阅读说明：本技术 绝缘体、包括该绝缘体的定子以及包括该绝缘体的电动机 (Insulator, stator including the same, and motor including the same ) 是由 菱田光起 米田博 国友浩胜 于 2019-01-15 设计创作，主要内容包括：绝缘体(5)包括线圈缠绕部(50)、第一凸缘部(51)以及第二凸缘部(52),线圈缠绕部(50)供线圈(7)缠绕,第一凸缘部(51)设在线圈缠绕部(50)的靠铁心扇形体(41)一侧,且具有将线圈(7)引导至线圈缠绕部(50)的线圈导入区域(53),第二凸缘部(52)设在线圈缠绕部(50)的靠齿(42)径向内端一侧。从外周面(50a)延伸出去的突起部(54)设为位于线圈导入区域(53)的出口(53a)附近且线圈(7)的第一层中第一周绕线(711)与第二周绕线(712)之间。(The insulator (5) includes a coil winding portion (50), a first flange portion (51) and a second flange portion (52), the coil winding portion (50) is wound with the coil (7), the first flange portion (51) is provided on the core segment (41) side of the coil winding portion (50) and has a coil introduction region (53) for guiding the coil (7) to the coil winding portion (50), and the second flange portion (52) is provided on the tooth (42) radially inner end side of the coil winding portion (50). A protrusion (54) extending from the outer peripheral surface (50a) is provided in the vicinity of an outlet (53a) of the coil introduction region (53) and between the first peripheral winding (711) and the second peripheral winding (712) in the first layer of the coil (7).)

1. An insulator comprising a coil winding portion for winding a coil formed of a wire so as to cover an axial end surface and at least a part of both circumferential side surfaces of a tooth protruding from a core segment, a first flange portion provided next to one of a tooth proximal end side and a tooth radially inner end side of the coil winding portion and having a coil introduction region for guiding the coil to the coil winding portion, and a second flange portion provided next to the other of the tooth proximal end side and the tooth radially inner end side of the coil winding portion, the insulator being characterized in that:

a protrusion protruding from a surface of the coil winding portion is provided so as to be located near an outlet of the coil introduction region and between the first and second peripheral wires in the first layer of the coil.

2. The insulator of claim 1, wherein:

the protrusion is provided across the bottom of the coil introduction region and the surface of the coil winding portion.

3. The insulator of claim 1, wherein:

the protrusions are provided at a predetermined distance in the circumferential direction from the center line of the coil insertion region.

4. The insulator of claim 1, wherein:

when the coil is wound around the coil winding portion, a portion of the side surface of the protrusion abutting against the first circumferential winding is a curved surface which is convex toward the first circumferential winding, and a portion of the side surface of the protrusion abutting against the second circumferential winding is a curved surface which is convex toward the second circumferential winding.

5. The insulator of claim 1, wherein:

the height of the protrusion in the axial direction is greater than or equal to the wire diameter of the coil and less than or equal to a multiple of the wire diameter of the coil.

6. A stator, characterized by:

the stator core of the present invention is characterized by comprising a plurality of stator segments each having the insulator according to claim 1 on each axial end face of the teeth of the core segment, the stator segments being formed by winding and attaching the coil on the coil winding portion of the insulator,

the stator is formed by connecting a plurality of stator segments into a ring shape, and the teeth protrude radially inward of the ring.

7. A stator, characterized by:

the stator core of the present invention is characterized by comprising a plurality of stator segments each having the insulator according to claim 1 on each axial end face of the teeth of the core segment, the stator segments being formed by winding and attaching the coil on the coil winding portion of the insulator,

the stator includes a plurality of stator segments connected in a ring shape and the teeth protrude radially inward of the ring,

the coils are wound in an array on the coil winding part.

8. A stator, characterized by:

the stator core of the present invention is characterized by comprising a plurality of stator segments each having the insulator according to claim 1 on each axial end face of the teeth of the core segment, the stator segments being formed by winding and attaching the coil on the coil winding portion of the insulator,

the stator includes a plurality of stator segments connected in a ring shape and the teeth protrude radially inward of the ring,

gaps between the teeth adjacent in the circumferential direction are configured as stator slots that receive the coils,

in the stator slot, insulating paper for insulating the core segment from the coil and the teeth from the coil is disposed so as to cover side surfaces of the teeth, and partially overlaps the first flange portion and the second flange portion of the insulator in the axial direction.

9. An electric motor characterized by:

the stator includes at least a stator and a rotor, the stator including a plurality of stator segments each having the insulator according to claim 1 on each axial end face of the teeth of the core segment, the stator segments being formed by winding and mounting the coil on the coil winding portion of the insulator, the stator including a plurality of stator segments connected in a ring shape, the teeth protruding radially inward of the ring,

the rotor includes a rotating shaft, and is disposed radially inward of the stator with a predetermined gap from the stator.

Technical Field

The present invention relates to an insulator on which a coil is wound, a stator including the insulator, and a motor including the insulator.

