WO2019142584A1

WO2019142584A1 - Insulator, and stator and motor comprising same

Info

Publication number: WO2019142584A1
Application number: PCT/JP2018/046804
Authority: WO
Inventors: 菱田　光起; 博米田; 浩勝国友
Original assignee: パナソニックＩｐマネジメント株式会社
Priority date: 2018-01-19
Filing date: 2018-12-19
Publication date: 2019-07-25
Also published as: CN111566906A; JPWO2019142584A1

Abstract

This insulator 5 comprises a first flange part 51 provided on a core segment 41 side of a coil-winding unit 50 on which a coil 7 is wound, and having a coil introduction groove 53 that guides the coil 7 to the coil-winding unit 50, and a second flange part 52 provided on the tip side of a tooth 42. A surface of the coil-winding unit 50 is provided with a movement restriction part 54 composed of an uneven part 54a, the movement restriction part 54 extending radially inward from the root of the first flange part 51. The average length of the uneven part 54a is shorter than the wire diameter of the coil 7, and the arithmetic average roughness Ra of the uneven part 54a is greater than the arithmetic average roughness Ra' of a smooth surface part 55 which is a part of the coil-winding unit 50 other than the movement restriction part 54.

Description

Insulator, stator provided with the same, motor

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

In recent years, the demand for motors has increased in industrial and automotive applications. Among them, there is a demand for improvement in motor efficiency and cost reduction.

It is known to improve the space factor of the coils disposed in the slots of the stator as one method of improving the efficiency of the motor. By improving the space factor of the coil, it is possible to suppress the loss due to the current flowing through the coil when the motor is driven.

As a structure for improving the space factor of the coil, a so-called aligned winding coil is generally known, in which the coil is in a state of being aligned and wound around the teeth of the stator. Configurations have been proposed (see, for example, Patent Documents 1 to 4). For example, Patent Document 1 discloses a configuration in which a step or an inclination is provided inside an end of a cylindrical body of an insulating coil bobbin on which a coil is wound or a ridge portion provided at both ends of the cylindrical body to realize an aligned winding coil. Proposed. Further, in Patent Document 2, a holding groove for holding a wound coil is provided on the surface of an insulator which is mounted on teeth and which insulates the coil from the teeth. An arrangement for realizing a coil is disclosed.

Japanese Patent Application Laid-Open No. 11-122855 JP, 2006-115565, A U.S. Pat. No. 6,356,001 WO 2011/118357

By the way, generally, the above-mentioned insulator and coil bobbin are formed by molding a resin material using a mold. On the other hand, since the motor performance varies depending on the user's specifications, even if the same stator core and teeth are used, the wire diameter and the number of turns of the coil are changed to adjust the current value etc. supplied to the coil, and the motor performance is adjusted to the individual specifications. Often included.

However, in the conventional configurations disclosed in Patent Documents 1 and 2, it is necessary to change the width of the holding groove or to change the width of the step or the inclination angle in accordance with the wire diameter of the coil. In order to form an insulator by re-creating a mold, it has been a factor of cost increase.

The present invention has been made in view of the foregoing, and an object thereof is to provide an insulator capable of aligning wound coils even when the wire diameter of the coil is changed.

In order to achieve the above object, in the insulator according to the present invention, the surface of the coil winding portion on which the winding start portion of the coil is wound is subjected to surface treatment, and radial movement of the wound winding is performed. To regulate.

Specifically, the insulator according to the present invention covers the axial end face of the tooth protruding from the core segment and at least a part of both circumferential side surfaces, and coil winding in which a coil constituted by a winding is wound. And a first ridge portion having a coil introduction groove continuously provided on one of the tooth base end side and the tooth tip end side of the coil winding portion and guiding the coil to the coil winding portion. In the insulator, a movement restricting portion composed of a concavo-convex portion that restricts the radial movement of the winding is provided on the surface of the coil winding portion near the first ridge portion, The average length of the concavo-convex portion is shorter than the wire diameter of the coil, and the arithmetic average roughness of the concavo-convex portion is larger than the arithmetic average roughness of the surfaces other than the movement restricting portion in the coil winding portion. .

According to this configuration, it is possible to restrict the movement of the winding start portion of the coil to the radially outer side or the inner side of the insulator and to align the coil with the winding wound around the movement restricting portion as a position reference . In addition, by appropriately selecting the width of the movement restricting portion and the arithmetic average roughness of the uneven portion, the aligned winding coil can be realized even when coils having different wire diameters are wound around the insulator.

