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
sections
yoke
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
Other languages
English (en)
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 claimed from JP2012025298A external-priority patent/JP2013162726A/ja
Priority claimed from JP2012025297A external-priority patent/JP5502115B2/ja
Priority claimed from JP2012040627A external-priority patent/JP5536123B2/ja
Priority claimed from JP2012095870A external-priority patent/JP5921309B2/ja
Priority claimed from JP2012095872A external-priority patent/JP5502131B2/ja
Priority claimed from JP2012252190A external-priority patent/JP6046987B2/ja
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
Priority to US15/420,108 priority Critical patent/US10491057B2/en
Priority to US16/591,364 priority patent/US20200036239A1/en
Abandoned legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/12—Stationary parts of the magnetic circuit
    • H02K1/14—Stator cores with salient poles
    • H02K1/146—Stator cores with salient poles consisting of a generally annular yoke with salient poles
    • H02K1/148—Sectional cores
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
    • H02K15/022—Methods 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
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/08—Forming windings by laying conductors into or around core parts
    • H02K15/095—Forming windings by laying conductors into or around core parts by laying conductors around salient poles
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/10—Applying solid insulation to windings, stators or rotors
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/18—Windings for salient poles
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/28—Layout of windings or of connections between windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/32—Windings characterised by the shape, form or construction of the insulation
    • H02K3/34—Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation
    • H02K3/345—Windings 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
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/46—Fastening of windings on the stator or rotor structure
    • H02K3/52—Fastening salient pole windings or connections thereto
    • H02K3/521—Fastening salient pole windings or connections thereto applicable to stators only
    • H02K3/522—Fastening salient pole windings or connections thereto applicable to stators only for generally annular cores with salient poles
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K2203/00—Specific aspects not provided for in the other groups of this subclass relating to the windings
    • H02K2203/06—Machines characterised by the wiring leads, i.e. conducting wires for connecting the winding terminations
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K2203/00—Specific aspects not provided for in the other groups of this subclass relating to the windings
    • H02K2203/12—Machines characterised by the bobbins for supporting the windings
    • Y—GENERAL 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49009—Dynamoelectric machine

Definitions

  • the present invention relates to a stator, a brushless motor, and a stator manufacturing method.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • the winding portions are pressed such that the pressing direction on the winding portions is a tangential direction to the respective stator configuration sections.
  • 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
  • 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 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.
  • 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.
  • 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.
  • 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 ;
  • FIG. 56 is a drawing to explain winding a coil wire in a stator according to a comparative example.
  • 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 12 U, a V-phase stator configuration section 12 V and a W-phase stator configuration section 12 W, as illustrated in FIG. 2A to FIG. 2C .
  • the U-phase stator configuration section 12 U is configured with plural core configuration sections 14 U, a coil wire 16 U, and an insulator 18 U.
  • the plural core configuration sections 14 U configure a core 20 , together with plural V-phase core configuration sections 14 V and plural W-phase core configuration sections 14 W, described later (see FIG. 1 for each).
  • the core configuration sections 14 U respectively include plural yoke configuration sections 22 U and plural teeth sections 24 U.
  • the plural yoke configuration sections 22 U configure a ring shaped yoke 40 , together with V-phase yoke configuration sections 22 V and W-phase yoke configuration sections 22 W, described later (see FIG. 1 for each), and are respectively circular arc shaped.
  • the plural teeth sections 24 U are integrally formed to the respective yoke configuration sections 22 U, and project from the yoke configuration sections 22 U towards a radial direction inside from the yoke 40 (see FIG. 1 ).
  • the coil wire 16 U configures the U-phase and includes plural winding portions 26 U and plural crossing wires 28 U.
  • the plural winding portions 26 U are wound concentrically on the teeth sections 24 U, with insulator portions 32 U, described later, disposed therebetween.
  • the winding portions 26 U are mutually connected to each other by the plural crossing wires 28 U.
  • the crossing wires 28 U are connected to the plural winding portions 26 U and are laid (wound) around the outer peripheral face of a connection portion 34 U formed to the insulator 18 U, described later.
  • Terminal portions 30 U at both end sides of the coil wire 16 U lead out from the teeth sections 24 U to a first axial direction side (the arrow Z 1 side) of the stator 10 .
  • the crossing wires 28 U are positioned on the same side in a first axial direction as the terminal portions 30 U.
  • the insulator 18 U is made from a resin, and includes integral plural insulator portions 32 U and the connection portion 34 U.
  • the number of plural insulator portions 32 U provided is the same as the number of the plural teeth sections 24 U mentioned above.
  • the plural insulator portions 32 U project out on a yoke configuration sections 22 U side (a yoke 40 side in FIG. 1 ) with respect to the connection portion 34 U, described later.
  • Each of the plural insulator portions 32 U includes an insulator main body portion 32 U 1 and an extending portion 32 U 2 .
  • the insulator main body portions 32 U 1 are integrated to respective surfaces of the plural core configuration sections 14 U mentioned above, for example by integral molding or interlock mounting.
  • the insulator main body portions 32 U 1 insulate between the teeth sections 24 U formed to the core configuration sections 14 U and the winding portions 26 U.
  • the extending portions 32 U 2 are positioned further to the radial direction inside than the core configuration sections 14 U, and extend from the insulator main body portion 32 U 1 to the first axial direction side (the arrow Z 1 side) of the yoke 40 .
  • connection portion 34 U is disposed displaced with respect to the plural insulator portions 32 U at the yoke 40 first axial direction side (the arrow Z 1 side) and is formed in a ring shape.
  • the connection portion 34 U connects together the plural insulator portions 32 U (or more specifically, extension end portions (end portions on the Z 1 side) of the extending portions 32 U 2 in the plural insulator portions 32 U), 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 14 U.
  • Plural projection shaped retaining portions 36 U project out towards a radial direction outside from between the plural insulator portions 32 U on the outer peripheral face of the connection portion 34 U.
  • the retaining portions 36 U retain the crossing wires 28 U mentioned above from a second axial direction side (arrow Z 2 side) of the connection portion 34 U.
  • Plural notches 38 U opening towards the second axial direction side (arrow Z 2 side) are formed to the connection portion 34 U between the plural insulator portions 32 U.
  • the V-phase stator configuration section 12 V illustrated in FIG. 2B has basically the same configuration as the U-phase stator configuration section 12 U mentioned above. Namely, the V-phase stator configuration section 12 V is configured including the plural V-phase yoke configuration sections 22 V, plural teeth sections 24 V, a coil wire 16 V and an insulator 18 V.
  • the plural yoke configuration sections 22 V, the plural teeth sections 24 V, the coil wire 16 V and the insulator 18 V correspond to the above mentioned plural yoke configuration sections 22 U, the plural teeth sections 24 U, the coil wire 16 U and the insulator 18 U (see FIG. 2A for each).
  • connection portion 34 V is formed in a ring shape, and formed with a smaller diameter than the U-phase connection portion 34 U mentioned above (see FIG. 2A ). Moreover, retaining portions 36 V retain the crossing wires 28 V from the first axial direction side (the arrow Z 1 side) of the connection portion 34 V, and are positioned further to the radial direction inside than the core configuration sections 14 V.
  • each of the plural insulator portions 32 V includes an insulator main body portion 32 V 1 and an extending portion 32 V 2 .
  • the insulator main body portions 32 V 1 are integrated to respective surfaces of the plural core configuration sections 14 V mentioned above, for example by integral molding or interlock mounting.
  • the insulator main body portions 32 V 1 insulate between the teeth sections 24 V formed to the core configuration sections 14 V and the winding portions 26 V.
  • the extending portions 32 V 2 are positioned further to the radial direction inside than the core configuration sections 14 V, and extend along a yoke 40 circumferential direction from the insulator main body portions 32 V 1 .
  • the connection portion 34 V is provided at the first axial direction side (the arrow Z 1 side) of the plural insulator portions 32 V.
  • the connection portion 34 V is formed in a ring shape, connects together the plural insulator portions 32 V, and is positioned further to the radial direction inside than the core configuration sections 14 V.
  • the W-phase stator configuration section 12 W illustrated in FIG. 2C has basically the same configuration as the U-phase stator configuration section 12 U mentioned above.
  • the W-phase stator configuration section 12 W is configured including the plural W-phase yoke configuration sections 22 W, plural teeth sections 24 W, a coil wire 16 W and an insulator 18 W.
  • the plural yoke configuration sections 22 W, the plural teeth sections 24 W, the coil wire 16 W and the insulator 18 W correspond to the above mentioned plural yoke configuration sections 22 U, the plural teeth sections 24 U, the coil wire 16 U and the insulator 18 U (see FIG. 2A for each).
  • connection portion 34 W is formed in a ring shape, and formed with a smaller diameter than the V-phase connection portion 34 V mentioned above (see FIG. 2B ).
  • the above mentioned notches are omitted from the connection portion 34 W.
  • retaining portions 36 W retain the crossing wires 28 W from the first axial direction side (the arrow Z 1 side) of the connection portion 34 W, and are positioned further to the radial direction inside than the core configuration sections 14 W.
  • each of the plural insulator portions 32 W includes an insulator main body portion 32 W 1 and an extending portion 32 W 2 .
  • the insulator main body portions 32 W 1 are integrated to respective surfaces of the plural core configuration sections 14 W mentioned above, for example by integral molding or interlock mounting.
  • the insulator main body portions 32 W 1 insulate between the teeth sections 24 W formed to the core configuration sections 14 W and the winding portions 26 W.
  • the extending portions 32 W 2 are positioned further to the radial direction inside than the core configuration sections 14 W, and extend from the insulator main body portions 32 W 1 towards a radial direction inside of the yoke 40 .
  • connection portion 34 W is provided at the first axial direction side (the arrow Z 1 side) of the plural insulator portions 32 W.
  • the connection portion 34 W is formed in a ring shape, connects together the plural insulator portions 32 W (or more specifically, extension end portions (end portions on the radial direction inside) of the extending portions 32 W 2 in the plural insulator portions 32 W), and is positioned further to the radial direction inside than the core configuration sections 14 W.
  • the plural stator configuration sections 12 U, 12 V, 12 W are, as explained in detail later, assembled together to configure the stator 10 .
  • the ring shaped yoke 40 is configured by the plural yoke configuration sections 22 U, 22 V, 22 W.
  • the yoke 40 is segmented in the circumferential direction into the plural yoke configuration sections 22 U, 22 V, 22 W.
  • Each of the plural yoke configuration sections 22 U, 22 V, 22 W is fitted between a respective pair of yoke configuration sections adjacent on both sides.
  • connection portions 34 U, 34 V, 34 W are disposed at the radial direction inside of the yoke 40 .
  • the plural connection portions 34 U, 34 V, 34 W 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 36 V are fitted against an inner peripheral face of the U-phase connection portion 34 U, and the W-phase retaining portions 36 W are fitted against an inner peripheral face of the V-phase connection portion 34 V.
  • the plural connection portions 34 U, 34 V, 34 W are thus retained in a state separated from each other in the radial direction.
  • the retaining portions 36 U, 36 V, 36 W are provided between the plural connection portions 34 U, 34 V, 34 W in the radial direction, and serve as projection shaped spacers to retain the plural connection portions 34 U, 34 V, 34 W in a state separated from each other in the radial direction.
  • the V-phase crossing wires 28 V pass through inside the notches 38 U formed at the U-phase connection portion 34 U (are housed inside the notches 38 U), and the W-phase crossing wires 28 W pass through inside the notches 38 U formed at the U-phase connection portion 34 U and inside the notches 38 V formed at the V-phase connection portion 34 V (are housed inside the notches 38 U and the notches 38 V (see FIG. 3B )).
  • the notches 38 U, 38 V are examples of a housing portion of the present invention.
  • 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.
  • the brushless motor 60 is for example an 8-pole 12 slot motor.
  • the core configuration sections 14 U are integrated to the insulator portions 32 U of the insulator 18 U to form a U-phase sub-assembly 42 U configured from the insulator 18 U and the plural core configuration sections 14 U.
  • the core configuration sections 14 V are integrated to the insulator portions 32 V of the insulator 18 V to form a V-phase sub-assembly 42 V configured from the insulator 18 V and the plural core configuration sections 14 V.
  • FIG. 2A the core configuration sections 14 U are integrated to the insulator portions 32 U of the insulator 18 U to form a U-phase sub-assembly 42 U configured from the insulator 18 U and the plural core configuration sections 14 V.
  • the core configuration sections 14 W are integrated to the insulator portions 32 W of the insulator 18 W to form a W-phase sub-assembly 42 W configured from the insulator 18 W and the plural core configuration sections 14 W.
  • the sub-assemblies 42 U, 42 V, 42 W are thus formed for each of the U-phase, the V-phase and the W-phase (the sub-assembly forming process).
  • a flyer machine 100 (see FIG. 5 ) is employed to wind the coil wire 16 U on each of the teeth sections 24 U of the U-phase sub-assembly 42 U from the radial direction outside, forming the U-phase stator configuration section 12 U with plural winding portions 26 U formed at the sub-assembly 42 U.
  • 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 .
  • the flyer machine 100 mentioned above is employed to wind the coil wire 16 V on each of the teeth sections 24 V of the V-phase sub-assembly 42 V from the radial direction outside, forming the V-phase stator configuration section 12 V with plural winding portions 26 V formed at the sub-assembly 42 V.
  • the flyer machine 100 mentioned above is employed to wind the coil wire 16 W on each of the teeth sections 24 W of the W-phase sub-assembly 42 W from the radial direction outside, forming the W-phase stator configuration section 12 W with plural winding portions 26 W formed on the sub-assembly 42 W.
  • the plural crossing wires 28 U are laid out along the outer peripheral face of the connection portion 34 U.
  • the plural crossing wires 28 U are also retained from the second axial direction side (arrow Z 2 side) of the connection portion 34 U by the projection shaped retaining portions 36 U.
  • the plural crossing wires 28 V are laid out along the outer peripheral face of the connection portion 34 V.
  • the plural crossing wires 28 V are also retained from the first axial direction side (the arrow Z 1 side) of the connection portion 34 V by the projection shaped retaining portions 36 V.
  • the plural crossing wires 28 W are laid out along the outer peripheral face of the connection portion 34 W.
  • the plural crossing wires 28 W are also retained from the connection portion 34 W from the first axial direction side (the arrow Z 1 side) by the projection shaped retaining portions 36 W.
  • the terminal portions 30 U at the two end sides of the coil wire 16 U are led out from the teeth sections 24 U to the first axial direction side (the arrow Z 1 side) of the stator 10 .
