Stator, motor and pump device

Abstract

The present invention provides a stator, a motor, and a pump device, which optimize the winding process of coils. It includes: a stator core (51) composed of a plurality of iron cores (52), a coil (53), and insulating components (54, 55, 55A) for insulating the iron core and the coil. The iron core has an outer peripheral portion (521) along the circumference and a salient pole portion (522) extending from the outer peripheral portion toward the center side. The insulating component has an end face covering portion (554, 554A) covering the end face of the outer peripheral portion and a guiding portion (555) guiding a jumper wire (56) in a radially outer portion of the circumference. Let the radius of the circumscribed circle of the plurality of guiding portions of the insulating components provided on each iron core arranged along the circumference be r, let the pitch of the salient pole portions when arranging each iron core in a straight line be A, let the number of iron cores be B, and let the radius of either the radius of the outer periphery of each insulating component or the radius of the outer periphery of the stator core when arranging each iron core along the circumference be C. In this case, 2πr ≤ A·B ≤ 2πC holds.

Description

Technical Field

[0001] The present invention relates to a stator, a motor, and a pump device having a jumper wire with a coil. Background Art

[0002] An existing motor includes a rotor and a cylindrical stator disposed on the outer peripheral side of the rotor. The stator includes a stator core and a drive coil wound around a salient pole portion of the stator core via an insulator.

[0003] The stator core is composed of cores arranged along the circumferential direction of the stator. Each core includes an outer peripheral portion on the radially outer side and a salient pole portion extending from the outer peripheral portion toward the center side.

[0004] When forming a coil on each salient pole portion of the above-described stator core, the outer peripheral portions of a plurality of cores equipped with insulators are arranged in a straight line, and the coil winding process is performed with each salient pole portion in a state of facing the same direction. At this time, when forming coils on a plurality of salient pole portions with the same wire, when the wire is wound around one salient pole portion, the wire crosses over the radially outer side of a wall portion erected along the axial direction on the outer peripheral portion of the insulator and is wound around another salient pole portion (the portion where the wire crosses over the radially outer side of the wall portion is referred to as a jumper wire).

[0005] In this way, when the winding process is performed on all the salient pole portions, the outer peripheral portions of a plurality of cores of the stator core are reconfigured from a linear arrangement to a circumferential arrangement to form a stator (for example, refer to Patent Document 1).

[0006] Prior Art Documents

[0007] Patent Documents

[0008] Patent Document 1: Japanese Patent No. 5952701 Summary of the Invention

[0009] Technical Problem to be Solved by the Invention

[0010] The above-described stator is configured such that a jumper wire that crosses over the radially outer side of the wall portion passes through a contact portion between adjacent cores when the cores are arranged in a linear shape. Thus, when reconfiguring each core from a linear arrangement to a circumferential arrangement, when the angle relatively changes between adjacent cores with the contact portion as a fulcrum, slackening of the jumper wire is suppressed.

[0011] However, the stator of the above-described existing motor needs to be wound such that the jumper wire passes through the contact portion between the cores, and there is a problem that the winding process is complicated and difficult.

[0012] An object of the present invention is to enable an easy winding process of an optimized coil.

[0013] Technical solution adopted to solve the technical problem

[0014] In order to solve the above technical problem, the stator of the present invention is characterized in that the stator includes: a stator core composed of a plurality of cores arranged along a circumference; a coil provided on the plurality of cores; and an insulating member respectively provided on the plurality of cores to achieve insulation between the core and the coil. The core has an outer peripheral portion along the circumference and a salient pole portion extending from the outer peripheral portion toward the center side of the circumference. The insulating member has: an end face covering portion that covers the end face of the outer peripheral portion in the axial direction of the circumference; and a guiding portion that stands upright from the end face covering portion along the axial direction and guides a jumper wire using a radially outer portion of the circumference. The jumper wire connects a wire of the coil and a wire of another coil. Let the radius of the circumscribed circle of the plurality of guiding portions of the insulating member provided on the plurality of cores arranged along the circumference be r, let the pitch of the salient pole portions in the direction of the straight line be A when the plurality of cores are arranged in a straight line, let the number of the cores be B, and let the smaller of the radii of the outer circumferences of the plurality of insulating members and the outer circumference of the stator core be C when the plurality of cores are arranged along the circumference. In this case,

[0015] 2πr ≤ A·B ≤ 2πC holds.

[0016] In the stator of the present invention, the value A·B obtained by multiplying the pitch A of the salient pole portions in the straight arrangement of the cores by the number B of the cores, that is, the value equivalent to the total length of the stator core extended linearly, is set to be not less than the circumference 2πr of the circumscribed circle of the plurality of guiding portions and not more than the circumference 2πC of the smaller of the outer circumferences of the insulating member and the outer circumference of the stator core in the circumferential arrangement of the cores.

[0017] Therefore, in the case of winding the coil in the state of the straight arrangement of the cores, when deforming to the circumferential arrangement of the cores later, since A·B is not less than 2πr, excessive tension generated on the jumper wire is suppressed, and the jumper wire and the coil can be protected.

[0018] In addition, since A·B is not more than 2πC, the slack generated on the jumper wire when the cores are deformed into the circumferential arrangement can be effectively reduced, thereby preventing the situation where the jumper wire protrudes to the outer circumference of the insulating member or the outer circumference of the stator core.

[0019] In addition, because A·B is limited to not more than 2πC, if it is set so that A·B has a margin within this limit, excessive tension can be avoided from being applied to the jumper wire within the range where no protrusion occurs.

[0020] Moreover, the present invention does not limit the passing position of the jumper wire, but optimizes the total length dimension of the stator core extending linearly. Therefore, if the winding process is performed in a state where the stator core is extended linearly, the jumper wire can be set to an appropriate length, and by simplifying the winding process, the productivity during device manufacturing can be improved.