The movement restricting portion is provided at a portion of half or more of a wire diameter of the coil and 1/3 or less of a radial length of the coil winding portion in a radially inward direction from the first collar portion. Is preferred.

According to this configuration, the movement of the winding wound around the movement restricting portion can be surely restricted.

Moreover, it is preferable that the arithmetic mean roughness of the said uneven part comprised to the said movement control part is 10 micrometers or more and 100 micrometers or less.

The uneven portion provided in the movement restricting portion may be formed by blasting the surface of the coil winding portion. The uneven portion may be formed by aluminum spraying on the surface of the coil winding portion, or the uneven portion may be formed by etching on the surface of the coil wound portion.

According to these configurations, the uneven portion can be formed by a simple method, and an increase in the manufacturing cost of the insulator can be suppressed.

Movement of the winding wound around the movement restricting portion is restricted radially outward or inward, and at the time of winding of the coil, from the last circumference of the first layer of the coil to other than the movement restricting portion It is preferable that the first layer of the coil is aligned and wound by the winding wound around the coil winding portion being pushed radially outward and moved.

According to this configuration, the winding wound around other than the movement restricting portion is moved inward in the radial direction sequentially so that the gap between the windings is eliminated by contacting the winding wound around the movement restricting portion. Then, the first layer coil can be aligned and wound around the coil winding portion.

In the stator according to the present invention, the insulator is provided on each of axial end faces of the teeth of the core segment, and a stator segment formed by winding a coil formed of a winding around the coil winding portion of the insulator A plurality of the stator segments are connected in an annular shape, and the teeth project radially inward of the annular ring.

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

It is preferable that the coil is aligned and wound around the coil winding portion.

A space between the teeth adjacent in the circumferential direction is configured as a slot for accommodating the coil, and an insulating paper for insulating the core segment and the tooth from the coil is covered in the slot so as to cover the side surface of the tooth And, it is disposed so as to partially overlap in an axial direction with a second ridge portion continuously provided on the other of the first ridge portion of the insulator and the other of the tooth base end side or the tooth tip side of the coil winding portion Is preferred.

According to this configuration, electrical insulation can be reliably made between the teeth adjacent in the circumferential direction of the stator.

The motor according to the present invention comprises the insulator at each axial end face of the tooth of the core segment, and a plurality of stator segments in which the coil is wound around the coil winding portion of the insulator, A stator including a plurality of stator segments connected in an annular shape, and including a structure in which the tooth protrudes inward in the radial direction of the annular ring, and arranged radially inward of the stator at a predetermined distance from the stator And at least a rotor including the rotating shaft.

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

As described above, according to the present invention, even when coils having different wire diameters are wound, occurrence of winding disorder can be suppressed, and an aligned winding coil can be realized.

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

Hereinafter, embodiments of the present invention will be described in detail based on the drawings. The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its applications or its uses.

(Embodiment)
[Configuration of motor and stator]
1 shows a top view showing a motor according to this embodiment, FIG. 2 shows an equivalent circuit diagram of the motor shown in FIG. 1, FIG. 3 shows a schematic diagram of a stator, and the stator 4 is a shaft 2 The figure seen from the axial direction is shown. Note that, for convenience of explanation, in FIGS. 1 and 3, illustration and description of some components and their functions are omitted. For example, the frame and the bus bar are not shown. Further, in FIG. 3, the insulator 5 is not shown. Moreover, the exterior body which accommodates the stator 4 is not shown in figure. The shape of the exterior body is, for example, a cylinder made of metal, a substantially rectangular parallelepiped, a substantially rectangular parallelepiped, a polygonal columnar body or the like, and is appropriately selected according to the specification of the motor 1. The components shown in the drawings are also simplified. For example, the insulator 5 shown in FIG. 1 is partially different from the actual shape, and the coils U1 to W4 and their lead terminals 71 shown in FIG. The shape of the is very different. Further, in FIG. 2, the symbol + indicates the winding start of the coil, and the symbol − indicates the winding end of the coil.

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

In addition, the lamination direction of the magnetic steel sheets to be described later and the above axial direction are the same direction and are synonymous.

In the following description, the term teeth (plural type of teeth) or tooth will be used selectively. The plurality of teeth projecting in the center direction of the annular stator core is referred to as teeth (a plurality of teeth). Further, among the plurality of teeth of the stator core 40, one tooth is described as a tooth 42. Similarly, a plurality of teeth in the core segment 41 described later is referred to as teeth. Further, one tooth portion of the plurality of tooth portions in the core segment 41 is described as a tooth 42. Incidentally, the above-mentioned Patent Document 3 and Patent Document 4 etc. are known documents in which usage of the words "tooth" and "tooth" is described.

