WO2022239097A1 - Stator, motor, blower, method for manufacturing stator, and method for manufacturing motor - Google Patents

Stator, motor, blower, method for manufacturing stator, and method for manufacturing motor Download PDF

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Publication number
WO2022239097A1
WO2022239097A1 PCT/JP2021/017811 JP2021017811W WO2022239097A1 WO 2022239097 A1 WO2022239097 A1 WO 2022239097A1 JP 2021017811 W JP2021017811 W JP 2021017811W WO 2022239097 A1 WO2022239097 A1 WO 2022239097A1
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WO
WIPO (PCT)
Prior art keywords
insulator
tooth
stator
teeth
core back
Prior art date
Application number
PCT/JP2021/017811
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French (fr)
Japanese (ja)
Inventor
正弥 後藤
Original Assignee
三菱電機株式会社
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
Application filed by 三菱電機株式会社 filed Critical 三菱電機株式会社
Priority to PCT/JP2021/017811 priority Critical patent/WO2022239097A1/en
Priority to JP2023520615A priority patent/JP7395061B2/en
Publication of WO2022239097A1 publication Critical patent/WO2022239097A1/en

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    • 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

Definitions

  • the present disclosure relates to a stator in which windings are wound around a stator core, an electric motor, an air blower, a method for manufacturing a stator, and a method for manufacturing an electric motor.
  • an inner rotor type electric motor in which a rotor is arranged on the inner circumference of a cylindrical stator.
  • the stator has a cylindrical core back, a plurality of teeth protruding from the inner peripheral surface of the core back and arranged in the circumferential direction of the core back, and slots formed between adjacent teeth.
  • a wire is wound around the teeth to form a coil.
  • a portion of the coil that protrudes in the central axis direction from the teeth as viewed along the direction orthogonal to the central axis of the core back is called a coil end.
  • Patent Document 1 As a method of forming a coil on a tooth, there is a method of inserting a coil formed in an annular shape in advance into the tooth. However, in such a method, since it is necessary to form the coil with a size that has a margin, there is a problem that the coil end becomes large. Therefore, in Patent Document 1, the core back and the teeth are formed separately, the windings are inserted into the slots from the slot openings of the slots, and the windings are inserted into the plurality of teeth arranged in the circumferential direction. A technique for miniaturizing the coil end by directly winding the coil and then assembling the core back and the tooth portion is disclosed.
  • the present disclosure has been made in view of the above.
  • the purpose is to obtain a stator.
  • a stator includes a cylindrical core back and a plurality of core backs arranged in the circumferential direction so as to protrude from the inner peripheral surface of the core back. a tooth portion, a plurality of insulators covering the plurality of tooth portions, respectively, and a coil formed by winding a wire around the tooth portion via the insulator.
  • a slot is formed between adjacent teeth.
  • the core back and the plurality of teeth are separated.
  • the insulator includes a first insulator covering one end portion of the tooth portion along the central axis of the core back, a second insulator covering the other end portion of the tooth portion along the central axis, and a core of the tooth portion. and a third insulator that covers a portion outside the center of the tooth portion along the radial direction of the bag. The third insulator is formed with a coil guard portion protruding into the slot.
  • FIG. 1 is an exploded perspective view of the electric motor according to Embodiment 1.
  • FIG. A perspective view of the stator core in Embodiment 1 Perspective view of core back in Embodiment 1
  • FIG. 3 is a perspective view showing a state in which a plurality of teeth are arranged radially according to Embodiment 1;
  • 4 is an exploded perspective view showing a state before the tooth portion is covered with the insulator in Embodiment 1.
  • FIG. FIG. 4 is a perspective view showing a state in which the teeth are covered with an insulator in the first embodiment;
  • FIG. 4 is a perspective view showing a state in which a plurality of tooth portions are covered with a plurality of insulators in Embodiment 1;
  • FIG. 4 is a diagram showing a state in which a plurality of tooth portions are covered with a plurality of insulators in Embodiment 1, and is a diagram viewed along the axial direction; A view of the third insulator viewed along the circumferential direction.
  • FIG. 9 is an axial view showing a state in which coils are being formed on the plurality of teeth shown in FIG. 8;
  • FIG. 9 is a view showing a state in which coils are formed on a plurality of teeth shown in FIG.
  • FIG. 4 is a cross-sectional view showing the method of manufacturing the stator, showing the first assembly step;
  • FIG. 4 is a cross-sectional view showing the method of manufacturing the stator, showing the arrangement process;
  • FIG. 4 is a cross-sectional view showing the method of manufacturing the stator, showing the winding process;
  • FIG. 10 is a cross-sectional view showing the method of manufacturing the stator, showing a second assembly step;
  • FIG. 10 is a cross-sectional view showing the method of manufacturing the stator, showing a second assembly step;
  • FIG. 10 is a cross-sectional view showing the method of manufacturing the stator, showing a second assembly step;
  • FIG. 10 is a cross-sectional view showing the method of manufacturing the stator, showing a second assembly step;
  • FIG. 10 is a cross-sectional view showing the method of manufacturing the stator, showing a second assembly step;
  • FIG. 10 is a cross-sectional view showing the method of manufacturing the stator, showing a second assembly step;
  • FIG. 10 is a cross-sectional view showing the method of manufacturing the stator, showing a second assembly step;
  • FIG. 10 is a cross-sectional view showing the method of manufacturing the stator, showing a second assembly step;
  • FIG. 10 is a cross-sectional view showing the method of manufacturing the stator, showing a second assembly step;
  • FIG. 10 is a cross-sectional view showing the method of manufacturing the stator, showing a second assembly step;
  • stator The stator, the electric motor, the air blower, the method for manufacturing the stator, and the method for manufacturing the electric motor according to the embodiment will be described in detail below with reference to the drawings.
  • FIG. 1 is an exploded perspective view of the electric motor 1 according to the first embodiment.
  • the electric motor 1 comprises a stator 2 , a rotor 3 , a shaft portion 4 , two bearings 5 and two shells 6 and 7 .
  • a core back 9 of the stator 2, which will be described later, is formed in a cylindrical shape having a central axis C.
  • the direction parallel to the central axis C is defined as the axial direction
  • the direction perpendicular to the central axis C is defined as the radial direction
  • the direction of rotation about the central axis C is defined as the circumferential direction. do.
  • the inner circumference and the outer circumference refer to the inner circumference and the outer circumference of the cylindrical core back 9 .
  • the electric motor 1 is an inner rotor type electric motor in which a rotor 3 is arranged inside a cylindrical stator 2 .
  • the rotor 3 is provided with a shaft portion 4 extending along the central axis C of the stator 2 .
  • the shaft portion 4 is rotatably supported by two bearings 5 .
  • the bearing 5 is supported by the outer shell 6 and the outer shell 7 .
  • the outer shell 6 and the outer shell 7 form a casing that accommodates the stator 2, the rotor 3, and the bearing 5 inside.
  • the stator 2 includes a stator core 8 and coils 17 formed by winding windings 16 around the stator core 8 .
  • FIG. 2 is a perspective view of the stator core 8 according to Embodiment 1.
  • the stator core 8 has a cylindrical core back 9 and a plurality of teeth 10 protruding radially inward from the inner peripheral surface of the core back 9 and arranged radially.
  • the core back 9 and the teeth 10 are formed by laminating a plurality of electromagnetic steel sheets along the central axis C.
  • Slots 11 are formed between adjacent teeth 10 . Although the number of slots 11 is eight in this embodiment, it may be other than eight.
  • FIG. 3 is a perspective view of the core back 9 according to Embodiment 1.
  • FIG. FIG. 4 is a perspective view showing a state in which a plurality of teeth 10 are arranged radially according to the first embodiment.
  • the stator core 8 is divided into core backs 9 and tooth portions 10 .
  • the core back 9 and the teeth 10 are formed separately.
  • the inner peripheral surface of the core back 9 is formed with grooves 9a into which the radially outer ends of the tooth portions 10 are fitted.
  • FIG. 5 is an exploded perspective view showing a state before the tooth portion 10 is covered with the insulator 12 in the first embodiment.
  • FIG. 6 is a perspective view showing a state where tooth portion 10 is covered with insulator 12 in the first embodiment.
  • Insulator 12 covers tooth portion 10 to electrically insulate tooth portion 10 from coil 17 shown in FIG.
  • the insulator 12 is made of an electrically insulating material.
  • the electrically insulating material is, for example, resin.
  • insulator 12 is divided into first insulator 13 , second insulator 14 and third insulator 15 .
  • the first insulator 13 covers one end of the tooth portion 10 along the central axis C.
  • the first insulator 13 has a first covering wall 13a and a first stopper portion 13b.
  • the first covering wall 13 a is a portion that covers one axial end surface of the tooth portion 10 and both circumferential side surfaces of the tooth portion 10 .
  • the first cover wall 13 a opens radially inward and outward and opens toward the tooth portion 10 .
  • the first stopper portion 13b serves to prevent the coil 17 from protruding radially inward.
  • the first stopper portion 13b extends axially away from the tooth portion 10 from the radially inner end of the first covering wall 13a.
  • the second insulator 14 covers the other end of the tooth portion 10 along the central axis C.
  • the second insulator 14 has a second covering wall 14a and a second stopper portion 14b.
  • the second covering wall 14 a is a portion that covers the other axial end surface of the tooth portion 10 and both circumferential side surfaces of the tooth portion 10 .
  • the second covering wall 14a is open radially inwardly and outwardly and is open toward the tooth portion 10.
  • the second stopper portion 14b serves to prevent the coil 17 from protruding radially inward.
  • the second stopper portion 14b extends in the direction away from the tooth portion 10 along the axial direction from the radially inner end portion of the second covering wall 14a.
  • the third insulator 15 covers a portion of the tooth portion 10 outside the center of the tooth portion 10 along the radial direction.
  • the third insulator 15 has a third covering wall 15a and a third stopper portion 15b.
  • the third covering wall 15a is a rectangular tubular portion that covers both axial end surfaces of the tooth portion 10 and both circumferential side surfaces of the tooth portion 10 .
  • the third covering wall 15a is open radially inwardly and outwardly. That is, the third covering wall 15a is a cylindrical wall that opens radially.
  • the third stopper portion 15b serves to prevent the coil 17 from protruding radially outward.
  • the third stopper portion 15b extends axially and circumferentially.
  • a rectangular opening 15c that is longer in the axial direction than in the circumferential direction is formed in the central portion of the third stopper portion 15b in the circumferential direction.
  • the third covering wall 15a protrudes radially inward from the peripheral edge of the opening 15c.
  • FIG. 7 is a perspective view showing a state in which a plurality of tooth portions 10 are covered with a plurality of insulators 12 in Embodiment 1.
  • FIG. FIG. 8 is a diagram showing a state in which a plurality of tooth portions 10 are covered with a plurality of insulators 12 in Embodiment 1, and is a diagram viewed along the axial direction. 7 and 8, illustration of the third insulator 15 is omitted.
  • each of the multiple teeth 10 is covered with an insulator 12 .
  • One insulator 12 is provided for each tooth portion 10 . Both radial side surfaces of each tooth portion 10 are exposed without being covered with the insulator 12 .
  • the same number of first insulators 13 , second insulators 14 and third insulators 15 as the number of teeth 10 are provided.
  • the number of insulators 12 is appropriately increased or decreased according to the number of teeth 10 .
  • FIG. 9 is a view of the third insulator 15 viewed along the circumferential direction.
  • the radially inner opening edge of the third covering wall 15a of the third insulator 15 is inclined radially inward.
  • the radially inner opening edge of the third covering wall 15a is inclined so as to be positioned radially inward from one axial end to the other axial end.
  • the radial length of the third covering wall 15a increases from one axial end to the other axial end.
  • FIG. 10 is a diagram of the third insulator 15 viewed along the axial direction. As shown in FIG. 10, three types of third insulators 15 having different shapes of ends in the circumferential direction are used as the third insulators 15 . In the following description, when distinguishing between the three types of third insulators 15, they are referred to as third insulator 15A, third insulator 15B, and third insulator 15C.