Background

In recent years, as the demand for industrial and vehicle-mounted motors has increased, it has been required to improve the efficiency of the motors and reduce the cost.

It is known that: one of the methods of improving the efficiency of the motor is to increase the space factor of the coils disposed in the stator slots of the stator. By increasing the space factor of the coil, it is possible to suppress loss of the motor due to the current flowing through the coil when the motor is in operation.

A so-called aligned winding coil, which is a state in which a coil is wound in alignment around a plurality of teeth (teeth) of a stator, is known as a structure for increasing a space factor of the coil. Various structures have been proposed to realize the aligned winding coil (see, for example, patent documents 1 to 4). Patent document 1 proposes the following configuration: a step or a slope is formed at the end of a cylinder of an insulated coil winding pipe for winding a coil or inside a flange part formed at both ends of the cylinder to realize the winding of the coil in an array. Patent document 2 discloses the following configuration: a receiving groove for receiving a wound coil is formed at a side surface of an insulator which is mounted on the plurality of teeth (teeth) and insulates the coil from the plurality of teeth (teeth), thereby realizing an array winding of the coil.

Patent document 1: japanese laid-open patent publication No. Hei 11-122855

Patent document 2: japanese laid-open patent publication No. 2006-115565

Patent document 3: specification of U.S. Pat. No. 6356001

Patent document 4: international publication No. 2011/118357

Disclosure of Invention

Technical problems to be solved by the invention

In general, the insulator and the coil bobbin are obtained by molding a resin material with a mold. On the other hand, since motor performance varies depending on user specifications, even if the same stator core or a plurality of teeth are used, the motor performance is often adjusted to each specification by changing the wire diameter or the number of turns of the coil to adjust the current value passing through the coil.

In the conventional structures disclosed in patent documents 1 and 2, it is necessary to change the width of the receiving groove or the width of the step or the angle of inclination depending on the wire diameter of the coil, and to form the insulator by newly manufacturing a mold each time, which causes an increase in cost.

The present invention has been made to solve the above problems, and an object of the present invention is to: provided is an insulator which can make the wound coil be wound in a whole column even if the wire diameter of the coil is changed.

Technical solution for solving technical problem

In order to achieve the above object, in the insulator according to the present invention, a protrusion extending from a surface of the coil winding portion is provided in the vicinity of an outlet of the coil introduction region, and positions of the first and second windings in the first layer of the coil are regulated.

Specifically, an insulator according to the present invention includes a coil winding portion for winding a coil formed of a winding wire so as to cover an axial end surface and at least a part of both circumferential side surfaces of a tooth protruding from a core segment, a first flange portion provided next to one of a tooth proximal end side and a tooth radially inner end side of the coil winding portion and having a coil introduction region for guiding the coil to the coil winding portion, and a second flange portion provided next to the other of the tooth proximal end side and the tooth radially inner end side of the coil winding portion, and is characterized in that: a protrusion protruding from a surface of the coil winding portion is provided so as to be located near an outlet of the coil introduction region and between the first and second peripheral wires in the first layer of the coil.

According to this configuration, the first and second peripheral wires are wound around the coil winding portion so as not to interfere with each other, and the coils can be wound in an aligned manner. In addition, the insulator provided with the same protrusion can be used for coils with different wire diameters, so that the cost of the insulator can be reduced.

Preferably, the protrusion is provided across a bottom of the coil introduction region and a surface of the coil winding portion.

According to this configuration, when the coil is wound on the coil winding portion obliquely with respect to the coil winding portion, the position of the second peripheral wire can be appropriately defined, and the coil can be reliably wound in an aligned manner.

Preferably, the protrusion is provided at a predetermined distance in the circumferential direction from a center line of the coil insertion region.

Preferably, when the coil is wound around the coil winding portion, a portion of a side surface of the protrusion abutting against the first winding is a curved surface which is convex toward the first winding, and a portion of a side surface of the protrusion abutting against the second winding is a curved surface which is convex toward the second winding.

According to this configuration, when the first peripheral wire abuts against the protrusion and the second peripheral wire abuts against the protrusion, the contact area therebetween can be reduced. In this way, the guiding direction of the first peripheral wire and the winding angle of the second peripheral wire with respect to the coil winding portion can be made to be desired values without being greatly affected by the shape of the protrusion, and the coil can be reliably wound in an aligned manner.

The height of the protrusion in the axial direction is greater than or equal to the wire diameter of the coil and less than or equal to a multiple of the wire diameter of the coil.

According to this configuration, the first and second peripheral wires can be reliably wound in an aligned manner without moving to the opposite side beyond the projection.

The stator according to the present invention is characterized in that: the stator is configured such that the plurality of stator segments are connected in a ring shape and the teeth protrude inward in a radial direction of the ring, and the plurality of stator segments are configured such that the insulator is provided on each axial end surface of the teeth of the core segment, and a coil formed of a wire is wound around the coil wound portion of the insulator.

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

Preferably, the coil is wound in an array on the coil winding part.