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

The rotor 3 includes a shaft 2 and magnets 31 in which N poles and S poles are alternately disposed along the outer peripheral direction of the shaft 2 so as to face the stator 4. In the present embodiment, a neodymium magnet is used as the magnet 31 used for the rotor 3. However, the material, shape, and material of the neodymium magnet can be appropriately changed according to the output of the motor. Further, when viewed from the axial direction, the rotor 3 is disposed radially inward of the stator 4 at a constant distance from the stator 4.

The stator 4 is a cylindrical body configured by connecting a plurality of stator segments 40a in an annular shape. In the stator segment 40a, the insulators 5 are respectively attached to the teeth 42 of the core segment 41 from the upper and lower end faces in the axial direction, and an insulator such as insulating paper 6 is attached between the insulators 5 Windings are wound around the coil winding portion 50 and the arrangement portion of the insulator such as the insulating paper 6 (see FIGS. 4A to 4C) to constitute, for example, the coil U1. The external appearance of the stator segment 40a configured as described above is a columnar body having a substantially sectoral cross-sectional shape.

The stator 4 and the stator segment 40 a have a plurality of core segments 41 and teeth 42 projecting radially inward from the inner circumferences of the core segments 41. The core segment 41 is formed by punching a magnetic steel sheet containing silicon or the like as a core segment sheet which forms a part of a substantially annular stator core sheet. It is a layered product which laminated this board (core segment sheet) in multiple layers. The appearance of the core segment 41 configured as described above is a columnar body having a cross-sectional shape that is a piece-like shape that constitutes a part of a substantially annular stator core sheet. The stacking direction of the plate is a normal direction to the plate surface of the plate. The core segment 41 has a yoke portion 41c and a tooth 42 projecting from a substantially central portion of the yoke portion 41c.

The core segment 41 has a recess 41a formed on one side of the yoke portion 41c located in the circumferential direction, and a protrusion 41b formed on the other side. Both the recess 41a and the protrusion 41b have an axis in each side. It is formed extending in the entire direction. Focusing on one core segment 41, the convex portion 41b of the core segment 41 adjacent in the circumferential direction fits into the concave portion 41a of the core segment 41, and the convex portion 41b of the core segment 41 extends in the circumferential direction. On the other hand, they are fitted and connected to the recesses 41 a of the adjacent core segments 41. The annularly shaped stator core 40 is configured by the core segments 41 adjacent in the circumferential direction being fitted and connected as described above.

As shown in FIGS. 1 and 3, by connecting the core segments 41 to constitute the annular stator core 40, the teeth 42 are arranged at equal intervals along the inner periphery of the stator core 40. Moreover, each space | interval of the tooth 42 adjacent to the circumferential direction comprises the slot 43. As shown in FIG.

In addition, the stator 4 has 12 coils U1 to W4. These coils are attached to each tooth 42 through the insulator 5 and the insulating paper 6 (see FIGS. 4A to 4C). As viewed from the direction, they are disposed in each slot 43. Although not shown, the coils U1 to W4 are each composed of a winding having a circular cross section made of a metal material such as copper with an insulating film applied on the surface, and wound in parallel with the insulator 5 by multilayer winding. It is done. The multi-layer winding refers to a state in which the coil 7 is wound around the insulator 5 in a plurality of layers. Further, "circular" means "circular" including processing tolerance of the winding and deformation of the winding when wound around the tooth 42, and the same applies to the following description. Further, in the following description, when one of the coils U1 to W4 is taken up to describe a structure or the like without specifying the coil U1 to W4, the coil 7 is called.

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

In the present embodiment, the number of magnetic poles of the rotor 3 is ten in total: five N poles and five S poles facing the stator 4 and the number of slots 43 is twelve, but in particular The present invention is not limited to the above, and may be applied to other combinations of the number of magnetic poles and the number of slots.

[Configuration of main part of stator segment]
4A to 4C respectively show a perspective view of a portion surrounded by a broken line in FIG. 1, and a side view seen from the radial direction and the circumferential direction. Note that the illustration of the coil 7 is omitted in FIGS. 4A to 4C for the convenience of description. Further, the insulating paper 6 sandwiched and attached between the insulator 5 and the core segment 41 and the tooth 42 is also illustrated, but shows the state before being folded so as to be accommodated in the slot 43.