[0021] In the stator of the present invention, it is characterized in that the radially outer portion of the circumference of the guiding portion is a circumferential surface that is arcuate when viewed in the axial direction.

[0022] In the stator of the present invention, the outer circumference of the guiding portion is a circumferential surface with an arcuate shape in the axial direction. Therefore, the length of the circumference of the circumcircle tangent to the guiding portion and the length of the jumper wire guided along the outer circumference of the guiding portion can be made more approximate, and the total length dimension of the stator core can be set within a more appropriate range.

[0023] In the stator of the present invention, it is characterized in that when the radius of the wire of the coil is set to D,

[0024] 2πr ≤ A·B ≤ 2π(r + 2D)

[0025] holds.

[0026] Since the stator of the present invention sets the value A·B to be less than or equal to 2π(r + 2D), the total length of the stator core extending linearly is limited to a circumference with a radius larger than the circumcircle of the plurality of guiding portions by the wire diameter 2D. Therefore, the jumper wire is not likely to separate from the guiding portion by more than its radius D, and the slack and protrusion of the jumper wire can be further reduced.

[0027] In the stator of the present invention, it is characterized in that

[0028] 2πr ≤ A·B ≤ 2π(r + D)

[0029] holds.

[0030] Since the stator of the present invention sets the value A·B to be less than or equal to 2π(r + D), there is less room for the jumper wire to have a gap with respect to the guiding portion, and the slack and protrusion of the jumper wire can be further reduced.

[0031] In the stator of the present invention, it is characterized in that each of the plurality of insulating members has the guiding portion.

[0032] In the stator of the present invention, since each of the plurality of insulating members has the guiding portion, even when the jumper wire is bridged at any position in the circumference of the stator core, the slack of the jumper wire can be effectively reduced by being guided by the guiding portion.

[0033] In the stator of the present invention, it is characterized in that the insulating member has a plurality of the guiding portions.

[0034] In the stator of the present invention, since the insulating member has a plurality of guiding portions, each guiding portion can guide the jumper wire along a trajectory close to an arc. By defining the range of the above values A·B, the effects of suppressing the tension and slack of the jumper wire can be appropriately obtained.

[0035] In the stator of the present invention, it is characterized in that the insulating member has three such guiding portions.

[0036] In the stator of the present invention, since the insulating member has three guiding portions, the jumper wire can be guided along a trajectory close to an arc with a minimum number.

[0037] In addition, to solve the above technical problems, the present invention provides a motor, which is characterized in that the motor includes the above stator.

[0038] In the stator of the present invention, since the motor includes the above stator, the jumper wire will not be subjected to excessive tension and cause damage, etc., and a motor capable of stable driving can be provided.

[0039] In addition, to solve the above technical problems, the present invention provides a pump device, which is characterized in that the pump device includes the above motor.

[0040] In the stator of the present invention, since the pump device includes the above motor, a pump device capable of stable driving can be provided.

[0041] Advantages of the Invention

[0042] In the present invention, the value A·B obtained by multiplying the pitch A of the salient pole portions in the linear arrangement of the iron core by the number B of the iron cores, that is, the value equivalent to the total length of the stator iron core extended linearly, is set to be not less than the circumference 2πr of the circumscribed circle of the plurality of guiding portions, and not more than the circumference 2πC of the smaller one of the outer circumferences of the insulating member and the outer circumference of the stator iron core in the circumferential arrangement of the iron core.

[0043] Therefore, when the coil winding process is carried out in the state where the iron cores are linearly arranged, when the iron cores are deformed into the circumferential arrangement later, since A·B is not less than 2πr, excessive tension of the jumper wire is suppressed, and the jumper wire and the coil can be protected.

[0044] In addition, since A·B is not more than 2πC, the slack generated by the jumper wire when the iron cores are deformed into the circumferential arrangement can be effectively reduced, so that the situation where the jumper wire extends out of the outer circumference of the insulating member or the outer circumference of the stator iron core can be avoided.

[0045] In addition, since A·B is limited to 2πC or less, if A·B is set to have a margin within this limit, it is possible to avoid applying excessive tension to the jumper wire within the range where no protrusion occurs.

[0046] Moreover, in the present invention, instead of limiting the passing position of the jumper wire, the total length dimension of the stator core extending linearly is optimized. Therefore, if the winding process is performed with the stator core extended linearly, the jumper wire can be set to an appropriate length, and by simplifying the winding process, the productivity during device manufacturing can be improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0047] Figure 1 It is a perspective view of a pump device as an embodiment of the invention.

[0048] Figure 2 It is a longitudinal sectional view of the pump device along the axis passing through the center of the rotor.

[0049] Figure 3 It is a perspective view of the stator.

[0050] Figure 4 It is a bottom view of the stator.

[0051] Figure 5 It is a partial bottom view of the state where the stator is linearly extended.

[0052] Figure 6 It is a partial bottom view of the state where the stator core is linearly extended.

[0053] Figure 7 It is a perspective view of the lower insulator.

[0054] Figure 8 It is a perspective view of the upper insulator.

[0055] Figure 9 It is a partial bottom view of the stator.

[0056] REFERENCE MARK DESCRIPTION

[0057] 10…Pump device; 30…Motor; 40…Rotor; 50…Stator; 51…Stator core; 52…Core; 521…Outer peripheral part; 522…Pole part; 522a…Center; 523…Opposing part; 524…Notch; 525…Connecting part; 53…Coil; 54, 55, 55A…Insulator (insulating component); 541, 551…Main body part; 542, 552…Outer flange part; 543, 553…Inner flange part; 544, 554, 554A…End face covering part; 545…Columnar part; 546…Terminal; 555…Guide part; 556A…Protrusion; 56…Jumper wire; 60…Resin sealing component; 70…Circuit board; 80…Separator plate; 90…Metal component; A…Pitch; B…Number; C1…Radius; C2…Radius; D…Radius; E…Circumscribed circle; L…Axis; N…Long side direction. Detailed implementation mode

[0058] [Summary of the implementation mode]

[0059] As an implementation mode of the invention, the pump device 10 will be described with reference to the accompanying drawings. Figure 1 is a perspective view of the pump device 10, Figure 2 is a longitudinal sectional view along the axis L passing through the center of the rotor 40 (described later) of the pump device 10.