  • a portion of the third stopper portion 15b of each of the third insulators 15A, 15B, 15C that protrudes into the slot 11 serves as a coil guard portion 15d that closes the slot opening of the slot 11.
  • Two coil guard portions 15d are formed in each of the third insulators 15A, 15B, 15C.
  • a curved stepped portion 15e is formed at the distal end portion in the circumferential direction of one coil guard portion 15d so as to be positioned more radially inward than the other portion, and the other coil guard portion 15d is formed at the distal end portion in the circumferential direction. are formed in a curved shape located on the same circumference.
  • a curved stepped portion 15e is formed at each circumferential tip of each of the two coil guard portions 15d so as to be positioned more radially inward than the other portions.
  • each of the two coil guard portions 15d is formed in a curved shape located on the same circumference.
  • the stepped portion 15e bends radially inward and extends in the radial direction, then bends toward the adjacent tooth portion 10 and extends in the circumferential direction.
  • a portion of the third insulator 15A and the third insulator 15B excluding the stepped portion 15e and the third insulator 15C are arranged so as to be positioned on the same circumference.
  • a coil guard portion 15 d is arranged in each slot 11 so as to protrude from each of the two third insulators 15 adjacent to the slot 11 .
  • One of the coil guard portions 15d arranged in the same slot 11 has a stepped portion 15e that is bent radially inward of the other circumferential tip portion. ing.
  • the stepped portion 15e of one of the two coil guard portions 15d and the distal end portion of the other in the circumferential direction are arranged so as to overlap in the radial direction.
  • a distal end portion of the coil guard portion 15 d in the circumferential direction is a portion located at the distal end of the third insulator 15 as a whole in the circumferential direction.
  • the circumferential tip portion of the coil guard portion 15 d may also be referred to as one end portion or the other end portion of the third insulator 15 .
  • FIG. 11 is a diagram showing a state in which the coils 17 are being formed on the plurality of tooth portions 10 shown in FIG. 8, and is a diagram viewed along the axial direction.
  • FIG. 12 is a diagram showing a state in which the coils 17 are formed on the plurality of tooth portions 10 shown in FIG. 8, viewed along the axial direction.
  • FIG. 13 is a perspective view of the stator 2 according to Embodiment 1.
  • a coil 17 is formed by winding a wire 16 around the tooth portion 10 via an insulator 12 .
  • FIG. 14 is a cross-sectional view of the stator 2 according to the first embodiment cut in a direction orthogonal to the central axis C.
  • FIG. 14 a case of manufacturing a stator 2 having eight teeth 10 shown in FIG. 14 will be described, but the number of teeth 10 is not limited.
  • the tooth portion 10A when distinguishing the eight tooth portions 10, the tooth portion 10 located at the upper side and the center of the paper surface among the tooth portions 10 in each figure is designated as the tooth portion 10A, and the tooth portions 10A and 10A are arranged in counterclockwise order. 10B, 10C, 10D, 10E, 10F, 10G, and 10H.
  • the manufacturing method of the stator 2 includes a first assembly process, an arrangement process, a winding process, a second assembly process, and a third assembly process.
  • FIG. 15 is a cross-sectional view of the tooth portion 10.
  • FIG. FIG. 16 is a cross-sectional view of the first insulator 13 and the second insulator 14.
  • FIG. 17 is a cross-sectional view showing the method of manufacturing the stator 2, showing the first assembly step. Since the cross-sectional shapes of the first insulator 13 and the second insulator 14 are the same, the reference numerals of the first insulator 13 and the second insulator 14 are also used in cross-sectional views such as FIGS. there is
  • the first assembling step is a step of assembling the first insulator 13 and the second insulator 14 to each of the plurality of tooth portions 10 . In the first assembly step, as shown in FIG. 5, the first insulator 13 and the second insulator 14 are fitted into the tooth portion 10 from both sides in the axial direction of the tooth portion 10 . By performing the first assembling step, as shown in FIG. It is covered with insulator 14 .
  • FIG. 18 is a cross-sectional view showing the manufacturing method of the stator 2, showing the arrangement process.
  • the arranging step is a step of arranging the plurality of tooth portions 10 covered with the first insulator 13 and the second insulator 14 side by side in the circumferential direction.
  • a plurality of teeth 10 are arranged radially and fixed immovably with a jig (not shown).
  • a cylindrical space for inserting the rotor 3 shown in FIG. 1 is formed in the inner periphery of the plurality of teeth 10 .
  • FIG. 19 is a cross-sectional view showing the manufacturing method of the stator 2, showing the winding process.
  • the winding step is a step of forming a coil 17 by winding the wire 16 around the tooth portion 10 via the first insulator 13 and the second insulator 14 .
  • the winding 16 is started from the radially outer side of the tooth 10 .
  • the winding method may be appropriately selected from known winding methods.
  • the winding 16 may be wound around the tooth portion 10 in a winding method as shown in FIGS. 11 and 12 .
  • Coils 17 are also arranged in slots 11 formed between adjacent teeth 10 .
  • FIG. 20 is a cross-sectional view of the third insulator 15A.
  • FIG. 21 is a cross-sectional view of the third insulator 15B.
  • FIG. 22 is a cross-sectional view of the third insulator 15C.
  • the second assembling step is a step of assembling the third insulator 15 from the radially outer side to each of the plurality of tooth portions 10 shown in FIG. 19 .
  • a portion of tooth portion 10 radially outside the center of tooth portion 10 is fitted into opening 15 c of third insulator 15 .
  • a part of the tooth portion 10 covered with the first insulator 13 and the second insulator 14 is fitted into the opening 15 c of the third insulator 15 .
  • FIG. 23 is a cross-sectional view showing the manufacturing method of the stator 2, showing the second assembly process.
  • FIG. 24 is a cross-sectional view showing the method of manufacturing the stator 2, showing the second assembly step.
  • FIG. 25 is a cross-sectional view showing the method of manufacturing the stator 2, showing the second assembling step.
  • FIG. 26 is a cross-sectional view showing the method of manufacturing the stator 2, showing the second assembling step.
  • a third insulator 15B having stepped portions 15e formed at both ends in the circumferential direction is assembled to the tooth portion 10A.
  • a third insulator 15A having a stepped portion 15e formed at one end in the circumferential direction is assembled to the adjacent tooth portion 10B positioned counterclockwise to the tooth portion 10A.
  • the other circumferential end portion of the third insulator 15A where the stepped portion 15e is not formed is radially outside the stepped portion 15e of the previously assembled third insulator 15B located counterclockwise.
  • the third insulator 15A is assembled counterclockwise in order of the tooth portion 10C, the tooth portion 10D, the tooth portion 10E, the tooth portion 10F, and the tooth portion 10G.
  • the stepped portion 15e of one adjacent third insulator 15A is located radially inside the other third insulator 15A.
  • the third insulator 15C in which the stepped portions 15e are not formed at both ends in the circumferential direction, is assembled to the tooth portion 10H.
  • one end portion in the circumferential direction of the third insulator 15C is overlapped radially outside of the stepped portion 15e of the previously assembled third insulator 15A positioned counterclockwise.
  • the other circumferential end of the third insulator 15C is overlapped radially outward of the clockwise stepped portion 15e of the previously assembled third insulator 15B.
  • FIG. 27 is a plan view of the core back 9.
  • the third assembling step is a step of assembling the core back 9 shown in FIG. 27 to each of the plurality of tooth portions 10 shown in FIG. 26 .
  • one tooth portion 10 is fitted into each of the plurality of grooves 9 a formed in the inner peripheral surface of the core back 9 .
  • a portion of the tooth portion 10 exposed from the third insulator 15 is fitted into the groove 9a.
  • the rotor 3 shown in FIG. 1 is inserted into the inner circumference of the stator 2 shown in FIG. 14, and the bearing 5 and outer shells 6 and 7 are assembled to complete the electric motor 1.
  • the core back 9 and the plurality of tooth portions 10 are separated.
  • the insulator 12 includes a first insulator 13 covering one end portion of the tooth portion 10 along the central axis C of the core back 9 and a tooth portion A second insulator 14 covering the other end portion of the tooth portion 10 along the central axis C, and a third insulator 15 covering a portion outside the center of the tooth portion 10 along the radial direction of the tooth portion 10 .
  • the third insulator 15 is formed with a coil guard portion 15 d projecting into the slot 11 .
  • the coil 17 is less likely to protrude out of the slot 11. ⁇ In particular, by assembling the third insulator 15 to the coil 17 from the outside in the radial direction after forming the coil 17, the coil 17 can be pushed back into the slot 11, so that the coil 17 can be further pushed out of the slot 11. It becomes difficult to stick out.
  • each slot 11 is provided with a coil guard portion 15d projecting from each of the two third insulators 15 adjacent to the slot 11.
  • one of the two coil guard portions 15d arranged in the same slot 11 has a stepped portion 15e bent so as to be positioned radially inside the other coil guard portion 15d. is formed.
  • the third insulator 15 has a cylindrical third covering wall 15a that opens radially.
  • the inner opening edge slopes radially inward. This makes it easier to assemble the third covering wall 15 a of the third insulator 15 to the tooth portion 10 .
  • FIG. 28 is a cross-sectional view of the stator 2A according to the second embodiment taken in a direction perpendicular to the central axis C.
  • FIG. 29 is a cross-sectional view showing the manufacturing method of the stator 2A, showing the second assembling step.
  • FIG. 30 is a sectional view showing the manufacturing method of the stator 2A, showing the second assembling step.
  • FIG. 31 is a cross-sectional view showing the manufacturing method of the stator 2A, showing the second assembling step.
  • This embodiment differs from the first embodiment described above in the ratio and arrangement of the three types of third insulators 15A, 15B, and 15C.
  • symbol is attached
  • the manufacturing method of the stator 2A includes a first assembly process, an arrangement process, a winding process, a second assembly process, and a third assembly process. Since the first assembling process, the arranging process, the winding process and the third assembling process are the same as those in the first embodiment, description thereof will be omitted and only the second assembling process will be described.
  • the third insulators 15B having stepped portions 15e formed at both ends in the circumferential direction are placed at symmetrical positions with respect to the central axis C, that is, 180 degrees apart from each other with respect to the central axis C. are assembled to the teeth 10A and 10E arranged at the positions where
  • a third insulator 15A having a stepped portion 15e formed only at one end in the circumferential direction is attached to a tooth portion 10B and a tooth portion 10C adjacent to the tooth portion 10A counterclockwise. , and to the teeth 10F and 10G adjacent to the tooth 10E in the counterclockwise direction.
  • the other circumferential end portion of the third insulator 15A where the stepped portion 15e is not formed is aligned with the counterclockwise stepped portion 15e of the previously assembled third insulator 15B. It overlaps radially outside of the portion 15e or the stepped portion 15e of the previously assembled third insulator 15A.
  • the tooth portion 10B and the tooth portion 10F are arranged at symmetrical positions with the central axis C interposed therebetween.
  • the tooth portion 10C and the tooth portion 10G are arranged at symmetrical positions with the central axis C interposed therebetween.
  • the third insulator 15C in which the stepped portions 15e are not formed at both ends in the circumferential direction, is attached to the tooth portion 10D and the tooth portion 10D arranged at symmetrical positions with respect to the central axis C. 10H, respectively.
  • one end portion in the circumferential direction of the third insulator 15C is superimposed on the radially outer side of the stepped portion 15e of the previously assembled third insulator 15A.
  • the other circumferential end of the third insulator 15C is superimposed on the radially outer side of the clockwise stepped portion 15e of the previously assembled third insulator 15B.
  • the third insulator 15 is assembled to each tooth portion 10 arranged symmetrically with respect to the central axis C, the parts of the stator 2A that are symmetrical with respect to the central axis C are The third insulator 15 can be attached to the tooth portion 10 while applying a uniform force.
  • FIG. 32 is a cross-sectional view of the stator 2B according to the third embodiment taken in a direction orthogonal to the central axis C.
