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

Abstract

The invention comprises: a stator core (1) having an annular yoke (11) and a plurality of teeth (12); a coil (7) formed on the plurality of teeth (12); and an insulating portion (2) disposed between the stator core (1) and the coil (7) to insulate the stator core (1) from the coil (7), the insulating portion (2) having a first protrusion (21) protruding from one side in the axial direction (Y) of the stator core (1), the first protrusion (21) having a groove portion (91, 92, 93) formed in multiple stages in the axial direction (Y) and a formed concave portion (96) formed in a concave shape toward the inner side (X2) in the radial direction (X) on the outer peripheral surface of the first protrusion (21) on the radial direction (X) outside (X1), the jumper wire (8) connecting the coils (7) of different teeth (12) to each other is a continuous wire and is held in the groove portion (91, 92, 93) and the formed concave portion (96).

Description

Technical Field

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

[0002] In the past, stators for rotating electrical machines such as motors and generators consisted of a stator core and a coil installed in slots between teeth of the stator core. The coil wire forming the coil is insulated and coated, and the coil is insulated from the stator core. However, in the stator of the rotating electrical machine, in order to ensure sufficient insulation between the coil and the stator core, an insulating portion is further provided at the portion where the stator core and the coil are in contact. Conventional stators have coils wound around the coil wire on the stator core via an insulating portion. The insulating portion has a cavity that can accommodate a crimping terminal. Then, in the stator, the coil wire and the crimping terminal are inserted, and the teeth are connected with jumper wires (for example, refer to Patent Document 1).

[0003] Prior art literature

[0004] Patent Literature

[0005] Patent Document 1: International Publication No. WO2016 / 51923 Summary of the invention

[0006] Problems to be solved by the invention

[0007] Generally speaking, in the manufacture of stators for rotating electrical machines, in order to reduce prices while ensuring quality, it is important to save materials and shorten the manufacturing time. For example, in conventional stators, crimping terminals and jumper wires that connect the teeth are used in wiring. In this case, for example, in a 9-tooth stator, 18 crimping terminals and 8 jumper wires are required. Therefore, a large number of wiring components are required, and there is a problem that material saving cannot be achieved, resulting in a higher price. In addition, in the process of inserting the crimping terminal, there is a problem of strength resistance in the cavity portion of the insulating portion, and there is a problem of reduced quality.

[0008] The present application discloses a technology for solving the above-mentioned problems, and an object of the present application is to provide a stator of a rotating electric machine, a rotating electric machine, a method for manufacturing a stator of a rotating electric machine, and a method for manufacturing a rotating electric machine that can reduce costs and improve quality.

[0009] Means for solving problems

[0010] The stator of the rotating electric machine disclosed in the present application comprises:

[0011] A stator core, the stator core having a yoke portion configured in an annular shape and a plurality of teeth, the plurality of teeth being formed on an inner circumferential surface on the radial inner side of the yoke portion at predetermined intervals in the circumferential direction and protruding inward in the radial direction; a coil, the coil being formed by winding coil wires around the plurality of teeth respectively; and an insulating portion, the insulating portion being disposed between the stator core and the coil and insulating the stator core from the coil,

[0012] The insulating portion has a first protrusion protruding from one side in the axial direction of the stator core.

[0013] The first protrusion has a groove portion formed of multiple stages in the axial direction and a molded concave portion that is concave toward the inside in the radial direction on the outer peripheral surface of the first protrusion in the radial direction.

[0014] The jumper wires connecting the coils of different teeth to each other are continuous wires and are held within the slots and within the shaped recesses.

[0015] Furthermore, the rotating electric machine disclosed in the present application includes the stator of the rotating electric machine described above and a rotor disposed facing the stator with a gap therebetween in a casing.

[0016] In addition, the manufacturing method of the stator of the rotating electric machine disclosed in the present application comprises the following steps: deforming the yoke into a straight shape or a reverse warping shape in which the radial protrusion direction of the teeth is opposite, and winding the coil wire on the teeth to form the coil.

[0017] The yoke is deformed into an annular shape so that the teeth protrude radially inward, the jumper wire is inserted into the groove of the first protrusion, and the jumper wire is pressed into the molding recess to be accommodated.

[0018] In addition, in the method for manufacturing a rotating electric machine disclosed in the present application, a rotor is provided in a housing with a gap between the rotor and the stator manufactured by the method for manufacturing a stator of a rotating electric machine described above.

[0019] Effects of the Invention

[0020] According to the stator of a rotating electric machine, the rotating electric machine, the method for manufacturing the stator of a rotating electric machine, and the method for manufacturing the rotating electric machine disclosed in the present application, it is possible to reduce costs and improve quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 It is a perspective view showing the structure of the stator of the rotating electrical machine according to the first embodiment.

[0022] Figure 2 It shows that Figure 1 The illustrated perspective view shows a state in which a yoke portion of a stator core of the stator is deformed into a linear shape.

[0023] Figure 3 It shows that Figure 1 The yoke portion of the stator core of the stator shown is a perspective view of a state in which the yoke portion of the stator core is deformed into a circular ring shape and the excess length of the jumper wire is not absorbed.

[0024] Figure 4 It is shown Figure 1 A perspective view showing the structures of two types of core plates of a stator core of a stator shown.

[0025] Figure 5 It shows that Figure 4 The two types of core plates shown are perspective views of the structure of a stator core formed by stacking a plurality of them in the axial direction.

[0026] Figure 6 It shows that it contains Figure 5 A top view of the structure of the core of one tooth of a stator core is shown.

[0027] Figure 7 It is shown Figure 1 A three-dimensional view of the structure of the first winding frame of the stator is shown.

[0028] Figure 8 It is shown Figure 1 A perspective view of the structure of the second winding frame of the stator is shown.

[0029] Fig. 9 It is shown in Figure 6 The core shown is equipped with Figure 7 The first winding frame and Figure 8 A perspective view of the structure of the second winding rack is shown.

[0030] Fig.10 The diagram is shown when viewed from the direction indicated by arrow A. Fig. 9 A front view of the structure of the core is shown.

[0031] Fig.11 The diagram is shown when viewed from the direction indicated by arrow B. Fig. 9 A side view of the structure of the core is shown.

[0032] Fig.12 The diagram is shown when viewed from the direction indicated by arrow C. Fig. 9 A top view of the structure of the core is shown.

[0033] Fig.13 It is shown Figure 1 A diagram showing a method of manufacturing a stator.

[0034] Fig.14 It is shown Figure 1 A diagram showing a method of manufacturing a stator.

[0035] Fig.15 It is shown Figure 1 A diagram showing a method of manufacturing a stator.

[0036] Fig.16 It is shown Figure 1 A diagram showing a method of manufacturing a stator.

[0037] Fig.17 It is shown Figure 1 A diagram showing a method of manufacturing a stator.

[0038] Fig.18 It is shown Figure 1 FIG. 2 is a diagram showing another method of manufacturing a stator.

[0039] Fig.19 It is a perspective view showing a state in which a yoke portion of a stator core of a stator of a rotating electric machine according to the second embodiment is deformed into a linear shape.