[0060] This pump device 10 is applicable to the following uses: the target fluid for suction and discharge is a liquid, for example, it is installed on a water heater, washing machine, dishwasher, etc., connected to a tap water pipe, and used to supply tap water to the device as the parent body.

[0061] In addition, in the following description, as Figure 1 and Figure 2 shown, for convenience, one direction along the axis L of the rotor shaft of the pump device 10 is defined as the "upper" side Z1 of the device, and the opposite direction is defined as the "lower" side Z2. In addition, the direction orthogonal to the axis L is set as the horizontal direction, and the direction along the circumference centered on the axis L is set as the circumferential direction. Moreover, the direction in which the lead connection part 71 of the circuit board 70 described later extends in the horizontal direction is set as the "front" side Y1 of the device, and the opposite direction is set as the "rear" side Y2. In addition, when observing the pump device 10 from the side of the lead connection part 71, the left side is set as the "left" side X1 of the device, and the opposite direction is set as the "right" side X2.

[0062] This pump device 10 includes a pump mechanism part 20 for sucking and discharging fluid and a motor 30 as its drive source, and has an integrated structure.

[0063] Moreover, the pump mechanism part 20 mainly includes a housing 21 that forms a pump chamber 22 inside and an impeller 23 disposed in the pump chamber 22.

[0064] In addition, the electric motor 30 includes a rotor 40, a stator 50 disposed around the rotor 40, a resin sealing member 60 covering the stator 50, a circuit board 70 connected to the coil 53 of the stator 50, a separation plate 80 that separates the resin sealing member 60 from the fluid in the pump chamber 22, and a metal member 90 provided on the upper end surface of the resin sealing member 60.

[0065] [Pump mechanism section]

[0066] As Figure 1 and Figure 2 shown, the housing 21 of the pump mechanism section 20 includes a substantially cylindrical peripheral wall portion 211 centered on the axis L and a bottom plate portion 212 that closes the lower end portion of the peripheral wall portion 211. Moreover, the upper end portion of the peripheral wall portion 211 is connected to the lower end portion of the resin sealing member 60 of the electric motor 30 via the separation plate 80.

[0067] In addition, the shape of the cross-section of the peripheral wall portion 211 perpendicular to the axis L is substantially circular, and the shape of the cross-section of the resin sealing member 60 perpendicular to the axis L is also substantially circular. Moreover, the peripheral wall portion 211 and the resin sealing member 60 are connected in a concentric manner.

[0068] A tubular fluid suction port 213 extending downward in the Z2 direction is formed at the center of the bottom plate portion 212. In addition, a tubular fluid discharge port 214 is formed on the outer periphery of the peripheral wall portion 211.

[0069] The fluid suction port 213 is formed concentrically with the peripheral wall portion 211 at the center of the bottom plate portion 212.

[0070] On the other hand, the fluid discharge port 214 extends in a horizontal direction parallel to the tangential direction of the peripheral wall portion 211 that is circular when viewed from above.

[0071] Both the above-mentioned fluid suction port 213 and fluid discharge port 214 communicate with the internal space of the housing 21, that is, the pump chamber 22.

[0072] A cylindrical first rotor support portion 215 centered on the axis L described later is provided at the center inside the housing 21. The first rotor support portion 215 opens upward in the Z1 direction, and the lower end portion of the rotating shaft 41 of the rotor 40 is inserted therein and supported.

[0073] The first rotor support portion 215 is located on the upper side Z1 of the fluid suction port 213 and on the path of the fluid flowing in from the fluid suction port 213. However, since it is supported by three blade-shaped legs (one is omitted in the drawing) 216 erected on the upper surface of the bottom plate portion 212, the fluid can pass between the respective legs 216 and does not hinder the inflow of the fluid.

[0074] As described above, in the center of the pump chamber 22, the impeller 23 is arranged so as to rotate about the axis L. The impeller 23 includes a circular rotating plate 232 with a central opening and a plurality of spiral blades 231 erected on the upper surface of the rotating plate 232.

[0075] The above-described first rotor support portion 215 and the leg portion 216 are loosely inserted into the opening at the center of the rotating plate 232.

[0076] In the impeller 23, the upper end portions of the respective blades 231 are fixedly connected to the lower end portion of the rotor 40.

[0077] Moreover, by driving the motor 30, the impeller 23 and the rotor 40 rotate together about the axis L, and the fluid in the pump chamber 22 flows in the rotation direction through the plurality of blades 231. As a result, the fluid generates a centrifugal force, with a low pressure on the radially inner side and a high pressure on the radially outer side, sucking the fluid from the fluid suction port 213 and discharging the fluid from the fluid discharge port 214.

[0078] [Motor: Resin Sealing Component and Separation Plate]

[0079] As Figure 2 shown, the resin sealing component 60 has a substantially cylindrical peripheral wall portion 61 centered on the axis L and an upper wall portion 62 closing the upper end portion of the peripheral wall portion 61. The peripheral wall portion 61 and the upper wall portion 62 constituting the resin sealing component 60 are integrally formed of BMC (Bulk Molding Compound), which is a thermosetting resin material.

[0080] Regarding the upper wall portion 62, its upper surface is flat and horizontal, and a metal component 90 is placed thereon.

[0081] In addition, on the upper wall portion 62, most of the substantially circular circuit board 70 with an outer diameter slightly smaller than that of the upper wall portion 62 is buried in a horizontal state.

[0082] The peripheral wall portion 61 is formed in a state where substantially the entire structure of the stator 50 is resin-sealed inside.

[0083] The peripheral wall portion 61 opens downward to the Z2 side, and the above-described housing 21 is installed via the separation plate 80 to close the opening portion.

