other in the yoke 40 axial direction, as illustrated in FIG. 20B, or disposed such that there are gaps present between each other in the yoke 40 radial direction, as illustrated in FIG. 20C. A space can also be secured in such configurations for laying the crossing wires 28 between the plural connection portions 34U, 34V, 34W.
  • Although the stator 10 is also configured for use in a so-called inner rotor type brushless motor in which the plural teeth sections 24 project towards the yoke 40 radial direction inside, the stator 10 may also be configured for use in a so-called outer rotor type brushless motor in which plural teeth sections 24 project towards the yoke 40 radial direction outside.
  • Moreover, the stator 10 is configured segmented into the stator configuration sections 12U, 12V, 12W configured for each of the plural phases, as an example of plural groups. However, as illustrated in FIG. 17 and FIG. 18A to FIG. 18C, the stator 10 may be segmented into stator configuration sections 12A, 12B, 12C configured by groups each containing a combination of plural phases.
  • Note that, for example, in the examples illustrated in FIG. 17 and FIG. 18A to FIG. 18C, a stator configuration section 12A configuring a first group includes +U-phase teeth sections 24U and −W-phase teeth sections 24W, and a stator configuration section 12B configuring a second group includes +V-phase teeth sections 24V and −U-phase teeth sections 24U. Moreover, a stator configuration section 12C configuring a third group includes +W-phase teeth sections 24W and −V-phase teeth sections 24V. Note that the brushless motor of this example is a 10-pole 12 slot or a 14-pole 12 slot motor. The coil wire is reverse wound on the −U-phase, −V-phase, and −W-phase teeth sections.
  • Although not particularly illustrated, as an example of a different combination, configuration may be made such that for example: a stator configuration section 12A configuring the first group includes +U-phase teeth sections and −V-phase teeth sections; a stator configuration section 12B configuring a second group includes +V-phase teeth sections and −U-phase teeth sections; and a stator configuration section 12C configuring a third group includes +W-phase teeth sections and −W-phase teeth sections.
  • Moreover, configuration may be made such that: a stator configuration section 12A configuring a first group includes +U-phase teeth sections and −U-phase teeth sections; a stator configuration section 12B configuring a second group includes +V-phase teeth sections and −V-phase teeth sections; and a stator configuration section 12C configuring a third group includes +W-phase teeth sections and −W-phase teeth sections.
  • Moreover, configuration may be made such that: a stator configuration section 12A configuring a first group includes +U-phase teeth sections and −U-phase teeth sections; a stator configuration section 12B configuring a second group includes +V-phase teeth sections and −W-phase teeth sections; and a stator configuration section 12C configuring a third group includes +W-phase teeth sections and −V-phase teeth sections.
  • In addition to the above, configuration may also be made with stator config