[0040] Fig. 20 It is shown in Fig.19 An exploded perspective view of a state before the first bobbin, the second bobbin, and the diaphragm portion are mounted on the stator shown.

[0041] Fig.21 It is shown Fig.19 A three-dimensional view of the structure of the membrane portion shown.

[0042] Fig.22A The figure shows the upper surface viewed from the axial direction. Fig.19 A perspective view of the structure of the first winding frame shown.

[0043] Fig. 22B The figure shows the bottom surface viewed from the axial direction. Fig.19 A perspective view of the structure of the first winding frame shown.

[0044] Fig.23 It is shown Fig.19 A perspective view of the structure of the second winding rack is shown.

[0045] Fig.24 It is shown that the use Figure 1 The schematic radial cross-sectional view of the structure of the stator of the rotating electrical machine shown.

[0046] Fig.25 It is shown that the use Figure 1 The figure is a schematic axial cross-sectional view of the structure of a stator of a rotating electrical machine.

[0047] Fig.26 It is shown Fig.24 Flowchart of a method for manufacturing a rotating electrical machine shown.

[0048] Fig. 27 It is shown Fig.26FIG. 1 is a flow chart of forming a coil of a method for manufacturing a rotating electrical machine.

[0049] Fig.28 It is shown Fig.26 FIG. 1 is a flow chart of forming a jumper wire in a method of manufacturing a rotating electrical machine.

[0050] Fig.29 It is shown Figure 1 A diagram showing a method of manufacturing a stator.

[0051] Fig.30 It is shown Figure 1 A diagram showing a method of manufacturing a stator.

[0052] Fig.31 It is a perspective view showing the structure of a stator core of a stator of a rotating electrical machine according to a third embodiment.

[0053] Fig.32 It is shown Fig.31 An enlarged top view of the structure of the main part of the stator core is shown.

[0054] Fig.33 It is a perspective view showing the structure of a divided core portion of a stator core of a rotating electric machine stator according to a fourth embodiment.

[0055] Fig.34 It is shown Fig.33 A perspective view of a fixing fixture for split cores is shown. DETAILED DESCRIPTION

[0056] In the following description, directions in the rotating electrical machine 200 are represented as the circumferential direction Z, the axial direction Y, the radial direction X, the outer side X1 of the radial direction X, and the inner side X2 of the radial direction X. Therefore, in the stator 100 and the rotor 102, and in other accompanying parts, directions are represented and described based on these directions.

[0057] Implementation method 1.

[0058] Figure 1 It is a perspective view showing the structure of the stator of the rotating electrical machine according to the first embodiment. Figure 2 It shows that Figure 1 The illustrated perspective view shows a state in which a yoke portion of a stator core of the stator is deformed into a linear shape. Figure 3 It shows that Figure 1 The yoke portion of the stator core of the stator shown is a perspective view of a state in which the yoke portion of the stator core is deformed into a circular ring shape and the excess length of the jumper wire is not absorbed. Figure 4 It is shown Figure 1 A perspective view showing the structures of two types of core plates of a stator core of a stator shown. Figure 5 It shows that Figure 4The two types of core plates shown are perspective views of the structure of a stator core formed by stacking a plurality of them in the axial direction.

[0059] Figure 6 It shows that it contains Figure 5 A top view of the structure of the core of one tooth of a stator core is shown. Figure 7 It is shown Figure 1 A three-dimensional view of the structure of the first winding frame of the stator is shown. Figure 8 It is shown Figure 1 A perspective view of the structure of the second winding frame of the stator is shown. Fig. 9 It is shown in Figure 6 The core shown is equipped with Figure 7 The first winding frame and Figure 8 A perspective view of the structure of the second winding rack is shown. Fig.10 The diagram is shown when viewed from the direction indicated by arrow A. Fig. 9 A front view of the structure of the core is shown. Fig.11 The diagram is shown when viewed from the direction indicated by arrow B. Fig. 9 A side view of the structure of the core is shown. Fig.12 The diagram is shown when viewed from the direction indicated by arrow C. Fig. 9 A top view of the structure of the core is shown.

[0060] Figures 13 to 17 , Fig.29 , Fig.30 It is shown Figure 1 A diagram showing a method of manufacturing a stator. Fig.18 It is shown Figure 1 FIG. 2 is a diagram showing another method of manufacturing a stator. Fig.24 It is shown that the use Figure 1 The schematic radial cross-sectional view of the structure of the stator of the rotating electrical machine shown. Fig.25 It is shown that the use Figure 1 The figure is a schematic axial cross-sectional view of the structure of a stator of a rotating electrical machine. Fig.26 It is shown Fig.24 Flowchart of a method for manufacturing a rotating electrical machine shown. Fig. 27 It is shown Fig.26 FIG. 1 is a flow chart of forming a coil of a method for manufacturing a rotating electrical machine. Fig.28 It is shown Fig.26 FIG. 1 is a flow chart of forming a jumper wire in a method of manufacturing a rotating electrical machine.

[0061] First, use Fig.24 and Fig.25The structure of the rotating electric machine 200 is described. In the figure, the rotating electric machine 200 includes a stator 100, a rotor 102, and a housing 101. The housing 101 accommodates the stator 100 and the rotor 102. The rotor 102 is arranged on the inner circumference of the stator 100 with a predetermined gap (air gap) G provided. The rotor 102 includes a shaft 221 and a rotor core 223. The shaft 221 is fitted with the inner ring of a bearing 211 provided in the housing 101 and is held to be rotatable.

[0062] The rotor core 223 is fixed to the outer periphery of the shaft 221, and the permanent magnet 222 is embedded in a V shape. In addition, the arrangement direction of the permanent magnet 222 is not limited to the V shape, and can also be a straight line or other shape arrangement direction. In addition, the permanent magnet 222 may not be embedded in the rotor core 223, but may be attached to the outer periphery of the rotor core 223 and arranged in a manner facing the stator 100. In addition, the number of magnetic poles generated by the permanent magnet 222 is not limited to the number of magnetic poles generated by the permanent magnet 222. Fig.24 The six poles shown are appropriately set according to the number of teeth 12 of the stator 100 to be described later.

[0063] For example, in the case where a jumper wire is required for a tooth 12 that is two teeth apart in the circumferential direction Z (UVWUVW...), when the number of teeth 12 is set to 3·N (N is an integer greater than or equal to 2), the number of magnetic poles may be ((3±1)·N). In addition, in the method of winding three teeth continuously around teeth 12 adjacent to each other in the circumferential direction Z (UU'UVV'VWW'W...), when winding the second tooth, winding in the opposite direction to the first tooth and the third tooth is required.

[0064] When the number of teeth 12 is set to 9·N (N is an integer greater than 1), the number of magnetic poles may be 8 (9±1)·N. In addition, in the method (UU'VV'WW'...) of winding the wires to the teeth 12 adjacent in the circumferential direction Z for two consecutive teeth in the circumferential direction Z, when the number of teeth 12 is set to 6·N (N is an integer greater than 1), the number of magnetic poles may be (6±1)5·N. In this case, when N is greater than 2, after winding the wires for two consecutive teeth in the circumferential direction Z, it is necessary to wind the wires to the next tooth 12 that is four teeth apart in the circumferential direction Z, so a jumper action is required that is four teeth apart in the circumferential direction Z. In addition, in the following embodiments, the rotating electrical machine 200 can also be configured in the same manner as in the first embodiment, so its description is appropriately omitted.