  • the terminal portions 30 V at the two end sides of the coil wire 16 V are led out from the teeth sections 24 V towards the first axial direction side of the stator 10 .
  • the terminal portions 30 W at the two end sides of the coil wire 16 W are led out from the teeth sections 24 W towards the first axial direction side of the stator 10 .
  • the stator configuration sections 12 U, 12 V, 12 W are thus formed for each of the U-phase, the V-phase and the W-phase (the stator configuration section forming process).
  • the V-phase stator configuration section 12 V is assembled to the W-phase stator configuration section 12 W from the first axial direction side (the arrow Z 1 side).
  • the U-phase stator configuration section 12 U is assembled to the V-phase stator configuration section 12 V and the W-phase stator configuration section 12 W from the first axial direction side (the arrow Z 1 side).
  • each of the plural yoke configuration sections 22 U, 22 V, 22 W is fitted between a pair of yoke configuration sections respectively adjacent on both sides.
  • the V-phase retaining portions 36 V are fitted against the inner peripheral face of the U-phase connection portion 34 U
  • the W-phase retaining portions 36 W are fitted against the inner peripheral face of the V-phase connection portion 34 V.
  • the plural connection portions 34 U, 34 V, 34 W are thus retained in a state separated from each other in the radial direction by the projection shaped retaining portions 36 U, 36 V, 36 W.
  • stator 10 (stator forming process).
  • terminal portions 30 U, 30 V, 30 W are connected by a buzz bar or the like, not shown in the drawings.
  • the stator 10 is accordingly manufactured by the above processes.
  • 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.
  • 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.
  • the flyer machine 100 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.
  • the notches 38 U, 38 V are formed in the U-phase connection portion 34 U and the V-phase connection portion 34 V, for the crossing wires 28 V, 28 W to pass through inside. Interference between the connection portions 34 U, 34 V and the crossing wires 28 V, 28 W can thereby be avoided, and the length of the crossing wires 28 V, 28 W can be suppressed from increasing.
  • the stator 10 can accordingly be made even more compact and at even lower cost.
  • the extending portions 32 U 2 are positioned further to the radial direction inside than the core configuration sections 14 U. Interference between the flyer of the flyer machine and the extending portions 32 U 2 and the connection portion 34 U can accordingly be suppressed when winding the coil wire 16 U on the teeth sections 24 U from the radial direction outside using the flyer machine.
  • connection portions 34 V, 34 W are respectively positioned further to the radial direction inside than the core configuration sections 14 V, 14 W. Interference between the flyer of the flyer machine and the connection portion 34 V, 34 W can accordingly be suppressed during winding the coil wires on the respective teeth sections 24 V, 24 W from the radial direction outside using the flyer machine.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • connection method of the plural coil wires 16 U, 16 V, 16 W 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.
  • retaining portions 36 and spacers may be independently provided.
  • the retaining portions 36 are formed at all of the connection portions 34 .
  • the retaining portions 36 U, 36 W may be omitted from the U-phase connection portion 34 U and the W-phase connection portion 34 W.
  • 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 34 V, to fit against the inner peripheral face of the U-phase connection portion 34 U and the outer peripheral face of the W-phase connection portion 34 W.
  • connection portions 34 are only provided at the first axial direction side (Z 1 side) of the plural insulator portions 32 U, however connection portions may be provided only on the second axial direction side (Z 2 side) of the plural insulator portions 32 U or on both axial direction sides of the plural insulator portions 32 U.
  • 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.
  • crossing wires 28 V, 28 W serving as an example of a member of the present invention, are housed in the notches 38 U, 38 V, 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 32 U 2 are only formed to the U-phase insulator 18 U, however similar extending portions to the extending portions 32 U 2 may be formed to the V-phase insulator 18 V and to the W-phase insulator 18 W.
  • connection portion 34 U is positioned further to the radial direction inside than the core configuration sections 14 U.
  • the connection portion 34 U may be positioned further to the radial direction outside than the core configuration sections 14 U.
  • the extending portions 32 U 2 may extend in one direction of axial direction, radial direction, or a direction that is a combination thereof of the yoke 40 .
  • connection portion 34 U is provided on the first axial direction side (Z 1 side) of the insulator portions 32 U and connects together the extension end portions of the extending portions 32 U 2 extending in the yoke 40 axial direction
  • configuration may be made, for example as illustrated in FIG. 16 , with the extending portions 32 U 2 extending in the yoke 40 circumferential direction, and the connection portion 34 U extending in the yoke 40 circumferential direction and connecting the extension end portions of the extending portions 32 U 2 .
  • connection portion 34 U may connect the extension end portions of the extending portions 32 U 2 , and may also connect other locations of the extending portions 32 U 2 other than the extension end portions.
  • extending portions and a connection portion are formed to the V-phase insulator 18 V and the W-phase insulator 18 W.
  • connection portions 34 U, 34 V, 34 W are disposed such that there are gaps present between each other in the yoke 40 radial direction and axial direction.
  • configuration may be made with the connection portions 34 U, 34 V, 34 W 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 34 U, 34 V, 34 W.
  • 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
  • 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.
  • stator 10 is configured segmented into the stator configuration sections 12 U, 12 V, 12 W configured for each of the plural phases, as an example of plural groups.
  • stator 10 may be segmented into stator configuration sections 12 A, 12 B, 12 C configured by groups each containing a combination of plural phases.
  • a stator configuration section 12 A configuring a first group includes +U-phase teeth sections 24 U and ⁇ W-phase teeth sections 24 W
  • a stator configuration section 12 B configuring a second group includes +V-phase teeth sections 24 V and ⁇ U-phase teeth sections 24 U
  • a stator configuration section 12 C configuring a third group includes +W-phase teeth sections 24 W and ⁇ V-phase teeth sections 24 V.
  • 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.
  • stator configuration section 12 A configuring the first group includes +U-phase teeth sections and ⁇ V-phase teeth sections; a stator configuration section 12 B configuring a second group includes +V-phase teeth sections and ⁇ U-phase teeth sections; and a stator configuration section 12 C configuring a third group includes +W-phase teeth sections and ⁇ W-phase teeth sections.
  • configuration may be made such that: a stator configuration section 12 A configuring a first group includes +U-phase teeth sections and ⁇ U-phase teeth sections; a stator configuration section 12 B configuring a second group includes +V-phase teeth sections and ⁇ V-phase teeth sections; and a stator configuration section 12 C configuring a third group includes +W-phase teeth sections and ⁇ W-phase teeth sections.
  • configuration may be made such that: a stator configuration section 12 A configuring a first group includes +U-phase teeth sections and ⁇ U-phase teeth sections; a stator configuration section 12 B configuring a second group includes +V-phase teeth sections and ⁇ W-phase teeth sections; and a stator configuration section 12 C configuring a third group includes +W-phase teeth sections and ⁇ V-phase teeth sections.
  • configuration may also be made with stator configuration sections configuring each of the groups including teeth sections of plural phases in a combination other than those listed above.
  • stator 110 The configuration of a stator 110 according to the second exemplary embodiment of the present invention varies from the stator 10 according to the first exemplary embodiment described above in the following manner. Note that in the second exemplary embodiment of the present invention, configuration similar to that of the first exemplary embodiment described above is allocated the same reference numerals and explanation thereof is abbreviated.
  • elongated plate shaped conductive terminal stations 112 U, 112 V, 112 W are respectively provided to each of plural insulators 18 U, 18 V, 18 W.
  • Terminal portions 30 U, 30 V, 30 W of plural coil wires 16 U, 16 V, 16 W are respectively connected to the terminal stations 112 U, 112 V, 112 W.
  • the terminal stations 112 U, 112 V, 112 W are provided at a first axial direction side of a yoke 40 (the arrow Z 1 side), namely at the same side as connection portions 34 .
  • Tongue shaped connector portions 113 U, 113 V, 113 W are formed respectively to the terminal stations 112 U, 112 V, 112 W for connecting to the terminal portions 30 U, 30 V, 30 W.
  • projection portions 114 U are formed at end portions of each of insulator portions 32 U on the opposite side to the yoke 40 (to yoke configuration sections 22 U).
  • the projection portions 114 U project out to a yoke 40 side from a connection portion 34 U.
  • the projection portions 114 U are formed in a plate shape extending along a yoke 40 axial direction, and are thicker than the connection portion 34 U.
  • End faces 114 U 1 are formed at the projection portions 114 U, facing towards the yoke 40 first axial direction side (the arrow Z 1 side).
  • An insertion groove 116 U is formed to the end face 114 U 1 of one of the insulator portions 32 U, opening in the yoke 40 axial direction.
  • the terminal station 112 U is provided at the projection portion 114 U by inserting (push-fitting) into the insertion groove 116 U.
  • the terminal station 112 U also projects out further than the connection portion 34 U in the yoke 40 axial direction.
  • insertion grooves 116 V, 116 W are also respectively formed to end faces of projection portions 114 V, 114 W of one of respective insulator portions 32 V, 32 W, and terminal stations 112 V, 112 W are provided to the projection portions 114 V, 114 W by inserting (push-fitting) into the insertion grooves 116 V, 116 W.
  • the terminal stations 112 U, 112 V, 112 W make contact with an outer peripheral face 34 U 1 (the surface on the yoke 40 side) of the connection portion 34 U.
  • groove shaped guide portions 118 U are also formed at the insulator 18 U along the yoke 40 axial direction (see FIG. 7 ).
  • the guide portions 118 U are, more specifically, formed to side faces 114 U 2 of the projection portions 114 U (side faces facing in the yoke 40 circumferential direction).
  • the terminal portions 30 U of the coil wire 16 U are guided by the guide portions 118 U. Note that the terminal portions 30 U in this case are, for example, fitted into the groove shaped guide portions 118 U with a snap fit.
  • guide portions 118 V, 118 W similar to the guide portions 118 U described above are also formed to side faces of the projection portions 114 V, 114 W, and the terminal portions 30 V, 30 W of the coil wires 16 V, 16 W are guided by the guide portions 118 V, 118 W.
  • the terminal stations 112 are respectively provided to the plural insulators 18 , and the terminal portions 30 of the respective plural coil wires 16 are connected to the terminal stations 112 . Positioning of the terminal portions 30 can accordingly be performed easily.
  • terminal stations 112 project out further in the yoke 40 axial direction than the connection portions 34 , and so as illustrated in FIG. 8 , the terminal stations 112 and a control circuit section can be easily connected together.
  • the terminal stations 112 are provided to the projection portions 114 that project out towards the yoke 40 side with respect to the connection portions 34 . Interference between the terminal stations 112 and the connection portions 34 can accordingly be suppressed, and the terminal portions 30 can be easily positioned.
  • the terminal stations 112 are inserted into the insertion grooves 116 formed to the projection portions 114 , enabling the terminal stations 112 to be easily fixed to the projection portions 114 .
  • the terminal stations 112 make contact with the outer peripheral face 34 U 1 of the connection portion 34 U, and rattling of the terminal stations 112 can be suppressed.
  • the guide portions 118 are also formed to the respective plural insulators 18 along the yoke 40 axial direction, and the respective terminal portions 30 of the plural coil wires 16 are guided by the guide portions 118 . This also enables positioning of the terminal portions to be performed easily.
  • the guide portions 118 are also provided to the projection portions 114 that project out to the yoke 40 side with respect to the connection portions 34 . Interference between the terminal portions 30 and the connection portions 34 can accordingly be suppressed, and the terminal portions 30 can be positioned easily.
  • the projection portions 114 are formed to each of the insulator portions 32 , however projection portions may only be formed to the insulator portions 32 that are disposed with the terminal stations 112 , out of the plural insulator portions 32 .
  • the guide portions 118 U, 118 V, 118 W are also formed in groove shapes, however they may be configured in a shape other than a groove shape.
  • the terminal stations 112 may also connect each of the terminal portions 30 as neutral points.
  • the terminal stations 112 U, 112 V, 112 W described above may be provided on the yoke 40 axial direction opposite side to the crossing wires 28 (the connection portions 34 ). Such a configuration enables connection to be performed easily between the terminal stations 112 and a control circuit section at the axial direction opposite side to the crossing wires 28 .
  • the terminal stations 112 described above may be omitted.
  • the terminal portions 30 may be connected directly to a control circuit section and not through the terminal stations 112 described above.
  • the guide portions 118 are formed respectively to side faces 114 U 2 on both sides of the projection portions 114 , the guide portions 118 may only be formed to one of the side faces 114 U 2 of the projection portions 114 .
  • configuration may be made such that an insertion groove 126 is formed to yoke configuration sections 22 of one of the plural yoke configuration sections 22 , opening in the yoke 40 axial direction, and with the terminal station 112 provided to this yoke configuration section 22 by inserting into the insertion groove 126 .
  • Such a configuration also enables positioning of the terminal portions 30 to be performed easily.
  • inserting the terminal stations 112 into the insertion groove 126 formed to the yoke configuration sections 22 enables the terminal stations 112 to be fixed to the yoke configuration sections 22 easily.
  • configuration may be made with the connector portion 113 formed in a groove shape, as illustrated in FIG. 12 , or formed as a tongue shape, as illustrated in FIG. 13 .
  • a covering of the terminal portion 30 is peeled off at the same time as insertion of the terminal station 112 into the insertion groove 126 is performed, and electrical continuity is made between the terminal portion 30 and the terminal station 112 .
  • an operator hooks the terminal portion 30 onto the connector portion 113 by hand, and electrical continuity is made between the terminal portion 30 and the terminal station 112 .
  • the plural insulator portions 32 may be connected by circular arc shaped reinforcement portions 128 at an opposite side to the yoke 40 axial direction to the connection portions 34 (the arrow Z 2 side). Such a configuration enables the rigidity of the insulators 18 to be raised.
  • configuration may be made with a reinforcement member 130 such as a metal ring or wire, buried in the connection portions 34 by insert molding.
  • Configuration may also be made such that the insulators 18 are configured with the connection portions 34 formed from a high strength resin, and portions other than the connection portions 34 formed from a normal strength resin by employing two-color molding.
  • a fluid pump 210 illustrated in FIG. 19 is applied with the stator 110 described above.
  • the fluid pump 210 is equipped, in addition to the stator 110 and the control circuit section 120 described above, with a pump housing 212 , a motor housing 214 , an end housing 216 , an impeller 218 , a rotor 220 and a motor shaft 222 .
  • the stator 110 and the rotor 220 configure a brushless motor.
  • a rotational magnetic field is formed by the stator 110 when current is supplied to the stator 110 from the control circuit section 120 , thereby rotating the impeller 218 together with the rotor 220 .