  • FIG. 33 is a cross-sectional view showing the method of manufacturing the stator 2B, showing the second assembling step.
  • FIG. 34 is a cross-sectional view showing the method of manufacturing the stator 2B, showing the second assembling step.
  • This embodiment differs from the first embodiment in that two types of third insulators 15B and 15C are used.
  • symbol is attached
  • the manufacturing method of the stator 2B includes a first assembly process, an arrangement process, a winding process, a second assembly process, and a third assembly process. Since the first assembling process, the arranging process, the winding process and the third assembling process are the same as those in the first embodiment, description thereof will be omitted and only the second assembling process will be described.
  • a third insulator 15B having stepped portions 15e formed at both ends in the circumferential direction is connected to a toothed portion 10A and a toothed portion 10A which are arranged at positions separated by 90 degrees around the central axis C. 10C, tooth portion 10E and tooth portion 10G are assembled respectively.
  • a third insulator 15C having no stepped portions 15e formed at both ends in the circumferential direction is combined with the tooth portion 10B arranged at a position separated by 90 degrees around the central axis C. They are attached to the tooth portion 10D, the tooth portion 10F, and the tooth portion 10H, respectively. That is, the third insulator 15C is arranged between two adjacent third insulators 15B. At this time, both ends of the third insulator 15C in the circumferential direction are superimposed on the radially outer side of the stepped portion 15e of the adjacent third insulator 15B.
  • the stator 2 can be manufactured using only two types of third insulators 15, the third insulator 15B and the third insulator 15C.
  • the method of assembling the third insulator 15 of the present embodiment can be used when the number of teeth 10 is even.
  • FIG. 35 is a front view of blower 18 according to the fourth embodiment.
  • symbol is attached
  • the electric motor 1 may be used for the blower 18 that connects the blades 19 to the shaft portion 4 and rotates the blades 19 to blow air.
  • the electric motor 1 may be used as a ventilation fan that rotates blades or impellers to flow air.

Abstract

A stator (2) comprises a core back (9), a plurality of teeth (10) placed in the circumferential direction of the core back (9), a plurality of insulators (12) covering the plurality of respective teeth (10), and coils (17), each being formed by winding a wire (16) around the tooth (10) via the insulator (12). A slot (11) is formed between the adjacent teeth (10). The core back (9) and the plurality of teeth (10) are separated. The insulator (12) is divided into a first insulator (13) covering one end of the tooth (10) along the central axis of the core back (9), a second insulator (14) covering the other end of the tooth (10) along the central axis, and a third insulator (15) covering the outer portion of the tooth (10) from the center of the tooth (10) along a radial direction. On the third insulator (15), a coil guard portion (15d) protruding to the inside of the slot (11) is formed.

Description

固定子、電動機、送風装置、固定子の製造方法および電動機の製造方法Stator, electric motor, blower, method for manufacturing stator, and method for manufacturing electric motor
　本開示は、固定子鉄心に巻線が巻き付けられた固定子、電動機、送風装置、固定子の製造方法および電動機の製造方法に関する。 The present disclosure relates to a stator in which windings are wound around a stator core, an electric motor, an air blower, a method for manufacturing a stator, and a method for manufacturing an electric motor.
　従来の電動機として、筒状の固定子の内周に回転子が配置されたインナーロータ型電動機が知られている。固定子は、筒状のコアバックと、コアバックの内周面から突出してコアバックの周方向に並べられた複数の歯部と、隣り合う歯部の間に形成されたスロットとを有する。歯部には、巻線が巻き付けられてコイルが形成される。コイルのうちコアバックの中心軸に直交する方向に沿って見て歯部から中心軸方向に突出する部分は、コイルエンドと呼ばれる。コイルに占めるコイルエンドの量が増えると、材料費の増加によりコストが増加するとともに、巻線が長くなることにより電気抵抗が増加して、電動機の効率が低下してしまう。 As a conventional electric motor, an inner rotor type electric motor is known in which a rotor is arranged on the inner circumference of a cylindrical stator. The stator has a cylindrical core back, a plurality of teeth protruding from the inner peripheral surface of the core back and arranged in the circumferential direction of the core back, and slots formed between adjacent teeth. A wire is wound around the teeth to form a coil. A portion of the coil that protrudes in the central axis direction from the teeth as viewed along the direction orthogonal to the central axis of the core back is called a coil end. When the amount of coil ends occupying the coil increases, the cost increases due to an increase in material costs, and the length of the windings increases the electrical resistance, which reduces the efficiency of the electric motor.
　歯部にコイルを形成する方法として、予め円環状に形成されたコイルを歯部に差し込む方法がある。しかし、このような方法では、余裕を持たせた大きさでコイルを形成する必要があるため、コイルエンドが大きくなるという問題がある。そこで、特許文献１には、コアバックと歯部とを分割して形成し、スロットのうちスロットオープンからスロット内に巻線を挿入して、周方向に並べた複数の歯部に巻線を直接巻き付けてから、コアバックと歯部とを組み付けることで、コイルエンドの小型化を図る技術が開示されている。また、特許文献１に開示された技術では、インシュレータのうちコアバックに対応する部分に周方向に延びるコイルガードを設けることにより、スロットオープンを狭めて、歯部に形成されたコイルをスロット外へはみ出しにくくしている。 As a method of forming a coil on a tooth, there is a method of inserting a coil formed in an annular shape in advance into the tooth. However, in such a method, since it is necessary to form the coil with a size that has a margin, there is a problem that the coil end becomes large. Therefore, in Patent Document 1, the core back and the teeth are formed separately, the windings are inserted into the slots from the slot openings of the slots, and the windings are inserted into the plurality of teeth arranged in the circumferential direction. A technique for miniaturizing the coil end by directly winding the coil and then assembling the core back and the tooth portion is disclosed. Further, in the technique disclosed in Patent Document 1, by providing a coil guard extending in the circumferential direction in a portion of the insulator corresponding to the core back, the slot opening is narrowed, and the coil formed in the tooth portion is pushed out of the slot. It is difficult to stick out.
特許第３１０２６６５号公報Japanese Patent No. 3102665
　しかしながら、特許文献１に開示された技術のように、スロットオープンを狭めると、スロット内に巻線を挿入しにくくなってしまう。そのため、巻線の巻き付け作業が行いにくくなり、歯部に巻線を効率良く巻き付けることができず、巻線が長くなることによるコストの増加、電動機の効率の低下といった問題が生じる可能性がある。 However, if the slot opening is narrowed as in the technique disclosed in Patent Document 1, it becomes difficult to insert the winding into the slot. As a result, it becomes difficult to wind the windings, and it is not possible to wind the windings around the teeth efficiently, which may lead to problems such as an increase in cost due to the longer windings and a decrease in the efficiency of the motor. .
　本開示は、上記に鑑みてなされたものであって、歯部への巻線の巻付時にスロット内に巻線を挿入しやすく、かつ、歯部に形成されたコイルがスロット外へはみ出しにくい固定子を得ることを目的とする。 The present disclosure has been made in view of the above. The purpose is to obtain a stator.
　上述した課題を解決し、目的を達成するために、本開示にかかる固定子は、筒状のコアバックと、コアバックの内周面から突出するようにコアバックの周方向に並べられた複数の歯部と、複数の歯部をそれぞれ覆う複数のインシュレータと、インシュレータを介して歯部に巻線が巻き付けられて形成されたコイルと、を備える。隣り合う歯部の間には、スロットが形成されている。コアバックと複数の歯部とは、分割されている。インシュレータは、歯部のうちコアバックの中心軸に沿った一端部を覆う第１のインシュレータと、歯部のうち中心軸に沿った他端部を覆う第２のインシュレータと、歯部のうちコアバックの半径方向に沿った歯部の中心より外側部分を覆う第３のインシュレータと、に分割されている。第３のインシュレータには、スロット内に向けて突出するコイルガード部が形成されている。 In order to solve the above-described problems and achieve an object, a stator according to the present disclosure includes a cylindrical core back and a plurality of core backs arranged in the circumferential direction so as to protrude from the inner peripheral surface of the core back. a tooth portion, a plurality of insulators covering the plurality of tooth portions, respectively, and a coil formed by winding a wire around the tooth portion via the insulator. A slot is formed between adjacent teeth. The core back and the plurality of teeth are separated. The insulator includes a first insulator covering one end portion of the tooth portion along the central axis of the core back, a second insulator covering the other end portion of the tooth portion along the central axis, and a core of the tooth portion. and a third insulator that covers a portion outside the center of the tooth portion along the radial direction of the bag. The third insulator is formed with a coil guard portion protruding into the slot.
　本開示によれば、歯部への巻線の巻付時にスロット内に巻線を挿入しやすく、かつ、歯部に形成されたコイルがスロット外へはみ出しにくいという効果を奏する。 According to the present disclosure, it is possible to easily insert the winding wire into the slot when winding the winding wire around the tooth portion, and to prevent the coil formed on the tooth portion from protruding out of the slot.
実施の形態１にかかる電動機の分解斜視図1 is an exploded perspective view of the electric motor according to Embodiment 1. FIG. 実施の形態１における固定子鉄心の斜視図A perspective view of the stator core in Embodiment 1 実施の形態１におけるコアバックの斜視図Perspective view of core back in Embodiment 1 実施の形態１における複数の歯部が放射状に並べられた状態を示した斜視図FIG. 3 is a perspective view showing a state in which a plurality of teeth are arranged radially according to Embodiment 1; 実施の形態１において歯部がインシュレータにより覆われる前の状態を示した分解斜視図4 is an exploded perspective view showing a state before the tooth portion is covered with the insulator in Embodiment 1. FIG. 実施の形態１において歯部がインシュレータにより覆われた状態を示した斜視図FIG. 4 is a perspective view showing a state in which the teeth are covered with an insulator in the first embodiment; 実施の形態１において複数の歯部が複数のインシュレータに覆われた状態を示した斜視図FIG. 4 is a perspective view showing a state in which a plurality of tooth portions are covered with a plurality of insulators in Embodiment 1; 実施の形態１において複数の歯部が複数のインシュレータに覆われた状態を示した図であって、軸方向に沿って見た図FIG. 4 is a diagram showing a state in which a plurality of tooth portions are covered with a plurality of insulators in Embodiment 1, and is a diagram viewed along the axial direction; 第３のインシュレータを周方向に沿って見た図A view of the third insulator viewed along the circumferential direction. 第３のインシュレータを軸方向に沿って見た図The figure which looked at the 3rd insulator along the axial direction 図８に示された複数の歯部にコイルが形成される途中の状態を示した図であって、軸方向に沿って見た図FIG. 9 is an axial view showing a state in which coils are being formed on the plurality of teeth shown in FIG. 8; 図８に示された複数の歯部にコイルが形成された状態を示した図であって、軸方向に沿って見た図FIG. 9 is a view showing a state in which coils are formed on a plurality of teeth shown in FIG. 8, viewed along the axial direction; 実施の形態１にかかる固定子の斜視図1 is a perspective view of a stator according to Embodiment 1 実施の形態１にかかる固定子を中心軸と直交する方向で切った断面図Sectional view of the stator according to the first embodiment cut in a direction orthogonal to the central axis 歯部の断面図Sectional view of teeth 第１のインシュレータおよび第２のインシュレータの断面図Sectional view of the first insulator and the second insulator 固定子の製造方法を示した断面図であって、第１の組付工程を示した図FIG. 4 is a cross-sectional view showing the method of manufacturing the stator, showing the first assembly step; 固定子の製造方法を示した断面図であって、配置工程を示した図FIG. 4 is a cross-sectional view showing the method of manufacturing the stator, showing the arrangement process; 固定子の製造方法を示した断面図であって、巻付工程を示した図FIG. 4 is a cross-sectional view showing the method of manufacturing the stator, showing the winding process; 第３のインシュレータの断面図Sectional view of the third insulator 第３のインシュレータの断面図Sectional view of the third insulator 第３のインシュレータの断面図Sectional view of the third insulator 固定子の製造方法を示した断面図であって、第２の組付工程を示した図FIG. 10 is a cross-sectional view showing the method of manufacturing the stator, showing a second assembly step; 固定子の製造方法を示した断面図であって、第２の組付工程を示した図FIG. 10 is a cross-sectional view showing the method of manufacturing the stator, showing a second assembly step; 固定子の製造方法を示した断面図であって、第２の組付工程を示した図FIG. 10 is a cross-sectional view showing the method of manufacturing the stator, showing a second assembly step; 固定子の製造方法を示した断面図であって、第２の組付工程を示した図FIG. 10 is a cross-sectional view showing the method of manufacturing the stator, showing a second assembly step; コアバックの平面図Top view of core back 実施の形態２にかかる固定子を中心軸と直交する方向で切った断面図Sectional view of the stator according to the second embodiment cut in a direction orthogonal to the central axis 固定子の製造方法を示した断面図であって、第２の組付工程を示した図FIG. 10 is a cross-sectional view showing the method of manufacturing the stator, showing a second assembly step; 固定子の製造方法を示した断面図であって、第２の組付工程を示した図FIG. 10 is a cross-sectional view showing the method of manufacturing the stator, showing a second assembly step; 固定子の製造方法を示した断面図であって、第２の組付工程を示した図FIG. 10 is a cross-sectional view showing the method of manufacturing the stator, showing a second assembly step; 実施の形態３にかかる固定子を中心軸と直交する方向で切った断面図Sectional view of the stator according to the third embodiment cut in a direction orthogonal to the central axis 固定子の製造方法を示した断面図であって、第２の組付工程を示した図FIG. 10 is a cross-sectional view showing the method of manufacturing the stator, showing a second assembly step; 固定子の製造方法を示した断面図であって、第２の組付工程を示した図FIG. 10 is a cross-sectional view showing the method of manufacturing the stator, showing a second assembly step; 実施の形態４にかかる送風機の正面図Front view of the blower according to the fourth embodiment
　以下に、実施の形態にかかる固定子、電動機、送風装置、固定子の製造方法および電動機の製造方法を図面に基づいて詳細に説明する。 The stator, the electric motor, the air blower, the method for manufacturing the stator, and the method for manufacturing the electric motor according to the embodiment will be described in detail below with reference to the drawings.