[0065] Next, the stator 100 of the rotating electrical machine 200 will be described. Figure 2In each of the figures, even when the yoke 11 of the stator core 1 of the stator 100 is deformed into a straight line or a reverse warp shape in which the protrusion direction of the teeth 12 is reversed, the directions are illustrated and described in each figure based on the direction of the state when the yoke 11 of the stator 100 is configured in a ring shape. In addition, in other embodiments, the directions are also illustrated and described based on the same reference.

[0066] like Figure 1 As shown, the stator 100 includes a stator core 1, a coil 7, a first winding frame 2 on the upper side of the axial direction Y as an insulating portion configured to insulate the stator core 1 and the coil 7, and a second winding frame 3 on the lower side of the axial direction Y. The stator core 1 includes a yoke 11 configured in an annular shape; and a plurality of teeth 12 (see Figure 6 ), the plurality of teeth 12 are formed on an inner peripheral surface 112 (refer to Figure 6 ) are formed at predetermined intervals along the circumferential direction Z and protrude toward the inner side X2 in the radial direction X.

[0067] The stator core 1 is connected by Figure 4 The two core plates 6A and 6B are formed by punching out the thin-walled magnetic steel plate shown in FIG. Figure 5 As shown in FIG. 1 , a plurality of stator cores are alternately stacked in the axial direction Y. Thus, the yokes 11 of the first core portion 61 to the ninth core portion 69 of the stator core 1 are connected by the connecting portion 111 provided at the end portion in the circumferential direction Z. Figure 5 In the embodiment, the stator core 1 is composed of nine core portions, namely, the first core portion 61 to the ninth core portion 69, which are connected linearly by a connecting portion 111. Here, the portion having one tooth 12 in the yoke portion 11 is described below as the core portion 60.

[0068] use Figure 6 The core 60 will be described in detail. The core 60 includes a yoke 11 and teeth 12. The yoke 11 has an outer peripheral surface 113 along the axial direction Y on the outer side X1 of the radial direction X. A first recess 114 extending along the axial direction Y is formed on the outer peripheral surface 113 of the yoke 11. The first recess 114 is used for positioning when the stator core 1 is mounted on a winding machine that forms the coil 7. The yoke 11 has an inner peripheral surface 112 along the axial direction Y on the inner side X2 of the radial direction X. The inner peripheral surface 112 of the yoke 11 has teeth 12. In addition, on the teeth 12, shoe portions 13 protruding in the circumferential direction Z are provided at the top ends of the inner side X2 of the radial direction X.

[0069] A first side surface 121 along the axial direction Y at both ends of the tooth 12 in the circumferential direction Z. A top end surface 122 along the axial direction Y at the top end of the inner side X2 in the radial direction X of the tooth 12. A second side surface 131 along the axial direction Y at the outer side X1 in the radial direction X of the shoe 13. In addition, the area surrounded by the inner circumferential surface 112 along the axial direction Y on the inner side X2 in the radial direction X of the yoke 11, the first side surface 121, and the second side surface 131 becomes the slot 14 for winding the coil wire 70 to form the coil 7. The stator core 1 is formed by connecting the yokes 11 of a plurality of core parts 60 in the circumferential direction Z by the connecting part 111.

[0070] Here, if Figure 5 As shown, the stator core 1 is composed of nine core parts 60 connected by a connecting part 111. At the connecting part 111, the yoke part 11 of the stator core 1 can be freely bent, thereby being deformed into a straight shape or a reversely warped shape in which the direction of protrusion of the teeth 12 in the radial direction X is reversed.

[0071] In addition, if Figure 2 and Figure 5 As shown, the cores 60 arranged in the circumferential direction Z are set as the first core 61, the second core 62, the third core 63, the fourth core 64, the fifth core 65, the sixth core 66, the seventh core 67, the eighth core 68 and the ninth core 69 from the winding start side of the coil wire 70. Here, it is a connection structure of star connection or delta connection composed of three phases of U phase, V phase and W phase and different phases are arranged for each adjacent core 60 in the circumferential direction Z. In all the drawings, the case of star connection is shown.

[0072] And, if Fig.15 As shown, the first core 61 is U phase (U1), the second core 62 is V phase (V1), the third core 63 is W phase (W1), the fourth core 64 is U phase (U2), the fifth core 65 is V phase (V2), the sixth core 66 is W phase (W2), the seventh core 67 is U phase (U3), the eighth core 68 is V phase (V3), and the ninth core 69 is W phase (W3). In addition, when the description of this order is not necessary, the core 60 is collectively referred to for description.

[0073] In addition, the core 60 is similarly provided with a coil 7, a first bobbin 2 on the upper side of the axial direction Y as an insulating portion, and a second bobbin 3 on the lower side of the axial direction Y. However, regardless of whether the core 60 is provided with the coil 7, the first bobbin 2 on the upper side of the axial direction Y as an insulating portion, and the second bobbin 3 on the lower side of the axial direction Y, or the core 60 is not provided with the coil 7, the first bobbin 2 on the upper side of the axial direction Y as an insulating portion, and the second bobbin 3 on the lower side of the axial direction Y, the core 60 adopts this description.

[0074] Next, use Figures 7 to 12The first winding frame 2 on the upper side of the axial direction Y and the second winding frame 3 on the lower side of the axial direction Y as the insulating portion will be described. Figure 7 As shown, the first winding frame 2 on the upper side of the axial direction Y is composed of a first protrusion 21 and a first leg 22. Figure 8 As shown, the second bobbin 3 on the lower side in the axial direction Y is composed of a second protrusion 31 and a second leg 32 . Fig. 9 The figure shows a state where the first winding frame 2 on the upper side of the axial direction Y and the second winding frame 3 on the lower side of the axial direction Y are provided on the core 60, and the first protrusion 21 is formed to protrude from one side of the axial direction Y of the core 60. In addition, the second protrusion 31 is formed to protrude from the other side of the axial direction Y of the core 60.

[0075] like Figure 7 As shown in FIG. 1 , a groove portion having multiple stages in the axial direction Y is formed on the outer peripheral surface of the first protrusion 21 on the outer side X1 in the radial direction X. Here, the groove portion is formed in three stages, namely, a first groove portion 91, a second groove portion 92, and a third groove portion 93, from the side away from the stator core 1 in the axial direction Y. Each groove portion 91, 92, 93 is formed parallel to the circumferential direction Z. For example, referring to Fig.14 and Fig.15 The first groove 91 of the first core portion 61 , the first groove 91 of the second core portion 62 adjacent to each other in the circumferential direction Z, and the first groove 91 of the third core portion 63 are formed in parallel.

[0076] Although not shown in the drawings, for example, it is conceivable that the grooves 91 , 92 , and 93 are not parallel to the circumferential direction Z but are formed to be inclined in the circumferential direction Z. In this case, a common insulating portion can be used in all teeth 12 .