Preferably, gaps between the teeth adjacent in the circumferential direction are configured as stator slots that receive the coils, and in the stator slots, insulating paper that insulates the core segments from the coils and the teeth from the coils is disposed so as to cover side surfaces of the teeth and to partially overlap the first flange portion and the second flange portion of the insulator, respectively, in the axial direction.

According to this configuration, the teeth adjacent to each other in the circumferential direction of the stator can be reliably electrically insulated from each other.

The motor of the present invention is characterized in that: the rotor includes a rotating shaft, and is disposed radially inside the stator with a predetermined gap from the stator.

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

Effects of the invention

As described above, according to the present invention, even when coils having different wire diameters are wound, it is possible to realize winding of coils in an aligned row while suppressing occurrence of winding disorder.

Drawings

Fig. 1 is a plan view of a motor according to an embodiment.

Fig. 2 is an equivalent circuit diagram of the motor shown in fig. 1.

Fig. 3 is a schematic view of the stator.

Fig. 4A is a perspective view illustrating a portion enclosed by a dotted line shown in fig. 1.

Fig. 4B is a side view of the configuration shown in fig. 4A, viewed from the radial direction.

Fig. 4C is a side view of the configuration shown in fig. 4A, as viewed from the circumferential direction.

Fig. 5A is a perspective view of a main part of an insulator according to an embodiment.

Fig. 5B is a schematic view of the insulator shown in fig. 5A as viewed from the axial direction.

Fig. 5C is a schematic view of a main part of the insulator according to the embodiment, as viewed from the axial direction, and the coil is wound around the insulator.

Fig. 6A is a schematic diagram of a main part of an insulator on which a first coil is wound for comparison, as viewed from the axial direction.

Fig. 6B is another schematic view of a main portion of an insulator on which a first coil is wound for comparison as viewed from the axial direction.

Fig. 6C is a schematic view of a main part of an insulator on which a second coil is wound for comparison, as viewed from the axial direction.

Fig. 6D is another schematic view of the main portion of the insulator on which the second coil is wound for comparison, as viewed from the axial direction.

Detailed Description

Embodiments of the present invention will be described in detail below with reference to 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 objects, or the applications of the invention.

(embodiment mode)

[ Structure of Motor and stator ]

Fig. 1 is a plan view of a motor according to the present embodiment, fig. 2 is an equivalent circuit diagram of the motor shown in fig. 1, and fig. 3 is a schematic view of a stator, which is a view of a stator 4 viewed from an axial direction of a shaft 2. For convenience of explanation, illustration and explanation of some constituent components and their functions are omitted in fig. 1 and 3. For example, frames, bus bars, and the like are not shown. In fig. 3, the insulator 5 is not shown. An outer housing for housing the stator 4 is not shown. The shape of the outer housing is, for example, a cylindrical body, a substantially square body, a substantially rectangular parallelepiped body, a polygonal columnar body, or the like made of metal, and can be appropriately selected according to the specification of the motor 1. The structural 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 shown in fig. 3 and the lead terminals 71 of these coils are greatly different from the actual shape. In fig. 2, the sign + indicates the start of coil winding, and the sign-indicates the end of coil winding.

In the following description, the longitudinal direction of the shaft 2 is sometimes referred to as the axial direction, the radial direction of the stator 4 is sometimes referred to as the radial direction, and the circumferential direction of the stator 4 is sometimes referred to as the circumferential direction. In the axial direction, the side of the coils U1 to W4 on which the lead terminals 71 are provided is referred to as "up", the opposite side thereof is referred to as "down", the center side of the stator 4, i.e., the side on which the shaft 2 and the rotor are provided, is referred to as "inside", and the opposite side thereof, i.e., the side on which the stator core 40 is provided, is referred to as "outside". Sometimes "left" and "right" in the circumferential direction are defined as viewed from the axially upper side.

The stacking direction of the electromagnetic steel sheets described later is the same as the axial direction, and means the same.

In the following description, terms such as a plurality of teeth (teeth: plural form of tooth) and tooth (tooth) are used in a differentiated manner. A plurality of teeth projecting in the center direction of the annular stator core 40 are referred to as a plurality of teeth (tooth: complex form) 42. One of the plurality of tooth portions of the stator core 40 is denoted as a tooth 42. Similarly, a plurality of teeth of the core segment 41 described later are referred to as a plurality of teeth 42. One of the plurality of teeth of the core segment 41 is denoted as a tooth 42. Patent documents 3 and 4 are well-known documents that use words such as a plurality of teeth and teeth separately.

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

The rotor 3 includes a shaft 2 and magnets 31, the magnets 31 being arranged to oppose the stator 4 with N poles and S poles alternating with each other along the outer circumferential direction of the shaft 2. In the present embodiment, the magnet 31 used for the rotor 3 is a neodymium magnet, but the material, shape, and material thereof may be appropriately changed in accordance with the output of the motor or the like. The rotor 3 is disposed radially inside the stator 4 with a certain space from the stator 4 as viewed in the axial direction.