[0084] The rotor 40 is arranged in the internal space of the peripheral wall portion 61. Moreover, the internal space of the peripheral wall portion 61 communicates with the pump chamber 22 of the housing 21. However, in this state, since the fluid in the pump chamber 22 can infiltrate into the stator 50 buried in the peripheral wall portion 61 through the pump mechanism portion 20, a separation plate 80 for sealing the fluid is provided between the resin sealing component 60 and the housing 21.

[0085] The separator plate 80 includes a flange portion 81 that is in close contact with the lower end surface of the peripheral wall portion 61 of the resin sealing member 60, a cylindrical portion 82 that is in close contact with the inner peripheral surface of the peripheral wall portion 61, a top portion 83 that is in close contact with the lower surface of the upper wall portion 62 of the resin sealing member 60, and an annular bulging portion 84 that is located between the flange portion 81 and the cylindrical portion 82 and bulges downward in the Z2 direction.

[0086] The flange portion 81, the cylindrical portion 82, the top portion 83, and the bulging portion 84 of the separator plate 80 are integrally formed without seams from a resin material, and they all have the function of isolating fluids.

[0087] The flange portion 81 is sandwiched between the lower end surface of the peripheral wall portion 61 of the resin sealing member 60 and the upper end surface of the peripheral wall portion 211 of the housing 21 to seal between them.

[0088] The bulging portion 84 bulges and fits inside the upper end portion of the peripheral wall portion 211 of the housing 21. Moreover, an O-ring 841 as a sealing material is provided between the outer periphery of the bulging portion 84 and the inner periphery of the peripheral wall portion 211, and fluid sealing is also achieved through this O-ring 841.

[0089] Inside the cylindrical portion 82, the rotor 40 is arranged with a gap. In addition, a stator 50 is arranged on the outer peripheral side of the cylindrical portion 82, and the rotor 40 and the stator 50 are arranged close to each other via the cylindrical portion 82.

[0090] At the center of the lower surface of the top portion 83, a cylindrical second rotor support portion 85 centered on the axis L is arranged. The second rotor support portion 85 opens downward in the Z2 direction, and the upper end portion of the rotation shaft 41 of the rotor 40 is inserted therein for support.

[0091] The second rotor support portion 85 is integrally formed with the top portion 83 from the same resin material as the top portion 83.

[0092] [Motor: Metal component]

[0093] As described above, the metal component 90 is a strengthening component provided on the upper surface of the resin sealing member 60.

[0094] The metal component 90 includes: a disk-shaped main body portion 91 that is in close contact with the upper surface of the resin sealing member 60; an annular rib 92 formed on the outer peripheral portion of the upper surface of the main body portion 91; and four protruding portions 93 (only two are shown in Figure 1 ) provided at uniform intervals along the circumferential direction on the outer peripheral portion of the lower surface of the main body portion 91. In the metal component 90, the main body portion 91, the annular rib 92, and the protruding portions 93 are integrally formed from a metal material such as by aluminum die-casting.

[0095] The annular rib 92 imparts high rigidity to the flat main body portion 91 and suppresses the flexure of the main body portion 91.

[0096] The protruding portion 93 is formed with a threaded hole penetrating the center, and is configured to integrally fasten and fix the metal component 90 to the housing 21, the separation plate 80, and the resin sealing member 60 by a screw 94 that penetrates the housing 21, the separation plate 80, and the resin sealing member 60 from the lower side Z2 of the pump device 10.

[0097] [Motor: Circuit Board]

[0098] The circuit board 70 is provided with Hall elements for detecting the rotational position of the rotor 40.

[0099] In addition, the circuit board 70 is connected to the wires of the coils 53 of the stator 50 described above, and forms a circuit for controlling the current flowing through each coil 53 based on the rotational position of the rotor 40 detected by the Hall elements.

[0100] Regarding the circuit board 70, the shape in plan view (the shape observed from the direction of the axis L) is generally circular, and the lead connection portion 71 for connecting the leads 72 for connecting this circuit board 70 to an external power supply circuit or the like extends radially outward.

[0101] The lead connection portion 71 protrudes outward from near the upper end of the front side Y1 of the resin sealing member 60, and the wire 72 is connected outside the resin sealing member 60.

[0102] A housing member 75 is provided at the upper end of the front side Y1 of the resin sealing member 60 to protect the surrounding of the lead connection portion 71 protruding outward.

[0103] [Motor: Rotor]

[0104] As Figure 2 shown, the rotor 40 includes a rotating shaft 41 disposed along the vertical direction with the axis L as the center, a magnet 42 provided on the outer periphery of the rotating shaft 41, and a holding member 43 that holds the magnet 42 at a position concentric with the rotating shaft 41.

[0105] The rotating shaft 41 is a round bar made of stainless steel, the lower end portion of which is supported by the first rotor support portion 215 described above, and the upper end portion of which is supported by the second rotor support portion 85 described above.

[0106] The holding member 43 has a cylindrical portion 431 for holding the magnet 42 at the upper part and a circular flange portion 432 at the lower part.

[0107] The flange portion 432 is a disk having approximately the same diameter as the impeller 23, and the impeller 23 is fixedly supported on the lower surface side thereof.

[0108] On the outer periphery of the cylindrical portion 431, a ring-shaped magnet 42 is held concentrically with the rotation axis 41. In addition, the cylindrical portion 431 has a sliding bearing, i.e., a sleeve 44, inside. Therefore, the holding member 43 can rotate integrally with the magnet 42 and the impeller 23 about the rotation axis 41.

[0109] In addition, enlarged-diameter portions 431a and 431b are respectively formed inside the lower end portion and the upper end portion of the cylindrical portion 431. Moreover, the above-mentioned first rotor support portion 215 is loosely inserted inside the enlarged-diameter portion 431a on the lower side Z2, and the above-mentioned second rotor support portion 85 is loosely inserted inside the enlarged-diameter portion 431b on the upper side Z1.