[0077] Here, three stages of the first groove portion 91, the second groove portion 92, and the third groove portion 93 are formed parallel to the circumferential direction Z, and the jumper wire 8 connecting the coils 7 of different teeth 12 is held. The jumper wire 8 is a continuous wire with the coils 7. In order to wind the coil wire 70 around the tooth 12, the introduction groove portion 94 holds the coil wire 70 in a manner of being introduced from the outer side X1 in the radial direction X of the stator core 1 to the inner side X2 in the radial direction X. The lead-out groove portion 95 holds the jumper wire 8 after being wound around the tooth 12 to form the coil 7 in a manner of being led out from the inner side X2 in the radial direction X of the stator core 1 to the outer side X1 in the radial direction X.

[0078] Therefore, the lead-out groove 95 of the first protrusion 21 of the first bobbin 2 formed on the upper side in the axial direction Y is aligned with the lead-out groove 95 provided on the Fig.10 The lead-out groove portion 95 is formed at the same height in the axial direction Y so as to be connected to the first groove portion 91 on the left side in the circumferential direction Z.

[0079] like Fig.30As shown, the first protrusion 21 of the first winding frame 2 has a molded concave portion 96 (see FIG. 1 ) which is concave toward the inner side X2 of the radial direction X at the central portion in the circumferential direction Z. Fig.30 The molded concave portion 96 has an inner bottom portion 960 on the inner side X2 in the radial direction X. The molded concave portion 96 accommodates the excess length of the jumper wire 8 generated when the stator core 1 is deformed from a straight state during winding to a circular state for wiring. In addition, the jumper wire 8 is held separately from the inner bottom portion 960 of the molded concave portion 96.

[0080] like Fig.12 As shown in FIG. 1 , when the distance between the connection part (connection part 111) of the stator core 1 and the center Q in the radial direction X is set to R1, and the distance between the part where the jumper wire 8 is arranged and the center Q is set to R2, the excess length S of the jumper wire 8 that separates two teeth in the circumferential direction Z and jumps to the third tooth is given by

[0081] S=2π(R1―R2) / 3

[0082] Therefore, the molded concave portion 96 needs to have a concave shape depth H on the inner side X2 in the radial direction X that can absorb the excess length S of the jumper line 8, that is, a depth H to the inner bottom 960. The depth H of the inner bottom 960 will be described later.

[0083] In order to prevent the coil wire 70 from loosening, the second bobbin 3 on the lower side in the axial direction Y has a bundling portion 310 for bundling the coil wire 70 at the winding end portion of each coil 7 at the second protruding portion 31. The first leg 22 of the first bobbin 2 and the second leg 32 of the second bobbin 3 are configured to cover the inner peripheral surface 112, the first side surface 121, and the second side surface 131 of the core 60. That is, each leg 22, 32 is fitted into the slot 14 to insulate the coil 7 from the stator core 1. In addition, in the present embodiment 1, an example is shown in which the lengths of the axial direction Y of the first leg 22 and the second leg 32 are formed to be substantially the same length, but this is not limited to this, and the lengths of the axial direction Y of each leg 22, 32 can be appropriately changed as long as the insulation between the stator core 1 and the coil 7 can be achieved by using the two legs 22, 32.

[0084] Next, use Fig.15The coil wire 70 is described. The coil wire 70 is a wire for forming the coil 7. Here, three coil wires 70, namely, a first coil wire 71, a second coil wire 72, and a third coil wire 73, are used. Among the coil wires 71, 72, and 73, the wires for starting the winding of the coil 7 are set as the first winding start wire 711, the second winding start wire 721, and the third winding start wire 731. In addition, when the first winding start wire 711, the second winding start wire 721, and the third winding start wire 731 are moved from the outer side X1 to the inner side X2 in the radial direction X of the stator core 1 and used as power lines, they are set as the first power line 713, the second power line 723, and the third power line 733.

[0085] In addition, in each coil wire 71, 72, 73, the wire at which the winding of the coil 7 ends is set as the first winding end wire 712, the second winding end wire 722, and the third winding end wire 732. The first winding end wire 712, the second winding end wire 722, and the third winding end wire 732 are connected to form a neutral point. In addition, as shown above, when it is not necessary to use each part of the coil wire 70 for description, it is collectively referred to as the coil wire 70 for description.

[0086] Next, use Fig.15 The jumper wire 8 is described. In addition, the jumper wire 8 is formed by the coil wire 70. The jumper wire 8 has a first jumper wire 81, a second jumper wire 82, a third jumper wire 83, a fourth jumper wire 84, a fifth jumper wire 85, and a sixth jumper wire 86. The first jumper wire 81 connects the coil 7 of the first core portion 61 with the coil 7 of the fourth core portion 64 which is separated by 3 core portions in the circumferential direction Z. The second jumper wire 82 connects the coil 7 of the second core portion 62 with the coil 7 of the fifth core portion 65 which is separated by 3 core portions in the circumferential direction Z. The third jumper wire 83 connects the coil 7 of the third core portion 63 with the coil 7 of the sixth core portion 66 which is separated by 3 core portions in the circumferential direction Z.

[0087] The fourth jumper wire 84 connects the coil 7 of the fourth core portion 64 to the coil 7 of the seventh core portion 67. The fifth jumper wire 85 connects the coil 7 of the fifth core portion 65 to the coil 7 of the eighth core portion 68 which is separated by three core portions in the circumferential direction Z. The sixth jumper wire 86 connects the coil 7 of the sixth core portion 66 to the coil 7 of the ninth core portion 69 which is separated by three core portions in the circumferential direction Z. In addition, as shown above, when there is no need to explain the various parts of the jumper wire 8, they are collectively referred to as the jumper wire 8 for explanation.

[0088] Next, based on Figure 26 to Figure 28 The flowchart of the present invention will explain the manufacturing method of the stator of the rotating electrical machine and the manufacturing method of the rotating electrical machine according to the first embodiment configured as described above. First, the magnetic steel sheet is punched to form Figure 4Then, the two types of core plates 6A and 6B are alternately stacked in the axial direction Y and connected by the connecting portion 111 of the yoke 11 to form a Figure 5 The stator core 1 ( Fig.26 Step ST1).

[0089] Next, the first winding frame 2 on the upper side of the axial direction Y and the second winding frame 3 on the lower side of the axial direction Y are formed by injection molding of an insulating resin, for example. Next, the first leg portion 22 of the first winding frame 2 on the upper side of the axial direction Y and the second leg portion 32 of the second winding frame 3 on the lower side of the axial direction Y are inserted and embedded into the first core 61 from both ends of the axial direction Y, as shown in FIG. Fig. 9 As shown, it is installed on the stator core 1 ( Fig.26 Step ST2).

[0090] Next, based on Fig. 27 To form coil 7 ( Fig.26 The process of step ST3) is described below. First, the first coil wire 71 is introduced from the outer side X1 to the inner side X2 in the radial direction X using the introduction groove 94 of the first core portion 61. In addition, the second coil wire 72 and the third coil wire 73 are also introduced from the outer side X1 to the inner side X2 in the radial direction X using the introduction groove 94 of the second core portion 62 and the third core portion 63, respectively.