The stator 4 is a cylindrical body formed by annularly connecting a plurality of stator segments 40 a. The specific structure of the stator segment 40a is as follows: the insulators 5 are attached to the teeth 42 of the core segment 41 from the upper and lower end surfaces, respectively, and insulators such as insulating paper 6 are further attached between the insulators 5, and a coil U1, for example, is formed by winding a wire around the coil winding portion 50 of the insulator 5 and the arrangement portion (see fig. 4A to 4C) of the insulators such as the insulating paper 6. The stator segment 40a having the above-described configuration has a cylindrical shape having a substantially fan-shaped cross section.

The stator 4 and the stator segment 40a have a plurality of core segments 41 and teeth 42 projecting radially inward from the inner periphery of each of the core segments 41. An electromagnetic steel sheet containing silicon or the like is punched into a substantially annular stator core plate (stator core sheet), the stator core plate is punched into an independent sheet-shaped core segment plate (core segment sheet) constituting a part of the stator core plate, and the core segment plates are laminated in multiple layers to form a laminated body, which is the core segment 41. The core segment 41 having the above-described configuration has an external appearance of a columnar body having a sectional shape of an independent sheet constituting a part of a substantially annular stator core plate. The stacking direction of the plate bodies is a normal direction to the plate surfaces of the plate bodies. The core segment 41 includes a yoke portion 41c and teeth 42 protruding from a substantially central portion of the yoke portion 41 c.

The core segment 41 has a recess 41a formed in one side surface of a yoke portion 41c located in the circumferential direction, a projection 41b formed in the other side surface, and the recess 41a and the projection 41b extend in the entire axial direction on each side surface. When one core segment 41 is described, the concave portion 41a of the core segment 41 is fitted into the convex portion 41b of the core segment 41 adjacent to one side in the circumferential direction and connected to each other, and the convex portion 41b of the core segment 41 is fitted into the concave portion 41a of the core segment 41 adjacent to the other side in the circumferential direction and connected to each other. By fitting and connecting the core segments 41 adjacent in the circumferential direction to each other in this way, the annular stator core 40 can be formed.

As shown in fig. 1 and 3, the teeth 42 can be arranged at equal intervals along the inner circumference of the stator core 40 by forming the annular stator core 40 by connecting the core segments 41. Each interval between circumferentially adjacent teeth 42 constitutes a stator slot 43.

The stator 4 has 12 coils U1 to W4, which are attached to the respective teeth 42 via insulators 5 and insulating paper 6 (see fig. 4A to 4D) and arranged in the respective stator slots 43 as viewed in the axial direction. The coils U1 to W4 are each formed of a wire having a circular cross section, which is made of a metal material such as copper having an insulating film coated on the surface thereof, wound in a row around the insulator 5, and wound in multiple layers, not shown. The multilayer winding refers to a state in which the coil 7 is wound on the insulator 5 in multiple layers. The "round shape" includes a machining tolerance of the winding wire and a deformation of the winding wire when the winding wire is wound on the teeth 42, and the same is meant in the following description. In the following description, the coils U1 to W4 are not particularly specified, and when the structure and the like are described by selecting one, they will be referred to as the coil 7.

As shown in fig. 2, coils U1 to U4, coils V1 to V4, and coils W1 to W4 are connected in series, and the three phases U, V, and W are connected by a star connection method. Three-phase currents of U-phase, V-phase, and W-phase having a phase difference of 120 ° in electrical angle are supplied to coils U1 to U4, coils V1 to V4, and coils W1 to W4, respectively, and are excited, thereby generating a rotating magnetic field. The rotating magnetic field generates a torque in the rotor 3, and the shaft 2 is supported by a bearing, not shown, to rotate.

In the present embodiment, the number of magnetic poles of the rotor 3 is 10 in total, and the number of stator slots 43 is 12, with 5N poles and 5S poles facing the stator 4, but the present invention is not limited to this, and other combinations of the number of magnetic poles and the number of stator slots are also applicable.

[ constitution of main portion of stator segment ]

Fig. 4A to 4C show a perspective view of a portion encircled by a broken line of fig. 1, and side views viewed from the radial direction and the circumferential direction, respectively. For convenience of explanation, the coil 7 is not shown in fig. 4A to 4C. Although the insulating paper 6 interposed between the insulator 5 and the core segment 41 and the insulating paper 6 interposed between the insulator 5 and the teeth 42 are also shown, they are shown in a state before they are bent and housed in the stator slots 43. In fig. 4A, the projection 54 described later is not shown.

As shown in fig. 4A to 4C, insulators 5 having the same shape are attached to teeth 42 protruding from one core segment 41 from both upper and lower end faces in the axial direction, respectively; insulating paper 6 is sandwiched between the core segment 41 and the insulator 5 and between the teeth 42 and the insulator 5. Thus, the insulator 5 is provided so as to cover both end surfaces in the axial direction of the teeth 42 and portions in the vicinity of both end surfaces.