実施の形態１．
　図１は、実施の形態１にかかる電動機１の分解斜視図である。電動機１は、固定子２と、回転子３と、軸部４と、２つの軸受け５と、２つの外郭６，７とを備える。固定子２の後記するコアバック９は、中心軸Ｃを有する円筒形状に形成されている。以下、電動機１の各構成要素について方向を説明するときには、中心軸Ｃと平行な方向を軸方向、中心軸Ｃと直交する方向を半径方向、中心軸Ｃを中心とする回転方向を周方向とする。本明細書において内周および外周といった場合には、円筒形状のコアバック９における内周および外周を意味する。 Embodiment 1.
FIG. 1 is an exploded perspective view of the electric motor 1 according to the first embodiment. The electric motor 1 comprises a stator 2 , a rotor 3 , a shaft portion 4 , two bearings 5 and two shells 6 and 7 . A core back 9 of the stator 2, which will be described later, is formed in a cylindrical shape having a central axis C. As shown in FIG. Hereinafter, when describing the direction of each component of the electric motor 1, the direction parallel to the central axis C is defined as the axial direction, the direction perpendicular to the central axis C is defined as the radial direction, and the direction of rotation about the central axis C is defined as the circumferential direction. do. In this specification, the inner circumference and the outer circumference refer to the inner circumference and the outer circumference of the cylindrical core back 9 .
　電動機１は、円筒形状の固定子２の内周に回転子３が配置されたインナーロータ型電動機である。回転子３には、固定子２の中心軸Ｃに沿って延びる軸部４が設けられている。軸部４は、２つの軸受け５により回転可能に支持されている。軸受け５は、外郭６と外郭７とにより支持されている。外郭６と外郭７とは、固定子２、回転子３、軸受け５を内部に収容するケーシングとなる。固定子２は、固定子鉄心８と、固定子鉄心８に巻線１６が巻き付けられて形成されたコイル１７とを備える。 The electric motor 1 is an inner rotor type electric motor in which a rotor 3 is arranged inside a cylindrical stator 2 . The rotor 3 is provided with a shaft portion 4 extending along the central axis C of the stator 2 . The shaft portion 4 is rotatably supported by two bearings 5 . The bearing 5 is supported by the outer shell 6 and the outer shell 7 . The outer shell 6 and the outer shell 7 form a casing that accommodates the stator 2, the rotor 3, and the bearing 5 inside. The stator 2 includes a stator core 8 and coils 17 formed by winding windings 16 around the stator core 8 .
　図２は、実施の形態１における固定子鉄心８の斜視図である。固定子鉄心８は、円筒形状のコアバック９と、コアバック９の内周面から半径方向内側に突出して放射状に並べられた複数の歯部１０とを有する。コアバック９および歯部１０は、複数枚の電磁鋼板が中心軸Ｃに沿って積層されて形成されている。隣り合う歯部１０の間には、スロット１１が形成されている。スロット１１の数は、本実施の形態では８個であるが、８個以外でもよい。 FIG. 2 is a perspective view of the stator core 8 according to Embodiment 1. FIG. The stator core 8 has a cylindrical core back 9 and a plurality of teeth 10 protruding radially inward from the inner peripheral surface of the core back 9 and arranged radially. The core back 9 and the teeth 10 are formed by laminating a plurality of electromagnetic steel sheets along the central axis C. As shown in FIG. Slots 11 are formed between adjacent teeth 10 . Although the number of slots 11 is eight in this embodiment, it may be other than eight.
　図３は、実施の形態１におけるコアバック９の斜視図である。図４は、実施の形態１における複数の歯部１０が放射状に並べられた状態を示した斜視図である。図３および図４に示すように、固定子鉄心８は、コアバック９と歯部１０とに分割されている。コアバック９と歯部１０とは、別体で形成されている。コアバック９の内周面には、歯部１０の半径方向外側の端部を嵌める溝９ａが形成されている。 FIG. 3 is a perspective view of the core back 9 according to Embodiment 1. FIG. FIG. 4 is a perspective view showing a state in which a plurality of teeth 10 are arranged radially according to the first embodiment. As shown in FIGS. 3 and 4, the stator core 8 is divided into core backs 9 and tooth portions 10 . The core back 9 and the teeth 10 are formed separately. The inner peripheral surface of the core back 9 is formed with grooves 9a into which the radially outer ends of the tooth portions 10 are fitted.
　図５は、実施の形態１において歯部１０がインシュレータ１２により覆われる前の状態を示した分解斜視図である。図６は、実施の形態１において歯部１０がインシュレータ１２により覆われた状態を示した斜視図である。インシュレータ１２は、歯部１０を覆って歯部１０と図１に示されるコイル１７とを電気的に絶縁する。インシュレータ１２は、電気絶縁性を有する材料により形成されている。電気絶縁性の材料は、例えば、樹脂である。図５に示すように、インシュレータ１２は、第１のインシュレータ１３と、第２のインシュレータ１４と、第３のインシュレータ１５とに分割されている。 FIG. 5 is an exploded perspective view showing a state before the tooth portion 10 is covered with the insulator 12 in the first embodiment. FIG. 6 is a perspective view showing a state where tooth portion 10 is covered with insulator 12 in the first embodiment. Insulator 12 covers tooth portion 10 to electrically insulate tooth portion 10 from coil 17 shown in FIG. The insulator 12 is made of an electrically insulating material. The electrically insulating material is, for example, resin. As shown in FIG. 5 , insulator 12 is divided into first insulator 13 , second insulator 14 and third insulator 15 .
　第１のインシュレータ１３は、歯部１０のうち中心軸Ｃに沿った一端部を覆う。第１のインシュレータ１３は、第１の被覆壁１３ａと、第１のストッパ部１３ｂとを有する。第１の被覆壁１３ａは、歯部１０の軸方向の一端面と歯部１０の周方向の両側面とを覆う部分である。第１の被覆壁１３ａは、半径方向内側および外側に開口するとともに歯部１０に向けて開口している。第１のストッパ部１３ｂは、コイル１７が半径方向内側にはみ出すのを防ぐ役割を果たす。第１のストッパ部１３ｂは、第１の被覆壁１３ａのうち半径方向内側の端部から軸方向に沿って歯部１０から離れる方向に延びている。 The first insulator 13 covers one end of the tooth portion 10 along the central axis C. The first insulator 13 has a first covering wall 13a and a first stopper portion 13b. The first covering wall 13 a is a portion that covers one axial end surface of the tooth portion 10 and both circumferential side surfaces of the tooth portion 10 . The first cover wall 13 a opens radially inward and outward and opens toward the tooth portion 10 . The first stopper portion 13b serves to prevent the coil 17 from protruding radially inward. The first stopper portion 13b extends axially away from the tooth portion 10 from the radially inner end of the first covering wall 13a.
　第２のインシュレータ１４は、歯部１０のうち中心軸Ｃに沿った他端部を覆う。第２のインシュレータ１４は、第２の被覆壁１４ａと、第２のストッパ部１４ｂとを有する。第２の被覆壁１４ａは、歯部１０の軸方向の他端面と歯部１０の周方向の両側面とを覆う部分である。第２の被覆壁１４ａは、半径方向内側および外側に開口するとともに歯部１０に向けて開口している。第２のストッパ部１４ｂは、コイル１７が半径方向内側にはみ出すのを防ぐ役割を果たす。第２のストッパ部１４ｂは、第２の被覆壁１４ａのうち半径方向内側の端部から軸方向に沿って歯部１０から離れる方向に延びている。 The second insulator 14 covers the other end of the tooth portion 10 along the central axis C. The second insulator 14 has a second covering wall 14a and a second stopper portion 14b. The second covering wall 14 a is a portion that covers the other axial end surface of the tooth portion 10 and both circumferential side surfaces of the tooth portion 10 . The second covering wall 14a is open radially inwardly and outwardly and is open toward the tooth portion 10. As shown in FIG. The second stopper portion 14b serves to prevent the coil 17 from protruding radially inward. The second stopper portion 14b extends in the direction away from the tooth portion 10 along the axial direction from the radially inner end portion of the second covering wall 14a.
　第３のインシュレータ１５は、歯部１０のうち半径方向に沿った歯部１０の中心より外側部分を覆う。第３のインシュレータ１５は、第３の被覆壁１５ａと、第３のストッパ部１５ｂとを有する。第３の被覆壁１５ａは、歯部１０の軸方向の両端面と歯部１０の周方向の両側面とを覆う四角筒状の部分である。第３の被覆壁１５ａは、半径方向内側および外側に開口している。すなわち、第３の被覆壁１５ａは、半径方向に開口する筒状の壁である。第３のストッパ部１５ｂは、コイル１７が半径方向外側にはみ出すのを防ぐ役割を果たす。第３のストッパ部１５ｂは、軸方向かつ周方向に延びている。第３のストッパ部１５ｂのうち周方向の中央部には、周方向よりも軸方向に長い四角形の開口１５ｃが形成されている。第３の被覆壁１５ａは、開口１５ｃの周縁から半径方向内側に突出している。 The third insulator 15 covers a portion of the tooth portion 10 outside the center of the tooth portion 10 along the radial direction. The third insulator 15 has a third covering wall 15a and a third stopper portion 15b. The third covering wall 15a is a rectangular tubular portion that covers both axial end surfaces of the tooth portion 10 and both circumferential side surfaces of the tooth portion 10 . The third covering wall 15a is open radially inwardly and outwardly. That is, the third covering wall 15a is a cylindrical wall that opens radially. The third stopper portion 15b serves to prevent the coil 17 from protruding radially outward. The third stopper portion 15b extends axially and circumferentially. A rectangular opening 15c that is longer in the axial direction than in the circumferential direction is formed in the central portion of the third stopper portion 15b in the circumferential direction. The third covering wall 15a protrudes radially inward from the peripheral edge of the opening 15c.