[0091] And, if Fig.13 As shown, three winding nozzles 51, 52, 53 are used to simultaneously wind the first coil wire 71, the second coil wire 72, and the third coil wire 73 around the teeth 12 ( Fig. 27 Step ST11). However, Fig.13 An example in which the core is wound around the seventh core portion 67 , the eighth core portion 68 , and the ninth core portion 69 is shown in the drawing.

[0092] After the coils 7 are formed on the teeth 12 of the first core 61, the second core 62, and the third core 63, the first coil wires 71, the second coil wires 72, and the third coil wires 73 are bundled to the bundling portion 310 of the second bobbin 3 on the lower side of the first core 61, the second core 62, and the third core 63 in the axial direction Y to prevent loosening. Next, the first coil wires 71, the second coil wires 72, and the third coil wires 73 are bundled to the bundling portion 310 of the second bobbin 3 on the lower side of the axial direction Y of the first core 61, the second core 62, and the third core 63 to prevent loosening. Fig.14 Then, it is determined whether the coil 7 is formed on all the teeth 12 ( Fig. 27 Step ST12).

[0093] Here, step ST12 becomes "No", such as Fig.14As shown, each winding nozzle 51, 52, 53 is moved in the direction of arrow E and circumferential direction Z by the amount of three teeth. In order to carry out the next winding process, the first coil wire 71 is moved to the position of the fourth core portion 64, the second coil wire 72 is moved to the position of the fifth core portion 65, and the third coil wire 73 is moved to the position of the sixth core portion 66.

[0094] At this time, each of the grooves 91 to 93 accommodates each of the jumper wires 81 to 83 ( Fig. 27 Then, the coil wires 71, 72, 73 are introduced from the outer side X1 to the inner side X2 in the radial direction X through the introduction grooves 94 of the fourth core portion 64, the fifth core portion 65, and the sixth core portion 66. Fig.13 As shown, three winding nozzles 51, 52, 53 are used to simultaneously wind the first coil wire 71, the second coil wire 72, and the third coil wire 73 around the teeth 12 ( Fig. 27 Step ST11).

[0095] After forming the coil 7 on each of the teeth 12 of the fourth core 64, the fifth core 65, and the sixth core 66, the first coil wire 71, the second coil wire 72, and the third coil wire 73 are bundled to the bundling portion 310 of the second winding frame 3 on the lower side of the fourth core 64, the fifth core 65, and the sixth core 66 in the axial direction Y to prevent loosening. Next, the lead-out groove 95 is led out from the inner side X2 to the outer side X1 in the radial direction X. Then, it is determined whether the coil 7 is formed on all the teeth 12 ( Fig. 27 Step ST12).

[0096] Here, step ST12 becomes "No", and each winding nozzle 51, 52, 53 is moved in the direction of arrow E and circumferential direction Z by the amount of 3 teeth. In order to carry out the next winding process, the first coil wire 71 moves to the position of the seventh core portion 67, the second coil wire 72 moves to the position of the eighth core portion 68, and the third coil wire 73 moves to the position of the ninth core portion 69.

[0097] At this time, each of the grooves 91 to 93 accommodates each of the jumper wires 84 to 86 ( Fig. 27 Then, the coil wires 71, 72, 73 are introduced from the outer side X1 to the inner side X2 in the radial direction X through the introduction grooves 94 of the seventh core portion 67, the eighth core portion 68, and the ninth core portion 69. Fig.13 As shown, three winding nozzles 51, 52, 53 are used to simultaneously wind the first coil wire 71, the second coil wire 72, and the third coil wire 73 around the teeth 12 ( Fig. 27 Step ST11).

[0098] After the coils 7 are formed on the teeth 12 of the seventh core 67, the eighth core 68, and the ninth core 69, the first coil wire 71, the second coil wire 72, and the third coil wire 73 are bundled to the bundling portion 310 of the second bobbin 3 on the lower side of the seventh core 67, the eighth core 68, and the ninth core 69 in the axial direction Y to prevent loosening. Then, the lead-out groove 95 is led out from the inner side X2 to the outer side X1 in the radial direction X.

[0099] Then, it is determined whether the coils 7 are formed on all the teeth 12 ( Fig. 27 Here, step ST12 becomes "yes", such as Fig.15 As shown, the first coil wire 71, the second coil wire 72 and the third coil wire 73 are cut to form a first winding end wire 712, a second winding end wire 722 and a third winding end wire 732 ( Fig. 27 Then, the coil forming process is completed.

[0100] Next, based on Fig.28 The yoke 11 of the stator core 1 is deformed into an annular shape so that the teeth 12 protrude toward the inner side X2 in the radial direction X, and each of the jumper wires 81 to 86 is formed in the forming recessed portion 96 ( Fig.26 The process of step ST4) is described below. Fig.16 As shown, the stator core 1 after the coil 7 is formed moves the pressing portion 47 from the outer side X1 to the inner side X2 in the radial direction X in a straight state, and the first jumper wire 81 and the fourth jumper wire 84 are held in the first groove portion 91 in a manner that they do not protrude from the first groove portion 91, the second jumper wire 82 and the fifth jumper wire 85 are held in the second groove portion 92 in a manner that they do not protrude from the second groove portion 92, and the third jumper wire 83 and the sixth jumper wire 86 are held in the third groove portion 93 in a manner that they do not protrude from the third groove portion 93 ( Fig.28 Step ST21).

[0101] Then, if Figure 3 As shown, by using the pressing portion 47, each jumper wire 81 to 86 is deformed from a straight state to a circular state while being held in each groove portion 91 to 93 ( Fig.28 Step ST22). In addition, Figure 3 In the figure, the pressing portion 47 is omitted. Figure 3 It can be seen that each of the jumper wires 81 to 86 has an excess length and is in a state of being away from the first bobbin 2 toward the outer side X1 in the radial direction X.

[0102] Then, if Fig.17 , Fig.29 , Fig.30As shown, the forming portion 48 is moved from the outer side X1 to the inner side X2 in the radial direction X, so that each jumper wire 81 to 86 is accommodated in the forming recess 96 and pressed and formed ( Fig.28 Therefore, in the forming recess 96, the excess length of each jumper wire 81 to 86 is absorbed. Fig.29 FIG. 2 shows a top view of the stator core 1 after forming. Fig.30 Show Fig.29 9 is an enlarged view of the first core portion 61. In order to reliably absorb the excess length S, the depth H of the molded concave portion 96 to the inner bottom 960 needs to satisfy H=S×1 / 2 or more.

[0103] When the forming portion 48 is pressed and cut to the inner bottom 960 of the inner side X2 of the radial direction X of the forming recess 96, an overload is applied to each jumper wire 81 to 86 (coil wire 70), resulting in poor quality. Therefore, for example, a structure is set to determine the position relative to the pressing portion 47, and the pressing portion 47 stops at a position where the excess length S can be reliably formed without excessive pressing. In the above description, after the pressing portion 47 is moved, the forming timing is set to be after the stator core 1 is deformed into a circular ring state, but it is also possible to press and accommodate the excess length of each jumper wire 81 to 86 in the forming recess 96 in sequence at the timing of bending each core portion 60, so as to form and absorb it.