[0110] Through these enlarged-diameter portions 431a and 431b, the first rotor support portion 215 and the second rotor support portion 85 can be arranged inside the cylindrical portion 431, and miniaturization of the pump device 10 in the vertical direction can be achieved.

[0111] As described above, the magnet 42 is ring-shaped, and N poles and S poles are alternately magnetized in the circumferential direction on its outer periphery.

[0112] [Motor: Stator]

[0113] Figure 3 It is a perspective view of the stator 50, Figure 4 It is a bottom view, Figure 3 It is shown with the bottom of the stator 50 facing the upper side Z1.

[0114] As Figure 3 and Figure 4 shown, the stator 50 includes a stator core 51 composed of a plurality of iron cores 52 arranged along a circumference centered on the axis L, a plurality of coils 53 provided on each iron core 52, and upper and lower insulators 54, 55, 55A provided on the plurality of iron cores 52 respectively as insulating members for insulating the iron core 52 and the coil 53.

[0115] Figure 5 It is a partial bottom view of the state where the stator 50 is linearly extended, Figure 6 It is a partial bottom view of the state where the stator core 51 is linearly extended.

[0116] The stator core 51 is formed by laminating a plurality of flat plates made of the same-shaped magnetic material along the direction of the axis L.

[0117] In addition, as Figure 5 and Figure 6 shown, the stator core 51 is a so-called wound core in which a plurality of iron cores 52 are integrally connected. In the present embodiment, a stator core 51 formed by connecting nine iron cores 52 is illustrated, but the number of iron cores 52 can be changed.

[0118] When the stator core 51 is connected at one end and the other end around the axis L with the iron cores 52 arranged along the circumference, the shape of the outer periphery as viewed from the direction along the axis L (hereinafter referred to as the axis-viewed shape) becomes a substantially perfect circle. Thus, the state in which the iron cores 52 are arranged along the circumference and the stator core 51 becomes a substantially perfect circle is set as the circular state. The stator core 51 is sealed in the resin sealing member 60 in a manner concentric with the axis L in the circular state.

[0119] In addition, the stator core 51 is flexible and can be deformed into a linearly extended state as a whole when the one end and the other end are not connected. Thus, the state in which the iron cores 52 are arranged in a straight line and the stator core 51 becomes linear is set as the linear state. The stator core 51 is maintained in the linear state, and the winding process of the coil 53 in the manufacture of the stator 50 is performed.

[0120] The iron core 52 constituting the stator core 51 has: an outer peripheral portion 521 whose axis-viewed shape is an arc shape, a salient pole portion 522 extending from the outer peripheral portion 521 toward the center side of the arc of the outer peripheral portion 521, and an opposing portion 523 extending in both circumferential directions at the extending end of the salient pole portion 522.

[0121] Each iron core 52 is a solid whose axial vertical cross-sectional shape is the same along the axis L.

[0122] The axis-viewed shape of the outer edge portion of the outer peripheral portion 521 is an arc that is a part of the outer edge portion of the stator core 51 whose axis-viewed shape is a substantially perfect circle. Therefore, the outer periphery of the outer peripheral portion 521 has a circumferential surface shape with the same diameter as the above-mentioned arc.

[0123] In addition, a small arc-shaped recess is formed at the central portion in the circumferential direction of the outer edge portion of the outer peripheral portion 521.

[0124] The axis-viewed shape of the salient pole portion 522 is in a band shape that extends straight with a certain width from the circumferential center position of the outer peripheral portion 521 toward the inner side in the radial direction of the outer edge portion.

[0125] The axis-viewed shape of the opposing portion 523 is in a small arc shape concentric with the arc of the outer peripheral portion 521. Therefore, the inner periphery of the opposing portion 523 has a concave circumferential surface shape concentric with the outer peripheral portion 521. The inner peripheral surface of the opposing portion 523 faces the outer peripheral surface of the magnet 42 of the rotor 40 with a predetermined gap via the cylindrical portion 82 of the separation plate 80.

[0126] In addition, each iron core 52 is connected to an adjacent iron core 52 disposed adjacent to the circumferential end portions of the outer peripheral portion 521. Cuts 524 extending from the radially inner side toward the outer side are formed at the boundaries of the outer peripheral portions 521 of these iron cores 52, and the outermost peripheral portion of the outer peripheral portion 521 forms a connecting portion 525. The cut 524 is opened in the linear state of the stator core 51 and closed in the circular state of the stator core 51.

[0127] Moreover, this connecting portion 525 serves as an axis, and the adjacent iron cores 52 rotate relative to each other, enabling the stator core 51 to deform between the circular state and the linear state.

[0128] Figure 7 It is a perspective view of the insulator 55 on the lower side Z2. Figure 8 It is a perspective view of the insulator 54 on the upper side Z1. Figure 7 The following shows the state with the bottom of the insulator 55 on the lower side Z2 facing upward. In these Figure 7 and Figure 8 the circumferential direction is denoted by the symbol P, the radially outer side is denoted by the symbol O, and the inner side is denoted by the symbol I.

[0129] The upper and lower insulators 54, 55, 55A are formed of an insulating material such as resin, and form an upper and lower pair to cover the salient pole portions 522 of the respective iron cores 52 and their peripheries so as not to be in direct contact with the coil 53.

[0130] The insulator 55 on the lower side Z2 includes: a main body portion 551 which is a cylindrical body divided into two halves covering the lower half of the salient pole portion 522 of the iron core 52, an outer flange portion 552 covering the lower half of the inner circumferential surface of the outer peripheral portion 521, and an inner flange portion 553 covering the lower half of the outer circumferential surface of the opposing portion 523.

[0131] Moreover, the insulator 55 on the lower side Z2 includes an end face covering portion 554 connected to the lower end portion of the outer flange portion 552 and covering the lower end face of the outer peripheral portion 521 of the iron core 52, and three plate-like guide portions 555 erected from the lower surface of the end face covering portion 554 to the lower side Z2.

