Stator of rotating electric machine and method for manufacturing stator of rotating electric machine

Abstract

Provided are a stator of a rotating electric machine capable of increasing the space factor of a coil and improving productivity, and a method for manufacturing the stator of a rotating electric machine. The stator (1) of the rotating electric machine of the present invention comprises: an iron core (20) having an annular connecting body and a plurality of teeth (22), the annular connecting body being formed by connecting a plurality of yokes (21) at intervals in a circular ring shape; and a bobbin (40) mounted on the teeth (22) for winding a conducting wire to form a coil (30), the teeth (22) being formed as a component separate from the yoke (21) and being capable of being held by the annular connecting body in a state of being oriented in a direction along the central axis of the annular connecting body.

Description

Technical Field

[0001] The present invention relates to a stator of a rotating electric machine and a method for manufacturing the stator of a rotating electric machine. Background Art

[0002] In order to achieve miniaturization and high output in the stator of a rotating electric machine, research has been conducted to improve the space factor of the coil. Patent document 1 describes a technique in which a plurality of laminated core sheets are connected into a ring shape after forming a coil for each laminated core sheet in order to improve the space factor.

[0003] Prior art literature

[0004] Patent Literature

[0005] Patent Document 1: Japanese Patent No. 3355700 Summary of the invention

[0006] Problems to be solved by the invention

[0007] In the technique described in Patent Document 1, the number of locations where the individually formed coils are connected to each other increases, thereby reducing the productivity of the stator.

[0008] The present invention has been made to solve the above-mentioned problems and has an object to provide a stator for a rotating electric machine and a method for manufacturing the stator for a rotating electric machine that can improve the space factor of the coil and increase productivity.

[0009] Means for solving problems

[0010] The stator of the rotating electric machine of the present invention comprises: an iron core, which has an annular connecting body and a plurality of teeth, the annular connecting body being formed by connecting a plurality of yokes in a circular ring at intervals; and a winding tube, which is installed on the teeth for winding the conductive wire to form a coil, the teeth being formed as a component separate from the yoke and capable of being held by the annular connecting body in a state oriented in a direction along the central axis of the annular connecting body.

[0011] The manufacturing method of the stator of a rotating electric machine of the present invention includes: a holding step, in which a plurality of teeth are held on an annular connection body in a state facing in a direction along the central axis of the annular connection body, wherein the annular connection body is formed by connecting a plurality of yokes at intervals in a circular ring shape; a coil forming step, in which conductive wires are sequentially wound around all the winding tubes respectively installed on the plurality of teeth; and a rotating step, in which the teeth are rotated relative to the yokes to face the radial inner side of the annular connection body.

[0012] Effects of the Invention

[0013] According to these inventions, the teeth are held by the annular connection body in a state of being oriented in a direction along the central axis of the annular connection body. Therefore, the space factor of the coil can be increased and productivity can be improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 This is a perspective view of the stator in the first embodiment.

[0015] Figure 2 This is a perspective view showing a state before the coil of the stator in the first embodiment is formed.

[0016] Figure 3 This is a perspective view of the annular connection body in the first embodiment.

[0017] Figure 4 This is an enlarged view of the yoke viewed from the circumferential direction of the annular connection body in the first embodiment.

[0018] Figure 5 This is a perspective view of the tooth portion in the first embodiment.

[0019] Figure 6 This is a schematic diagram for explaining the method for manufacturing the stator in the first embodiment.

[0020] Figure 7 This is a schematic diagram for explaining the method for manufacturing the stator in the first embodiment.

[0021] Figure 8 This is a schematic diagram for explaining the method for manufacturing the stator in the first embodiment.

[0022] Fig. 9 This is a schematic diagram for explaining the method for manufacturing the stator in the first embodiment.

[0023] Fig.10 This is a schematic diagram for explaining the method for manufacturing the stator in the first embodiment.

[0024] Fig.11 This is a flowchart showing the method for manufacturing the stator in the first embodiment. DETAILED DESCRIPTION

[0025] Hereinafter, the embodiments will be described with reference to the accompanying drawings. In each figure, the same reference numerals are given to the same or corresponding parts, and repeated descriptions are appropriately simplified or omitted.