[0104] For example, only the first core portion 61 is bent, and only the first jumper wire 81 is formed and accommodated in the forming recess 96 of the first core portion 61. Then, only the second core portion 62 is bent, and only the second jumper wire 82 is formed and accommodated in the forming recess 96 of the second core portion 62. This process is repeated until the ninth core portion 69. In this way, the remaining part of the absorbed excess length can be transferred to the end. Then, the pressing portion 47 and the forming portion 48 are retracted to discharge the stator 100 ( Fig.28 Step ST24).

[0105] The first coil wire 71 thus formed is not cut but is a continuous wire, and is composed of the first winding start wire 711, the coil 7 of the first core 61, the first jumper wire 81, the coil 7 of the fourth core 64, the fourth jumper wire 84, the coil 7 of the seventh core 67, and the first winding end wire 712. The second coil wire 72 is not cut but is a continuous wire, and is composed of the second winding start wire 721, the coil 7 of the second core 62, the second jumper wire 82, the coil 7 of the fifth core 65, the fifth jumper wire 85, the coil 7 of the eighth core 68, and the second winding end wire 722. The third coil wire 73 is not cut but is a continuous wire, and is composed of the third winding start wire 731, the coil 7 of the third core 63, the third jumper wire 83, the coil 7 of the sixth core 66, the sixth jumper wire 86, the coil 7 of the ninth core 69, and the third winding end wire 732.

[0106] Next, the first winding start wire 711, the second winding start wire 721, and the third winding start wire 731 are used as power lines. When the stator 100 is set to a circular ring shape, the three first winding start wires 711, the second winding start wires 721, and the third winding start wires 731 need to be arranged on the inner side X2 of the radial direction X of the stator 100. Therefore, if Fig.15 As shown by the dotted line, the power lines 713, 723, and 733 are arranged on the inner side X2 in the radial direction X of the stator 100. The power lines 713, 723, and 733 are covered with an insulating tube on the inner side X2 in the radial direction X to maintain insulation and are wired.

[0107] Next, the stator core 1 is made into an annular shape, and the ends of the stator core 1 are fixed to each other by welding to form the stator 100 ( Fig.26 Next, the outer circumferential surface of the stator 100 is fixed to the inner circumferential surface of the housing 101 ( Fig.26 Step ST6). Next, the bearing 211 supports the shaft 221 in such a manner that the rotor 102 can rotate freely in the housing 101. Then, the rotor 102 is arranged to face the stator 100 with the gap G interposed therebetween, thereby forming the rotating electrical machine 200 ( Fig.26 Step ST7).

[0108] In the above-mentioned embodiment 1, a method of deforming the yoke 11 of the stator core 1 into a straight shape and winding the coil wire 70 around the teeth 12 to form the coil 7 is shown, but it is not limited to this. As another method, a case where the yoke 11 of the stator core 1 is deformed into a reverse warping shape opposite to the direction in which the teeth protrude in the radial direction X using the connecting portion 111 is described.

[0109] Fig.18 The stator 100 of the present embodiment 1 is the same as the stator 100 of the embodiment 1 except that the winding method is different. The winding machine 400 has a hexagonal chuck mechanism 40. The chuck mechanism 40 has chucks 41, 42, 43, 44, 45, and 46. Winding nozzles 54, 55, and 56 for winding the coil wire 70 are provided at positions facing the chucks 41, 42, and 43 in the chuck mechanism 40. Each winding nozzle 54, 55, and 56 rotates around the rotation axis T, the rotation axis M, and the rotation axis N to wind the coil wire 70 around each tooth 12.

[0110] but, Fig.18 and Figure 1 In the case of , the axis Y is reversed and shown. That is, Fig.18 1 is a diagram showing a state where the second winding frame 3 can see the core 60. However, the bundling portion 310 of the second winding frame 3 is omitted. Fig.18 The state after the coils 7 are formed on all the core portions 61 to 69 is shown.

[0111] First, the stator core 1 fixes the first core portion 61, the second core portion 62, and the third core portion 63 to the chucks 41, 42, and 43, respectively. Then, the winding nozzles 54, 55, and 56 are rotated around the rotation axes T, M, and N, and the coil wire 70 is wound around each tooth 12 to form the coil 7. After the first winding is completed, the winding nozzles 54, 55, and 56 are moved forward and backward and up and down, and the coil wire 70 is bundled to the bundling portion 310 of the second winding frame 3 on the lower side of the axial direction Y (wherein, Fig.18 The bundling portion 310 is omitted in the figure).

[0112] Next, by rotating the chuck mechanism 40, the jumper wire 8 is connected to the predetermined core 60 in the same manner as in the above-mentioned case. At this time, the chuck mechanism 40 rotates at a pitch of 60°. That is, the fourth core 64 repeatedly rotates at a pitch of 60° three times and moves to the position of the chuck 41 to which the first core 61 is fixed in the first winding. The other cores 60 also move at the same time. Since the stator core 1 is ejected from the position of the chuck 46, it is not fixed at the position of the chuck 45.

[0113] According to this method, the coil 7 can be formed by winding the coil wire 70 around the teeth 12 while ensuring a large interval between the teeth 12 adjacent to each other in the circumferential direction Z. Fig.18 As shown, the winding can be performed with the rotation axes T, M, and N of the winding nozzles 54, 55, and 56 always directed toward the teeth 12. Therefore, the coil wire 70 can be wound around the teeth 12 at high speed, and the winding cycle time can be shortened.

[0114] According to the stator of the rotating electrical machine of the first embodiment configured as described above, the stator includes:

[0115] A stator core, the stator core having a yoke portion configured in an annular shape and a plurality of teeth, the plurality of teeth being formed on an inner circumferential surface on the radial inner side of the yoke portion at predetermined intervals in the circumferential direction and protruding inward in the radial direction; a coil, the coil being formed by winding coil wires around the plurality of teeth respectively; and an insulating portion, the insulating portion being disposed between the stator core and the coil and insulating the stator core from the coil,

[0116] The insulating portion has a first protrusion protruding from one side in the axial direction of the stator core.

[0117] The first protrusion has a groove portion formed of multiple stages in the axial direction and a molded concave portion that is concave toward the inside in the radial direction on the outer peripheral surface of the first protrusion in the radial direction.

[0118] The jumper wires connecting the coils of different teeth to each other are continuous wires and are held in the grooves and the formed recesses, thereby preventing poor insulation of the jumper wires and improving productivity, thereby reducing costs and improving quality.

[0119] In addition, poor insulation of the jumper wire can be prevented, so the number of wiring members can be reduced, and the manufacturing time can be shortened to improve productivity. Therefore, a stator can be obtained that can prevent pulsation and vibration while suppressing the material cost and processing cost of the wiring members and has stable electrical characteristics. In addition, low cost can be achieved due to material saving, and quality can be improved due to the strength resistance of the insulation part.