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

The insulator 5 is an insulating member formed by molding an insulating resin material, and a coil winding portion 50 on which the coil 7 (see FIG. 6) is wound and a first portion formed at one end of the coil winding portion 50. It has a collar 51 and a second collar 52 formed at the other end. In the present embodiment, the first collar 51 is mounted on the core segment 41 side, and the second collar 52 is mounted on the tip of the tooth 42 located radially inward of the stator 4. In addition, a coil introduction groove 53 (see FIGS. 5A and 5B) is formed in the first collar portion 51, and when the coil 7 is wound around the coil winding portion 50, the winding constituting the coil 7 is formed. The wire passes through the coil introduction groove 53, and the inner surface 51a of which the winding start portion faces the second ridge 52 in the first ridge 51 (hereinafter referred to as the inner surface 51a of the first ridge 51, see FIGS. 5A to 5C). It is guided to the coil winding part 50 in contact. The inner surface 51 a of the first flange portion 51 is a surface provided parallel to a surface orthogonal to the axial upper end surface or the axial lower end surface of the tooth 42. In the present specification, the winding start portion of the coil 7 refers to the vicinity of the first turn of the first layer coil wound around the coil winding portion 50 in the coil 7.

The movement restricting portion 54 extends radially inward from the root of the first collar portion 51 on the outer peripheral surfaces 50a to 50d of the coil winding portion 50 (hereinafter may be simply referred to as the surface of the coil winding portion 50). It is formed. As will be described later, in the movement restricting portion 54, the arithmetic average roughness Ra (see FIG. 5C) is larger than the surface of the coil winding portion 50 other than the movement restricting portion 54 (hereinafter referred to as the smooth surface portion 55). Surface treatment. In addition, coil winding unit 50 is, for example, 0. 0. to maintain electrical insulation between coil 7 and tooth 42. It is formed with a thickness of several mm to several mm.

Further, among the outer peripheral surfaces of the coil winding portion 50, surfaces 50c, 50d covering both circumferential end surfaces of the tooth 42 are formed to be orthogonal to the axial upper end surface of the tooth 42. The term “perpendicular” means “perpendicular” including the processing tolerance of the insulator 5, the processing tolerance of the tooth 42, and the assembly tolerance at the time of attaching the insulator 5 to the tooth 42. It means “parallel” including the processing tolerance of and the assembly tolerance at the time of attaching the insulator 5 to the tooth 42, and the same applies to the following description.

The insulator 5 has a function to electrically insulate the core segment 41 and the tooth 42 from the coil 7 together with the insulating paper 6. Further, the insulator 5 has a function of stably maintaining the alignment winding of the coil 7 described later.

The insulating paper 6 is impregnated with, for example, an insulating oil, so as to cover both side surfaces of the tooth 42 in the circumferential direction, and in the axial direction with the first and

second flange portions

51, 52 of the insulator 5, respectively. It is arranged so as to partially overlap. Further, although not shown, the insulating paper 6 is folded so as to cover the inside of the slot 43 when assembling the motor 1. As a result, the core segment 41 and the tooth 42 and the coil 7 can be electrically isolated from each other, and the core segment 41 and the tooth 42 adjacent in the circumferential direction can be electrically isolated.

[Configuration of main part of insulator]
FIG. 5A shows a perspective view of the main part of the insulator according to the present embodiment, FIG. 5B shows a schematic view of the main part of the insulator around which the coil is wound, viewed from the axial direction, and FIG. 5C shows FIG. The cross section schematic diagram in the VC-VC line in is shown. Although the insulator 5 shown in FIGS. 5A to 5C is the same as that shown in FIGS. 4A to 4C, the structure of the insulator 5 is simplified and shown in FIGS. 5A to 5C for the convenience of description.