[0026] Implementation Method 1

[0027] Figure 1 This is a perspective view of the stator in the first embodiment.

[0028] Figure 1 FIG. 1 shows the stator 1 viewed from obliquely above. Figure 1 As a reference, the up-down direction of each component of the stator 1 is specified.

[0029] The stator 1 of the rotating electrical machine includes an iron core 20 and a plurality of coils 30 . Figure 1 The stator 1 including twelve coils 30 is exemplified.

[0030] The core 20 includes a plurality of yokes 21 and a plurality of teeth 22. The plurality of yokes 21 are connected in an annular shape at equal intervals to form an annular connection body. The teeth 22 are not formed as a component integral with the yokes 21.

[0031] The tooth portion 22 is, for example, in a prism shape. A bobbin 40 formed of an insulating material is mounted on the tooth portion 22. The bobbin 40 is provided so as to cover the periphery of the tooth portion 22 along the length direction. One end portion of the tooth portion 22 in the length direction protrudes from the bobbin 40, for example. The other end portion of the tooth portion 22 in the length direction does not protrude from the bobbin 40, for example. The coil 30 is formed by winding a conductive wire around the bobbin 40.

[0032] The tooth portion 22 is mounted on the annular connecting body. Figure 1 As shown, in the completed stator 1, one end of the tooth portion 22 is located between two adjacent yokes 21 separated by a gap. At this time, the upper surface of the tooth portion 22 is located between the upper surfaces of the two yokes 21. At this time, the outer diameter surface of the tooth portion 22 is located between the outer diameter surfaces of the two yokes 21. The other end of the tooth portion 22 faces the radial inner side of the annular connection body. The end surface of the winding tube 40 is in contact with or opposite to the inner diameter surface of the annular connection body. A portion of the end surface of the winding tube 40 is located above the upper surface of the annular connection body.

[0033] Figure 2 This is a perspective view showing a state before the coil of the stator in the first embodiment is formed.

[0034] Figure 2 The upper surface of the annular connector faces downward.

[0035] Figure 2 The tooth portion 22 in the embodiment is held in a manner that one end is suspended from the annular connecting body. At this time, the outer diameter surface of the tooth portion 22 faces upward, and the lower surface of the tooth portion 22 faces the radial inner side of the annular connecting body. In the first embodiment, the coil 30 is wound by winding the wire around Figure 2 The bobbin 40 in the state shown is formed.

[0036] Figure 3 This is a perspective view of the annular connection body in the first embodiment.

[0037] Figure 3 The ring linker in Figure 1 Again, the upper surface faces upward.

[0038] The yoke 21 has a groove 21a. The groove 21a is formed on both ends of the annular connection body in the circumferential direction. That is, one yoke 21 has two grooves 21a. The groove 21a is formed from the outer diameter surface toward the inside at a height close to the upper surface of the yoke 21, for example.

[0039] The annular connection body has a plurality of connection parts 21b. The connection parts 21b connect the circumferential end surfaces of two spaced-apart adjacent yokes 21. The connection parts 21b are formed to protrude in the circumferential direction from the edge where the lower surface of the yoke 21 intersects with the outer diameter surface, for example.

[0040] Figure 4 This is an enlarged view of the yoke viewed from the circumferential direction of the annular connection body in the first embodiment.

[0041] Figure 4 The yoke 21 and Figure 3 Again, the upper surface faces upward. Figure 5 In the viewpoint of , the left side is the radially outer side of the annular connection body, and the right side is the radially inner side of the annular connection body.

[0042] like Figure 4 As shown, the groove 21a is in a curved shape. The groove 21a has a horizontal portion and a vertical portion. The horizontal portion is formed from the outer diameter surface of the yoke 21 toward the radial inner side. The vertical portion is formed from the innermost part of the horizontal portion toward the direction along the central axis of the annular connection body. The vertical portion is formed, for example, from the innermost part of the horizontal portion toward the lower surface side of the yoke 21.

[0043] Figure 5 This is a perspective view of the tooth portion in the first embodiment.