  • the impeller 218 rotates, fluid is sucked in through a suction inlet 230 and conveyed into a pump chamber 228 , and then the fluid conveyed into the pump chamber 228 is discharged through a discharge outlet 232 .
  • fluid pump 210 (brushless motor), greater compactness and lower cost can be realized due to being equipped with the stator 110 .
  • a stator 310 according to the third exemplary embodiment of the present invention is illustrated in FIG. 21 , and is employed for example in an inner rotor type brushless motor, and is configured including a U-Phase stator configuration section 312 U, a V-phase stator configuration section 312 V and a W-phase stator configuration section 312 W, illustrated in FIG. 22A to FIG. 22C .
  • the U-phase stator configuration section 312 U is configured with plural core configuration sections 314 U, a coil wire 316 U, and an insulator 318 U. Note that the coil wire 316 U is omitted from illustration in FIG. 22A .
  • the plural core configuration sections 314 U configure a stator core 320 together with plural V-phase core configuration sections 314 V and plural W-phase core configuration sections 314 W, described later.
  • Each of the core configuration sections 314 U includes a teeth section 322 U and a yoke configuration section 324 U.
  • the teeth sections 322 U extend along a radial direction of the stator core 320 , and the yoke configuration sections 324 U are formed to leading end portions of the teeth sections 322 U.
  • the yoke configuration sections 324 U configure a ring shaped yoke 326 , together with plural V-phase yoke configuration sections 324 V and plural W-phase yoke configuration sections 324 W, described later, and are respectively circular arc shaped.
  • the coil wire 316 U illustrated in FIG. 21 configures the U-phase and includes plural coil wire winding portions 328 U and plural crossing wires 330 U.
  • the coil wire 316 U is wound concentrically on the teeth sections 322 U of the core configuration sections 314 U, with teeth section insulator portions 342 U, 352 U, described later, disposed therebetween.
  • the coil wire winding portions 328 U are connected to each other by the plural crossing wires 330 U.
  • the crossing wires 330 U are laid out (wrapped) around the outer peripheral face of a connection portion 336 U formed to the insulator 318 U, described later. Terminal portions 332 U at both end sides of the coil wire 316 U are led out from the core configuration sections 314 U to a first axial direction side (the arrow Z 1 side) of the stator core 320 .
  • the insulator 318 U is made from a resin, and includes the plural insulator portions 334 U and the connection portion 336 U that have been integrated together, as illustrated in FIG. 22A .
  • the number of the plural insulator portions 334 U provided is the same as the number of the plural core configuration sections 314 U mentioned above, and the insulator portions 334 U are disposed at even intervals in a ring shape.
  • Each of the plural insulator portions 334 U includes a first insulator portion 340 U and a second insulator portion 350 U segmented in an axial direction of the stator core 320 .
  • the first insulator portion 340 U and the second insulator portion 350 U respectively include the teeth section insulator portions 342 U, 352 U, yoke configuration section insulator portions 344 U, 354 U, and extension side wall portions 346 U, 356 U.
  • the teeth section insulator portions 342 U, 352 U, the yoke configuration section insulator portions 344 U, 354 U, and the extension side wall portions 346 U, 356 U together configure an insulator main body portion 360 U that insulates between the core configuration sections 314 U and the coil wire winding portions 328 U (see FIG. 21 ).
  • the teeth section insulator portions 342 U, 352 U are installed to the teeth sections 322 U from both axial direction sides of the stator core 320 and are configured to cover the teeth sections 322 U.
  • the yoke configuration section insulator portions 344 U, 354 U are formed at leading end portions of the teeth section insulator portions 342 U, 352 U, are installed to the yoke configuration sections 324 U from both axial direction sides of the stator core 320 , and are configured to cover portions of the yoke configuration sections 324 U other than the outer peripheral face.
  • the extension side wall portions 346 U, 356 U are respectively formed at base end portions of the teeth section insulator portions 342 U, 352 U.
  • the extension side wall portions 346 U, 356 U are formed as plate shapes extending along the stator core 320 axial direction with their plate thickness direction aligned with a radial direction of the stator core 320 .
  • the extension side wall portions 346 U, 356 U are formed along the stator core 320 circumferential direction and are wider in width than the teeth section insulator portions 342 U, 352 U mentioned above.
  • the guide grooves 348 U, 358 U that extend along the stator core 320 axial direction are respectively formed at side portions in a circumferential direction of the stator core 320 of the extension side wall portions 346 U, 356 U.
  • the guide grooves 348 U, 358 U are present to guide the terminal portions 332 U (see FIG. 21 ).
  • An extending portion 362 U is formed at the extension side wall portions 346 U of the first insulator portion 340 U, extending towards a first axial direction side of the stator core 320 .
  • An extension end portion of the extending portion 362 U is connected to a connection portion 336 U, described later.
  • connection portion 336 U is disposed at the stator core 320 first axial direction side (the arrow Z 1 side) with respect to the insulator portions 334 U, and is formed in a ring shape along the stator core 320 circumferential direction.
  • the connection portion 336 U is provided at a radial direction inside of the stator core 320 with respect to the teeth section insulator portions 342 U, 352 U.
  • Projection shaped retaining portions 364 U are respectively formed at an outer peripheral face of the connection portion 336 U between the plural insulator portions 334 U so as to project towards outside of the stator core 320 radial direction.
  • the retaining portions 364 U retain the crossing wires 330 U mentioned above from a second axial direction side of the stator core 320 (the arrow Z 2 side) (see FIG. 21 ). Moreover, portions between the plural extending portions 362 U of the connection portion 336 U are formed with notches 366 U open to the stator core 320 second axial direction side.
  • the V-phase stator configuration section 312 V illustrated in FIG. 21 and FIG. 22B has a similar basic configuration to the U-phase stator configuration section 312 U mentioned above. Namely, the V-phase stator configuration section 312 V is configured including plural core configuration sections 314 V, a coil wire 316 V and an insulator 318 V. Note that the coil wire 316 V is omitted from illustration in FIG. 22B .
  • Each of the core configuration sections 314 V is configured similarly to the core configuration sections 314 U mentioned above, and includes a teeth section 322 V and a yoke configuration section 324 V.
  • the coil wire 316 V illustrated in FIG. 21 configures the V-phase and includes plural coil wire winding portions 328 V and plural crossing wires 330 V.
  • the coil wire 316 V is wound concentrically on the teeth sections 322 V of the core configuration sections 314 V, with teeth section insulator portions 342 V, 352 V, described later, disposed therebetween.
  • the coil wire winding portions 328 V are connected to each other by the plural crossing wires 330 V.
  • the crossing wires 330 V are laid out (wrapped) around the outer peripheral face of a connection portion 336 V formed to the insulator 318 V, described later. Terminal portions 332 V at both end sides of the coil wire 316 V are led out from the core configuration sections 314 V to a first axial direction side (the arrow Z 1 side) of the stator core 320 .
  • the insulator 318 V is made from a resin, and includes plural insulator portions 334 V and the connection portion 336 V that have been integrated together, as illustrated in FIG. 22B .
  • the number of the plural insulator portions 334 V provided is the same as the number of the plural core configuration sections 314 V mentioned above, and the insulator portions 334 V are disposed at even intervals in a ring shape.
  • Each of the plural insulator portions 334 V includes a first insulator portion 340 V and a second insulator portion 350 V segmented in an axial direction of the stator core 320 .
  • the first insulator portion 340 V and the second insulator portion 350 V respectively include the teeth section insulator portions 342 V, 352 V, yoke configuration section insulator portions 344 V, 354 V and extension side wall portions 346 V, 356 V.
  • the teeth section insulator portions 342 V, 352 V, the yoke configuration section insulator portions 344 V, 354 V and the extension side wall portions 346 V, 356 V together configure an insulator main body portion 360 V that insulates between the core configuration sections 314 V and the coil wire winding portions 328 V (see FIG. 21 ).
  • the insulator main body portion 360 V is configured similarly to the insulator main body portion 360 U mentioned above.
  • Guide grooves 348 V, 358 V that extend along the stator core 320 axial direction are respectively formed to side portions in a circumferential direction of the stator core 320 of the extension side wall portions 346 V, 356 V.
  • the guide grooves 348 V, 358 V are present to guide the terminal portions 332 V mentioned above (see FIG. 21 ).
  • An extending portion 362 V is also formed at each of the extension side wall portions 346 V of the first insulator portion 340 V, extending towards inside in the stator core 320 radial direction.
  • An extension end portion of the extending portion 362 V is connected to a connection portion 336 V, described later.
  • connection portion 336 V is disposed at the stator core 320 first axial direction side (the arrow Z 1 side) with respect to the insulator portions 334 V.
  • the connection portion 336 V is formed in a circular ring plate shape extending along a circumferential direction of the stator core 320 and with a plate thickness direction aligned with the stator core 320 axial direction.
  • the connection portion 336 V is provided at inside in the stator core 320 radial direction with respect to the teeth section insulator portions 342 V, 352 V.
  • Projection shaped retaining portions 364 V are respectively formed at the outer peripheral face of the connection portion 336 V between the plural insulator portions 334 V so as to project outside in the stator core 320 radial direction.
  • the retaining portions 364 V retain the crossing wires 330 V mentioned above from a second axial direction side of he stator core 320 (the arrow Z 2 side) (see FIG. 21 ). Moreover, portions between the plural extending portions 362 V of the connection portion 336 V are formed with notches 366 V open to the stator core 320 second axial direction side.
  • the W-phase stator configuration section 312 W illustrated in FIG. 21 and FIG. 22C has a similar basic configuration to the U-phase stator configuration section 312 U and the V-phase stator configuration section 312 V mentioned above. Namely, the W-phase stator configuration section 312 W is configured including the plural core configuration sections 314 W, a coil wire 316 W and an insulator 318 W. Note that the coil wire 316 W is omitted from illustration in FIG. 22C .
  • Each of the core configuration sections 314 W is configured similarly to the core configuration sections 314 U, 314 V mentioned above, and includes a teeth section 322 W and a yoke configuration section 324 W.
  • the coil wire 316 W illustrated in FIG. 21 configures the W-phase and includes plural coil wire winding portions 328 W and plural crossing wires 330 W.
  • the coil wire 316 W is wound concentrically on the teeth sections 322 W of the core configuration sections 314 W, with teeth section insulator portions 342 W, 352 W, described later, disposed therebetween.
  • the coil wire winding portions 328 W are connected to each other by the plural crossing wires 330 W.
  • the crossing wires 330 W are laid out (wrapped) around the outer peripheral face of a connection portion 336 W formed to the insulator 318 W, described later. Terminal portions 332 W at both end sides of the coil wire 316 W are led out from the core configuration sections 314 W to a first axial direction side (the arrow Z 1 side) of the stator core 320 .
  • the insulator 318 W is made from a resin, and includes plural insulator portions 334 W and the connection portion 336 W that have been integrated together, as illustrated in FIG. 22C .
  • the number of the plural insulator portions 334 W provided is the same as the number of the plural core configuration sections 314 W mentioned above, and the insulator portions 334 W are disposed at even intervals in a ring shape.
  • Each of the plural insulator portions 334 W includes a first insulator portion 340 W and a second insulator portion 350 W segmented in an axial direction of the stator core 320 .
  • the first insulator portion 340 W and the second insulator portion 350 W respectively include the teeth section insulator portions 342 W, 352 W, yoke configuration section insulator portions 344 W, 354 W and extension side wall portions 346 W, 356 W.
  • the teeth section insulator portions 342 W, 352 W, the yoke configuration section insulator portions 344 W, 354 W and the extension side wall portions 346 W, 356 W together configure an insulator main body portion 360 W that insulates between the core configuration sections 314 W and the coil wire winding portions 328 W (see FIG. 21 ).
  • the insulator main body portion 360 W is configured similarly to the insulator main body portions 360 U, 360 V mentioned above.
  • Guide grooves 348 W, 358 W that extend along an axial direction of the stator core 320 are respectively formed at side portions in a circumferential direction of the stator core 320 at the extension side wall portions 346 W, 356 W.
  • the guide grooves 348 W, 358 W are present to guide the terminal portions 332 W mentioned above (see FIG. 21 ).
  • An extending portion 362 W is also formed to each of the extension side wall portions 346 W of the first insulator portion 340 W, extending towards inside in the stator core 320 radial direction.
  • An extension end portion of the extending portion 362 W is connected to a connection portion 336 W, described later.
  • connection portion 336 W is disposed at the first axial direction side of the stator core 320 (the arrow Z 1 side) with respect to the insulator portions 334 W, and formed in a ring shape extending in a circumferential direction along the stator core 320 .
  • the connection portion 336 W is provided at the stator core 320 radial direction inside with respect to the teeth section insulator portions 342 W, 352 W.
  • the connection portion 336 W includes a circular ring shaped retaining portion 364 W with its plate thickness direction aligned with the stator core 320 axial direction, and a ring shaped spacer 368 W that extends from locations at an radial direction inner side of the retaining portion 364 W towards the first axial direction side of the stator core 320 .
  • the retaining portion 364 W retains the crossing wires 330 W from a second axial direction side of the stator core 320 (the arrow Z 2 side) (see FIG. 21 ).
  • the plural stator configuration sections 312 U, 312 V, 312 W are assembled together to configure the stator 310 .
  • the ring shaped stator core 320 is configured by the plural core configuration sections 314 U, 314 V, 314 W
  • the ring shaped yoke 326 is formed by the plural yoke configuration sections 324 U, 324 V, 324 W.
  • the stator core 320 is segmented in the circumferential direction into the plural core configuration sections 314 U, 314 V, 314 W
  • the yoke 326 is segmented in the circumferential direction into the plural yoke configuration sections 324 U, 324 V, 324 W.
  • the plural yoke configuration sections 324 U, 324 V, 324 W respectively fit between pairs of yoke configuration sections adjacent on the two sides thereof.
  • connection portions 336 U, 336 V, 336 W are provided coaxially to the stator core 320 .
  • the plural connection portions 336 U, 336 V, 336 W and the plural extending portions 362 U, 362 V, 362 W mentioned above are positioned at the stator core 320 radial direction inside with respect to each of the core configuration sections 314 U, 314 V, 314 W.
  • the connection portion 336 U is disposed at the radial direction outside of the connection portions 336 V, 336 W, with a gap present between the connection portions 336 V, 336 W.
  • the connection portion 336 V is disposed at the first axial direction side of the connection portion 336 W, with a gap present between the connection portion 336 V and the connection portion 336 W.