[0120] In addition, the insulating portion has a forming concave portion on one side of the axial direction for absorbing the excess length of the jumper wire and a groove portion for insulating and accommodating the jumper wire of each phase at a predetermined position. For example, the jumper wire can be implemented in the groove portions with different heights such as the upper section, the middle section, and the lower section, and the excess length of the jumper wire generated when it is deformed from a straight state to a circular state is accommodated in the forming concave portion for absorption, thereby preventing the quality of the jumper wire wound as a continuous wire in a high-voltage rotating electric machine from being poor. In addition, the slack of the coil wire when the coil is formed can be prevented, the number of wiring components can be reduced, and the manufacturing time can be shortened to improve productivity.

[0121] Moreover, according to the rotating electrical machine, the stator of the rotating electrical machine described above and the rotor arranged to face the stator with a gap therebetween are provided in the casing, so that the jumper wire can be prevented from contacting the casing and short-circuiting, and insulation failure of the jumper wire can be prevented.

[0122] Moreover, according to the manufacturing method of the stator of a rotating electric machine, after the yoke is deformed into a straight shape or a reverse warping shape in the opposite direction of the radial protrusion of the teeth and the coil wire is wound on the teeth to form the coil, the yoke is deformed into a ring shape in such a manner that the teeth protrude radially inward, and the jumper wire is inserted into the groove portion of the first protrusion, and the jumper wire is pressed into and accommodated in the forming recess, so that when the excess length of the jumper wire is formed in the forming recess, the jumper wire is maintained in different multi-level grooves, thereby preventing interference of multiple jumper wires.

[0123] Moreover, according to the manufacturing method of the rotating electric machine, a rotor is arranged in a housing with a gap between the stator manufactured by the manufacturing method of the stator of the rotating electric machine described above, so that the jumper wire is accommodated and held in the groove portion and the formed recessed portion formed in the insulating portion, thereby preventing a short circuit with the housing due to the extension of the jumper wire.

[0124] Moreover, according to the stator of the rotating electrical machine, the molded recess has an inner bottom on the radially inner side, and the jumper wire is held separately from the inner bottom of the molded recess, so that overload on the jumper wire can be reduced and quality can be improved.

[0125] Moreover, according to the stator of the rotating electric machine, the insulating portion has a second protrusion protruding from the other side of the axial direction of the stator core, and the second protrusion has a bundling portion of the coil wire for bundling the winding end portion of each of the coils. Therefore, it is possible to prevent the jumper wires between the coils from loosening, prevent the winding disorder of the coils, and achieve uniformity of the coils.

[0126] Furthermore, according to the stator of the rotating electrical machine, the yoke is formed to be deformable into a straight shape or a reversely warped shape in which the radially protruding direction of the teeth is reversed, so that the coil wire can be easily wound around the teeth of the stator core.

[0127] Implementation method 2.

[0128] Fig.19 This is a perspective view showing a state in which the yoke 11 of the stator core 1 is deformed into a linear shape and the first protrusion 21 , the second protrusion 31 , and the film 230 as insulating portions are attached in the stator of the rotating electrical machine according to the second embodiment. Fig. 20 It shows that Fig.19 The illustrated exploded perspective view is a state before the first protrusion 21 , the second protrusion 31 , and the film portion 230 are mounted on the stator core 1 . Fig.21 It is shown Fig.19 A perspective view of the structure of the membrane portion 230 is shown. Fig.22A The figure shows the upper surface viewed from the axial direction. Fig.19 A perspective view of the structure of the first winding frame shown. Fig. 22B The figure shows the bottom surface viewed from the axial direction. Fig.19 A perspective view of the structure of the first winding frame shown. Fig.23 It is shown Fig.19 A perspective view of the structure of the second protrusion 31 is shown.

[0129] In each figure, the same reference numerals are given to the same parts as those in the first embodiment, and description thereof is omitted. As shown in the figure, in the stator 100 of the second embodiment, the structure of the insulating portion for insulating the stator core 1 and the coil 7 shown in the first embodiment is different. In the second embodiment, in order to insulate the stator core 1 and the coil 7, the insulating portion is composed of the first protrusion 21 on the upper side of the axial direction Y, the second protrusion 31 on the lower side of the axial direction Y, and the membrane portion 230.

[0130] Therefore, the first winding frame 2 on the upper side of the axial direction Y of the second embodiment has only the first protrusion 21 and does not have the first leg 22 of the first embodiment. In addition, the second winding frame 3 on the lower side of the axial direction Y has only the second protrusion 31 and does not have the second leg 32 of the first embodiment.

[0131] The first protrusion 21 includes claws 411, 412, 413, 414 for fixing the film 230 described later. In addition, the second protrusion 31 includes claws 421, 422, 423, 424 for fixing the film 230. In addition, the first protrusion 21 and the second protrusion 31 are respectively provided with convex parts 415, 425 for determining the position with the stator core 1. The stator core 1 includes the second concave part 115 at both ends of the tooth 12 in the axial direction Y. The convex parts 415, 425 are respectively fitted in the second concave part 115 provided in the stator core 1.

[0132] The membrane portion 230 is formed of a thin-walled insulating membrane material, for example, a membrane material with a thickness of 0.125 mm can be used. Fig.21 The diaphragm 230 is formed by providing a fold as shown. Through the fold, the diaphragm 230 includes a first side surface 231 covering the inner side X2 of the yoke 11 in the radial direction X and along the inner peripheral surface 112 along the axial direction Y, a second side surface 232 covering the first side surface 121 of the tooth 12 along the axial direction Y and the second side surface 131 of the shoe 13 along the axial direction Y, and a third side surface 233 covering the top end surface 122 of the tooth 12 along the axial direction Y.

[0133] In addition, when the film portion 230 is mounted on the stator core 1, it is connected to the first protrusion 21 and the second protrusion 31 in the axial direction Y. In addition, the film portion 230 is continuously formed corresponding to all of the core portions 61 to 69 of the stator core 1. After the coil 7 is wound around the tooth 12, the central portion of the circumferential direction Z of the third side surface 233 of the film portion 230 is cut along the axial direction Y and bent between the coils 7 in a manner covering the side surface of the coil 7 in the circumferential direction Z. In addition, the other structures and the manufacturing method of the stator of the rotating electric machine are the same as those in the above-mentioned embodiment 1.

[0134] According to the stator of a rotating electric machine, a rotating electric machine, a method for manufacturing a stator of a rotating electric machine, and a method for manufacturing a rotating electric machine according to embodiment 2 constructed as described above, the same effect as that of embodiment 1 described above is achieved, and since the insulating portion comprises: a second protrusion, which protrudes from the other axial end side of the stator core; and a membrane portion, which is axially connected to the first protrusion and the second protrusion and covers the axial side surface of the tooth and the radial inner axial side surface of the yoke, the insulating portion can be formed by a thin-walled membrane portion.

[0135] Implementation method 3.

[0136] The stator of the rotating electric machine of the third embodiment has a different structure from the stator core of the above-mentioned embodiments. Therefore, except for the different structure of the stator core, it is the same as the above-mentioned embodiments, and the description will be mainly focused on the parts different from the above-mentioned embodiments.