[0044] The tooth portion 22 has a rotation shaft 22a. The rotation shaft 22a protrudes from one end of the tooth portion 22 toward the circumferential direction of the annular connection body. The rotation shaft 22a is provided on both sides of the two side surfaces adjacent to the lower surface and the outer diameter surface of the tooth portion 22. The rotation shaft 22a is provided on the side surface of the tooth portion 22, for example, at a position close to the outer diameter surface.

[0045] A notch 22b is formed at one end of the tooth portion 22. The notch 22b is formed at an edge portion along the circumferential direction of the annular connection body. The notch 22b is formed, for example, at an edge portion where the lower surface of the tooth portion 22 intersects with the outer diameter surface.

[0046] The bobbin 40 may be formed by, for example, clamping the tooth portion 22 with left-right symmetrical parts. The bobbin 40 may be formed in one piece, for example. A plurality of protrusions 40a are provided on the end surface of the bobbin 40 located on the side of one end of the tooth portion 22. The protrusions 40a of the bobbin 40 are appropriately arranged according to the specifications of the rotating electrical machine.

[0047] Figures 6 to 10 This is a schematic diagram for explaining the method for manufacturing the stator in the first embodiment. Fig.11 This is a flowchart showing the method for manufacturing the stator in the first embodiment.

[0048] Figures 6 to 10 This is a diagram showing the change in the positional relationship between the annular coupling body and one tooth portion 22 during the manufacturing process of the stator 1 as viewed from a fixed viewpoint. Figures 6 to 10 In the figure, the portion other than one end portion of the tooth portion 22 and the bobbin 40 are omitted from illustration.

[0049] Figure 6 and Figure 7 The yoke 21 and Figure 2 Again, the top surface faces downward. Figure 6 and Figure 7 In the viewpoint of , the left side is the radial inner side of the annular connection body, and the right side is the radial outer side of the annular connection body.

[0050] Figures 8 to 10 The yoke 21 and Figure 1 Again, the upper surface faces upward. Figures 8 to 10 In the viewpoint of , the left side is the radially outer side of the annular connection body, and the right side is the radially inner side of the annular connection body.

[0051] Below, refer to Figures 6 to 11 , an example of a process for manufacturing the stator 1 is described.

[0052] In step S101, a holding process is performed. In the holding process, for example, Figure 6 As shown in FIG. 1 , for a horizontally arranged annular connection body with the upper surface facing downward, the two rotating shafts 22a of the tooth portion 22 are inserted into the two grooves 21a from the radially outer side. Figure 6 The state moves radially inward, then Figure 7 As shown in FIG. 1 , the rotating shaft 22a is pressed into the innermost part of the horizontal portion of the groove 21a. As a result, the tooth portion 22 is held between two adjacent yokes 21 spaced apart from each other. If the holding process is performed on all the tooth portions 22, as shown in FIG. Figure 2 As shown, a plurality of teeth 22 are held downward from a horizontally arranged annular connecting body.

[0053] In step S102, a coil forming process is performed. In the coil forming process, for example, Figure 2 As shown, while the plurality of teeth 22 are held in the annular coupling body, the conducting wire is sequentially wound around all the bobbins 40. In the coil forming step, for example, one conducting wire is not cut in the middle but is continuously wound around all the bobbins 40.

[0054] In step S103 , a vertical inversion step is performed. In the vertical inversion step, the annular connection body is vertically inverted so that the upper surface of the yoke 21 faces upward. Figure 8 Shown in maintaining Figure 6 and Figure 7 The yoke 21 is a state in which the annular connection body is turned upside down around the axis along the depth direction when viewed from the perspective of FIG.

[0055] In step S104, a rotation process is performed. In the rotation process, Figure 8 As shown in FIG. 2 , the tooth portion 22 rotates toward the radial inner side of the annular connection body with the rotation axis 22a located at the innermost part of the horizontal portion of the groove 21a as a fulcrum. Fig. 9 As shown, the tooth portion 22 is rotated until the cutout 22b contacts the connecting portion 21b.