  • the V-phase retaining portions 364 V are fitted against an inner peripheral face of the U-phase connection portion 336 U, and the connection portion 336 U and the connection portion 336 V are thereby retained in a state separated from each other in the radial direction.
  • the retaining portions 364 V are provided in the radial direction between the connection portion 336 U and the connection portion 336 V, and also perform the role of spacers for retaining the connection portion 336 U and the connection portion 336 V in a state separated from each other in the radial direction.
  • the spacers 368 W make contact with a face in the second axial direction side (the arrow Z 2 side) of the V-phase connection portion 336 V, thereby retaining the connection portion 336 V and the connection portion 336 W in a state separated from each other in the axial direction.
  • the V-phase crossing wires 330 V pass through inside the notches 366 U formed at the U-phase connection portion 336 U (are housed inside the notches 366 U).
  • the W-phase crossing wires 330 W pass through inside the notches 366 U, 366 V formed respectively at the U-phase connection portion 336 U and the V-phase connection portion 336 V (are housed inside the notches 366 U, 366 V).
  • the notches 366 U, 366 V are examples of a housing portion of the present invention.
  • the above insulator 318 U is formed by resin molding.
  • the second insulator portions 350 U are formed so as to be adjacent to the first insulator portions 340 U along tangential directions of the connection portion 336 U, and bridging sections 370 U are formed so as to connect together the yoke configuration section insulator portions 344 U, 354 U in the first insulator portions 340 U and the second insulator portions 350 U.
  • the first insulator portions 340 U and the second insulator portions 350 U are molded in a state connected together by the bridging sections 370 U. Moreover, when this is performed, the plural second insulator portions 350 U are each formed displaced to the same side (the same side in the connection portion 336 U tangential direction) with respect to the respective first insulator portions 340 U.
  • Each of the bridging sections 370 U is also formed with the same length as each other.
  • the first insulator portions 340 U and the second insulator portions 350 U are molded so as to have U-shaped cross-section teeth section insulator portions 342 U, 352 U opening in opposite directions to each other
  • the first insulator portions 340 U and the second insulator portions 350 U may be molded so as to have U-shaped cross-section teeth section insulator portions 342 U, 352 U opening in the same direction as each other.
  • the insulator 318 U is installed to a jig 380 .
  • the second insulator portions 350 U are mounted to movable tables 382 .
  • Each of the plural core configuration sections 314 U is then installed to the respective second insulator portion 350 U from the vertical direction upper side.
  • each of the bridging sections 370 is cut off using a punching tool 384 .
  • connection portion 336 U is raised, together with the plural first insulator portions 340 U, using a lifting tool 386 .
  • the first insulator portions 340 U are positioned at a higher position than the core configuration sections 314 U.
  • the movable tables 382 are then slid, together with the second insulator portions 350 U, in connection portion 336 U tangential directions such that the core configuration sections 314 U are positioned below the first insulator portions 340 U.
  • positional alignment is performed between the core configuration sections 314 U installed to the second insulator portions 350 U and the first insulator portions 340 U.
  • the positional alignment here is performed in a state in which the core configuration sections 314 U remain installed vertically above the second insulator portions 350 U.
  • connection portion 336 U is lowered by the lifting tool 386 together with the plural first insulator portions 340 U, and the first insulator portions 340 U are installed on the core configuration sections 314 U installed to the second insulator portions 350 U.
  • the first insulator portions 340 U are pressed against the core configuration sections 314 U by a press tool 388 .
  • the coil wire 316 U is wound on the core configuration sections 314 U, with the first insulator portions 340 U and the second insulator portions 350 U interposed therebetween.
  • the coil wire winding portions 328 U are thereby formed with the coil wire 316 U on the core configuration sections 314 U.
  • the stator configuration section 312 U is completed by the above processes.
  • stator configuration sections 312 V, 312 W are also manufactured similarly to the stator configuration section 312 U.
  • the first insulator portions 340 V and the second insulator portions 350 V are integrally formed to the bridging sections 370 V for connecting together the first insulator portions 340 V and the second insulator portions 350 V.
  • the first insulator portions 340 W and the second insulator portions 350 W are integrally formed to the bridging sections 370 W for connecting together the first insulator portions 340 W and the second insulator portions 350 W.
  • the plural core configuration sections 314 V, 314 W are respectively installed to the second insulator portions 350 V, 350 W, and then each of the bridging sections 370 V, 370 W are cut off.
  • positional alignment is performed between the core configuration sections 314 V, 314 W installed to the second insulator portions 350 U, 350 W and the first insulator portions 3340 V, 340 W, and in the installation process, the first insulator portions 340 V, 340 W are then installed to the core configuration sections 314 V, 314 W installed to the second insulator portions 350 V, 350 W.
  • the coil wires 316 V, 316 W are wound on the core configuration sections 314 V, 314 W, thereby forming the coil wire winding portions 328 V, 328 W with the coil wires 316 V, 316 W on the core configuration sections 314 V, 314 W.
  • the stator configuration sections 312 V, 312 W are completed by the above processes.
  • stator 310 is completed by assembling together the plural stator configuration sections 312 U, 312 V, 312 W.
  • the first insulator portions 340 and the second insulator portions 350 of the insulators 318 are integrally formed with the bridging sections 370 interposed therebetween.
  • the number of components required for assembling the stator 310 can accordingly be reduced compared to cases in which the first insulator portions 340 and the second insulator portions 350 are formed separately.
  • the bridging sections 370 are cut off after the core configuration sections 314 have been installed to the second insulator portions 350 .
  • the whole body of each of the insulators 318 including the second insulator portions 350 can be set in the jig 380 all in one operation.
  • the number of processes for setting the insulators 318 in the jig 380 can accordingly be reduced in comparison to cases in which the bridging sections 370 are cut off prior to installing the core configuration sections 314 in the second insulator portions 350 .
  • the plural first insulator portions 340 arrayed in a ring shape are connected together by each of the connection portions 336 .
  • positional alignment can be easily performed between the core configuration sections 314 installed to the second insulator portions 350 and the first insulator portions 340 .
  • the plural first insulator portions 340 are arrayed in the ring shape at even intervals therebetween, and the plural second insulator portions 350 are formed displaced to the same side with respect to each of the first insulator portions 340 .
  • Each of the bridging sections 370 is also formed with the same length as each other.
  • the core configuration sections 314 are installed to the second insulator portions 350 in the installation and cutoff process subsequent to the molding process.
  • positional alignment is performed between the core configuration sections 314 and the first insulator portions 340 in a state in which the core configuration sections 314 have been installed from the vertical direction upper side in the second insulator portions 350 .
  • the core configuration sections 314 can accordingly be easily retained in an installed state in the second insulator portions 350 , enabling positional alignment between the core configuration sections 314 and the first insulator portions 340 to be performed easily.
  • stator core 320 plural of the insulators 318 are formed for a single stator core 320 .
  • the stator core 320 can be segmented into the plural stator configuration sections 312 U, 312 V, 312 W by assembling each of the plural core configuration sections 314 , which are segmented in the stator core 320 circumferential direction, to each of the insulators 318 . It is accordingly possible to manufacture each of the stator configuration sections 312 U, 312 V, 312 W, resulting in an easy assembly operation for the stator core 320 (in particular easy winding operations of the coil wires 316 ).
  • the notches 366 U for housing the V-phase and W-phase crossing wires 330 V, 330 W, which are examples of another member, are formed in the U-phase connection portion 336 U, and the notches 366 V for housing the W-phase crossing wires 330 W, which is an example of another member, are formed in the V-phase connection portion 336 V. Therefore in the assembled state of the stator 310 , interference between the connection portion 336 U and the crossing wires 330 V, 330 W and interference between the connection portion 336 V and the crossing wires 330 W can be avoided.
  • connection portions 336 U, 336 V, 336 W the retaining portions 364 U, 364 V, 364 W are formed in order to respectively retain the crossing wires 330 U, 330 V, 330 W. Good operating efficiency can accordingly be achieved when assembling together the plural stator configuration sections 312 U, 312 V, 312 W.
  • the crossing wires 330 U, 330 V, 330 W are still retained at the connection portions 336 U, 336 V, 336 W by the retaining portions 364 U, 364 V, 364 W, and so flapping of the crossing wires 330 U, 330 V, 330 W can be suppressed, enabling the occurrence of noise and faults to be suppressed.
  • connection portion 336 V that function as spacers so as to retain the connection portion 336 U and the connection portion 336 V in a state separated from each other are formed to the connection portion 336 V
  • spacers 368 W that retain the connection portion 336 V and the connection portion 336 W in a state separated from each other are formed to the connection portion 336 W.
  • the plural connection portions 336 U, 336 V, 336 W can accordingly be retained in a state separated from each other in the assembled state of the stator 310 .
  • connection portions 336 U, 336 V, 336 W are provided coaxially to the stator core 320 when the plural insulators 318 U, 318 V, 318 W have been assembled to the stator core 320 .
  • the structure of the stator 310 can accordingly be simplified.
  • connection portions 336 is positioned to the radial direction inside with respect to the stator core 320 when the plural insulators 318 U, 318 V, 318 W are assembled to the stator core 320 . Interference between the flyer 390 and the connection portions 336 can accordingly be suppressed when using the flyer 390 to wind the coil wires 316 on the core configuration sections 314 from outside in the radial direction of the stator core 320 .
  • the extending portions 362 also extend out from the insulator main body portions 360 (the extension side wall portions 346 of the first insulator portions 340 ) that insulate between the core configuration sections 314 and the coil wire winding portions 328 , and the extending portions 362 are connected together by the connection portions 336 .
  • the extending portions 362 are positioned at the stator core 320 radial direction inside with respect to the core configuration sections 314 . Hence, interference between the flyer 390 and the extending portions 362 and the connection portions 336 can be suppressed when using the flyer 390 to wind the coil wires 316 on the core configuration sections 314 from outside in the radial direction of the stator core 320 .
  • the teeth sections 322 are locations where the coil wires 316 are wound to form the coil wire winding portions 328 .
  • Guide portions (the guide grooves 348 , 358 ), for example, for guiding the terminal portions 332 of the coil wires 316 are also formed to base end sides of the teeth sections 322 .
  • the bridging sections 370 are formed so as to connect between the yoke configuration section insulator portions 344 , 354 of the first insulator portions 340 and the second insulator portions 350 .
  • the bridging sections 370 is formed, it can accordingly be suppressed for the bridging sections 370 from influencing the coil wire winding portions 328 , the guide portions and the like.
  • the second insulator portions 350 are formed so as to be to adjacent to the first insulator portions 340 in the connection portions 336 tangential direction.
  • the second insulator portions 350 may be formed so as to be adjacent to the first insulator portions 340 in the connection portions 336 circumferential direction.
  • the second insulator portions 350 are connected by the bridging sections 370 to only one of the first insulator portions 340 out of the two adjacent first insulator portions 340 on the two sides of the second insulator portions 350 .
  • the second insulator portions 350 may be connected through the bridging sections 370 to each of the first insulator portions 340 of the two adjacent first insulator portions 340 on the two sides of the second insulator portions 350 .
  • stator configuration sections 312 are manufactured by a method that is similar to the above manufacturing method, as illustrated in FIG. 26A to FIG. 26D , but differs from the above manufacturing method in the following points.
  • movable tables capable of sliding in the connection portions 336 circumferential direction are employed for the movable tables 382 .
  • plural bridging sections 370 arranged at intervals along the connection portions 336 circumferential direction are cut off.
  • the movable tables 382 are slid together with the second insulator portions 350 U in the connection portion 336 U circumferential direction such that the core configuration sections 314 U are positioned below the first insulator portions 340 U. Note that the installation process and the coil wire winding process are similar to those described above.
  • the first insulator portions 340 are then installed to the core configuration sections 314 in the subsequent installation process.
  • configuration may be made such that, after the first insulator portions 340 have been installed to the core configuration sections 314 from the vertical direction upper side in the installation and cutoff process, the second insulator portions 350 are then installed to the core configuration sections 314 from the vertical direction lower side in a subsequent installation process.
  • a recessed and protruding interlocking structure or a friction structure, or a jig or the like may be employed in order to prevent the core configuration sections 314 from falling out from the first insulator portions 340 .
  • the core configuration sections 314 may also be installed to the first insulator portions 340 that have been resiliently deformed by for example a jig, such that the core configuration sections 314 are retained in the first insulator portions 340 by rebound force of the first insulator portions 340 .
  • the insulators 318 may be configured in a vertically inverted state to that described above, such that the first insulator portions 340 are in a state opening upwards in the vertical direction, and the core configuration sections 314 then installed to the first insulator portions 340 from the vertical direction upper side in this state.
  • the second insulator portions 350 installed with the core configuration sections 314 are moved with respect to the first insulator portions 340 in the positional alignment process.
  • the first insulator portions 340 may be moved together with the connection portions 336 with respect to the second insulator portions 350 installed with the core configuration sections 314 .
  • both the second insulator portions 350 installed with the core configuration sections 314 and the first insulator portions 340 may be moved.
  • the bridging sections 370 are cut off after the core configuration sections 314 have been installed to the second insulator portions 350 , however the bridging sections 370 may be cut off prior to installation of the core configuration sections to the second insulator portions 350 .
  • connection portion 336 U and the connection portions 336 V, 336 W may be disposed such that there is a gap present in one direction out of the stator core 320 radial direction and axial direction, or in a direction that is a combination thereof.
  • a notch shaped housing portion may for example be formed to the connection portion 336 W for housing another member other than the crossing wires 330 .
  • the extending portions 362 U may extend from the extension side wall portions 346 U towards the stator core 320 first axial direction side.
  • the extending portions 362 U may extend from the extension side wall portions 356 U towards the stator core 320 second axial direction side.
  • the teeth section insulator portions 342 , 352 and the yoke configuration section insulator portions 344 , 354 , excluding the extension side wall portions 346 , 356 may configure the insulator main body portions 360 , and a portion of the extension side wall portions 346 extending in the stator core 320 circumferential direction from the teeth section insulator portions 342 may also be configured as an extending portion.
  • the teeth section insulator portions 342 , 352 and the yoke configuration section insulator portions 344 , 354 may configure the insulator main body portions 360 , and a portion of the extension side wall portions 356 extending in the stator core 320 circumferential direction from the teeth section insulator portions 352 may also be configured as an extending portion. Each of the extending portions may also be connected by the connection portions 336 .
  • the extending portion 362 may extend from the insulator main body portions 360 in one direction out of the stator core 320 axial direction, radial direction, or circumferential direction, or a direction that is a combination thereof.
  • the retaining portions 364 V have a function to act as retaining portions for retaining the crossing wires 330 and a function to act as spacers to retain the connection portions 336 U, 336 V in a stated separated from each other in the radial direction.