[0132] Figure 9 It is a partial bottom view of the stator 50.

[0133] As Figure 9 shown, in the end face covering portion 554, the shape observed from the axis is arc-shaped, and the outer diameter of its outer edge portion is slightly smaller than the diameter of the outer edge portion of the outer peripheral portion 521 of the iron core 52. Therefore, the outer edge portion of the lower end face of the outer peripheral portion 521 of the iron core 52 is exposed from the end face covering portion 554.

[0134] The three guide portions 555 are at the radially central portion on the lower surface of the end face covering portion 554, and are erected at the central portion and both end portions in the circumferential direction.

[0135] Each guiding portion 555 is in the shape of a plate whose radial thickness is thinner than the radial width of the lower surface of the end face covering portion 554, and when viewed from the axial direction, it is in an arc shape concentric with the stator core 51 in a circular state.

[0136] Moreover, the outer peripheral surfaces of all the insulators 55 on the lower side Z2 provided on the stator 50 and all the guiding portions 555 provided on the insulator 55A described later are arranged so as to be located on the same circumferential surface.

[0137] In addition, as Figure 3 and Figure 4 shown, among the nine insulators 55 and 55A on the lower side Z2, only the outer diameter of the outer edge portion of the end face covering portion 554A of the two insulators 55A is slightly larger than the diameter of the outer edge portion of the outer peripheral portion 521 of the iron core 52, and it protrudes slightly outward in the radial direction compared to the outer peripheral portion 521. Moreover, a protruding portion 556A extending outward in the radial direction is also provided at the central portion in the circumferential direction of the outer edge portion of the end face covering portion 554A.

[0138] The protruding portion 556A is engaged with a claw (not shown) provided on the separation plate 80, and is used to maintain a relatively appropriate positional relationship between the separation plate 80 and the stator 50 during the resin molding of the resin sealing member 60. In addition, in the insulator 55A, regarding the structure other than the above, since it is the same as the insulator 55, the same reference numerals are given and its description is omitted.

[0139] As Figure 8 shown, the insulator 54 on the upper side Z1 includes a main body portion 541 which is a cylindrical body divided into two halves covering the upper half of the salient pole portion 522 of the iron core 52, an outer flange portion 542 covering the upper half of the inner circumferential surface of the outer peripheral portion 521, and an inner flange portion 543 covering the upper half of the outer circumferential surface of the opposing portion 523.

[0140] Moreover, the insulator 54 on the upper side Z1 includes an end face covering portion 544 connected to the upper end portion of the outer flange portion 542 and covering the upper end face of the outer peripheral portion 521 of the iron core 52, and two columnar portions 545 erected at both ends in the circumferential direction on the upper surface of the end face covering portion 544 on the upper side Z1.

[0141] The shape of the end face covering portion 544 when viewed from the axis is an arc shape, which is the same diameter as the end face covering portion 544 of the insulator 55 on the lower side Z2 described above, and covers the outer edge portion of the outer peripheral portion 521 of the iron core 52 so as to be exposed.

[0142] Both of the two columnar portions 545 are prismatic, as Figure 8As shown, a terminal 546 extending upward from the upper end portion of the columnar portion 545 on one side is provided on a part of the insulator 54 regarding the multiple upper insulators 54. This terminal 546 is a terminal for electrically connecting the wire of the coil 53 to the circuit board 70.

[0143] In addition, regarding the upper and lower insulators 54, 55, and 55A, a configuration is illustrated in which the peripheries of the pole portions 522 of the stator core 51 are covered by a structure split in half vertically, but a configuration in which the insulator is integrally formed with the stator core 51 by insert molding the stator core 51 may also be adopted.

[0144] The coil 53 is composed of a wire, and the wire is wound around the pole portions 522 of the respective cores 52 via the upper and lower insulators 54 and 55, and is composed of an aluminum alloy or a copper alloy.

[0145] When the motor 30 is, for example, a three-phase brushless motor, the nine coils 53 formed on each of the nine pole portions 522 are composed of three U-phase coils, three V-phase coils, and three W-phase coils. Moreover, these coils 53 are arranged in such a manner that they are repeatedly arranged in a certain circumferential direction in the order of U-phase coil - V-phase coil - W-phase coil.

[0146] Furthermore, the wires of the three coils of the same phase are connected via a plurality of jumper wires 56 described later, and each coil of each phase is energized simultaneously from the circuit board 70.

[0147] When the nine coils 53 are arranged in such a manner that they are repeatedly arranged in a certain circumferential direction in the order of U-phase coil - V-phase coil - W-phase coil, the jumper wires 56 connecting the wires of the two coils 53 of the same phase are arranged in such a manner that they pass through and straddle the arrangement regions of the two coils with different phases arranged between the coils of the same phase.

[0148] Moreover, as Figure 3 and Figure 4 shown, each jumper wire 56 is arranged to abut against the outer peripheral surfaces of the plurality of guide portions 555 of the insulators 55 and 55A provided on the lower side Z2 and straddle between the coils in a state where its outer side follows along the outer peripheral surface.

[0149] Furthermore, the three coils 53 of the same phase and the jumper wires 56 connecting them are originally composed of one wire.

[0150] As Figure 5As shown, in the winding process of the manufacturing process of the stator 50, for example, when winding a wire around the leftmost salient pole portion 522 of the stator core 51 maintained in a straight state in the figure, the wire crosses the outer peripheral surface side of the guide portion 555 therebetween and is wound around the fourth leftmost salient pole portion 522 in the figure. Moreover, when winding around the fourth leftmost salient pole portion 522 in the figure, the wire crosses the outer peripheral surface side of the guide portion 555 therebetween and is wound around the seventh leftmost salient pole portion 522 in the figure. Thus, for example, the winding process of all the coils 53 of the U phase is completed.