As shown in FIGS. 5A to 5C, the surface of the coil winding portion 50 of the insulator 5 is radially inward from the root of the first flange 51, that is, the lower end in the axial direction of the inner surface 51a of the first flange 51. The movement restricting portion 54 is provided with a predetermined width W. As shown in FIG. 5C, the movement restricting portion 54 is composed of uneven portions 54a formed randomly, and the uneven portions 54a are formed such that the arithmetic average roughness Ra of the surface is 2 μm or more and 200 μm or less. On the other hand, the arithmetic mean roughness Ra ′ of the surface of the smooth surface portion 55 is smaller than the arithmetic mean roughness Ra of the concavo-convex portion 54a, and is about one to several hundredths of several tens of Ra. In, for example, Ra ′ is about 0.25 μm to 0.30 μm. Further, the average length L of the concavo-convex portion 54a is a value substantially equal to the arithmetic average roughness Ra, and the average length L is shorter than the wire diameter of the coil 7 wound around the coil winding portion 50. The uneven portion 54a is formed on the As shown in FIG. 5C, the average length L is, for example, the average value of the distance between the convex portion and the convex portion adjacent to the convex portion 54a, or the distance between the concave portion and the concave portion adjacent to the concave It corresponds to the average value of Moreover, it is common that the winding which comprises the coil 7 forms an insulating film in the surface of the electric wire which consists of copper etc. FIG. Therefore, the wire diameter of the coil 7 means the wire diameter including the thickness of the insulating film. In the present embodiment, the wire diameter of the wire used for the coil 7 is, for example, about 0.3 mm to 2.3 mm, and the wire diameter of the coil 7 is twice the thickness of the insulating film by the wire diameter of the wire. It will be the added value.

By performing surface treatment on the surface of the coil winding portion 50, the uneven portion 54a is formed. Various methods can be used as surface treatment. For example, the surface of the coil winding portion 50 is covered with a protective material (not shown) except for the portion where the movement restricting portion 54 is formed. The uneven portion 54a can be formed by blasting the surface not covered by the protective material. Arithmetic mean roughness Ra of the concavo-convex portion 54a can be set to a desired value by adjusting the average particle diameter, the spraying speed, the processing time, and the like of the abrasive to be sprayed. In addition, it is possible to form a concavo-convex portion 54 a by spraying particles obtained by melting and softening aluminum to the surface of the coil winding portion 50 not covered by the protective material. By performing the aluminum spraying process, the arithmetic average roughness Ra of the concavo-convex portion 54a can be made a relatively large value. For example, it is possible to set Ra to about several tens of μm to about 100 μm.

It is also possible to form the concavo-convex portion 54 a by performing an etching process on the surface of the comment winding portion 50. The "etching process" referred to here includes both so-called physical etching and chemical etching. As an example of physical etching, the uneven portion 54a can be formed by performing plasma etching using argon gas or the like on the surface of the coil winding portion 50 not covered with the protective material. Further, as an example of the chemical etching, the uneven portion 54a can be formed by performing an etching process using a chemical solution on the surface of the coil winding portion 50 which is not covered by the protective material. If the material of the insulator 5 is, for example, a polyamide-based resin, the unevenness 54 a can be formed by performing surface treatment using a chemical solution containing a strong acid such as concentrated hydrochloric acid or concentrated sulfuric acid. In addition, the formation method of the uneven | corrugated | grooved part 54a is not specifically limited to these methods, According to the value of desired Ra, the material of the insulator 5, etc., another method can be suitably taken. Further, it goes without saying that the protective material is removed after the surface treatment for forming the concavo-convex portion 54a is performed.

FIG. 6 is a schematic view of a process in which the coils are wound in alignment on the insulator according to the present embodiment. In addition, in FIG. 6, the process in which the 1st layer of the coil 7 is wound is shown.

As shown in FIG. 6A, when the winding of the coil 7 is wound around the movement restricting portion 54, the movement of the winding in the radial direction due to the friction generated with the movement restricting portion 54. Is regulated. As the winding process proceeds, as shown in FIG. 6B, the winding of the coil 7 is also wound around the smooth surface portion 55, and the winding process of the coil 7 is further advanced, 7 is wound to the last lap. In this winding process, as shown in FIG. 6C, the winding of the ith turn (i is an integer and 2 ≦ i ≦ n, n is the number of turns of the first layer of the coil 7) is i-1) Allowing the wire to run on the winding of the turn by a predetermined offset, and at the winding start portion of the coil 7, winding is performed by being inclined at a predetermined angle in the axial direction. In particular, when winding the n-th turn winding, the above procedure is performed. Thus, by winding the winding of the coil 7 around the coil winding portion 50, it is pushed out to the winding of the i-th turn, and is directed radially outward to the winding of the (i-1) -th turn Power is added. The offset is adjusted to be half or less of the wire diameter of the coil 7.