  • a retaining portion and a spacer may be provided independently from each other.
  • connection portions 336 U, 336 V, 336 W are provided coaxially to the stator core 320 , they may be provided not coaxial to the stator core 320 .
  • Each of the connection portions 336 U, 336 V, 336 W are also formed in a ring shape, however they may be formed in another shape, such as a polygonal shape or a shape with a portion missing such as a C-shape.
  • connection portions 336 U, 336 V, 336 W are positioned to the stator core 320 radial direction inside with respect to the core configuration sections 314 , however as long as the extending portions 362 U, 362 V, 362 W are positioned to the stator core 320 radial direction inside with respect to the core configuration sections 314 , each of the connection portions 336 U, 336 V, 336 W may be positioned at the stator core 320 radial direction outside with respect to the core configuration sections 314 .
  • stator 310 is also configured for use in an inner rotor type brushless motor, the stator 310 may also be configured for use in an outer rotor type brushless motor.
  • stator 310 is segmented into the stator configuration sections 312 U, 312 V, 312 W configured for each of the plural phases, as an example of plural groups, the stator 310 may be segmented into plural stator configuration sections configuring groups that each contain a combination of plural phases.
  • configuration may also be made with stator configuration sections configuring each of the groups including other combinations of core configuration sections of plural phases.
  • brushless motor applied with the stator 310 is configured as an example by an 8-pole 12 slot motor, configuration may be made with a motor having another combination of numbers of poles and numbers of slots.
  • connection method of the plural coil wires 316 may be configured in star connection pattern or a delta connection pattern, both in series or in parallel.
  • a stator 410 according to a fourth exemplary embodiment of the present invention illustrated in FIG. 27 has portions similar to those of the stator of the third exemplary embodiment. Explanation hence focuses on differing portions and explanation regarding similar portions is omitted as appropriate.
  • a first connection portion 436 U is disposed at a first axial direction side (the arrow Z 1 side) of a stator core 420 and is formed in a ring shape extending around a circumferential direction of the stator core 420 .
  • the first connection portion 436 U is provided further to a stator core 420 radial direction inside than teeth section insulator portions 442 U, 452 U (namely, than winding portions 428 U wound on teeth sections 422 U).
  • Axial direction extending portions 447 U extend from the first connection portion 436 U towards a stator core 420 second axial direction side (arrow Z 2 side), and the leading end portions of the axial direction extending portions 447 U are connected to end portions at the axial direction first side of extension side wall portions 446 U.
  • the axial direction extending portions 447 U, the extension side wall portions 446 U, and extension side wall portions 456 U configure an extending portion 462 U that is part of an insulator portion 434 U.
  • a first connection portion 436 V is disposed at the first axial direction side (the arrow Z 1 side) of the stator core 420 .
  • the first connection portion 436 V is formed in a circular ring plate shape extending around the stator core 420 circumferential direction and having its thickness direction aligned with the stator core 420 axial direction.
  • the first connection portion 436 V is provided further to the stator core 420 radial direction inside than teeth section insulator portions 442 V, 452 V (namely, than winding portions 428 V wound on teeth sections 422 V).
  • Axial direction extending portions 447 V extend from the first connection portion 436 V towards the stator core 420 second axial direction side (arrow Z 2 side). Moreover, radial direction extending portions 449 V also extend towards the stator core 420 radial direction outside from leading end portions of the axial direction extending portions 447 V. Leading end portions of the radial direction extending portions 449 V are connected to end portions at the first axial direction side of extension side wall portions 446 V.
  • the axial direction extending portions 447 V, the radial direction extending portions 449 V, the extension side wall portions 446 V, and extension side wall portions 456 V configure an extending portion 462 V that is part of an insulator portion 434 V.
  • a first connection portion 436 W is disposed at the first axial direction side (the arrow Z 1 side) of the stator core 420 and is formed in a ring shape extending around the circumferential direction of the stator core 420 .
  • the first connection portion 436 W is provided further to the stator core 420 radial direction inside than teeth section insulator portions 442 W, 452 W (namely, than winding portions 428 W wound on teeth sections 422 W).
  • Radial direction extending portions 449 W extend towards the stator core 420 radial direction outside from the first connection portion 436 W.
  • Leading end portions of the radial direction extending portions 449 W are connected to end portions at the axial direction first side of extension side wall portions 446 W.
  • the radial direction extending portions 449 W, the extension side wall portions 446 W, and extension side wall portions 456 W configure extending portions 462 W that are part of insulator portions 434 W.
  • the first connection portion 436 W mentioned above includes a circular ring shaped retaining portion 464 W that has a plate thickness direction aligned with the stator core 420 axial direction, and a ring shaped spacer 468 W that extends from a location at the radial direction inside of the retaining portion 464 W towards the first axial direction side of the stator core 420 .
  • the retaining portion 464 W retains the crossing wires 430 W mentioned above from the stator core 420 second axial direction side (arrow Z 2 side) (see FIG. 27 ).
  • second connection portions 438 W are formed at the extension side wall portions 446 W that are positioned on the stator core 420 first axial direction side.
  • the second connection portions 438 W are formed in circular arc shapes extending around the stator core 420 circumferential direction, and connect end portions at the stator core 420 second axial direction side of the adjacent extension side wall portions 446 W.
  • the second connection portions 438 W are disposed further to the stator core 420 radial direction inside than the teeth section insulator portions 442 W, 452 W (namely than winding portions 428 W wound on teeth sections 422 W with the teeth section insulator portions 442 W, 452 W interposed).
  • stator configuration section 412 U, the stator configuration section 412 V and the stator configuration section 412 W are disposed in sequence from the stator core 420 first axial direction side towards the second axial direction side, thereby assembling the plural stator configuration sections 412 U, 412 V, 412 W together.
  • the plural stator configuration sections 412 U, 412 V, 412 W are assembled together such that plural core configuration members 414 U, 414 V, 414 W are arranged in the sequence U-phase, V-phase, W-phase around the circumferential direction of the stator core 420 .
  • the stator 410 is configured by the plural stator configuration sections 412 U, 412 V, 412 W.
  • the plural insulators 418 U, 418 V, 418 W have an interlocking structure 470 for positioning with respect to each other.
  • recess shaped fitting portions 472 are formed at the second connection portions 438 W.
  • Protrusion shaped fitted-to portions 474 onto which the fitting portions 472 fit are formed to insulator portions 438 U, 438 V (more specifically, end portions at the stator core 420 second axial direction side of the extension side wall portions 446 U, 446 V) disposed between pairs of insulator portions 434 W that are connected together by the second connection portions 438 W.
  • the fitting portions 472 and the fitted-to portions 474 configuring the interlocking structure 470 fit together with each other, thereby positioning and fixing the plural insulators 418 U, 418 V, 418 W with respect to each other.
  • the plural first connection portions 436 U, 436 V, 436 W are positioned coaxially to each other, and provided coaxially to the stator core 420 .
  • the plural first connection portions 436 U, 436 V, 436 W and the plural extending portions 462 U, 462 V, 462 W mentioned above are also positioned further to the stator core 420 radial direction inside than each of the insulator main body portions 460 U, 460 V, 460 W (the core configuration members 414 U, 414 V, 414 W).
  • the first connection portion 436 V external diameter is smaller than the first connection portion 436 U external diameter
  • the first connection portion 436 W external diameter is smaller than the first connection portion 436 V external diameter.
  • the first connection portion 436 U is disposed at the radial direction outside of the first connection portions 436 V, 436 W, with a gap present to the first connection portions 436 V, 436 W.
  • the first connection portion 436 V is disposed to the radial direction outside and on the first axial direction side of the first connection portion 436 W, with a gap present to the first connection portion 436 W.
  • the V-phase retaining portions 464 V fit against an inner peripheral face of the U-phase first connection portion 436 U, thereby retaining the first connection portion 436 U and the first connection portion 436 V in a state separated from each other in the radial direction.
  • the retaining portions 464 V are provided in the radial direction between the first connection portion 436 U and the first connection portion 436 V, and perform as the spacers to retain the first connection portion 436 U and the first connection portion 436 V in mutually separated state in the radial direction.
  • the spacer 468 W makes contact with a face at the second axial direction side (arrow Z 2 side) of the V-phase first connection portion 436 V, and thereby retains the first connection portion 436 V and the first connection portion 436 W in mutually separate state in the axial direction.
  • the V-phase crossing wires 430 V pass through inside notches 466 U formed at the U-phase first connection portion 436 U (are housed in the notches 466 U).
  • the W-phase crossing wires 430 W pass through inside the notches 466 U, 466 V formed at the U-phase and V-phase first connection portions 436 U, 436 V (are housed in the notches 466 U, 466 V).
  • the notches 466 U, 466 V are examples of housing portions of the present invention.
  • the plural insulator portions 434 W are connected by the second connection portions 438 W, as well as by the first connection portion 436 W.
  • the rigidity between the plural insulator portions 434 W (the first insulator portions 440 W), and hence the rigidity of the plural insulator portions 434 U, 434 V, 434 W, can accordingly be secured by the second connection portions 438 W. As a result, rigidity can be secured for the stator 410 as a whole after assembly.
  • connection portions 438 W are separated in the stator core 420 axial direction with respect to the first connection portions 436 U, 436 V, 436 W.
  • Well balanced rigidity can accordingly be secured after assembling the stator 410 .
  • the second connection portions 438 W are formed at the insulator 418 W positioned furthest to the stator core 420 second axial direction side when the plural insulators are arranged along the stator core 420 axial direction in a state prior to assembling the plural insulators (see FIG. 30 ).
  • interference of the insulator portions 434 U, 434 V (the extension side wall portions 446 U, 446 V) formed to the other insulators 418 U, 418 V with the second connection portions 438 W can be avoided when the plural insulators 418 U, 418 V, 418 W are being assembled along the stator core 420 axial direction.
  • the plural first insulator portions 440 W are connected together by the second connection portions 438 W as well as the first connection portions 436 W.
  • the plural first insulator portions 440 W can accordingly be easily assembled to the core configuration member 414 W by the second connection portions 438 W, and the plural first insulator portions 440 W can also be stabilized and fixed thereby after assembly.
  • the second connection portions 438 W are also formed to the insulator 418 W that has the first connection portion 436 W with the smallest external diameter.
  • interference of the insulator portions 434 U, 434 V (the extension side wall portions 446 U, 446 V) formed to the other insulators 418 U, 418 V with the second connection portions 438 W can be avoided when the other insulators 418 U, 418 V are being assembled to the insulator 418 W from the stator core 420 first axial direction side.
  • the second connection portions 438 W are disposed further to the stator core 420 radial direction inside than the teeth section insulator portions 442 W, 452 W (namely, than winding portions 428 W wound on teeth sections 422 W with the teeth section insulator portions 442 W, 452 W interposed).
  • interference between a flyer and the second connection portions 438 W can be avoided when for example coil wire 416 W is being wound onto the teeth sections 422 U by using the flyer.
  • each of the insulator portions 434 W includes the respective extending portions 462 W that extend from the first connection portion 436 W (the radial direction extending portions 449 W, the extension side wall portions 446 W, 456 W), rigidity between the plural insulator portions 434 W, and hence rigidity of the plural insulator portions 434 U, 434 V, 434 W, can be secured.
  • connection portions 438 W are formed to leading end portions of the extension side wall portions 446 W. Rigidity between the plural insulator portions 434 U, 434 V, 434 W can accordingly be secured efficiently.
  • stator 410 is formed with the second connection portions 438 W on only the insulator 418 W. A simplified structure is accordingly enabled.
  • the plural insulators 418 U, 418 V, 418 W have the interlocking structure 470 for mutual positioning.
  • the insulators 418 U, 418 V, 418 W can accordingly be positioned with respect to each other by the interlocking structure 470 , thereby facilitating easy assembly of the stator 410 .
  • the interlocking structure 470 includes the fitting portions 472 and the fitted-to portions 474 , the fitting portions 472 are formed to the second connection portions 438 W, and the fitted-to portions 474 are formed to the insulator portions 434 U, 434 V positioned between pairs of the insulator portions 434 W that are connected together by the second connection portions 438 W. Fitting together of the fitting portions 472 and the fitted-to portions 474 can accordingly be easily performed.
  • the second connection portions 438 W are formed at the end portion on the stator core 420 second axial direction side of the extension side wall portions 446 W.
  • the second connection portions 438 W may be formed between a base end portion and an extension end portion of the extending portions 462 W (namely between the base end portion of the radial direction extending portions 449 W and the end portions on the stator core 420 second axial direction side of the extension side wall portions 446 W).
  • the second connection portions 438 W preferably have inset portions 439 W inset towards s center side of the first connection portion 436 W such that interference with, for example, the other extension side wall portions 446 U, 446 V, 456 U, 456 V is avoided.
  • configuration is made such that the second connection portions 438 W connect together the plural first insulator portions 440 W (the end portions on the stator core 420 second axial direction side of the extension side wall portions 446 W)
  • configuration may be made, as illustrated in FIG. 32 , in which the second connection portions 438 W connect together plural second insulator portions 450 W (end portions on the stator core 420 second axial direction side of the extension side wall portions 456 W) are connected together.
  • rigidity between the plural first insulator portions 440 W and rigidity between the plural second insulator portions 450 W can be increased with good balance due to the first connection portion 436 W and the second connection portions 438 W. Rigidity of the stator 410 as a whole after assembly can accordingly also be secured.
  • the plural second insulator portions 450 W are connected together by the second connection portions 438 W.
  • the plural second insulator portions 450 W can accordingly be easily assembled to the core configuration member 414 W using the second connection portions 438 W, enabling stability and fixing to be achieved after assembly.
  • the fitting portions 472 may be formed to the second connection portions 438 W.
  • the fitted-to portions 474 illustrated in FIG. 29 are formed to end portions on the stator core 420 second axial direction side of the extension side wall portions 456 U, 456 V. Adopting such a configuration positions the first insulator portions 440 U, 440 V, 440 W and the second insulator portions 450 U, 450 V, 450 W with respect to each other during assembly, enhancing efficient assembly and enabling the first insulator portions 440 U, 440 V, 440 W and the second insulator portions 450 U, 450 V, 450 W to be stabilized and fixed.
  • fitting portions 472 may be omitted from the second connection portions 438 W when the plural first insulator portions 440 W are connected together by the second connection portions 438 W.
  • the plural first insulator portions 440 W are connected together by the second connection portions 438 W in addition to by the first connection portion 436 W, and so the plural first insulator portions 440 W can be easily assembled to the core configuration member 414 W by means of the second connection portions 438 W, and enabling stabilization and fixing to be achieved after assembly.