The insulator 5 is an insulating member obtained by molding an insulating resin material, and includes a coil winding portion 50 around which the coil 7 (see fig. 5C) is wound, a first flange portion 51 formed at one end of the coil winding portion 50, and a second flange portion 52 formed at the other end of the coil winding portion 50. In the present embodiment, the first flange portion 51 is attached to the core segment 41 side, and the second flange portion 52 is attached to the radial inner end of the tooth 42 located on the radial inner side of the stator 4. A coil introduction region 53 is formed in the first flange portion 51, and when the coil is wound around the coil winding portion 50, the coil constituting the coil 7 is guided toward the coil winding portion 50 through the coil introduction region 53, and the winding start portion is brought into contact with an inner surface 51a of the first flange portion 51 facing the second flange portion 52 (hereinafter, referred to as an inner surface 51a of the first flange portion 51) and is guided to the coil winding portion 50. In this specification, the winding start portion of the coil 7 refers to a portion of the coil 7 near the first turn of the first layer coil wound on the coil winding portion 50.

Outer circumferential surfaces 50a, 50b of the outer circumferential surface of the coil winding portion 50, which cover both axial end surfaces of the teeth 42, are inclined surfaces that are monotonically inclined from the first flange portion 51 toward the second flange portion 52 and that gradually increase in height from the axial upper end surface or the axial lower end surface of the teeth 42. Surfaces 50c, 50d of the outer peripheral surface of the coil winding portion 50 covering both circumferential end surfaces of the teeth 42 are formed to be orthogonal to the axial upper end surfaces of the teeth 42. In the following description, the outer peripheral surfaces 50a to 50d may be referred to as surfaces of the coil wound portions 50. The surface of the coil winding portion 50 is a smooth surface on which no groove or the like is provided. However, on this surface, there remain irregularities (not shown) that are generated when the insulator 5 is molded with a mold or the like. The arithmetic mean roughness of the irregularities is, for example, about 0.25 μm to about 0.3 μm. Note that "orthogonal" means "orthogonal" including a machining tolerance of the insulator 5, a machining tolerance of the tooth 42, and an assembly tolerance when the insulator 5 is attached to the tooth 42, and "parallel" means "parallel" including a machining tolerance of the insulator 5 and an assembly tolerance when the insulator 5 is attached to the tooth 42, and the same applies to the following description.

The inner surface 51a of the first flange 51 is parallel to a surface perpendicular to the axial upper end surface or the axial lower end surface of the teeth 42.

The radially inner end of the coil introduction region 53 corresponds to the outlet 53a of the coil introduction region 53, and the coil 7 is wound around the coil wound portion 50 through the outlet 53a (see fig. 5C). The projection 54 is provided near the exit 53a of the coil introduction region 53, and the projection 54 is also provided across the bottom of the coil introduction region 53 and the outer peripheral surface 50a of the coil winding portion 50 (see fig. 5A and 5B). The function and configuration of the projection 54 will be described in detail later.

The insulator 5 and the insulating paper 6 both have a function of electrically insulating the core segment 41 from the coil 7 and the teeth 42 from the coil 7. The insulator 5 also has a function of stably maintaining the winding of the coil 7 in an aligned state as described later.

The insulating paper 6 is impregnated with insulating oil, for example, and is provided so as to cover both circumferential side surfaces of the teeth 42 or to partially overlap the first flange portion 51 and the second flange portion 52 of the insulator 5 in the axial direction. When assembling the motor 1, the insulating paper 6 is bent to cover the inside of the stator groove 43, and is not shown. In this way, the core segments 41 and the coils 7 and the teeth 42 and the coils 7 can be electrically insulated from each other, and the core segments 41 and the teeth 42 adjacent to each other in the circumferential direction can be electrically insulated from each other.

[ constitution of the main portion of the insulator ]

Fig. 5A is a perspective view showing a main part of the insulator according to the present embodiment. Fig. 5B shows a schematic view of the insulator shown in fig. 5A as viewed from the axial direction. Fig. 5C is a schematic view of a main part of the insulator according to the present embodiment, as viewed in the axial direction, and a coil is wound around the insulator. The insulator 5 shown in fig. 5A to 5C is the same as that shown in fig. 4A to 4C, and for convenience of explanation, the structure of the insulator 5 is simplified and shown in fig. 5A to 5C.

As shown in fig. 5A to 5C, the insulator 5 is provided with a protrusion 54 near an exit 53a of the coil introduction region 53 having a slot width W. Specifically, the protrusion 54 is provided across a portion of the bottom of the coil introduction region 53 located near the outlet 53a and the outer peripheral surface 50a of the coil winding portion 50. The protrusion 54 is a substantially columnar resin member integrally molded when the insulator 5 is molded. The center of the projection 54 is located at a position spaced apart by a predetermined distance in the circumferential direction from a virtual contour line passing through the circumferential center of the coil introduction region 53 (hereinafter, simply referred to as a center line C of the coil introduction region 53) when viewed in the axial direction, and in this case, located at a position spaced apart by a predetermined distance to the left side. The predetermined pitch is appropriately changed in accordance with the wire diameter and rigidity of the coil 7, the width of the coil introduction region 53, and the like. The projection 54 is also located at a position projecting from the outlet 53a of the coil introduction region 53 toward the outer peripheral surface 50a of the coil winding portion 50 by a predetermined length L. However, the upper limit of the predetermined length L is a half value r of the wire diameter of the coil 7. As is apparent from fig. 5C, if the center of the protrusion 54 is located on the center line C of the coil introduction region 53 and the predetermined length L exceeds the half value r of the wire diameter of the coil 7 when viewed in the axial direction, the second peripheral wire 712 is separated from the inner surface of the first flange 51, and winding disorder of the coil 7 may occur.