[0151] In the case of the coils of the V phase, the winding process is similarly performed on the second, fifth, and eighth leftmost salient pole portions 522 in the figure. In the case of the coils of the W phase, the winding process is similarly performed on the third, sixth, and ninth leftmost salient pole portions 522 in the figure.

[0152] Moreover, when the winding process of all the coils 53 is completed, the stator core 51 is wound from a straight state into a circular state. However, at this time, since each core 52 rotates relative to each other with the connecting portion 525 as an axis between the adjacent cores 52, the respective jumper wires 56 will be stretched or slackened.

[0153] Therefore, prescribed conditions are set for the dimensions of each part of the stator 50. Based on Figure 5 and Figure 9 this condition will be described.

[0154] As Figure 5 shown, in the stator core 51 in a straight state where the cores 52 are arranged in a straight line, the pitch between the respective salient pole portions 522 in the long side direction N of the stator core 51 is set as A, and the number of cores 52 is set as B.

[0155] In a state where all the salient pole portions 522 are along a direction orthogonal to the long side direction N, the pitch A of the salient pole portions 522 represents the interval between the centers 522a of the adjacent salient pole portions 522 in the long side direction N. In addition, the pitch A of the salient pole portions 522 is the same as the entire width of one core 52 in the long side direction N.

[0156] In addition, as described above, the number of cores 52, B = 9.

[0157] The total length of the stator core 51 in a straight state is obtained by multiplying the pitch A of the salient pole portions 522 by the number of cores 52, B, that is, A·B.

[0158] On the other hand, as Figure 9 shown, in the stator core 51 in a circular state where the cores 52 are arranged along a circumference, the radius of the circumscribed circle E of the guide portions 555 provided on the respective insulators 55, 55A is set as r.

[0159] Further, in the stator core 51 in the circular state, the radius of the outer edge portion of the end face covering portion 554, which is the outer periphery of each insulator 55, is set as C1, and the radius of the outer edge portion of the outer periphery of the stator core 51, that is, the outer peripheral portion 521 of each iron core 52, is set as C2.

[0160] In addition, as in the case of a part of the insulator 55A, when the radius of the outer edge portion of the end face covering portion 554A includes a relatively large radius, it is desirable to set the radius C1 based on the insulator 55 with a smaller radius.

[0161] Moreover, the above value A·B (the total length of the stator core 51 in the linear state) is set to a numerical range that satisfies the following formula (1).

[0162] 2πr ≤ A·B ≤ 2πC1…(1)

[0163] That is, the value A·B is set to be not less than the circumference 2πr of the circumscribed circle E of the guiding portion 555, and is set to be not more than the circumference 2πC1 with any one of the smaller values of the radius C1 and the radius C2 (here C1) as the radius.

[0164] As described above, in the winding process of the coil 53, the jumper wire 56 is bridged along the stator core 51 held in the linear state. Therefore, by setting the value A·B corresponding to the total length of the stator core 51 in the linear state to be not less than the circumference 2πr of the circumscribed circle E of the guiding portion 555 provided on each insulator 55, when the stator core 51 is deformed into the circular state, it is possible to suppress the application of tension to the jumper wire 56 in a state of being in contact with the outer peripheral surface of any guiding portion 555.

[0165] In addition, by setting the value A·B equal to the total length of the stator core 51 in the linear state to be not more than the outer circumference 2πC1 of each insulator 55, when the stator core 51 is deformed into the circular state, it is possible to suppress the slack of the jumper wire 56 and its protrusion outward from the outer periphery of the insulator 55.

[0166] In addition, the radius D of the wire of the coil 53 can also be considered. For the value A·B, it is set to satisfy the condition of the following formula (2) in addition to satisfying the above formula (1).

[0167] 2πr ≤ A·B ≤ 2π(r + 2D)…(2)

[0168] In this case, as Figure 9 shown, since the value A·B is at most the circumference of the circle with a radius of r + 2D, the jumper wire 56 is not likely to deviate from each guiding portion 555 by a distance greater than the radius D of the wire, and it is possible to further suppress the slack or protrusion of the jumper wire 56.

[0169] More preferably, the radius D of the wire of the coil 53 may also be considered. For the value A·B, in addition to satisfying the above formulas (1) and (2), the condition of the following formula (3) is also satisfied.

[0170] 2πr ≤ A·B ≤ 2π(r + D)…(3)

[0171] In this case, as Figure 9 shown, even when the value A·B is maximum, it is below the circumference of the circle with a radius of r + D. Therefore, the distance at which the jumper wire 56 separates from each guide portion 555 is further reduced, and thus the slack or protrusion of the jumper wire 56 can be further suppressed.

[0172] [Operation of the pump device]

[0173] The pump device 10 configured with the above structure energizes each of the coils 53 of the U-phase, V-phase, and W-phase of the stator 50 of the motor 30 in a specified order from a power source outside the device (not shown) through the circuit board 70, and the rotor 40 rotates.

[0174] Subsequently, the impeller 23 of the pump mechanism portion 20 rotates, and in the pump chamber 22, the fluid flows in the circumferential direction around the axis L, sucks the fluid into the pump chamber 22 from the fluid suction port 213, and discharges the sucked fluid from the fluid discharge port 214.

[0175] [Technical effects of the embodiment of the invention]

[0176] As described above, in the stator 50 of the motor 30 included in the pump device 10, the value A·B obtained by multiplying the pitch A of the salient pole portions and the number B of the iron cores 52 is set to be not less than the circumference 2πr of the circumscribed circle E of each guide portion 555 and not more than the circumference along the outer edge portion of the end face covering portion 554 of each insulator 55.

[0177] Therefore, when the coil 53 is wound around the linear stator core 51 and then deformed into a circular state, it is possible to suppress the excessive tension or slack applied to the jumper wire 56 and prevent each insulator 55 from protruding outward.