[0056] In step S105, a fixing process is performed. In the fixing process, Fig.10 As shown, the rotating shaft 22a is pressed into the innermost part of the vertical part of the groove 21a, thereby fixing the tooth part 22 to the annular connection body. The connection part 21b is fitted into the cutout 22b when the rotating shaft 22a is located at the innermost part of the vertical part of the groove 21a.

[0057] Through the fixing process, the tooth portion 22 is fixed with the other end facing the radial inner side of the annular connection body. If the fixing process is performed on all the tooth portions 22, the Figure 1 The stator 1 is shown.

[0058] In addition, the upside-down turning process and the rotation process can implement any process as long as they are after the coil forming process. In addition, for example, in order to omit the upside-down turning process, in the holding process, the annular joint body horizontally arranged in the upward mode of the above surface can also be kept upwardly a plurality of teeth 22.

[0059] According to the embodiment 1 described above, the core 20 has an annular connector and a plurality of teeth 22, and the annular connector is formed by connecting a plurality of yokes 21 in a circular ring at intervals. The bobbin 40 is installed on the teeth 22 in order to wind the conductive wire that forms the coil 30. The tooth 22 is formed as a component separate from the yoke 21, and can be held by the annular connector in a state facing the direction along the central axis of the annular connector. Thus, the conductive wire can be wound on the bobbin 40 in a state where the intervals between the teeth 22 are enlarged. That is, the space through which the winding nozzle passes can be enlarged. In addition, the conductive wire is continuously wound on a plurality of bobbins 40 without being cut, which can reduce the wiring time. Therefore, the space factor of the coil 30 can be increased and productivity can be improved.

[0060] In addition, the yoke 21 has a groove 21a formed on the end surface of the annular connection body in the circumferential direction. The tooth portion 22 has a rotating shaft 22a protruding in the circumferential direction of the annular connection body, and the rotating shaft 22a is inserted into the groove 21a, so that the tooth portion 22 is held or fixed between two adjacent yokes 21 separated by a gap. That is, the tooth portion 22 is not welded to the annular connection body, but is mechanically mounted. Therefore, the vibration and noise of the rotating electric machine caused by thermal strain can be suppressed.

[0061] In addition, the groove 21a of the yoke 21 has a horizontal portion formed from the outer diameter surface of the annular connection body toward the radial inside, and a vertical portion formed from the innermost portion of the horizontal portion toward the direction along the central axis of the annular connection body. The tooth portion 22 can rotate toward the inner side of the annular connection body around the rotation axis 22a when the rotation axis 22a is located at the innermost portion of the horizontal portion of the groove 21a. Therefore, the tooth portion 22 can be rotated from the state of being in the direction along the central axis of the annular connection body to the state of being in the radial inside.

[0062] In addition, the annular connection body has a connection portion 21b that connects the circumferential end faces of two yokes 21 adjacent to each other at a distance. The tooth portion 22 has a cutout 22b formed in the edge portion along the circumferential direction of the annular connection body. The connection portion 21b is inserted into the cutout 22b of the tooth portion 22 in a state where the tooth portion 22 faces the radial inner side of the annular connection body and the rotation axis 22a is located at the innermost part of the vertical portion of the groove 21a. Therefore, the connection portion 21b can also be used as a stopper and positioning member for the rotatable tooth portion 22.

[0063] In addition, the manufacturing method of the stator of the rotating electric machine includes, for example, a holding step of holding a plurality of teeth 22 in a state facing the direction along the central axis of the annular connection body, wherein the annular connection body is formed by connecting a plurality of yokes 21 at intervals in an annular shape; a coil forming step of sequentially winding the wire around all the bobbins 40 respectively mounted on the plurality of teeth 22; and a rotating step of rotating the teeth 22 to face the radial inner side of the annular connection body relative to the yoke 21. Therefore, the space factor of the coil 30 can be increased and productivity can be improved.

[0064] In addition, the manufacturing method of the stator of the rotating electric machine includes, for example, an upside-down turning process performed after the coil forming process. In this case, in the holding process, the plurality of teeth 22 are held downward from the horizontally arranged annular connecting body. In the upside-down turning process, the annular connecting body is turned upside down. In this case, the coil forming process can be performed in a state where the teeth 22 are stably held in a suspended manner from the annular connecting body.