Generally, the coil 7 is formed by forming an insulating coating on the surface of an electric wire made of copper or the like. Therefore, when referring to the wire diameter of the coil 7, it means the wire diameter including the thickness of the insulating coating. As a result, the wire diameter of the coil 7 is a value obtained by adding 2 times the thickness of the insulating coating to the wire diameter of the electric wire.

The diameter D of the projection 54 and the height H in the axial direction are set to be equal to or larger than the wire diameter of the coil 7. The diameter D of the projection 54 is set smaller than half the width W of the coil introduction region 53, and the height H in the axial direction is set to be several times or less the wire diameter of the coil 7. The width W of the coil introduction region 53 is set larger than the sum of the diameter D of the protrusion 54 and the wire diameter of the coil 7.

As shown in fig. 5C, at the outlet 53a of the coil introduction region 53, the first and second peripheral wires 711 and 712 of the first layer, which is the winding start portion of the coil 7, are wound on the coil winding portion 50 without interfering with each other. Specifically, the movement of the first peripheral wire 711 to the radially inner side is restricted by the projection 54 and is guided in a predetermined direction, in this case, in a direction along the inner surface 51a of the first flange 51. On the other hand, the second peripheral wire 712 is restricted from moving radially outward by the circumferential left end of the outlet 53a and the projection 54, and is wound thereon obliquely with respect to the coil winding portion 50. The inclination angle is automatically determined by the layout of the first peripheral winding 711, the wire diameter of the coil 7, the circumferential width of the coil winding portion 50, and the like. Note that the subsequent winding wire is also wound obliquely at the same inclination angle. In a region where the coil 7 is wound on the coil winding portion 50 through the exit 53a of the coil introduction region 53, that is, in fig. 5C, on the left side in the circumferential direction of the coil winding portion 50 in the vicinity of the exit 53a, the first peripheral winding 711 and the second peripheral winding 712 are arranged at a pitch corresponding to the diameter D of the protrusion 54.

[ Effect and the like ]

As described above, the insulator 5 according to the present embodiment includes the coil winding portion 50, the first flange portion 51, and the second flange portion 52, the coil winding portion 50 covers a part of one axial end surface and both circumferential side surfaces of the teeth 42 protruding from the core segment 41, and the coil 7 formed of a winding is wound, the first flange portion 51 is provided next to the coil winding portion 50 on the proximal end side of the teeth 42 and has the coil introduction region 53 for guiding the coil 7 to the coil winding portion 50, and the second flange portion 52 is provided next to the coil winding portion 50 on the radially inner end side of the teeth 42. The protrusion 54 protruding from the surface of the coil winding portion 50 is located near the outlet 53a of the coil introduction region 53 and between the first and second peripheral wires 711 and 712. In this way, the first and second windings 711 and 712 of the first layer of the coil 7 can be wound around the coil winding portion 50 without interfering with each other, and the coil 7 can be wound in an aligned manner. By providing the protrusion 54 across the bottom of the coil introduction region 53 and the outer peripheral surface 50a of the coil winding portion 50, when the coil 7 is wound obliquely to the coil winding portion 50, the position of the second peripheral wire 712 can be appropriately determined, and the coil 7 can be reliably wound in an aligned manner.

This point will be described below by comparing the configurations shown in fig. 6A to 6D. Fig. 6A shows a schematic view of a main part of an insulator on which a first coil is wound for comparison, as viewed from the axial direction. Fig. 6B is another schematic view of a main portion of an insulator on which a first coil is wound for comparison as viewed from the axial direction. Fig. 6C shows a schematic view of a main part of an insulator on which a second coil is wound for comparison, as viewed from the axial direction. Fig. 6D is another schematic view of the main portion of the insulator on which the second coil is wound for comparison, as viewed from the axial direction.

The insulator 5 shown in fig. 6A to 6D is not provided with the protrusion 54 shown in fig. 5A to 5C. The configuration shown in fig. 6C shows a state in which the factor of the bulging of the coil 7 differs depending on the width W of the coil introduction region 53, as compared with the configuration shown in fig. 6A. In this state, after the first peripheral wire 711 of the coil 7 is wound around the coil winding portion 50 through the coil introduction region 53, for example, as shown in fig. 6A and 6C, the first peripheral wire 711 is bent in the vicinity of the outlet 53a of the coil introduction region 53, and largely bulges radially inward to be wound around the coil winding portion 50. Therefore, the portion on the right side in the circumferential direction of the second peripheral wire 712 is greatly displaced radially inward from the position where winding is originally planned due to the bulging portion. As a result, the coil 7 is wound irregularly, and the coil cannot be wound in a row on the coil winding portion 50.