Here, since the arithmetic mean roughness Ra ′ of the smooth surface portion 55 is smaller than the arithmetic mean roughness Ra of the concavo-convex portion 54 a, friction generated between the winding and the smooth surface portion 55 is also restricted from the winding and the movement It is smaller than the friction generated with the part 54. That is, the smooth surface portion 55 has a smooth surface to the extent that the coil 7 can move in the radial direction along the surface when the wound winding receives an external force in the radial direction. Therefore, the winding on the smooth surface 55 pushed into the winding of the final circumference moves radially outward along the surface of the smooth surface 55, including the winding of the final circumference. At this time, as described above, the movement of the winding wound around the movement restricting portion 54 in the radial direction is restricted. Therefore, among the windings wound around the smooth surface portion 55, the winding positioned on the outermost side in the radial direction abuts against the winding wound around the movement restricting portion 54, and movement is restricted. Based on the contact position, the winding wound on the smooth surface portion 55 is sequentially moved so that the gap between the windings is eliminated, and the first layer coil 7 is aligned and wound on the coil winding portion 50. Ru.

After the final circumference of the coil 7 is wound, the coil 7 of the second layer is wound on the opposite side to the first layer, that is, from the second ridge 52 to the first ridge 51. In the case of single-layer winding, the winding of the final circumference is further pulled toward the first collar portion 51 in order to draw the winding to the outside. By the pulling force at this time, the winding wound around the smooth surface portion 55 is pushed radially outward from the winding of the final circumference. Also by these, the position of the winding of the first layer coil 7 is corrected so as to be aligned and wound. Further, when the radial length of the coil winding portion 50 is substantially equal to an integral multiple of the wire diameter of the coil 7, the winding of the final circumference abuts against the inner surface of the second flange portion 52 and the force is applied radially outward. Receive Also in this case, the position of the winding of the first layer coil 7 is corrected so as to be aligned and wound. In addition, since the winding wound on the smooth surface portion 55 radially moves outward in the radial direction in contact with the winding of the final circumference, alignment winding of the coil 7 becomes possible. As long as an external force is applied to the winding wound on the surface portion 55 radially outward, it is not necessary to wind the coil 7 with an offset as described above.

In order to restrict the movement of the winding of the coil 7, the predetermined width W of the movement restricting portion 54 may be half or more of the wire diameter of the coil 7 to be wound. However, in order to correspond to the coils 7 of different wire diameters, it is preferable to set the predetermined width W to about the maximum wire diameter or more of the coils 7 to be used. In addition, the predetermined width W is preferably set to 1/3 or less of the radial length of the coil winding portion 50. If the radial width of the movement restricting portion 54 is further increased, the winding distortion of the movement restricting portion 54 can not be neglected, and the aligned winding of the coil 7 can not be performed well. Therefore, the movement restricting portion 54 is provided at a portion of half or more of the wire diameter of the coil 7 and 1/3 or less of the radial length of the coil winding portion 50 in the radial direction from the first collar portion 51. Is preferred.

[Effects, etc.]
As described above, the insulator 5 according to the present embodiment covers the axial end surface of the tooth 42 projecting from the core segment 41 and a part of both side surfaces in the circumferential direction, and the coil 7 formed of a winding is wound. A coil winding portion 50, and a first ridge portion 51 having a coil introduction groove 53 continuously provided on the base end side of the tooth 42 in the coil winding portion 50 and guiding the coil 7 to the coil winding portion 50; And.

On the surface of the coil winding portion 50, a movement restricting portion 54 formed of an uneven portion 54a extending radially inward with a predetermined width W from the root of the first ridge portion 51 corresponding to the winding start portion of the coil 7 is formed The movement restricting portion 54 restricts the movement of the wound winding radially outward or inward. Further, on the surface of the coil winding portion 50, a smooth surface portion 55 having a smooth surface to the extent that the winding of the coil 7 can be moved along the radial direction continuously to the movement restricting portion 54 is provided.

Thus, when the coil 7 is wound, the position of the coil 7 pushed outward in the radial direction from the winding of the final circumference is restricted by the winding wound around the movement restricting portion 54, so that the coil 7 is coiled. Alignment winding is performed on the winding unit 50. Thus, the insulator 5 according to the present embodiment is useful when the single-layer or multi-layer coiled coil 7 is aligned.

Further, by appropriately selecting the width W of the movement restricting portion 54, it is possible to cope with the case where the wire diameter of the coil 7 to be wound is changed. For example, if the radial length of the coil winding portion 50 is about 10 mm to several tens mm, the wire diameter of the coil 7 used is 0 by setting the width W of the movement restricting portion 54 to about 3 mm. The coil 7 can be wound in alignment with the coil winding portion 50 even if it fluctuates in the range of 3 mm to 2.3 mm. Thus, even if the wire diameter of the coil 7 to be wound is changed, as disclosed in Patent Document 2, the width of the holding groove of the coil provided in the insulator is changed, or disclosed in Patent Document 1 As described above, it is not necessary to change the width of the step provided in the insulator or the angle of inclination, and it is possible to suppress an increase in the manufacturing cost of the insulator 5. Furthermore, since the movement restricting portion 54 can be formed by performing a simple surface treatment, the manufacturing cost of the insulator 5 can be suppressed. Moreover, even if the wire diameter of the coil 7 is changed with respect to the core segment 41 and the tooth 42 of the same specification, one type of insulator 5 can be coped with, and the development cost when developing various motors It can be reduced.