  • the plural first insulator portions 440 W (the end portions on the stator core 420 first axial direction side and the end portions on the stator core 420 second axial direction side of the extension side wall portions 446 W) may be connected together by the first connection portion 436 W and the second connection portions 438 W, and the plural second insulator portions 450 W (the end portions on the stator core 420 second axial direction side of the extension side wall portions 456 W) may be connected together by third connection portions 478 W.
  • Adopting such a configuration enables the rigidity between the plural first insulator portions 440 W and the rigidity between the plural second insulator portions 450 W to be raised by the first connection portion 436 W, the second connection portions 438 W and the third connection portions 478 W.
  • the rigidity of the stator 410 as a whole after assembly can hence also be raised.
  • the fitting portions 472 may be formed to the third connection portions 478 W when the plural second insulator portions 450 W are connected together by the third connection portions 478 W.
  • the fitted-to portions 474 illustrated in FIG. 29 are formed to end portions on the stator core 420 second axial direction side of the extension side wall portions 456 U, 456 V. Adopting such a configuration positions the first insulator portions 440 U, 440 V, 440 W and the second insulator portions 450 U, 450 V, 450 W with respect to each other during assembly, enhancing efficient assembly and enabling the first insulator portions 440 U, 440 V, 440 W and the second insulator portions 450 U, 450 V, 450 W to be stabilized and fixed.
  • the second connection portions 438 W may be formed at the other insulators 418 U, 418 V, or may be formed at all of the insulators 418 U, 418 V, 418 W.
  • the third connection portions 478 W may also be formed at the other insulators 418 U, 418 V, or may be formed at all the insulators 418 U, 418 V, 418 W.
  • first connection portion 436 U and the first connection portions 436 V, 436 W are disposed with a gap present therebetween in the stator core 420 radial direction, and the first connection portion 436 V and the first connection portion 436 W are disposed with a gap present therebetween in the stator core 420 radial direction and axial direction
  • the plural first connection portions 436 U, 436 V, 436 W may be disposed such that there is a gap present therebetween in any direction out of the stator core 420 radial direction or axial direction or a direction that is a combination thereof.
  • fitting portions 472 are formed in recess shapes, and the fitted-to portions 474 are formed in protrusion shapes, the fitting portions 472 may be formed in protrusion shapes and the fitted-to portions 474 may be formed in recess shapes.
  • stator 410 is configured for use in an inner rotor type brushless motor
  • stator 410 may also be configured for use in an outer rotor type brushless motor.
  • stator 410 is configured segmented into the stator configuration sections 412 U, 412 V, 412 W configured for each of the plural phases, as an example of plural groups, the stator 410 may be segmented into plural stator configuration sections configured by groups each containing a combination of plural phases.
  • stator configuration sections configuring each of the groups including teeth of plural phases in other combinations.
  • brushless motor applied with the stator 410 is configured as an example by an 8-pole 12 slot motor, configuration may be made with a motor having another combination of numbers of poles and numbers of slots.
  • connection method of the plural coil wires 416 may be configured as a star connection or a delta connection both in series and in parallel.
  • the fifth exemplary embodiment of the present invention illustrated in FIG. 34 has an interlocking structure 570 that differs from that of the fourth exemplary embodiment of the present invention in the following respects.
  • fitting portions 572 are formed at one member of adjacent yoke configuration section insulator portions 554 , and fitting protrusions 573 are formed to the fitting portions 572 .
  • Recess shaped fitted-to portions 574 are moreover formed at the other member of the adjacent yoke configuration section insulator portions 554 . Insulator portions 534 of any insulators 518 out of the plural insulators are accordingly fixed together by the fitting portions 572 and the fitted-to portions 574 fitting together.
  • the rigidity between the plural insulator portions 534 , and hence the rigidity of the stator 510 as a whole after assembly can also be secured by fixing the plural insulator portions 534 together with the interlocking structure 570 .
  • fitting portions 572 are formed to one member of adjacent yoke configuration section insulator portions 554
  • the fitted-to portions 574 are formed to the other member of the adjacent yoke configuration section insulator portions 554 , fitting together of the fitting portions 572 and the fitted-to portions 574 can be easily accomplished.
  • the fitting portions 572 may be formed as recess shapes in one member of the adjacent yoke configuration section insulator portions 554
  • the fitted-to portions 574 may be formed as protrusion shapes on the other member of the adjacent yoke configuration section insulator portions 554 .
  • the insulator portions 534 may be sloped so as to approach each other on progression towards an second axial direction side (arrow Z 2 side) of the stator 510 .
  • a gap between any given pair of insulator portions 534 adjacent in the circumferential direction of the stator 510 gets gradually tighter on progression towards the stator 510 second axial direction side (arrow Z 2 side), and so plural yoke configuration sections 524 make close contact with each other after assembly of the stator 510 .
  • the yoke configuration sections 524 can thereby be assembled without rattling, enabling the magnetic path formed by the yoke configuration sections 524 to be more efficiently formed.
  • the configuration of an interlocking structure 670 differs from that of the fifth exemplary embodiment of the present invention in the following respects.
  • fitting portions 672 U are formed to a first connection portion 636 U so as to extend towards the radial direction inside.
  • Fitting protrusions 673 U are formed at leading end portions of the fitting portions 672 U.
  • Recess shaped fitted-to portions 674 V are formed at a first connection portion 636 V.
  • Fitting portions 672 V are also formed to the first connection portion 636 V so as to extend towards the radial direction inside.
  • Fitting protrusions 673 V are also formed at leading end portions of the fitting portions 672 V.
  • Recess shaped fitted-to portions 674 W are also formed at a first connection portion 636 W.
  • the first connection portions 636 U, 636 V, 636 W that serve as connection portions are fixed by the fitting portions 672 U and the fitted-to portions 674 V fitting together, and the fitting portions 672 V and the fitted-to portions 674 W fitting together.
  • the rigidity between the plural first connection portions 636 U, 636 V, 636 W, and hence the rigidity of the stator as a whole after assembly, can be secured by the interlocking structure 670 in which the plural first connection portions 636 U, 636 V, 636 W are fixed together.
  • fitting portions 672 U and the fitted-to portions 674 V are respectively formed to the first connection portions 636 U, 636 V, fitting together of the fitting portions 672 U and the fitted-to portions 674 V can be easily accomplished.
  • fitting portions 672 V and the fitted-to portions 674 W are respectively formed to the first connection portions 636 V, 636 W, fitting together of the fitting portions 672 V and the fitted-to portions 674 W can be performed easily.
  • fitting portions 672 U, 672 V may be formed as recess shapes and the fitted-to portions 674 V, 672 W may be formed as protrusion shapes.
  • a stator 710 according to a seventh exemplary embodiment of the present invention illustrated in FIG. 39 has portions similar to those of the stator of the first exemplary embodiment. Explanation hence focuses on differing portions and explanation of similar portions is omitted as appropriate.
  • a coil wire 716 U configuring a U-phase includes plural winding portions 726 U and plural crossing wires 728 U.
  • the coil wire 716 U is formed continuously from one end to the other end.
  • the coil wire 716 U is wound concentrically around the plural winding portions 726 U on teeth sections 724 U, with insulator portions 732 U (insulator main body portions 733 U), described later, respectively disposed therebetween.
  • the winding portions 726 U are mutually connected to each other by the plural crossing wires 728 U.
  • the crossing wires 728 U are laid out (wrapped) around the outer peripheral face of a connection portion 734 U formed to an insulator 718 U, described later.
  • Terminal portions 730 U at both end sides of the coil wire 716 U is led out from the teeth sections 724 U to a first axial direction side (the arrow Z 1 side) of the stator 710 .
  • the insulator 718 U is made from a resin, and includes plural insulator portions 732 U and a connection portion 734 U that have been integrated together.
  • the number of the plural insulator portions 732 U provided is the same as the number of the plural teeth sections 724 U mentioned above.
  • the plural insulator portions 732 U include insulator main body portions 733 U, extension side wall portions 735 U and radial direction extension portions 737 U.
  • the insulator main body portions 733 U are integrated to the respective surfaces of the plural core configuration sections 714 U, for example by integral molding or interlock mounting.
  • the insulator main body portions 733 U insulate between the teeth sections 724 U formed to the core configuration sections 714 U and the winding portions 726 U.
  • the extension side wall portions 735 U are positioned further inside in a radial direction of the stator configuration section 712 U than the core configuration sections 714 U (than the insulator main body portions 733 U).
  • the radial direction extension portions 737 U extend out in the radial direction of the stator configuration section 712 U from the connection portion 734 U.
  • the extension side wall portions 735 U extend towards a second axial direction side (Z 2 side) of the stator configuration section 712 U from extending ends of the radial direction extension portions 737 U and connect together the insulator main body portions 733 U and the radial direction extension portions 737 U.
  • the extension side wall portions 735 U and the radial direction extension portions 737 U configure extending portions 739 U that connect together the insulator main body portions 733 U and the connection portion 734 U.
  • connection portion 734 U is provided at a first axial direction side (Z 1 side) of the plural insulator portions 732 U.
  • the connection portion 734 U is formed in a ring shape, connects together the plural insulator portions 732 U (or more specifically, base end portions of the radial direction extension portions 737 U of the plural insulator portions 732 U), and is positioned further to a radial direction inside than the core configuration sections 714 U.
  • Plural projection shaped retaining portions 736 U project out from an outer peripheral face of the connection portion 734 U towards a radial direction outside between the plural insulator portions 732 U.
  • the retaining portions 736 U retain the crossing wires 728 U mentioned above from the second axial direction side (arrow Z 2 side) of the connection portion 734 U.
  • a V-phase stator configuration section 712 V illustrated in FIG. 40B has a similar basic configuration to the U-phase stator configuration section 712 U described above.
  • a connection portion 734 V is formed in a ring shape, and is formed with a smaller diameter than the U-phase connection portion 734 U described above (see FIG. 40A ).
  • Retaining portions 736 V retain crossing wires 728 V from a first axial direction side (the arrow Z 1 side) of the connection portion 734 V, and are positioned further to a radial direction inside than core configuration sections 714 V.
  • the plural insulator portions 732 V include insulator main body portions 733 V, extension side wall portions 735 V and radial direction extension portions 737 V.
  • the insulator main body portions 733 V are integrated to respective surfaces of the plural core configuration sections 714 V, for example by integral molding or interlock mounting.
  • the insulator main body portions 733 V insulate between teeth sections 724 V formed to the core configuration sections 714 V and winding portions 726 V.
  • the extension side wall portions 735 V are positioned further inside in a radial direction of the stator configuration section 712 V than the core configuration sections 714 V (than the insulator main body portions 733 V).
  • the radial direction extension portions 737 V extend out in the radial direction of the stator configuration section 712 V from the connection portion 734 V.
  • the extension side wall portions 735 V extend towards a second axial direction side (Z 2 side) of the stator configuration section 712 V from extending ends of the radial direction extension portions 737 V and connect together the insulator main body portions 733 V and the radial direction extension portions 737 V.
  • the extension side wall portions 735 V and the radial direction extension portions 737 V configure extending portions 739 V that connect together the insulator main body portions 733 V and the connection portion 734 V.
  • the connection portion 734 V is provided at the first axial direction side (Z 1 side) of the plural insulator portions 732 V.
  • the connection portion 734 V is formed in a ring shape, connects together the plural insulator portions 732 V, and is positioned further to a radial direction inside than the core configuration sections 714 V.
  • a W-phase stator configuration section 712 W illustrated in FIG. 40C also has a similar basic configuration to the U-phase stator configuration section 712 U described above.
  • a connection portion 734 W is formed in a ring shape, and is formed with a smaller diameter than the V-phase connection portion 734 V described above (see FIG. 40B ).
  • the retaining portions 736 W retain crossing wires 728 W from a first axial direction side (the arrow Z 1 side) of a connection portion 734 W, and are positioned further inside in a radial direction than the core configuration sections 714 W.
  • the plural insulator portions 732 W include insulator main body portions 733 W, extension side wall portions 735 W and radial direction extension portions 737 W.
  • the insulator main body portions 733 W are integrated to respective surfaces of the plural core configuration sections 714 W, for example by integral molding or interlock mounting.
  • the insulator main body portions 733 W insulate between teeth sections 724 W formed to the core configuration sections 714 W and winding portions 726 W.
  • the extension side wall portions 735 W are positioned further inside in a radial direction of a stator configuration section 712 W than the core configuration sections 714 W (than the insulator main body portions 733 W).
  • the radial direction extension portions 737 W extend out in the stator configuration section 712 W radial direction from the connection portion 734 W.
  • the extension side wall portions 735 W extend towards a second axial direction side (Z 2 side) of the stator configuration section 712 W from extending ends of the radial direction extension portions 737 W and connect together the insulator main body portions 733 W and the radial direction extension portions 737 W.
  • the extension side wall portions 735 W and the radial direction extension portions 737 W configure extending portions 739 W that connect together the insulator main body portions 733 W and the connection portion 734 W.
  • the connection portion 734 W is provided at the first axial direction side (Z 1 side) of the plural insulator portions 732 W.
  • connection portion 734 W is formed in a ring shape, connects together the plural insulator portions 732 W (or more specifically, extension end portions (end portions on the radial direction inside) of the extension side wall portions 735 W of the plural insulator portions 732 W), and is positioned further to the radial direction inside than the core configuration sections 714 W.
  • connection portions 734 U, 734 V, 734 W are disposed at a radial direction inside of a yoke 740 .
  • the plural connection portions 734 U, 734 V, 734 W are disposed with gaps between each other in the yoke 740 radial direction and axial direction, and are provided coaxially to the yoke 740 .
  • the V-phase retaining portions 736 V fit against an inner peripheral face of the U-phase connection portion 734 U, and the W-phase retaining portions 736 W fit against an inner peripheral face of the V-phase connection portion 734 V.
  • the plural connection portions 734 U, 734 V, 734 W are accordingly retained in a radial direction mutually separated state.
  • the retaining portions 736 U, 736 V, 736 W are provided in the radial direction between the plural connection portions 734 U, 734 V, 734 W, and also perform as projection shaped spacers that retain the plural connection portions 734 U, 734 V, 734 W in a radial direction mutually separated state.
  • a crossing wire 728 U 1 connected to the winding start end portion of one of the winding portions 726 U and a crossing wire 728 U 2 connected to a winding finish end portion of this winding portion 726 U cross over at the radial direction extension portions 737 U of the connection portion 734 U and the insulator portions 732 U.