[0065] In the first embodiment, the stator 1 having twelve teeth 22 and twelve coils 30 is exemplified, but the number of teeth 22 and the number of phases can be appropriately changed according to the specifications of the rotating electrical machine.

[0066] In Embodiment 1, the plurality of protrusions 40a provided on the end surface of the bobbin 40 are used, for example, when forming a coil. By passing the overlapping wires between the protrusions 40a, the distance between the overlapping wires is ensured, and the insulation distance can be ensured.

[0067] The stator 1 in the first embodiment is for an inner rotor type rotating electric machine because the lap wire does not become loose when the tooth portion 22 is rotated. However, it can also be applied to an outer rotor type rotating electric machine by winding the conductor in a state where the lap wire is loosened by hooking the lap wire on a pin or an auxiliary tool, and then pulling out the hooked lap wire from the pin or the auxiliary tool before the tooth portion 22 rotates.

[0068] Industrial Applicability

[0069] As described above, the present invention can be used when manufacturing a stator for a rotating electric machine.

[0070] Description of symbols

[0071] 1: stator;

[0072] 20: iron core;

[0073] 21: yoke;

[0074] 21a: slot;

[0075] 21b: connecting part;

[0076] 22: tooth;

[0077] 22a: rotation axis;

[0078] 22b: incision;

[0079] 30: coil;

[0080] 40: bobbin;

[0081] 40a: protrusion.

Claims

1. A stator of a rotating electrical machine, comprising: an iron core having an annular connection body and a plurality of teeth, wherein the annular connection body is formed by connecting a plurality of yokes at intervals in an annular shape; and a bobbin mounted on the tooth portion for winding a conducting wire to form a coil, The tooth portion is formed as a component separate from the yoke and can be held by the annular connection body in a state of being oriented in a direction along the central axis of the annular connection body. The yoke has a groove formed on an end surface of the annular connecting body in the circumferential direction. The tooth portion has a rotation shaft protruding in the circumferential direction of the annular connection body, and the rotation shaft is inserted into the groove, whereby the tooth portion is held between two of the yokes adjacent to each other at a distance.

2. The stator of a rotating electrical machine according to claim 1, wherein: The slot of the yoke has: a horizontal portion formed from the outer diameter surface of the annular connection body toward the radial inside; and a vertical portion formed from the innermost portion of the horizontal portion toward a direction along the central axis of the annular connection body, The tooth portion can rotate toward the inside of the annular connection body around the rotation axis in a state where the rotation axis is located at the innermost part of the horizontal portion of the groove.

3. The stator of a rotating electrical machine according to claim 2, wherein: The annular connecting body has a connecting portion that connects the end surfaces in the circumferential direction of two adjacent yokes spaced apart from each other. The tooth portion has a cutout formed at an edge portion along the circumference of the annular connection body. The connection portion is fitted into the cutout of the tooth portion in a state where the tooth portion faces radially inward of the annular connection body and the rotation axis is located at the innermost part of the vertical portion of the groove.

4. A method for manufacturing a stator of a rotating electric machine, the stator comprising an iron core and a bobbin, the iron core having an annular connection body and a plurality of teeth, the annular connection body being formed by connecting a plurality of yokes at intervals in an annular shape, the bobbin being mounted on the teeth for winding a conducting wire to form a coil, the teeth being formed as a component separate from the yoke and capable of being held by the annular connection body in a state of being oriented in a direction along a central axis of the annular connection body, the manufacturing method comprising: A holding step of holding the plurality of teeth on the annular connection body in a state of being oriented in a direction along a central axis of the annular connection body; a coil forming step of sequentially winding conductive wires around all the bobbins respectively mounted on the plurality of teeth; as well as The rotating step rotates the teeth relative to the yoke so as to face radially inward of the annular connection body.

5. The method for manufacturing a stator of a rotating electrical machine according to claim 4, wherein: The method for manufacturing the stator of the rotating electrical machine further includes a step of turning the stator upside down after the coil forming step. In the holding step, the plurality of teeth are held downward from the horizontally arranged annular connection body. In the upside-down turning step, the annular connection body is turned upside down.

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