As shown in fig. 6B, if the second winding 712 is wound at a position where the winding is originally planned, the second winding 712 is overlapped on the first winding 711, and the winding of the coil 7 is disordered, so that the coil 7 cannot be wound in an aligned manner. As is apparent from the above, the protrusion 54 functions to prevent the first peripheral wire 711 of the coil 7 from bulging radially inward. The projection 54 also functions to prevent the second peripheral wire 712 of the coil 7 from bulging radially outward. Fig. 6D shows this state. When the width W of the coil introduction region 53 is large, the second peripheral wire 712 of the coil 7 is not supported and is pushed radially outward. In this case, the second peripheral wire 712 of the coil 7 and the first peripheral wire 711 of the coil 7 are interleaved and cannot be wound in a full row.

On the other hand, according to the insulator 5 of the present embodiment, by providing the protrusion 54 at a position that is apart from the center line C of the coil introduction region 53 by a predetermined distance in the circumferential direction across the outlet 53a of the coil introduction region 53 and the outer peripheral surface 50a of the coil winding portion 50, the first peripheral wire 711 can be guided in the direction along the inner surface 51a of the first flange portion 51, and the second peripheral wire 712 can be restricted from moving radially outward. Thus, the first and second peripheral wires 711 and 712 can be wound around the coil winding portion 50 without interfering with each other, and the coils 7 can be wound in an aligned manner. Further, by providing the projection 54, it is possible to avoid interference between the first and second peripheral windings 711 and 712 similarly for coils 7 having different wire diameters, and to wind the coils 7 in an aligned manner. Therefore, when the wire diameter of the coil 7 is changed, the core segments 41 and the teeth 42 of the same specification can be dealt with by one type of the insulator 5, and development cost for developing various motors can be reduced.

Further, by applying the insulator 5 according to the present embodiment to, for example, the stator 4 of the motor 1 shown in fig. 1, the coils 7 can be wound in an aligned manner, and a dead space in the coil winding portion 50 where the coils 7 are not wound can be reduced. This can increase the space factor of the coil 7 in the stator slot 43, and can improve the efficiency of the motor 1.

Note that, by forming the protrusion 54 in a cylindrical shape, the contact area between the first peripheral wire 711 and the protrusion 54 can be reduced when they are brought into contact with each other, and in addition, the same contact area can be obtained by the introduction angle of the coil 7. In this way, the first peripheral wire 711 can be guided in a desired direction without being greatly affected by the shape of the protrusion 54. Similarly, when the second peripheral wire 712 abuts against the protrusion 54, the contact area therebetween can be reduced. Thus, the second peripheral wire 712 can be wound at a desired angle without greatly affecting the angle of inclination of the second peripheral wire 712 with respect to the coil-wound portion 50 by the shape of the protrusion 54. As a result, the coil 7 can be reliably wound in an aligned manner.

The shape of the protrusion 54 is not limited to a cylindrical shape. In order to make the guiding direction of the first peripheral wire 711 and the inclination angle of the second peripheral wire 712 desirable, the contact area between the protrusion 54 and the first peripheral wire 711 and the contact area between the protrusion 54 and the second peripheral wire 712 may be made small. For example, the portion of the side surface of the protrusion 54 that abuts the first peripheral winding 711 may have a curved surface shape that is convex toward the first peripheral winding 711, and the portion of the side surface of the protrusion 54 that abuts the second peripheral winding 712 may have a curved surface shape that is convex toward the second peripheral winding 712.

As described above, the height H of the projection 54 in the axial direction is set to be equal to or greater than the wire diameter of the coil 7 and equal to or less than several times the wire diameter of the coil 7. Thus, the first and second windings 711 and 712 of the coil 7 do not move to the opposite side beyond the projection 54, and the coil 7 can be reliably wound in an aligned manner. The projection 54 is not excessively high and is not bent or broken by collision or the like. In the present specification, the term "the same" as used herein means that the axial height H of the protrusion 54 is the same as the wire diameter of the coil 7, including the machining tolerance of the protrusion 54 and the machining tolerance of the coil 7.

In the present embodiment, the example in which the protrusion 54 is formed integrally with the insulator 5 has been described, but the protrusion 54 may be formed separately from the insulator 5 and fixed to a predetermined position of the insulator 5.

(other embodiments)

In the above embodiment, the example in which the coil 7 is wound from the first flange portion 51 located closer to the base end of the tooth 42, that is, closer to the core segment 41, has been described, but the present invention is not limited thereto, and the winding may be started from the second flange portion 52 located closer to the radially inner end of the tooth 42. In this case, the coil introduction region 53 is provided in the second flange portion 52. In addition, although the coil 7 is formed of a wire having a circular cross section, the present invention is not limited thereto, and the coil 7 may be formed of a wire having a rectangular cross section, for example. The winding method of the coil 7 is not particularly limited, and a general nozzle winding method, a fly winding method, or the like can be used.