  • the radial direction extension portions 737 U are examples of a connection vicinity between the connection portion 734 U and the insulator portions 732 U.
  • intersection portions 729 U between the crossing wire 728 U 1 connected to the winding start end portion of one of the winding portions 726 U and the crossing wire 728 U 2 connected to a winding finish end portion of this winding portion 726 U are disposed at positions overlapping with the radial direction extension portions 737 U as viewed along the stator configuration section 712 U axial direction.
  • the crossing wires 728 V, 728 W are similar to the crossing wires 728 U described above. Namely, as illustrated in FIG. 40B , intersection portions 729 V between the crossing wire 728 V 1 connected to the winding start end portion of one of the V-phase winding portions 726 V and the crossing wire 728 V 2 connected to a winding finish end portion of this winding portion 726 V are disposed at positions overlapping with the radial direction extension portions 737 V as viewed along the stator configuration section 712 V axial direction. As illustrated in FIG.
  • intersection portions 729 W between the crossing wire 728 W 1 connected to the winding start end portion of one of the W-phase winding portions 726 W and the crossing wire 728 W 2 connected to a winding finish end portion of this winding portion 726 W are disposed at positions overlapping with the radial direction extension portions 737 W as viewed along the stator configuration section 712 W axial direction.
  • the U-phase stator configuration section 712 U illustrated in FIG. 40A has terminal portions 730 U connected to two of the winding portions 726 U out of the four winding portions 726 U, and has crossing wires 728 U connected to the remaining two winding portions 726 U. Out of the two winding portions 726 U connected to these crossing wires 728 U, one of the crossing wires 728 U 2 that is connected the winding finish end portion of a first of the winding portions 726 U is in turn connected to the winding start end portion of another of the winding portions 726 U.
  • the crossing wire 728 U 1 that is connected to the winding start end portion of one of the winding portions 726 U is connected to the winding finish end portion of one of the winding portions 726 U out of the two winding portions 726 U connected to the terminal portions 730 U.
  • a crossing wire 728 U 2 that is connected to the winding finish end portion of another of the winding portions 726 U is connected to the winding start end portion of the other winding portions 726 U out of the two winding portions 726 U that are connected to the terminal portions 730 U. Similar applies to the coil wires 716 V, 716 W illustrated in FIG. 40B and FIG. 40C .
  • the stator 710 configured as described above configures an inner rotor type brushless motor 760 , together with a rotor 750 and a housing 770 .
  • Configuration in the brushless motor 760 is such that a rotational magnetic field is formed by the stator 710 , and the rotor 750 is rotated thereby.
  • the brushless motor 760 is for example an 8-pole 12 slot motor.
  • the core configuration sections 714 U are integrated to the insulator portions 732 U of the insulator 718 U to form a U-phase sub-assembly 742 U configured from the insulator 718 U and the plural core configuration sections 714 U.
  • the core configuration sections 714 V are integrated to the insulator portions 732 V of the insulator 718 V to form a V-phase sub-assembly 742 V configured from the insulator 718 V and the plural core configuration sections 714 V.
  • FIG. 40A the core configuration sections 714 U are integrated to the insulator portions 732 U of the insulator 718 U to form a U-phase sub-assembly 742 U configured from the insulator 718 U and the plural core configuration sections 714 V.
  • the core configuration sections 714 W are integrated to the insulator portions 732 W of the insulator 718 W to form a W-phase sub-assembly 742 W configured from the insulator 718 W and the plural core configuration sections 714 W.
  • the sub-assemblies 742 U, 742 V, 742 W are thus formed for each of the U-phase, the V-phase and the W-phase (the sub-assembly forming process).
  • a flyer machine 100 (see FIG. 5 ) is employed to wind the coil wire 716 U on each of the teeth sections 724 U of the U-phase sub-assembly 742 U from the radial direction outside, forming the U-phase stator configuration section 712 U with the plural winding portions 726 U formed at the sub-assembly 742 U.
  • the flyer machine 100 is, as illustrated in FIG.
  • a flyer 101 that winds the coil wires 716 in a circular motion so as to circle the periphery of each of the teeth sections 724 , a variable former 102 that aligns the coil wires 716 wound onto the teeth sections 724 , and a drive circuit 103 that controls the flyer 101 and the variable former 102 .
  • the flyer machine 100 mentioned above is employed to wind the coil wire 716 V on each of the teeth sections 724 V of the V-phase sub-assembly 742 V from the radial direction outside, forming the V-phase stator configuration section 712 V with the plural winding portions 726 V formed at the sub-assembly 742 V.
  • the flyer machine 100 mentioned above is employed to wind the coil wire 716 V on each of the teeth sections 724 V of the V-phase sub-assembly 742 V from the radial direction outside, forming the V-phase stator configuration section 712 V with the plural winding portions 726 V formed at the sub-assembly 742 V.
  • the flyer machine 100 mentioned above is employed to wind the coil wire 716 W on each of the teeth sections 724 W of the W-phase sub-assembly 742 W from the radial direction outside, forming the W-phase stator configuration section 712 W with the plural winding portions 726 W formed at the sub-assembly 742 W.
  • the plural crossing wires 728 U are laid out along an outer peripheral face of the connection portion 734 U.
  • the plural crossing wires 728 U are also retained from a second axial direction side (arrow Z 2 side) of the connection portion 734 U by the projection shaped retaining portions 736 U.
  • configuration is made such that the crossing wire 728 U 1 that is connected to the winding start end portion of one of the winding portions 726 U and the crossing wire 728 U 2 that is connected to the winding finish end portion of this winding portion 726 U cross over on the respective radial direction extension portion 737 U of the connection portion 734 U and the insulator portion 732 U.
  • the crossing wire 728 U 1 and the crossing wire 728 U 2 are tightly crossed over such that slack does not occur in the winding portions 726 U.
  • the plural crossing wires 728 V are laid out along an outer peripheral face of the connection portion 734 V.
  • the plural crossing wires 728 V are also retained from the first axial direction side (the arrow Z 1 side) of the connection portion 734 V by the projection shaped retaining portions 736 V.
  • configuration is made such that the crossing wire 728 V 1 that is connected to the winding start end portion of one of the winding portions 726 V and the crossing wire 728 V 2 that is connected to the winding finish end portion of this winding portion 726 V cross over on the respective radial direction extension portion 737 V of the connection portion 734 V and the insulator portion 732 V.
  • the plural crossing wires 728 W are laid out along an outer peripheral face of the connection portion 734 W.
  • the plural crossing wires 728 W are also retained from the first axial direction side (the arrow Z 1 side) of the connection portion 734 W by the projection shaped retaining portions 736 W.
  • configuration is made such that the crossing wire 728 W 1 that is connected to the winding start end portion of one of the winding portions 726 W and the crossing wire 728 W 2 that is connected to the winding finish end portion of this winding portion 726 W cross over on the respective radial direction extension portion 737 W of the connection portion 734 W and the insulator portion 732 W.
  • the terminal portions 730 U at the two end sides of the coil wire 716 U are led out from the teeth sections 724 U to the first axial direction side (the arrow Z 1 side) of the stator 710 .
  • the terminal portions 730 V at the two end sides of the coil wire 716 V are led out from the teeth sections 724 V towards the first axial direction side of the stator 710 .
  • the terminal portions 730 W at the two end sides of the coil wire 716 W are led out from the teeth sections 724 W towards the first axial direction side of the stator 710 .
  • the stator configuration sections 712 U, 712 V, 712 W are thus formed for each of the U-phase, the V-phase and the W-phase (the stator configuration section forming process).
  • the V-phase stator configuration section 712 V is assembled to the W-phase stator configuration section 712 W from the first axial direction side (the arrow Z 1 side).
  • the U-phase stator configuration section 712 U is assembled to the V-phase stator configuration section 712 V and the W-phase stator configuration section 712 W from the first axial direction side (the arrow Z 1 side).
  • each of the plural yoke configuration sections 722 U, 722 V, 722 W is fitted between respective pairs of yoke configuration sections adjacent on both sides.
  • the V-phase retaining portions 736 V are fitted against n inner peripheral face of the U-phase connection portion 734 U
  • the W-phase retaining portions 736 W are fitted against n inner peripheral face of the V-phase connection portion 734 V.
  • the plural connection portions 734 U, 734 V, 734 W are thus retained in a state separated from each other in the radial direction by the projection shaped retaining portions 736 U, 736 V, 736 W.
  • stator configuration sections 712 U, 712 V, 712 W are thus assembled together in this manner to form the stator 710 (stator forming process).
  • the terminal portions 730 U, 730 V, 730 W are connected by a buzz bar or the like, not shown in the drawings.
  • the stator 710 is accordingly manufactured by the above processes.
  • the yoke 740 is configured by the plural yoke configuration sections 722 U 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 724 project towards inside in a yoke 740 radial direction, the sub-assemblies 742 for each of the U-phase, V-phase and W-phase are formed as described above, and the coil wires 716 can be wound using the flyer machine 100 (see FIG. 5 ) onto each of the teeth sections 724 of each of the sub-assemblies 742 from outside in the radial direction of the yoke 740 . There is accordingly no need to secure space between the teeth sections 724 , as would be required when a nozzle machine is employed, enabling a higher dense arrangement of the coil wires 716 to be achieved, and enabling a more compact stator 710 to be realized.
  • the yoke 740 is segmented in the circumferential direction into the plural yoke configuration sections 722 , and so, for example, the stator 710 can be made more compact in the axial direction in comparison to cases in which the yoke 740 is segmented into plural yoke configuration sections in the axial direction.
  • the flyer machine 100 since the winding speed of the coil wires 716 is higher than when using a nozzle machine, the process of winding the coil wires 716 can be speeded up, and accordingly a reduction in cost of the stator 710 can be achieved due to reducing the number of equipment units.
  • each of the plural groups (the U-phase, V-phase, W-phase) of the stator configuration sections 712 adjacent of the plural core configuration sections 714 are disposed with a gap corresponding to two core configuration sections present between each other.
  • the flyer machine 100 can be suppressed from interfering with the other core configuration sections 714 even when using the flyer machine 100 to wind the coil wires 716 onto each of the teeth sections 724 of each of the sub-assemblies from the radial direction outside.
  • the coil wire 716 U is formed continuously from one end to the other, and including the crossing wires 728 U that are laid out along the connection portion 734 U and that connect together the plural winding portions 726 U. Slack of the winding portions 726 U from the teeth sections 724 U can accordingly be suppressed from occurring.
  • crossing wire 728 U 1 that is connected to the winding start end portion of one of the winding portions 726 U and the crossing wire 728 U 2 that is connected to the winding finish end portion of this winding portions 726 U cross over in the connection vicinity between the connection portion 734 U and the respective insulator portion 732 U. Slack of the winding portions 726 U from the teeth sections 724 U can accordingly be more effectively suppressed from occurring.
  • the radial direction extension portions 737 U that extend in the radial direction of the stator configuration section 712 U are formed to the extending portions 739 U that connect together insulator main body portions 733 U and the connection portion 734 .
  • the intersection portions 729 U of the crossing wires 728 U 1 , 728 U 2 described above are disposed at positions overlapping with the radial direction extension portions 737 U as viewed along the stator configuration section 712 U axial direction.
  • the crossing wires 728 U 1 , 728 U 2 described above accordingly cross over in space secured by the radial direction extension portions 737 U, and so slackening of the winding portions 726 U from the teeth sections 724 U can accordingly be even more effectively suppressed from occurring.
  • the yoke 740 is configured by the plural yoke configuration sections 722 segmented in the yoke 740 circumferential direction, and so the coil wires 716 can be wound on each of the teeth sections 724 of each of the sub-assemblies using the flyer machine 100 from the radial direction outside.
  • connection portions 734 are respectively positioned further to the radial direction inside than the core configuration sections 714 . Interference between the flyer of the flyer machine 100 and the connection portions 734 can accordingly be suppressed from occurring when the coil wires 716 are respectively wound on the teeth sections 724 from the radial direction outside using the flyer machine 100 .
  • the plural yoke configuration sections 722 are integrally formed to the teeth sections 724 .
  • 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.
  • magnetic loss occurs at three locations in the two-part type core, at the bridging sections between the leading end portions of pairs of adjacent teeth sections, at the base end portions of pairs of teeth sections, and at connection portion of the yoke.
  • stator 710 of the present exemplary embodiment magnetic loss only occurs at one location, the connection portion between pairs of the adjacent yoke configuration sections 722 , enabling magnetic loss to be reduced. It is accordingly possible to achieve even greater compactness and reduction in weight.
  • configuration may be made such that one or more of the crossing wires 728 do not cross over, as illustrated in FIG. 43 . Namely, where there are cases in which the crossing wires 728 are tightly wound so as to cross over as illustrated in FIG. 40C , configuration may be made with any of the crossing wires 728 wound loosely without cross over.
  • the radial direction extension portions 737 that extend in the radial direction of the stator configuration sections 712 are formed to the extending portions 739 , and the intersection portions 729 of the crossing wires 728 described above are disposed at positions overlapping with the radial direction extension portions 737 as viewed along the stator configuration sections 712 axial direction.
  • configuration may be made such that axial direction extension portions are formed to the extending portions 739 to extend in an axial direction of the stator configuration sections 712 , and the intersection portions 729 of the above crossing wires 728 are disposed at positions overlapping with the axial direction extension portions as viewed along a stator configuration sections 712 radial direction. Slacking of the winding portions 726 from the teeth sections 724 can also be suppressed from occurring by adopting such a configuration.
  • crossing wires 728 are laid out along the connection portions 734 , configuration may also be made with a straight line stretched formation in which tension is applied to crossing wires not laid out along the connection portions 734 .
  • a stator 810 according to the eighth exemplary embodiment of the present invention illustrated in FIG. 44 has portions similar to those of the stator of the first exemplary embodiment. Explanation hence focuses on differing portions and explanation of similar portions is omitted as appropriate.
  • an insulator 818 U includes plural resin-formed insulator portions 832 U.
  • the number of plural insulator portions 832 U provided is the same as the number of plural teeth sections 824 U.
  • the plural insulator portions 832 U include respective insulator main body portions 833 U and extension side wall portions 835 U.
  • the insulator main body portions 833 U are integrated to respective surfaces of plural core configuration sections 814 U, for example by integral molding or interlock mounting.
  • the insulator main body portions 833 U insulate between the teeth sections 824 U formed to the core configuration sections 814 U and winding portions 826 U.
  • the extension side wall portions 835 U are positioned further inside in a radial direction of stator configuration section 812 U than the core configuration sections 814 U (than the insulator main body portions 833 U).