　図７は、実施の形態１において複数の歯部１０が複数のインシュレータ１２に覆われた状態を示した斜視図である。図８は、実施の形態１において複数の歯部１０が複数のインシュレータ１２に覆われた状態を示した図であって、軸方向に沿って見た図である。なお、図７および図８では、第３のインシュレータ１５の図示を省略している。図７および図８に示すように、複数の歯部１０のそれぞれは、インシュレータ１２により覆われる。インシュレータ１２は、１つの歯部１０ごとに１つ設けられている。各歯部１０のうち半径方向の両側面は、インシュレータ１２により覆われることなく露出している。第１のインシュレータ１３、第２のインシュレータ１４および第３のインシュレータ１５は、歯部１０の数と同数設けられる。インシュレータ１２の数は、歯部１０の数に合わせて適宜増減される。 FIG. 7 is a perspective view showing a state in which a plurality of tooth portions 10 are covered with a plurality of insulators 12 in Embodiment 1. FIG. FIG. 8 is a diagram showing a state in which a plurality of tooth portions 10 are covered with a plurality of insulators 12 in Embodiment 1, and is a diagram viewed along the axial direction. 7 and 8, illustration of the third insulator 15 is omitted. As shown in FIGS. 7 and 8, each of the multiple teeth 10 is covered with an insulator 12 . One insulator 12 is provided for each tooth portion 10 . Both radial side surfaces of each tooth portion 10 are exposed without being covered with the insulator 12 . The same number of first insulators 13 , second insulators 14 and third insulators 15 as the number of teeth 10 are provided. The number of insulators 12 is appropriately increased or decreased according to the number of teeth 10 .
　図９は、第３のインシュレータ１５を周方向に沿って見た図である。図９に示すように、第３のインシュレータ１５の第３の被覆壁１５ａのうち半径方向内側の開口縁部は、半径方向内側に傾斜している。詳しくは、第３の被覆壁１５ａのうち半径方向内側の開口縁部は、軸方向の一端部から他端部に向かうにつれて半径方向内側に位置するように傾斜している。言い換えると、第３の被覆壁１５ａの半径方向に沿った長さは、軸方向の一端部から他端部に向かうにつれて長くなっている。 FIG. 9 is a view of the third insulator 15 viewed along the circumferential direction. As shown in FIG. 9, the radially inner opening edge of the third covering wall 15a of the third insulator 15 is inclined radially inward. Specifically, the radially inner opening edge of the third covering wall 15a is inclined so as to be positioned radially inward from one axial end to the other axial end. In other words, the radial length of the third covering wall 15a increases from one axial end to the other axial end.
　図１０は、第３のインシュレータ１５を軸方向に沿って見た図である。図１０に示すように、第３のインシュレータ１５には、周方向の端部の形状が異なる３種類の第３のインシュレータ１５が用いられている。以下の説明において、３種類の第３のインシュレータ１５を区別する場合には、第３のインシュレータ１５Ａ、第３のインシュレータ１５Ｂ、第３のインシュレータ１５Ｃと称する。 FIG. 10 is a diagram of the third insulator 15 viewed along the axial direction. As shown in FIG. 10, three types of third insulators 15 having different shapes of ends in the circumferential direction are used as the third insulators 15 . In the following description, when distinguishing between the three types of third insulators 15, they are referred to as third insulator 15A, third insulator 15B, and third insulator 15C.
　各第３のインシュレータ１５Ａ，１５Ｂ，１５Ｃの第３のストッパ部１５ｂにおいてスロット１１内に向けて突出する部分は、スロット１１のうちスロットオープンを塞ぐコイルガード部１５ｄとなる。各第３のインシュレータ１５Ａ，１５Ｂ，１５Ｃには、２つのコイルガード部１５ｄが形成されている。第３のインシュレータ１５Ａでは、一方のコイルガード部１５ｄの周方向の先端部に他の部分よりも半径方向内側に位置するように屈曲した段差部１５ｅが形成されていて、他方のコイルガード部１５ｄが同一円周上に位置する曲線状に形成されている。第３のインシュレータ１５Ｂでは、２つのコイルガード部１５ｄのそれぞれの周方向の先端部に他の部分よりも半径方向内側に位置するように屈曲した段差部１５ｅが形成されている。第３のインシュレータ１５Ｃでは、２つのコイルガード部１５ｄのそれぞれが同一円周上に位置する曲線状に形成されている。段差部１５ｅは、半径方向内側に屈曲して半径方向に延びた後、隣の歯部１０に向けて屈曲して周方向に延びている。第３のインシュレータ１５Ａと第３のインシュレータ１５Ｂとのうち段差部１５ｅを除く部分と第３のインシュレータ１５Ｃとは、同一円周上に位置するように配置されている。 A portion of the third stopper portion 15b of each of the third insulators 15A, 15B, 15C that protrudes into the slot 11 serves as a coil guard portion 15d that closes the slot opening of the slot 11. Two coil guard portions 15d are formed in each of the third insulators 15A, 15B, 15C. In the third insulator 15A, a curved stepped portion 15e is formed at the distal end portion in the circumferential direction of one coil guard portion 15d so as to be positioned more radially inward than the other portion, and the other coil guard portion 15d is formed at the distal end portion in the circumferential direction. are formed in a curved shape located on the same circumference. In the third insulator 15B, a curved stepped portion 15e is formed at each circumferential tip of each of the two coil guard portions 15d so as to be positioned more radially inward than the other portions. In the third insulator 15C, each of the two coil guard portions 15d is formed in a curved shape located on the same circumference. The stepped portion 15e bends radially inward and extends in the radial direction, then bends toward the adjacent tooth portion 10 and extends in the circumferential direction. A portion of the third insulator 15A and the third insulator 15B excluding the stepped portion 15e and the third insulator 15C are arranged so as to be positioned on the same circumference.
　各スロット１１内には、スロット１１に隣接する２つの第３のインシュレータ１５のそれぞれから１つずつ突出するコイルガード部１５ｄが配置されている。同一のスロット１１内に配置されるコイルガード部１５ｄのうち一方の周方向の先端部には、他方の周方向の先端部の半径方向内側に位置するように屈曲された段差部１５ｅが形成されている。２つのコイルガード部１５ｄのうち一方の段差部１５ｅと他方の周方向の先端部とは、半径方向に重なるように配置されている。コイルガード部１５ｄの周方向の先端部は、第３のインシュレータ１５全体の中で最も周方向の末端に位置する部分である。以下の説明において、コイルガード部１５ｄの周方向の先端部を第３のインシュレータ１５の一端部または他端部と称する場合もある。 A coil guard portion 15 d is arranged in each slot 11 so as to protrude from each of the two third insulators 15 adjacent to the slot 11 . One of the coil guard portions 15d arranged in the same slot 11 has a stepped portion 15e that is bent radially inward of the other circumferential tip portion. ing. The stepped portion 15e of one of the two coil guard portions 15d and the distal end portion of the other in the circumferential direction are arranged so as to overlap in the radial direction. A distal end portion of the coil guard portion 15 d in the circumferential direction is a portion located at the distal end of the third insulator 15 as a whole in the circumferential direction. In the following description, the circumferential tip portion of the coil guard portion 15 d may also be referred to as one end portion or the other end portion of the third insulator 15 .
　図１１は、図８に示された複数の歯部１０にコイル１７が形成される途中の状態を示した図であって、軸方向に沿って見た図である。図１２は、図８に示された複数の歯部１０にコイル１７が形成された状態を示した図であって、軸方向に沿って見た図である。図１３は、実施の形態１にかかる固定子２の斜視図である。図１１および図１２に示すように、歯部１０には、インシュレータ１２を介して巻線１６が巻き付けられてコイル１７が形成される。 FIG. 11 is a diagram showing a state in which the coils 17 are being formed on the plurality of tooth portions 10 shown in FIG. 8, and is a diagram viewed along the axial direction. FIG. 12 is a diagram showing a state in which the coils 17 are formed on the plurality of tooth portions 10 shown in FIG. 8, viewed along the axial direction. FIG. 13 is a perspective view of the stator 2 according to Embodiment 1. FIG. As shown in FIGS. 11 and 12 , a coil 17 is formed by winding a wire 16 around the tooth portion 10 via an insulator 12 .
　次に、本実施の形態にかかる固定子２の製造方法について説明する。図１４は、実施の形態１にかかる固定子２を中心軸Ｃと直交する方向で切った断面図である。ここでは、図１４に示される８個の歯部１０を有する固定子２を製造する場合について説明するが、歯部１０の数を限定する趣旨ではない。以下の説明において８個の歯部１０を区別する場合には、各図の歯部１０のうち紙面上側かつ中央に位置する歯部１０を歯部１０Ａとして、歯部１０Ａから反時計回りに順番に、歯部１０Ｂ、歯部１０Ｃ、歯部１０Ｄ、歯部１０Ｅ、歯部１０Ｆ、歯部１０Ｇ、歯部１０Ｈと称する。固定子２の製造方法は、第１の組付工程と、配置工程と、巻付工程と、第２の組付工程と、第３の組付工程とを含む。 Next, a method for manufacturing the stator 2 according to this embodiment will be described. FIG. 14 is a cross-sectional view of the stator 2 according to the first embodiment cut in a direction orthogonal to the central axis C. FIG. Here, a case of manufacturing a stator 2 having eight teeth 10 shown in FIG. 14 will be described, but the number of teeth 10 is not limited. In the following description, when distinguishing the eight tooth portions 10, the tooth portion 10 located at the upper side and the center of the paper surface among the tooth portions 10 in each figure is designated as the tooth portion 10A, and the tooth portions 10A and 10A are arranged in counterclockwise order. 10B, 10C, 10D, 10E, 10F, 10G, and 10H. The manufacturing method of the stator 2 includes a first assembly process, an arrangement process, a winding process, a second assembly process, and a third assembly process.
　図１５は、歯部１０の断面図である。図１６は、第１のインシュレータ１３および第２のインシュレータ１４の断面図である。図１７は、固定子２の製造方法を示した断面図であって、第１の組付工程を示した図である。なお、第１のインシュレータ１３および第２のインシュレータ１４の断面形状は同一であるため、図１６、図１７などの断面図では、第１のインシュレータ１３および第２のインシュレータ１４の符号を併記している。第１の組付工程は、複数の歯部１０のそれぞれに第１のインシュレータ１３および第２のインシュレータ１４を組み付ける工程である。第１の組付工程では、図５に示すように、歯部１０の軸方向の両側から第１のインシュレータ１３および第２のインシュレータ１４を歯部１０に嵌め込む。第１の組付工程を行うことにより、図６に示すように、歯部１０のうち軸方向の両端面と歯部１０の周方向の両側面とが、第１のインシュレータ１３および第２のインシュレータ１４により覆われる。 15 is a cross-sectional view of the tooth portion 10. FIG. FIG. 16 is a cross-sectional view of the first insulator 13 and the second insulator 14. FIG. FIG. 17 is a cross-sectional view showing the method of manufacturing the stator 2, showing the first assembly step. Since the cross-sectional shapes of the first insulator 13 and the second insulator 14 are the same, the reference numerals of the first insulator 13 and the second insulator 14 are also used in cross-sectional views such as FIGS. there is The first assembling step is a step of assembling the first insulator 13 and the second insulator 14 to each of the plurality of tooth portions 10 . In the first assembly step, as shown in FIG. 5, the first insulator 13 and the second insulator 14 are fitted into the tooth portion 10 from both sides in the axial direction of the tooth portion 10 . By performing the first assembling step, as shown in FIG. It is covered with insulator 14 .
　図１８は、固定子２の製造方法を示した断面図であって、配置工程を示した図である。配置工程は、第１のインシュレータ１３および第２のインシュレータ１４により覆われた複数の歯部１０を周方向に並べて配置する工程である。配置工程では、複数の歯部１０を放射状に配置して、図示しない治具で複数の歯部１０を移動不能に固定する。複数の歯部１０の内周には、図１に示される回転子３を挿入するための円筒形状の空間が形成される。 FIG. 18 is a cross-sectional view showing the manufacturing method of the stator 2, showing the arrangement process. The arranging step is a step of arranging the plurality of tooth portions 10 covered with the first insulator 13 and the second insulator 14 side by side in the circumferential direction. In the arranging step, a plurality of teeth 10 are arranged radially and fixed immovably with a jig (not shown). A cylindrical space for inserting the rotor 3 shown in FIG. 1 is formed in the inner periphery of the plurality of teeth 10 .