From the viewpoint of easily forming the concavo-convex portion 54a, the arithmetic average roughness Ra of the concavo-convex portion 54a is preferably 2 μm or more and 100 μm or less. Further, from the viewpoint of increasing the friction with the winding, the arithmetic mean roughness Ra of the concavo-convex portion 54a is preferably several tens of μm, for example, 30 μm or more, and taking account of ease of formation, arithmetic mean The roughness Ra is more preferably 30 μm or more and 100 μm or less.

Note that the insulator 5 according to the present embodiment covers an axial end surface of the tooth 42 projecting from the core segment 41 and a part of both side surfaces in the circumferential direction, and coil winding in which the coil 7 formed of a winding is wound. And a first ridge portion 51 having a coil introduction groove 53 continuously provided on the base end side of the tooth 42 in the coil winding portion 50 and guiding the coil 7 to the coil winding portion 50; A second collar 52 may be provided continuously on the tip side of the tooth 42 in the part 50.

Also in this case, on the surface of the coil winding portion 50 near the first flange portion 51, the movement restricting portion 54 formed of the uneven portion 54a that restricts the movement of the winding in the radial direction is provided. Further, the average length L of the concavo-convex portion 54 a is shorter than the wire diameter of the coil 7, and the arithmetic average roughness Ra of the concavo-convex portion 54 a is a smooth surface portion 55 which is a portion other than the movement restricting portion 54 in the coil winding portion 50. Greater than the arithmetic mean roughness Ra 'of the surface.

(Other embodiments)
In the above embodiment, an example in which the coil 7 is started from the first ridge 51 located on the core segment 41 side which is the base end side of the tooth 42 has been described, but it is not particularly limited thereto. You may start winding from the 2nd ridge 52 located. In this case, the coil introduction groove 53 is provided in the second ridge 52, and the movement restricting portion 54 is formed with a predetermined width W from the root of the second ridge 52.

Moreover, it does not specifically limit about the winding method of the coil 7, A general nozzle winding method, a flyer winding method, etc. can be used.

Moreover, although the insulator 5 is what is called a division type insulator and showed the example mounted | worn from the axial direction up-down direction of the tooth 42 respectively, it is not specifically limited to this, The coil winding part 50 is cylindrical shape, The integral structure which covers the whole outer peripheral surface of the tooth 42 may be sufficient. For example, when the stator 4 has a structure in which the tooth 42 is attached to the core segment 41 later, the insulator 5 having this integrated structure may be used. Moreover, the insulators 5 mounted from the upper and lower sides of one tooth may not have the same shape. In addition, the kind of insulator 5 can be decreased by using the thing of the same shape as the insulator 5 with which one tooth 42 is mounted | worn from the upper and lower sides, and manufacturing cost etc. can be reduced.

The outer

circumferential surfaces

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

In the above embodiment, the insulator 5 is mounted on the tooth 42 of the core segment 41, and the coil 7 is wound around the coil winding portion 50 to form the stator segment 40a. A mode may be adopted in which each of the teeth 42 of the stator core is mounted and the coil 7 is wound around the coil winding portion 50. In addition, the annular stator core said here is comprised laminating | stacking the board which pierce | punched the electromagnetic steel plate in annular shape. The annular stator core has a plurality of teeth (so-called teeth).

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

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

Further, as shown in FIG. 3, two concave grooves are provided at the tip (radially inner end) of the tooth 42. The concave grooves are also referred to as supplemental grooves in, for example, US Pat. No. 6,104,117 and Japanese Patent Application Laid-Open No. 10-42531. The effect of the auxiliary groove suppresses cogging torque and torque ripple in the rotational operation of the rotor 3 of the motor 1, and contributes to the reduction of vibration and noise in the characteristics of the motor.