[0178] In addition, since the value A·B corresponds to the total length of the linear stator core 51 and the optimization of this total length is achieved, if the coils are wound around each salient pole portion 522 of the stator core 51, it is possible to obtain the effect of suppressing the excessive tension or slack applied to the jumper wire 56. There is no need to wind the wire in such a way that the jumper wire passes through a strictly set position, which reduces the complexity of the winding process and enables the winding process to be simply performed.

[0179] In addition, when considering the radius D of the wire of the coil and limiting the value A·B to the circumference of a circle larger than the circumscribed circle E of the guide portion 555 by an outer diameter of the wire, i.e., 2D, it is possible to prevent the jumper wire 56 from leaving each guide portion 555 by more than the radius D due to slack, and effectively suppress the protrusion of the jumper wire 56.

[0180] Moreover, when limiting the value A·B to the circumference of a circle larger than the radius D of the wire by the circumscribed circle E of the guide portion 555, it is possible to further prevent the slack of the jumper wire 56.

[0181] In addition, since the stator 50 has a circumferential surface with an arc shape in the axial direction on the outer periphery of each guide portion 555, it is possible to make the length of the arc that is a part of the circumference of the circumscribed circle E of the guide portion 555 and the length of the jumper wire 56 guided along the outer periphery of the guide portion 555 more approximate. Thus, when setting the above value A·B corresponding to the total length of the stator core 51 to a value close to 2πr, it is possible to appropriately obtain the effect of reducing the slack of the jumper wire 56.

[0182] In addition, since each of the insulators 55, 55A has a guide portion 555, even when the jumper wire 56 is bridged at any position on the circumference of the stator core 51, it can be guided by the guide portion 555, and the slack of the jumper wire 56 can be effectively reduced.

[0183] In particular, by providing a plurality of guide portions 555, specifically three guide portions 555, on each of the insulators 55, 55A, it is possible to guide the jumper wire 56 throughout the entire circumferential direction at the outer edge portions of the end face covering portions 554, 554A. In addition, if the number of guide portions 555 is three, it is possible to guide the entire circumferential direction of the end face covering portions 554, 554A, and the manufacturing of the insulators 55, 55A is also easy, and an increase in cost is suppressed.

[0184] Since the motor 30 includes the above-described stator 50, it is possible to reduce the occurrence of disconnection or the like caused by excessive tension of the jumper wire 56, and stable driving can be performed for a long time.

[0185] Moreover, by including such a motor 30, it is possible to provide a pump device 10 with high reliability that can be stably driven for a long time.

[0186] [Other]

[0187] In addition, the details shown in the embodiments can be appropriately changed without departing from the gist of the invention.

[0188] For example, in the stator 50, the radius C1 of the outer periphery of the end face covering portion 554 of each insulator 55 in the stator core 51 in a circular state is made smaller than the radius C2 of the outer periphery of the outer peripheral portion 521 of the stator core 51, but the magnitude relationship between them may be reversed. In this case, in formula (1), the range of the value A·B is preferably set to 2πr ≤ A·B ≤ 2πC2.

[0189] In addition, the guide portions 555 may not be provided on all of the insulators 55, 55A of the stator 50. For example, when the portion where the jumper wire 56 does not cross over is clear on the outer periphery of the stator 50, the guide portions 555 may not be provided on the insulators 55, 55A of this portion.

[0190] In addition, the number of the guide portions 555 provided on the insulators 55, 55A can be increased or decreased. Moreover, when the number of the guide portions 555 increases, the shape of the outer periphery thereof as observed from the axis may not be an arc shape but a straight shape.

[0191] In addition, the number of the iron cores 52 can be increased or decreased, but when the motor 30 is a three-phase brushless motor, the number of the iron cores 52 becomes a multiple of three.

Claims

1. A stator, characterized in that, The stator includes: a stator core formed by a plurality of iron cores arranged along a circumference; coils disposed on the plurality of iron cores; and insulating members respectively disposed on the plurality of iron cores to insulate the iron cores and the coils, the iron core having an outer peripheral portion along the circumference and salient pole portions extending from the outer peripheral portion toward the center side of the circumference, the insulating member having: an end face covering portion that covers an end face of the outer peripheral portion in an axial direction of the circumference; and a guiding portion that stands upright from the end face covering portion along the axial direction and guides a jumper wire, which connects a wire of one coil and a wire of another coil, using an outer radial portion of the circumference, let the radius of the circumscribed circle of the plurality of guiding portions of the insulating members disposed on the plurality of iron cores arranged along the circumference be r, let the pitch of the salient pole portions in a direction of a straight line when the plurality of iron cores are arranged in a straight line be A, let the number of the iron cores be B, let the smaller of the radius of the outer circumferences of the plurality of insulating members and the radius of the outer circumference of the stator core when the plurality of iron cores are arranged along the circumference be C, and in this case, 2πr ≤ A·B ≤ 2πC holds, in a case where the radius of the wire of the coil is D, 2πr ≤ A·B ≤ 2π(r + 2D) holds.

2. The stator according to claim 1, wherein the outer radial portion of the circumference of the guiding portion is a circumferential surface that is arc-shaped when viewed in the axial direction.

3. The stator according to claim 1 or 2, characterized in that 2πr ≤ A·B ≤ 2π(r + D) holds.

4. The stator according to claim 1 or 2, characterized in that, Each of the plurality of insulating members has the guiding portion.

5. The stator according to claim 4, wherein the insulating member has a plurality of the guiding portions.

6. The stator according to claim 5, wherein the insulating member has three of the guiding portions.

7. The stator according to claim 3, wherein each of the plurality of insulating members has the guiding portion.

8. The stator according to claim 7, wherein the insulating member has a plurality of the guiding portions.

9. The stator according to claim 8, wherein the insulating member has three of the guiding portions.

10. A motor, wherein the motor includes the stator according to any one of claims 1 to 9.

11. A pump device, wherein the pump device includes the motor according to claim 10.

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