　図１９は、固定子２の製造方法を示した断面図であって、巻付工程を示した図である。巻付工程は、第１のインシュレータ１３および第２のインシュレータ１４を介して歯部１０に巻線１６を巻き付けてコイル１７を形成する工程である。巻付工程では、歯部１０の半径方向外側から巻線１６を巻き始める。巻き方は、公知の巻き方の中から適宜選択すればよく、例えば、図１１および図１２に示されるような巻き方で巻線１６を歯部１０に巻き付けてもよい。コイル１７は、隣り合う歯部１０の間に形成されたスロット１１内にも配置される。 FIG. 19 is a cross-sectional view showing the manufacturing method of the stator 2, showing the winding process. The winding step is a step of forming a coil 17 by winding the wire 16 around the tooth portion 10 via the first insulator 13 and the second insulator 14 . In the winding process, the winding 16 is started from the radially outer side of the tooth 10 . The winding method may be appropriately selected from known winding methods. For example, the winding 16 may be wound around the tooth portion 10 in a winding method as shown in FIGS. 11 and 12 . Coils 17 are also arranged in slots 11 formed between adjacent teeth 10 .
　図２０は、第３のインシュレータ１５Ａの断面図である。図２１は、第３のインシュレータ１５Ｂの断面図である。図２２は、第３のインシュレータ１５Ｃの断面図である。第２の組付工程では、図２０から図２２に示される３種類の第３のインシュレータ１５Ａ，１５Ｂ，１５Ｃを使用する。第２の組付工程は、図１９に示される複数の歯部１０のそれぞれに半径方向外側から第３のインシュレータ１５を組み付ける工程である。第２の組付工程では、図５および図６に示されるように歯部１０のうち半径方向に沿った歯部１０の中心より外側部分が第３のインシュレータ１５の開口１５ｃに嵌め込まれる。歯部１０のうち第１のインシュレータ１３および第２のインシュレータ１４により覆われた部分の一部が、第３のインシュレータ１５の開口１５ｃに嵌め込まれる。 FIG. 20 is a cross-sectional view of the third insulator 15A. FIG. 21 is a cross-sectional view of the third insulator 15B. FIG. 22 is a cross-sectional view of the third insulator 15C. In the second assembly process, three types of third insulators 15A, 15B, 15C shown in FIGS. 20 to 22 are used. The second assembling step is a step of assembling the third insulator 15 from the radially outer side to each of the plurality of tooth portions 10 shown in FIG. 19 . In the second assembling step, as shown in FIGS. 5 and 6 , a portion of tooth portion 10 radially outside the center of tooth portion 10 is fitted into opening 15 c of third insulator 15 . A part of the tooth portion 10 covered with the first insulator 13 and the second insulator 14 is fitted into the opening 15 c of the third insulator 15 .
　図２３は、固定子２の製造方法を示した断面図であって、第２の組付工程を示した図である。図２４は、固定子２の製造方法を示した断面図であって、第２の組付工程を示した図である。図２５は、固定子２の製造方法を示した断面図であって、第２の組付工程を示した図である。図２６は、固定子２の製造方法を示した断面図であって、第２の組付工程を示した図である。 FIG. 23 is a cross-sectional view showing the manufacturing method of the stator 2, showing the second assembly process. FIG. 24 is a cross-sectional view showing the method of manufacturing the stator 2, showing the second assembly step. FIG. 25 is a cross-sectional view showing the method of manufacturing the stator 2, showing the second assembling step. FIG. 26 is a cross-sectional view showing the method of manufacturing the stator 2, showing the second assembling step.
　はじめに、図２３に示すように、周方向の両端部に段差部１５ｅが形成された第３のインシュレータ１５Ｂを歯部１０Ａに組み付ける。続いて、図２４に示すように、周方向の一端部に段差部１５ｅが形成された第３のインシュレータ１５Ａを、歯部１０Ａの反時計回りに位置する隣の歯部１０Ｂに組み付ける。このとき、第３のインシュレータ１５Ａのうち段差部１５ｅが形成されていない周方向の他端部を、先に組み付けた第３のインシュレータ１５Ｂのうち反時計回りに位置する段差部１５ｅの半径方向外側に重ねる。以下同様の組み付け方で、図２５に示すように、反時計回りに、歯部１０Ｃ、歯部１０Ｄ、歯部１０Ｅ、歯部１０Ｆ、歯部１０Ｇの順に第３のインシュレータ１５Ａを組み付ける。各スロット１１内では、隣接する一方の第３のインシュレータ１５Ａの段差部１５ｅが他方の第３のインシュレータ１５Ａの半径方向内側に位置する。 First, as shown in FIG. 23, a third insulator 15B having stepped portions 15e formed at both ends in the circumferential direction is assembled to the tooth portion 10A. Subsequently, as shown in FIG. 24, a third insulator 15A having a stepped portion 15e formed at one end in the circumferential direction is assembled to the adjacent tooth portion 10B positioned counterclockwise to the tooth portion 10A. At this time, the other circumferential end portion of the third insulator 15A where the stepped portion 15e is not formed is radially outside the stepped portion 15e of the previously assembled third insulator 15B located counterclockwise. overlaid on In the same manner, as shown in FIG. 25, the third insulator 15A is assembled counterclockwise in order of the tooth portion 10C, the tooth portion 10D, the tooth portion 10E, the tooth portion 10F, and the tooth portion 10G. In each slot 11, the stepped portion 15e of one adjacent third insulator 15A is located radially inside the other third insulator 15A.
　続いて、図２６に示すように、周方向の両端部に段差部１５ｅが形成されていない第３のインシュレータ１５Ｃを、歯部１０Ｈに組み付ける。このとき、第３のインシュレータ１５Ｃのうち周方向の一端部を、先に組み付けた第３のインシュレータ１５Ａのうち反時計回りに位置する段差部１５ｅの半径方向外側に重ねる。また、第３のインシュレータ１５Ｃのうち周方向の他端部を、先に組み付けた第３のインシュレータ１５Ｂのうち時計回りに位置する段差部１５ｅの半径方向外側に重ねる。第３のインシュレータ１５Ｃを歯部１０Ｈに組み付けることにより、全ての歯部１０への第３のインシュレータ１５の組み付けが完了する。 Subsequently, as shown in FIG. 26, the third insulator 15C, in which the stepped portions 15e are not formed at both ends in the circumferential direction, is assembled to the tooth portion 10H. At this time, one end portion in the circumferential direction of the third insulator 15C is overlapped radially outside of the stepped portion 15e of the previously assembled third insulator 15A positioned counterclockwise. In addition, the other circumferential end of the third insulator 15C is overlapped radially outward of the clockwise stepped portion 15e of the previously assembled third insulator 15B. By assembling the third insulator 15C to the teeth 10H, the assembling of the third insulators 15 to all the teeth 10 is completed.
　図２７は、コアバック９の平面図である。第３の組付工程は、図２６に示される複数の歯部１０のそれぞれに図２７に示されるコアバック９を組み付ける工程である。図１４に示すように、第３の組付工程では、コアバック９の内周面に形成された複数の溝９ａのそれぞれに歯部１０を１つずつ嵌め込む。歯部１０のうち第３のインシュレータ１５から露出する部分を溝９ａに嵌め込む。以上の工程を行うことにより、図１４に示される固定子２が完成する。 27 is a plan view of the core back 9. FIG. The third assembling step is a step of assembling the core back 9 shown in FIG. 27 to each of the plurality of tooth portions 10 shown in FIG. 26 . As shown in FIG. 14 , in the third assembly step, one tooth portion 10 is fitted into each of the plurality of grooves 9 a formed in the inner peripheral surface of the core back 9 . A portion of the tooth portion 10 exposed from the third insulator 15 is fitted into the groove 9a. By performing the above steps, the stator 2 shown in FIG. 14 is completed.
　なお、図１４に示される固定子２の内周に図１に示される回転子３が挿入されて、軸受け５および外郭６，７が組み付けられることにより、電動機１が完成する。 The rotor 3 shown in FIG. 1 is inserted into the inner circumference of the stator 2 shown in FIG. 14, and the bearing 5 and outer shells 6 and 7 are assembled to complete the electric motor 1.
　次に、本実施の形態にかかる固定子２の効果について説明する。 Next, the effect of the stator 2 according to this embodiment will be explained.
　本実施の形態では、図３および図４に示すように、コアバック９と複数の歯部１０とは、分割されている。また、本実施の形態では、図５および図６に示すように、インシュレータ１２は、歯部１０のうちコアバック９の中心軸Ｃに沿った一端部を覆う第１のインシュレータ１３と、歯部１０のうち中心軸Ｃに沿った他端部を覆う第２のインシュレータ１４と、歯部１０のうち半径方向に沿った歯部１０の中心より外側部分を覆う第３のインシュレータ１５とに分割されている。また、本実施の形態では、図１０に示すように、第３のインシュレータ１５には、スロット１１内に向けて突出するコイルガード部１５ｄが形成されている。これらの構成により、図２３に示すように、歯部１０に巻線１６を巻き付けてコイル１７を形成してから、スロットオープンを塞ぐコイルガード部１５ｄを有する第３のインシュレータ１５を歯部１０に組み付けることが可能になる。したがって、図１９に示すように、歯部１０への巻線１６の巻付時には、コイルガード部１５ｄで閉ざされていないスロットオープンから巻線１６を挿入できるため、歯部１０への巻線１６の巻付時にスロット１１内に巻線１６を挿入しやすくなる。これにより、巻き付け作業が行いやすくなって巻線１６を整列させやすくなるため、巻線１６が長くなることによるコストの増加および電動機１の効率の低下を抑制できる。一方、図２３から図２６に示すように、コイル１７を形成してから、スロットオープンを塞ぐコイルガード部１５ｄを有する第３のインシュレータ１５を歯部１０に組み付けることにより、歯部１０に形成されたコイル１７がスロット１１外へはみ出しにくくなる。特に、コイル１７を形成した後に、第３のインシュレータ１５をコイル１７に対して半径方向外側から組み付けることにより、コイル１７をスロット１１内へ押し戻すことができるため、コイル１７がスロット１１外へより一層はみ出しにくくなる。 In the present embodiment, as shown in FIGS. 3 and 4, the core back 9 and the plurality of tooth portions 10 are separated. In the present embodiment, as shown in FIGS. 5 and 6, the insulator 12 includes a first insulator 13 covering one end portion of the tooth portion 10 along the central axis C of the core back 9 and a tooth portion A second insulator 14 covering the other end portion of the tooth portion 10 along the central axis C, and a third insulator 15 covering a portion outside the center of the tooth portion 10 along the radial direction of the tooth portion 10 . ing. Further, in the present embodiment, as shown in FIG. 10 , the third insulator 15 is formed with a coil guard portion 15 d projecting into the slot 11 . With these configurations, as shown in FIG. It becomes possible to assemble. Therefore, as shown in FIG. 19, when the winding 16 is wound around the tooth portion 10, the winding 16 can be inserted through the slot opening that is not closed by the coil guard portion 15d. The winding 16 can be easily inserted into the slot 11 during winding. As a result, the winding work can be easily performed and the windings 16 can be easily aligned, so that an increase in cost and a decrease in the efficiency of the electric motor 1 due to the lengthening of the windings 16 can be suppressed. On the other hand, as shown in FIGS. 23 to 26, after the coil 17 is formed, the third insulator 15 having the coil guard portion 15d for closing the slot opening is assembled to the tooth portion 10, thereby forming the coil 17 on the tooth portion 10. Thus, the coil 17 is less likely to protrude out of the slot 11.例文帳に追加In particular, by assembling the third insulator 15 to the coil 17 from the outside in the radial direction after forming the coil 17, the coil 17 can be pushed back into the slot 11, so that the coil 17 can be further pushed out of the slot 11. It becomes difficult to stick out.