  • the extension side wall portions 835 U extend from a connection portion 834 U towards a second axial direction side (arrow Z 2 side) of the stator configuration section 812 U, and connect together the insulator main body portions 833 U and the connection portion 834 U.
  • a V-phase stator configuration section 812 V illustrated in FIG. 45B also has a similar basic configuration to the U-phase stator configuration section 812 U described above.
  • the plural insulator portions 832 V include respective insulator main body portions 833 V, extension side wall portions 835 V and radial direction extension portions 837 V.
  • the insulator main body portions 833 V are integrated to respective surfaces of plural core configuration sections 814 V, for example by integral molding or interlock mounting.
  • the insulator main body portions 833 V insulate between teeth sections 824 V formed to the core configuration sections 814 V and winding portions 826 V.
  • the extension side wall portions 835 V are positioned further inside in a radial direction of the stator configuration section 812 V than the core configuration sections 814 V (than the insulator main body portions 833 V).
  • the radial direction extension portions 837 V extend outside in the radial direction of the stator configuration section 812 V from connection portion 834 V.
  • the extension side wall portions 835 V extend from extending ends of the radial direction extension portions 837 V towards a second axial direction side (Z 2 side) of the stator configuration section 812 V and connect together the insulator main body portions 833 V and the radial direction extension portions 837 V.
  • the connection portion 834 V is provided at a first axial direction side (Z 1 side) of the plural insulator portions 832 V.
  • the connection portion 834 V is formed in a ring shape, connects together the plural insulator portions 832 V, and is positioned further to the radial direction inside than the core configuration sections 814 V.
  • a W-phase stator configuration section 812 W illustrated in FIG. 45C also has a similar basic configuration to the U-phase stator configuration section 812 U described above.
  • the plural insulator portions 832 W include respective insulator main body portions 833 W, extension side wall portions 835 W and radial direction extension portions 837 W.
  • the insulator main body portions 833 W are integrated to respective surfaces of plural core configuration sections 814 W, for example by integral molding or interlock mounting.
  • the insulator main body portions 833 W insulate between teeth sections 824 W formed to the core configuration sections 814 W and winding portions 826 W.
  • the extension side wall portions 835 W are positioned further inside in a radial direction of the stator configuration section 812 W than the core configuration sections 814 W (than the insulator main body portions 833 W).
  • the radial direction extension portions 837 W extend outside in the radial direction of the stator configuration section 812 W from connection portion 834 W.
  • the extension side wall portions 835 W extend from extending ends of the radial direction extension portions 837 W towards a second axial direction side (arrow Z 2 side) of the stator configuration section 812 W, and connect together the insulator main body portions 833 W and the radial direction extension portions 837 W.
  • the connection portion 834 W is provided at a first axial direction side (the arrow Z 1 side) of the plural insulator portions 832 W.
  • connection portion 834 W is formed in a ring shape, connects together the plural insulator portions 832 W (or more specifically, extension end portions (end portions on the radial direction inside) of the extension side wall portions 835 W of the plural insulator portions 832 W), and is positioned further to the radial direction inside than the core configuration sections 814 W.
  • V-phase crossing wires 828 V pass through inside notches 838 U formed in the U-phase connection portion 834 U (are housed in the notches 838 U)
  • W-phase crossing wires 828 W pass through inside notches 838 V formed in the V-phase connection portion 834 V and through inside notches 838 U formed in the U-phase connection portion 834 U (are housed in the notches 838 U and notches 838 V) (see FIG. 46B ).
  • the notches 838 U, 838 V are examples of housing portion of the present invention.
  • the imaginary tangent line X may pass through the extension side wall portions 835 at any position on the extension side wall portion 835 , in plan view.
  • stator configuration sections 812 U, 812 V, 812 W of the plural groups the winding portions are pressed and compression deformed (high density packed) by a press 104 , as described later (see FIG. 49 and FIG. 50 ).
  • stator 810 configured as described above.
  • a sub-assembly forming process and a stator configuration section forming process are substantially the same as those of the first exemplary embodiment.
  • the winding portions 826 are pressed and compression deformed by the press 104 (compression process). When this is performed, the winding portions 826 are pressed from both side in a direction intersecting with (for example orthogonal to) the teeth sections 824 axial direction. Moreover, the winding portions 826 are pressed such that pressing direction to the winding portions 826 is arranged in a tangential direction to the stator configuration section 812 .
  • each of the stator configuration section 812 of the plural groups as illustrated in FIG. 48 , when the imaginary tangent line X passes through the extension side wall portion 835 in a tangential direction to the stator configuration section 812 , the circumferential direction end portions 822 A of the yoke configuration section 822 of one of the core configuration sections 814 are positioned on the opposite side with respect to the imaginary tangent line X to the other core configuration sections 814 that are adjacent to this core configuration section 814 .
  • the flyer machine 100 can be suppressed from interfering with the other core configuration sections 814 , and in particular interfering with the circumferential direction end portions 822 A of the yoke configuration section 822 .
  • the winding portions 826 are pressed and compression deformed (high density packed) by the press 104 . Bulges in the winding portions 826 are accordingly suppressed, a high dense arrangement of the coil wires 816 can be achieved, and space for the pressing operation of the press 104 can also be secured.
  • the winding portions 826 are pressed in a direction intersecting with the teeth sections 824 axial direction. Therefore, as illustrated in FIG. 49 , even in cases in which gaps occur between the teeth sections 824 and the winding portions 826 or in cases in which gaps are left between individual strands of coil wire in the winding portions 826 , bulging of the winding portions 826 can be better suppressed, and a high dense arrangement of the coil wires 816 can be achieved.
  • the coil wires 816 can be better compression deformed due to pressing the winding portions 826 from both sides in a direction intersecting with the teeth sections 824 axial direction.
  • the winding portions 826 are pressed such that the pressing direction on the winding portions 826 is a tangential direction to the stator configuration section 812 .
  • adjacent core configuration sections 814 are disposed while a space of two core configuration sections is maintained between the adjacent core configuration sections 814 .
  • the winding portions 826 can accordingly be pressed while still suppressing the press 104 from interfering with the core configuration sections 814 .
  • the stator 810 is employed in an inner rotor type motor, and the teeth sections 824 protrude from the yoke configuration section 822 towards the yoke 840 radial direction inside.
  • a stator 910 according to the ninth exemplary embodiment of the present invention is employed in an outer rotor type motor.
  • the teeth sections 924 project out from a yoke configuration section 922 towards an outside in a radial direction of a yoke 940 .
  • Yoke configuration sections 923 are formed to leading end portions of the teeth sections 924 .
  • the stator 910 is employed in a 10-pole, 12-slot or a 14-pole, 12-slot motor.
  • configuration of the present exemplary embodiment is substantially similar to that of the eighth exemplary embodiment of the present invention.
  • the adjacent yoke configuration sections 922 may fit together with recess and protrusion shaped fitting portions 944 . Adopting such a configuration enables the rigidity of the yoke 940 to be raised.
  • a stator 10140 according to the tenth exemplary embodiment of the present invention illustrated in FIG. 53 has a configuration changed in the following manner from the stator 910 according to the ninth exemplary embodiment of the present invention described above. Namely, the stator 10140 , as illustrated in FIG. 54A to FIG. 54C , is segmented into stator configuration sections 1012 A, 1012 B, 1012 C configured for each of groups that include plural phases. Note that the stator 10140 is, for example, applied to a 10-pole, 12-stroke brushless motor 1060 .
  • the stator configuration section 1012 A configuring a first group includes a +U-phase teeth section 1024 U, a ⁇ U-phase teeth section 1024 U, a +W-phase teeth section 1024 W and a ⁇ W-phase teeth section 1024 W.
  • the stator configuration section 1012 B configuring a second group includes a +V-phase teeth section 1024 V, a ⁇ V-phase teeth section 1024 V, a +W-phase teeth section 1024 W and a ⁇ W-phase teeth section 1024 W.
  • FIG. 54A the stator configuration section 1012 A configuring a first group includes a +U-phase teeth section 1024 U, a ⁇ U-phase teeth section 1024 U, a +W-phase teeth section 1024 W and a ⁇ W-phase teeth section 1024 W.
  • the stator configuration section 1012 C configuring a third group includes a +U-phase teeth section 1024 U, a ⁇ U-phase teeth section 1024 U, a +V-phase teeth section 1024 V and ⁇ V-phase teeth section 1024 V.
  • Each of the stator configuration sections 1012 A, 1012 B, 1012 C are thus configured by a combination of mutually different phases (U-phase, V-phase, W-phase).
  • each of the stator configuration sections 1012 A, 1012 B, 1012 C the plural teeth sections 1024 are disposed at even intervals from each other (at for example 90 degrees in the present exemplary embodiment).
  • two core configuration sections 1014 (teeth sections 1024 ) from other stator configuration sections are disposed between each adjacent pair of core configuration sections 1014 (teeth sections 1024 ).
  • the coil wire 1016 U is wound in a tightening direction (forwards) on the ⁇ U-phase teeth section 1024 and in a loosening direction (reverse direction) on the +U-phase teeth section 1024 .
  • the winding portions 1026 U and the crossing wires 1028 U in the coil wire 1016 U are connected together by a lead portion 1046 that is led out from the teeth section 1024 U.
  • the coil wire 1016 U is wound in the tightening direction when, as viewed along an axial direction of the stator configuration section 1012 A, the lead portion 1046 extends so as to intersect the stator configuration section 1012 A radial direction (when overlapping with the core configuration section 1014 U).
  • the coil wire 1016 U is wound in the loosening direction when, as viewed along the axial direction of the stator configuration section 1012 A, the lead portion 1046 extends along the stator configuration section 1012 A radial direction (when not overlapping with the core configuration section 1014 U).
  • the coil wire 1016 W is wound in the tightening direction on the +W-phase teeth section 1024 and the coil wire 1016 W is wound in the loosening direction on the ⁇ W-phase teeth section 1024 .
  • the coil wire 1016 V is wound in the tightening direction on the ⁇ V-phase teeth section 1024 and the coil wire 1016 V is wound in the loosening direction on the +V-phase teeth section 1024 .
  • the coil wire 1016 W is wound in the tightening direction on the +W-phase teeth section 1024 and coil wire 1016 W is wound in the loosening direction on the ⁇ W-phase teeth section 1024 .
  • FIG. 54A the coil wire 1016 W is wound in the tightening direction on the +W-phase teeth section 1024 and the coil wire 1016 W is wound in the loosening direction on the ⁇ W-phase teeth section 1024 .
  • the coil wire 1016 U is wound in the tightening direction on the +U-phase teeth section 1024 U and coil wire 1016 U is wound in the loosening direction on the ⁇ U-phase teeth section 1024 U.
  • the coil wire 1016 V is wound in the tightening direction on the +V-phase teeth section 1024 V and the coil wire 1016 V is wound in the loosening direction on the ⁇ V-phase teeth section 1024 V.
  • pairs of winding portions 1026 facing each other across central axes of the plural stator configuration sections 1012 A, 1012 B, 1012 C are formed with the same coil wire 1016 and are formed with opposite winding directions to each other.
  • two circuit systems are configured without parallel circuits, or plural parallel circuits are combined such that circulating currents are not generated (so-called cancelling winding) even though parallel circuits are formed.
  • a protrusion portion 1048 is formed to an insulator 1018 , and the lead portion 1046 is anchored to the protrusion portion 1048 .
  • the insulator 1018 is formed with insulator main body portions 1033 and extension side wall portions 1035 .
  • the insulator main body portions 1033 insulate between the teeth sections 1024 integrated to the core configuration sections 1014 and the winding portions 1026 .
  • the extension side wall portions 1035 extend in an axial direction of the stator configuration section 1012 from a connection portion 1034 and connect together the insulator main body portions 1033 and the connection portion 1034 .
  • the protrusion portion 1048 is, more specifically, formed at an end portion in an extension direction of the extension side wall portions 1035 (the same direction as the stator configuration section 1012 axial direction). Out of the pairs of winding portions 1026 described above, at the winding portion 1026 wound in the loosening direction on the teeth section 1024 , the lead portion 1046 is restricted from slackening by anchoring on the protrusion portion 1048 .
  • the plural teeth sections 1024 are disposed at even intervals in each of the stator configuration sections 1012 , and separation between the teeth sections 1024 is secured.
  • the coil wires 1016 can accordingly be easily wound on the teeth sections 1024 .
  • the winding portions 1026 that are wound in the loosening direction on the teeth sections 1024 are restricted from slackening by anchoring the lead portions 1046 on the projection portions 1048 . Slackening of the winding portions 1026 that are wound in the loosening direction onto the teeth sections 1024 can accordingly be suppressed.
  • the stator 10140 is, as illustrated in FIG. 53 , employed in an outer rotor type motor, and the teeth sections 1024 project out from a yoke configuration sections 1022 towards a yoke 1040 radial direction outside.
  • the stator 10140 may be employed in an inner rotor type motor, with the teeth sections 1024 configured to project out from the yoke configuration sections 1022 towards the yoke 1040 radial direction inside.
  • stator 10140 is as an example applied to a 10-pole, 12-slot brushless motor, application may be made to a 14-pole, 12-slot brushless motor.
US13/752,396 2012-02-08 2013-01-29 Stator, brushless motor, stator manufacturing method Abandoned US20130200742A1 (en)

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JP2012-025298 2012-02-08
JP2012025298A JP2013162726A (ja) 2012-02-08 2012-02-08 ステータ及びブラシレスモータ
JP2012025297A JP5502115B2 (ja) 2012-02-08 2012-02-08 ステータ、ブラシレスモータ、ステータの製造方法
JP2012-025297 2012-02-08
JP2012-040627 2012-02-27
JP2012040627A JP5536123B2 (ja) 2012-02-27 2012-02-27 ステータの製造方法
JP2012-095870 2012-04-19
JP2012095870A JP5921309B2 (ja) 2012-04-19 2012-04-19 ステータ
JP2012-095872 2012-04-19
JP2012-095871 2012-04-19
JP2012095871 2012-04-19
JP2012095872A JP5502131B2 (ja) 2012-04-19 2012-04-19 ステータ、ブラシレスモータ、ステータの製造方法
JP2012-252190 2012-11-16
JP2012252190A JP6046987B2 (ja) 2012-04-19 2012-11-16 ステータ、ブラシレスモータ、ステータの製造方法

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US10491057B2 (en) 2019-11-26
US20200036239A1 (en) 2020-01-30
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US20170141627A1 (en) 2017-05-18
CN103248145A (zh) 2013-08-14

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