Moreover, the winding in the said embodiment is also called an electric wire for winding, and is marketed. The conductor portion of the winding or the wire for winding includes copper or aluminum containing unavoidable impurities. Here, the unavoidable impurities mean a trace amount of impurity elements which can not be avoided to be mixed into copper and aluminum during the manufacturing process. In the case of copper, unavoidable impurities include As, Bi, Sb, Pb, Fe, S, oxygen and the like. In the case of aluminum, unavoidable impurities are Si, Mn, Ti, V, Zr, Fe, Cu and the like. The conductor portion of the winding is covered with an insulating layer of insulating resin. As the insulating resin, for example, a polyimide, a polyamideimide, a polyesterimide, a polyesteramide imide, a polyamide, a polyhydantoin, a polyurethane, a polyacetal, an epoxy resin and the like are appropriately selected according to the specification of the motor 1. In addition to the circular shape in the present embodiment, the cross-sectional shape of the winding may be various, such as approximately square or approximately rectangular.

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

The insulator according to the present invention can realize an aligned winding coil corresponding to a coil having a different wire diameter, and therefore is useful for application to a motor or the like that requires high efficiency.

Reference Signs List 1 motor 2 shaft 3 rotor 4 stator 5 insulator 6 insulating paper 7 coil 31 magnet 40 stator core 40 a stator segment 41 core segment 41 c yoke portion 42 tooth (tooth)
43 slot 50 coil winding portion 51 first ridge portion 51a inner surface of first ridge portion 51 second ridge portion 53 coil introduction groove 54 movement restricting portion 54a uneven portion 55 smooth surface portion U1 to W4 coil W movement restricting portion 54 Radial width

Claims

A coil winding portion covering an axial end face of the tooth protruding from the core segment and at least a part of both circumferential side surfaces and in which a coil constituted by a winding is wound; and a tooth base end of the coil winding portion An insulator provided continuously with one of a side and a tip end of the tooth and having a coil introduction groove for guiding the coil to the coil winding portion, the insulator comprising:
The surface of the coil winding portion near the first ridge portion is provided with a movement restricting portion composed of an uneven portion which restricts the movement of the winding in the radial direction,
The average length of the uneven portion is shorter than the wire diameter of the coil, and the arithmetic average roughness of the uneven portion is larger than the arithmetic average roughness of the surfaces other than the movement restricting portion in the coil winding portion. Insulator.
In the insulator according to claim 1,
The movement restricting portion is provided at a portion of half or more of a wire diameter of the coil and 1/3 or less of a radial length of the coil winding portion in a radially inward direction from the first collar portion. An insulator characterized by
In the insulator according to claim 1,
The insulator characterized in that the arithmetic average roughness of the uneven portion provided in the movement restricting portion is 10 μm or more and 100 μm or less.
In the insulator according to claim 1,
Movement of the winding wound around the movement restricting portion is restricted in the radial direction, and at the time of winding of the coil, the coil winding other than the movement restricting portion from the last circumference of the first layer of the coil An insulator characterized in that the first layer of the coil is aligned and wound by the winding wound around the winding portion being pushed radially outward and moved.
The insulator according to claim 1 is provided on each of axial end faces of the teeth of the core segment, and the coil winding portion of the insulator is provided with a plurality of stator segments formed by winding the coil.
A stator characterized in that a plurality of the stator segments are connected in an annular shape, and the teeth project radially inward of the annular ring.
The insulator according to claim 1 is provided on each of axial end faces of the teeth of the core segment, and the coil winding portion of the insulator is provided with a plurality of stator segments formed by winding the coil.
Including a configuration in which a plurality of the stator segments are connected in an annular shape, and the teeth project radially inward of the annular ring,
The stator is characterized in that the coils are wound in alignment around the coil winding portion.
The insulator according to claim 1 is provided on each of axial end faces of the teeth of the core segment, and the coil winding portion of the insulator is provided with a plurality of stator segments formed by winding the coil.
Including a configuration in which a plurality of the stator segments are connected in an annular shape, and the teeth project radially inward of the annular ring,
Between the teeth adjacent in the circumferential direction is configured as a slot for receiving the coil,
An insulating paper, which insulates the core segment and the tooth from the coil, covers the side surface of the tooth in the slot, and the first base of the insulator and the tooth base end of the coil winding part A stator characterized in that it is arranged to partially overlap in the axial direction with a second ridge portion provided continuously on the other side of the side or the tooth tip side.
The insulator according to claim 1 is provided on each of axial end faces of the tooth of the core segment, and a plurality of stator segments including the coil wound around the coil winding portion of the insulator are provided. A stator including a configuration in which a plurality of the stator segments are connected in an annular shape, and the teeth project radially inward of the annular ring;
A motor comprising at least a rotor including a rotating shaft disposed radially inward of the stator at a predetermined distance from the stator.