　本実施の形態では、図１４に示すように、各スロット１１内には、スロット１１に隣接する２つの第３のインシュレータ１５のそれぞれから突出するコイルガード部１５ｄが配置されている。また、本実施の形態では、同一のスロット１１内に配置される２つのコイルガード部１５ｄのうち一方には、他方のコイルガード部１５ｄの半径方向内側に位置するように屈曲された段差部１５ｅが形成されている。これらの構成により、第３のインシュレータ１５を歯部１０に組み付けた状態で、隣接する２つのコイルガード部１５ｄの周方向の先端部同士を半径方向に重なるように配置して、スロット１１のうちスロットオープンを確実に塞ぐことができる。そのため、コイル１７とコアバック９との間の電気的絶縁性を向上させることができる。 In the present embodiment, as shown in FIG. 14, each slot 11 is provided with a coil guard portion 15d projecting from each of the two third insulators 15 adjacent to the slot 11. As shown in FIG. Further, in the present embodiment, one of the two coil guard portions 15d arranged in the same slot 11 has a stepped portion 15e bent so as to be positioned radially inside the other coil guard portion 15d. is formed. With these configurations, in a state in which the third insulator 15 is assembled to the tooth portion 10, two adjacent coil guard portions 15d are arranged so that the distal end portions in the circumferential direction overlap in the radial direction. To surely block a slot opening. Therefore, electrical insulation between the coil 17 and the core back 9 can be improved.
　本実施の形態では、図５に示すように、第３のインシュレータ１５は、半径方向に開口する筒状の第３の被覆壁１５ａを有しており、第３の被覆壁１５ａのうち半径方向内側の開口縁部は、半径方向内側に傾斜している。これにより、第３のインシュレータ１５の第３の被覆壁１５ａを歯部１０に組み付けやすくなる。 In the present embodiment, as shown in FIG. 5, the third insulator 15 has a cylindrical third covering wall 15a that opens radially. The inner opening edge slopes radially inward. This makes it easier to assemble the third covering wall 15 a of the third insulator 15 to the tooth portion 10 .
実施の形態２．
　次に、図２８から図３１を参照して、実施の形態２にかかる固定子２Ａについて説明する。図２８は、実施の形態２にかかる固定子２Ａを中心軸Ｃと直交する方向で切った断面図である。図２９は、固定子２Ａの製造方法を示した断面図であって、第２の組付工程を示した図である。図３０は、固定子２Ａの製造方法を示した断面図であって、第２の組付工程を示した図である。図３１は、固定子２Ａの製造方法を示した断面図であって、第２の組付工程を示した図である。本実施の形態では、３種類の第３のインシュレータ１５Ａ，１５Ｂ，１５Ｃの割合および配置が前記した実施の形態１と相違する。なお、実施の形態２では、前記した実施の形態１と重複する部分については、同一符号を付して説明を省略する。 Embodiment 2.
Next, a stator 2A according to Embodiment 2 will be described with reference to FIGS. 28 to 31. FIG. FIG. 28 is a cross-sectional view of the stator 2A according to the second embodiment taken in a direction perpendicular to the central axis C. FIG. FIG. 29 is a cross-sectional view showing the manufacturing method of the stator 2A, showing the second assembling step. FIG. 30 is a sectional view showing the manufacturing method of the stator 2A, showing the second assembling step. FIG. 31 is a cross-sectional view showing the manufacturing method of the stator 2A, showing the second assembling step. This embodiment differs from the first embodiment described above in the ratio and arrangement of the three types of third insulators 15A, 15B, and 15C. In addition, in Embodiment 2, the same code|symbol is attached|subjected about the part which overlaps with above-mentioned Embodiment 1, and description is abbreviate|omitted.
　固定子２Ａの製造方法は、第１の組付工程と、配置工程と、巻付工程と、第２の組付工程と、第３の組付工程とを含む。第１の組付工程、配置工程、巻付工程および第３の組付工程は、実施の形態１と同様であるため、その説明を省略して、第２の組付工程のみを説明する。 The manufacturing method of the stator 2A includes a first assembly process, an arrangement process, a winding process, a second assembly process, and a third assembly process. Since the first assembling process, the arranging process, the winding process and the third assembling process are the same as those in the first embodiment, description thereof will be omitted and only the second assembling process will be described.
　はじめに、図２９に示すように、周方向の両端部に段差部１５ｅが形成された第３のインシュレータ１５Ｂを、中心軸Ｃを挟んで対称となる位置、すなわち中心軸Ｃを中心に１８０度離隔した位置に配置された歯部１０Ａと歯部１０Ｅとにそれぞれ組み付ける。 First, as shown in FIG. 29, the third insulators 15B having stepped portions 15e formed at both ends in the circumferential direction are placed at symmetrical positions with respect to the central axis C, that is, 180 degrees apart from each other with respect to the central axis C. are assembled to the teeth 10A and 10E arranged at the positions where
　続いて、図３０に示すように、周方向の一端部のみに段差部１５ｅが形成された第３のインシュレータ１５Ａを、歯部１０Ａの反時計回りに位置する隣の歯部１０Ｂと歯部１０Ｃとにこの順番で組み付けるとともに、歯部１０Ｅの反時計回りに位置する隣の歯部１０Ｆと歯部１０Ｇとにこの順番で組み付ける。このとき、第３のインシュレータ１５Ａのうち段差部１５ｅが形成されていない周方向の他端部を、先に組み付けた第３のインシュレータ１５Ｂの段差部１５ｅのうち反時計回りに位置する方の段差部１５ｅまたは先に組み付けた第３のインシュレータ１５Ａの段差部１５ｅの半径方向外側に重ねる。なお、歯部１０Ｂと歯部１０Ｆとは、中心軸Ｃを挟んで対称となる位置に配置されている。歯部１０Ｃと歯部１０Ｇとは、中心軸Ｃを挟んで対称となる位置に配置されている。 Subsequently, as shown in FIG. 30, a third insulator 15A having a stepped portion 15e formed only at one end in the circumferential direction is attached to a tooth portion 10B and a tooth portion 10C adjacent to the tooth portion 10A counterclockwise. , and to the teeth 10F and 10G adjacent to the tooth 10E in the counterclockwise direction. At this time, the other circumferential end portion of the third insulator 15A where the stepped portion 15e is not formed is aligned with the counterclockwise stepped portion 15e of the previously assembled third insulator 15B. It overlaps radially outside of the portion 15e or the stepped portion 15e of the previously assembled third insulator 15A. The tooth portion 10B and the tooth portion 10F are arranged at symmetrical positions with the central axis C interposed therebetween. The tooth portion 10C and the tooth portion 10G are arranged at symmetrical positions with the central axis C interposed therebetween.
　続いて、図３１に示すように、周方向の両端部に段差部１５ｅが形成されていない第３のインシュレータ１５Ｃを、中心軸Ｃを挟んで対称となる位置に配置された歯部１０Ｄと歯部１０Ｈとにそれぞれ組み付ける。このとき、第３のインシュレータ１５Ｃのうち周方向の一端部を、先に組み付けた第３のインシュレータ１５Ａの段差部１５ｅの半径方向外側に重ねる。また、第３のインシュレータ１５Ｃのうち周方向の他端部を、先に組み付けた第３のインシュレータ１５Ｂの段差部１５ｅのうち時計回りに位置する方の段差部１５ｅの半径方向外側に重ねる。第３のインシュレータ１５Ｃを歯部１０Ｄと歯部１０Ｈとにそれぞれ組み付けることにより、全ての歯部１０への第３のインシュレータ１５の組み付けが完了する。 Subsequently, as shown in FIG. 31, the third insulator 15C, in which the stepped portions 15e are not formed at both ends in the circumferential direction, is attached to the tooth portion 10D and the tooth portion 10D arranged at symmetrical positions with respect to the central axis C. 10H, respectively. At this time, one end portion in the circumferential direction of the third insulator 15C is superimposed on the radially outer side of the stepped portion 15e of the previously assembled third insulator 15A. In addition, the other circumferential end of the third insulator 15C is superimposed on the radially outer side of the clockwise stepped portion 15e of the previously assembled third insulator 15B. By assembling the third insulator 15C to each of the teeth 10D and 10H, the assembling of the third insulators 15 to all the teeth 10 is completed.
　本実施の形態では、中心軸Ｃを挟んで対称となる位置に配置された歯部１０ごとに第３のインシュレータ１５を組み付けるため、固定子２Ａのうち中心軸Ｃを挟んで対称となる部分に均一に力を加えながら歯部１０への第３のインシュレータ１５の組み付けを行うことができる。 In the present embodiment, since the third insulator 15 is assembled to each tooth portion 10 arranged symmetrically with respect to the central axis C, the parts of the stator 2A that are symmetrical with respect to the central axis C are The third insulator 15 can be attached to the tooth portion 10 while applying a uniform force.
実施の形態３．
　次に、図３２から図３４を参照して、実施の形態３にかかる固定子２Ｂについて説明する。図３２は、実施の形態３にかかる固定子２Ｂを中心軸Ｃと直交する方向で切った断面図である。図３３は、固定子２Ｂの製造方法を示した断面図であって、第２の組付工程を示した図である。図３４は、固定子２Ｂの製造方法を示した断面図であって、第２の組付工程を示した図である。本実施の形態では、２種類の第３のインシュレータ１５Ｂ，１５Ｃを用いた点が前記した実施の形態１と相違する。なお、実施の形態３では、前記した実施の形態１と重複する部分については、同一符号を付して説明を省略する。 Embodiment 3.
Next, a stator 2B according to Embodiment 3 will be described with reference to FIGS. 32 to 34. FIG. FIG. 32 is a cross-sectional view of the stator 2B according to the third embodiment taken in a direction orthogonal to the central axis C. FIG. FIG. 33 is a cross-sectional view showing the method of manufacturing the stator 2B, showing the second assembling step. FIG. 34 is a cross-sectional view showing the method of manufacturing the stator 2B, showing the second assembling step. This embodiment differs from the first embodiment in that two types of third insulators 15B and 15C are used. In addition, in Embodiment 3, the same code|symbol is attached|subjected about the part which overlaps with above-mentioned Embodiment 1, and description is abbreviate|omitted.
　固定子２Ｂの製造方法は、第１の組付工程と、配置工程と、巻付工程と、第２の組付工程と、第３の組付工程とを含む。第１の組付工程、配置工程、巻付工程および第３の組付工程は、実施の形態１と同様であるため、その説明を省略して、第２の組付工程のみを説明する。 The manufacturing method of the stator 2B includes a first assembly process, an arrangement process, a winding process, a second assembly process, and a third assembly process. Since the first assembling process, the arranging process, the winding process and the third assembling process are the same as those in the first embodiment, description thereof will be omitted and only the second assembling process will be described.
　はじめに、図３３に示すように、周方向の両端部に段差部１５ｅが形成された第３のインシュレータ１５Ｂを、中心軸Ｃを中心に９０度離隔した位置に配置された歯部１０Ａと歯部１０Ｃと歯部１０Ｅと歯部１０Ｇとにそれぞれ組み付ける。 First, as shown in FIG. 33, a third insulator 15B having stepped portions 15e formed at both ends in the circumferential direction is connected to a toothed portion 10A and a toothed portion 10A which are arranged at positions separated by 90 degrees around the central axis C. 10C, tooth portion 10E and tooth portion 10G are assembled respectively.