Further, an example is shown in which the insulator 5 is a so-called split insulator and is mounted thereon from the axial upper and lower directions of the teeth 42, respectively, but not limited thereto, and may be: the coil winding portion 50 is cylindrical and has an integral structure covering the entire outer peripheral surface of the teeth 42. For example, when the stator 4 is constructed such that the teeth 42 are later attached to the core segments 41, the insulator 5 of the integral structure may be employed. The insulator 5 attached to one tooth 42 from the upper and lower directions may also be different in shape. By using the insulator 5 having the same shape as the insulator 5 to be attached to one tooth from the upper and lower directions, the number of types of insulators 5 can be reduced, and the manufacturing cost can be reduced.

The outer peripheral surfaces 50a and 50b of the coil winding portion 50 may be substantially parallel to the axial upper end surfaces of the teeth 42. The inner surface 51a of the first flange 51 may be inclined radially outward with respect to a plane perpendicular to the axial upper end surface or the axial lower end surface of the tooth 42.

When the coil 7 is wound in a single layer or in multiple layers, the insulator 5 of the present embodiment can also be applied.

In the above embodiment, the description has been given of the mode in which the stator segment 40a is configured by attaching the insulator 5 to the teeth 42 of the core segment 41 and winding the coil 7 around the coil wound portion 50, but the insulator 5 of the present invention may be attached to each of the teeth 42 of the annular stator core 40 and the coil 7 may be wound around the coil wound portion 50. Here, the annular stator core is formed by laminating annular plate bodies formed by punching electromagnetic steel plates. The annular stator core has a plurality of teeth (so-called multiple teeth (teeth)).

In the above embodiment, the embodiment has been described in which each core segment 41 has one tooth portion (so-called tooth), but a plurality of tooth portions (so-called teeth) may be provided for each core segment 41.

The motor 1 of the above embodiment has been described as being used for an inner rotor motor, but it is obvious that the insulator 5 of the present embodiment can be applied to other types of motors.

As shown in fig. 3, the teeth 42 have two concave grooves at their radially inner ends (radially inner ends). The concave groove is also referred to as an auxiliary groove (auxiliary grooves) in the specification of U.S. Pat. No. 6104117 and Japanese patent application laid-open No. Hei 10-42531, etc. The auxiliary groove has an effect of suppressing cogging torque and torque ripple during rotation of the rotor 3 of the motor 1, and contributes to reduction in vibration and noise of the motor.

The winding wire of the above embodiment is also referred to as a wire for winding, and is a commercially available product. The wire or the conductor part of the wire for winding contains copper or aluminum containing inevitable impurities. The inevitable impurities are trace impurity elements that are inevitably mixed into copper and aluminum during the production process. In the case of copper, unavoidable impurities are arsenic (As), bismuth (Bi), antimony (Sb), lead (Pb), iron (Fe), sulfur (S), oxygen, etc. In the case of aluminum, inevitable impurities are silicon (Si), manganese (Mn), titanium (Ti), vanadium (V), zirconium (Zr), iron (Fe), copper (Cu), and the like. The conductor portion of the winding is covered with an insulating layer made of an insulating resin. The insulating resin can be selected from, for example, polyimide, polyamideimide, polyesterimide, polyesteramideimide, polyamide, polyhydantoin, polyurethane, polyacetal, epoxy resin, and the like, as appropriate according to the specification of the motor 1. The cross-sectional shape of the winding may be any of various shapes such as a substantially square shape and a substantially rectangular shape, in addition to the circular shape in the present embodiment.

The material composition of magnet 31 in the above embodiment contains iron (Fe), boron (B), and at least one of scandium (Sc), yttrium (Y), and a lanthanoid element, or the material composition of magnet 31 in the present embodiment contains iron (Fe), cobalt (Co), and boron (B), and at least one of scandium (Sc), yttrium (Y), and a lanthanoid element. Specifically, magnet 31 is a rare earth sintered magnet, so-called neodymium sintered magnet, or the like. The surface layer of the rare earth sintered magnet has a rust preventive film (rust preventive layer) for preventing rust.

Industrial applicability-

The insulator according to the present invention can be applied to a motor or the like which requires high efficiency because it can wind coils in an aligned manner in accordance with the wire diameters of coils having different wire diameters.

-description of symbols-

1 electric motor

2 axle

3 rotor

4 stator

5 insulating body

6 insulating paper

7 coil

711 first layer of the first winding of the coil 7

712 second turn of the first layer of coil 7

31 magnet

40 stator core

40a stator segment

41 iron core segment

41c yoke

42 teeth (tooth)

43 stator slot

50 coil winding part

51 first flange part

51a inner surface of the first flange 51

52 second flange portion

53 coil lead-in area

53a coil lead-in area 53

54 projection

Coil U1-W4