　続いて、図３４に示すように、周方向の両端部に段差部１５ｅが形成されていない第３のインシュレータ１５Ｃを、中心軸Ｃを中心に９０度離隔した位置に配置された歯部１０Ｂと歯部１０Ｄと歯部１０Ｆと歯部１０Ｈとにそれぞれ組み付ける。すなわち、第３のインシュレータ１５Ｃを、隣り合う２つの第３のインシュレータ１５Ｂの間に配置する。このとき、第３のインシュレータ１５Ｃのうち周方向の両端部を、隣接する第３のインシュレータ１５Ｂの段差部１５ｅの半径方向外側に重ねる。歯部１０Ｂと歯部１０Ｄと歯部１０Ｆと歯部１０Ｈとにそれぞれ第３のインシュレータ１５Ｃを組み付けることにより、全ての歯部１０への第３のインシュレータ１５の組み付けが完了する。 Subsequently, as shown in FIG. 34, a third insulator 15C having no stepped portions 15e formed at both ends in the circumferential direction is combined with the tooth portion 10B arranged at a position separated by 90 degrees around the central axis C. They are attached to the tooth portion 10D, the tooth portion 10F, and the tooth portion 10H, respectively. That is, the third insulator 15C is arranged between two adjacent third insulators 15B. At this time, both ends of the third insulator 15C in the circumferential direction are superimposed on the radially outer side of the stepped portion 15e of the adjacent third insulator 15B. By assembling the third insulators 15C to the teeth 10B, the teeth 10D, the teeth 10F, and the teeth 10H, the assembly of the third insulators 15 to all the teeth 10 is completed.
　本実施の形態では、第３のインシュレータ１５Ｂと第３のインシュレータ１５Ｃとの２種類の第３のインシュレータ１５のみを用いて固定子２を製造することができる。なお、本実施の形態の第３のインシュレータ１５の組み付け方は、歯部１０の数が偶数の場合に利用することができる。 In this embodiment, the stator 2 can be manufactured using only two types of third insulators 15, the third insulator 15B and the third insulator 15C. The method of assembling the third insulator 15 of the present embodiment can be used when the number of teeth 10 is even.
実施の形態４．
　次に、図３５を参照して、実施の形態４にかかる送風機１８について説明する。図３５は、実施の形態４にかかる送風機１８の正面図である。なお、実施の形態４では、前記した実施の形態１と重複する部分については、同一符号を付して説明を省略する。 Embodiment 4.
Next, the blower 18 according to the fourth embodiment will be described with reference to FIG. 35 . FIG. 35 is a front view of blower 18 according to the fourth embodiment. In addition, in Embodiment 4, the same code|symbol is attached|subjected about the part which overlaps with above-described Embodiment 1, and description is abbreviate|omitted.
　図３５に示すように、軸部４に羽根１９を連結し、羽根１９を回転させて送風する送風機１８に電動機１を用いてもよい。なお、羽根または羽根車を回転させて空気を流動させる換気扇に電動機１を用いてもよい。 As shown in FIG. 35, the electric motor 1 may be used for the blower 18 that connects the blades 19 to the shaft portion 4 and rotates the blades 19 to blow air. The electric motor 1 may be used as a ventilation fan that rotates blades or impellers to flow air.
　以上の実施の形態に示した構成は、一例を示したものであり、別の公知の技術と組み合わせることも可能であるし、実施の形態同士を組み合わせることも可能であるし、要旨を逸脱しない範囲で、構成の一部を省略、変更することも可能である。 The configurations shown in the above embodiments are examples, and can be combined with another known technique, or can be combined with other embodiments without departing from the gist of the invention. It is also possible to omit or change part of the configuration within the scope.
　１　電動機、２，２Ａ，２Ｂ　固定子、３　回転子、４　軸部、５　軸受け、６，７　外郭、８　固定子鉄心、９　コアバック、９ａ　溝、１０，１０Ａ，１０Ｂ，１０Ｃ，１０Ｄ，１０Ｅ，１０Ｆ，１０Ｇ，１０Ｈ　歯部、１１　スロット、１２　インシュレータ、１３　第１のインシュレータ、１３ａ　第１の被覆壁、１３ｂ　第１のストッパ部、１４　第２のインシュレータ、１４ａ　第２の被覆壁、１４ｂ　第２のストッパ部、１５，１５Ａ，１５Ｂ，１５Ｃ　第３のインシュレータ、１５ａ　第３の被覆壁、１５ｂ　第３のストッパ部、１５ｃ　開口、１５ｄ　コイルガード部、１５ｅ　段差部、１６　巻線、１７　コイル、１８　送風機、１９　羽根、Ｃ　中心軸。 1 electric motor, 2, 2A, 2B stator, 3 rotor, 4 shaft, 5 bearing, 6, 7 shell, 8 stator core, 9 core back, 9a groove, 10, 10A, 10B, 10C, 10D, 10E , 10F, 10G, 10H tooth portion, 11 slot, 12 insulator, 13 first insulator, 13a first covering wall, 13b first stopper portion, 14 second insulator, 14a second covering wall, 14b second 2 stopper portions, 15, 15A, 15B, 15C third insulator, 15a third covering wall, 15b third stopper portion, 15c opening, 15d coil guard portion, 15e stepped portion, 16 winding, 17 coil, 18 blower, 19 blades, C center shaft.

Claims (7)

  1. 　筒状のコアバックと、
    　前記コアバックの内周面から突出するように前記コアバックの周方向に並べられた複数の歯部と、
    　複数の前記歯部をそれぞれ覆う複数のインシュレータと、
    　前記インシュレータを介して前記歯部に巻線が巻き付けられて形成されたコイルと、を備え、
    　隣り合う前記歯部の間には、スロットが形成されており、
    　前記コアバックと複数の前記歯部とは、分割されており、
    　前記インシュレータは、
    　前記歯部のうち前記コアバックの中心軸に沿った一端部を覆う第１のインシュレータと、
    　前記歯部のうち前記中心軸に沿った他端部を覆う第２のインシュレータと、
    　前記歯部のうち前記コアバックの半径方向に沿った前記歯部の中心より外側部分を覆う第３のインシュレータと、に分割されており、
    　前記第３のインシュレータには、前記スロット内に向けて突出するコイルガード部が形成されていることを特徴とする固定子。     A cylindrical core back,
    a plurality of teeth arranged in the circumferential direction of the core back so as to protrude from the inner peripheral surface of the core back;
    a plurality of insulators respectively covering the plurality of teeth;
    a coil formed by winding a wire around the tooth through the insulator,
    slots are formed between adjacent teeth;
    The core back and the plurality of teeth are divided,
    The insulator is
    a first insulator covering one end of the tooth portion along the central axis of the core back;
    a second insulator covering the other end of the tooth along the central axis;
    a third insulator that covers a portion of the tooth portion outside the center of the tooth portion along the radial direction of the core back,
    A stator according to claim 1, wherein the third insulator is formed with a coil guard portion projecting into the slot.
  2. 　各前記スロット内には、前記スロットに隣接する２つの第３のインシュレータのそれぞれから突出する前記コイルガード部が配置されており、
    　同一の前記スロット内に配置される前記コイルガード部のうち一方には、他方の前記コイルガード部よりも前記半径方向内側に位置するように屈曲された段差部が形成されていることを特徴とする請求項１に記載の固定子。     The coil guard portions projecting from each of two third insulators adjacent to the slot are arranged in each of the slots,
    One of the coil guard portions arranged in the same slot is formed with a stepped portion that is bent so as to be positioned more inward in the radial direction than the other coil guard portion. A stator according to claim 1.
  3. 　前記第３のインシュレータは、前記半径方向に開口する筒状の被覆壁を有しており、
    　前記被覆壁のうち前記半径方向内側の開口縁部は、前記半径方向内側に傾斜していることを特徴とする請求項１または２に記載の固定子。     The third insulator has a cylindrical covering wall opening in the radial direction,
    3. The stator according to claim 1, wherein the radially inner opening edge of the covering wall is inclined radially inward.
  4. 　請求項１から３のいずれか１項に記載の固定子と、
    　複数の前記歯部の内周に配置された回転子と、を備えたことを特徴とする電動機。     A stator according to any one of claims 1 to 3;
    and a rotor disposed on the inner periphery of the plurality of teeth.
  5. 　請求項４に記載の電動機を備えたことを特徴とする送風装置。 A blower device comprising the electric motor according to claim 4.
  6. 　筒状のコアバックと、前記コアバックの内周面から突出するように前記コアバックの周方向に並べられた複数の歯部と、複数の前記歯部をそれぞれ覆う複数のインシュレータと、前記インシュレータを介して前記歯部に巻線が巻き付けられて形成されたコイルと、を備え、隣り合う前記歯部の間には、スロットが形成されており、前記コアバックと複数の前記歯部とは、分割されており、前記インシュレータは、前記歯部のうち前記コアバックの中心軸に沿った一端部を覆う第１のインシュレータと、前記歯部のうち前記中心軸に沿った他端部を覆う第２のインシュレータと、前記歯部のうち前記コアバックの半径方向に沿った前記歯部の中心より外側部分を覆う第３のインシュレータと、に分割されており、前記第３のインシュレータには、前記スロット内に向けて突出するコイルガード部が形成された固定子の製造方法であって、
    　複数の前記歯部のそれぞれに前記第１のインシュレータおよび前記第２のインシュレータを組み付ける第１の組付工程と、
    　複数の前記歯部を周方向に並べて配置する配置工程と、
    　前記第１のインシュレータおよび前記第２のインシュレータを介して前記歯部に前記巻線を巻き付けて前記コイルを形成する巻付工程と、
    　複数の前記歯部のそれぞれに前記半径方向外側から前記第３のインシュレータを組み付ける第２の組付工程と、
    　複数の前記歯部のそれぞれに前記コアバックを組み付ける第３の組付工程と、
    　を含むことを特徴とする固定子の製造方法。     a tubular core back; a plurality of teeth arranged in a circumferential direction of the core back so as to protrude from an inner peripheral surface of the core back; a plurality of insulators covering the plurality of teeth; a coil formed by winding a wire around the teeth through the core-back, and a slot is formed between the teeth adjacent to each other; and the core-back and the plurality of teeth are , and the insulator is divided into a first insulator covering one end portion of the tooth portion along the central axis of the core back, and a first insulator covering the other end portion of the tooth portion along the central axis. It is divided into a second insulator and a third insulator covering a portion of the tooth portion outside the center of the tooth portion along the radial direction of the core-back, and the third insulator includes: A method for manufacturing a stator in which a coil guard portion protruding into the slot is formed,
    a first assembling step of assembling the first insulator and the second insulator to each of the plurality of tooth portions;
    an arrangement step of arranging the plurality of tooth portions side by side in the circumferential direction;
    a winding step of winding the winding around the tooth portion via the first insulator and the second insulator to form the coil;
    a second assembling step of assembling the third insulator to each of the plurality of tooth portions from the radially outer side;
    a third assembling step of assembling the core back to each of the plurality of tooth portions;
    A method for manufacturing a stator, comprising:
  7. 　請求項６に記載の固定子の製造方法により製造された前記固定子に対して、複数の前記歯部の内周に回転子を配置することを特徴とする電動機の製造方法。 A method of manufacturing an electric motor, wherein a rotor is arranged on the inner circumference of a plurality of the tooth portions in the stator manufactured by the method of manufacturing the stator according to claim 6.
PCT/JP2021/017811 2021-05-11 2021-05-11 Stator, motor, blower, method for manufacturing stator, and method for manufacturing motor WO2022239097A1 (en)

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20020113518A1 (en) * 2001-02-20 2002-08-22 Chun-Pu Hsu Composite stator structure
JP2006129590A (en) * 2004-10-28 2006-05-18 Nippon Densan Corp Motor and manufacturing method for armature
WO2014061101A1 (en) * 2012-10-16 2014-04-24 三菱電機株式会社 Armature for rotating electrical machine
WO2016136384A1 (en) * 2015-02-25 2016-09-01 三菱電機株式会社 Armature and rotating electric machine

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20020113518A1 (en) * 2001-02-20 2002-08-22 Chun-Pu Hsu Composite stator structure
JP2006129590A (en) * 2004-10-28 2006-05-18 Nippon Densan Corp Motor and manufacturing method for armature
WO2014061101A1 (en) * 2012-10-16 2014-04-24 三菱電機株式会社 Armature for rotating electrical machine
WO2016136384A1 (en) * 2015-02-25 2016-09-01 三菱電機株式会社 Armature and rotating electric machine

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