[0137] Fig.31 It is a perspective view showing the structure of a stator core of a stator of a rotating electrical machine in the third embodiment. Fig.32 It is shown Fig.31 FIG. 1 is an enlarged top view of the structure of the main part of the stator core shown in FIG. In each figure, the same reference numerals are given to the same parts as those in the above-mentioned embodiments and the description thereof is omitted. As shown in the figure, the yoke 11 has a thin-walled connecting portion 152 between teeth 12 adjacent in the circumferential direction Z. Therefore, the cores 60 are connected to each other by the thin-walled connecting portion 152.

[0138] Thus, the difference between the stator core 1 of the above-mentioned embodiments and the stator core 1 of the present embodiment 3 lies in that, in the stator core 1 of the above-mentioned embodiments, the core portions 60 adjacent in the circumferential direction Z of the yoke portion 11 are connected to each other by a rotatable connecting portion 111, whereas, in the stator core 1 of the present embodiment 3, the core portions 60 are connected to each other by a thin-walled connecting portion 152 that can be bent.

[0139] The stator core 1 of each of the above embodiments is as follows Figure 4 As shown, two types of core plates 6A and 6B formed by punching out thin-walled magnetic steel plates are alternately stacked in the axial direction Y to form the connecting portion 111, but in this embodiment 3, a plurality of core plates 6C formed by punching out thin-walled magnetic steel plates are stacked in the axial direction Y.

[0140] The core plates 6C are formed in such a way that the stacked portions forming the yoke portions 11 are arranged in a straight line, that is, the teeth 12 are arranged in parallel, and the yoke portions 11 adjacent to each other in the circumferential direction Z are not physically separated from each other, but are connected by the thin-walled connecting portion 152. Therefore, by simply stacking a plurality of core plates 6C in the axial direction Y, the adjacent core portions 60 can be connected by the thin-walled connecting portion 152.

[0141] When multiple core plates 6C are stacked in the axial direction Y, the yokes 11 of the core parts 60 are kept in a linear arrangement. The stator 100 of the present embodiment 3 has the same insulating portion as the above-mentioned embodiments. After the winding of each tooth 12 is completed, the thin-walled connecting portion 152 is plastically deformed and bent in a manner that the yoke 11 becomes annular. At this time, the positional relationship between the yoke 11 and each tooth 12 is the same as that of the above-mentioned embodiments.

[0142] According to the stator of the rotating electric machine of the third embodiment constructed as described above, similarly to the above embodiments, it comprises: a stator core having a yoke portion and a plurality of teeth arranged in an annular shape, wherein the plurality of teeth are formed on the inner peripheral surface of the radial inner side of the yoke portion at predetermined intervals in the circumferential direction and protrude inwardly in the radial direction; a coil formed by winding coil wires around the plurality of teeth respectively; and an insulating portion, which is arranged between the stator core and the coil and insulates the stator core from the coil.

[0143] The insulating portion has a first protrusion protruding from one side in the axial direction of the stator core.

[0144] The first protrusion has a groove portion formed of multiple stages in the axial direction and a molded concave portion that is concave toward the inside in the radial direction on the outer peripheral surface of the first protrusion in the radial direction.

[0145] The jumper wires connecting the coils of different teeth to each other are continuous wires and are held in the grooves and the formed recesses, thereby preventing poor insulation of the jumper wires and improving productivity, thereby reducing costs and improving quality.

[0146] In addition, poor insulation of the jumper wire can be prevented, so the number of wiring members can be reduced, and the manufacturing time can be shortened to improve productivity. Therefore, a stator can be obtained that can prevent pulsation and vibration while suppressing the material cost and processing cost of the wiring members and has stable electrical characteristics. In addition, low cost can be achieved due to material saving, and quality can be improved due to the strength resistance of the insulation part.

[0147] In addition, the insulating portion has a forming concave portion on one side of the axial direction for absorbing the excess length of the jumper wire and a groove portion for insulating and accommodating the jumper wire of each phase at a predetermined position. For example, the jumper wire can be implemented in the groove portions with different heights such as the upper section, the middle section, and the lower section, and the excess length of the jumper wire generated when it is deformed from a straight state to a circular state is accommodated in the forming concave portion for absorption, thereby preventing the quality of the jumper wire wound as a continuous wire in a high-voltage rotating electric machine from being poor. In addition, the slack of the coil wire when the coil is formed can be prevented, the number of wiring components can be reduced, and the manufacturing time can be shortened to improve productivity.

[0148] Moreover, according to the rotating electrical machine, the stator of the rotating electrical machine described above and the rotor arranged to face the stator with a gap therebetween are provided in the casing, so that the jumper wire can be prevented from contacting the casing and short-circuiting, and insulation failure of the jumper wire can be prevented.

[0149] Moreover, according to the manufacturing method of the stator of a rotating electric machine, after the yoke is deformed into a straight shape or a reverse warping shape in the opposite direction of the radial protrusion of the teeth and the coil wire is wound on the teeth to form the coil, the yoke is deformed into a ring shape in such a manner that the teeth protrude radially inward, and the jumper wire is inserted into the groove portion of the first protrusion, and the jumper wire is pressed into and accommodated in the forming recess, so that when the excess length of the jumper wire is formed in the forming recess, the jumper wire is maintained in different multi-level grooves, thereby preventing interference of multiple jumper wires.

[0150] Moreover, according to the manufacturing method of the rotating electric machine, a rotor is arranged in a housing with a gap between the stator manufactured by the manufacturing method of the stator of the rotating electric machine described above, so that the jumper wire is accommodated and held in the groove portion and the formed recessed portion formed in the insulating portion, thereby preventing a short circuit with the housing due to the extension of the jumper wire.

[0151] Moreover, according to the stator of the rotating electrical machine, the molded recess has an inner bottom on the radially inner side, and the jumper wire is held separately from the inner bottom of the molded recess, so that overload on the jumper wire can be reduced and quality can be improved.

[0152] Moreover, according to the stator of the rotating electric machine, the insulating portion has a second protrusion protruding from the other side of the axial direction of the stator core, and the second protrusion has a bundling portion of the coil wire for bundling the winding end portion of each of the coils. Therefore, it is possible to prevent the jumper wires between the coils from loosening, prevent the winding disorder of the coils, and achieve uniformity of the coils.

[0153] Furthermore, according to the stator of the rotating electrical machine, the yoke portion includes the thin-walled connecting portion between the teeth adjacent to each other in the circumferential direction, and thus can be easily formed by plastic deformation of the thin-walled connecting portion.

[0154] Furthermore, according to the stator of the rotating electrical machine, the yoke is formed to be deformable into a straight shape or a reversely warped shape in which the radially protruding direction of the teeth is reversed, so that the coil wire can be easily wound around the teeth of the stator core.

[0155] Implementation method 4.

[0156] The stator of the rotating electric machine of the present embodiment 4 has a different structure from the stator core of the above-mentioned embodiments 1 and 2. Therefore, except for the different structure of the stator core, it is the same as the above-mentioned embodiments 1 and 2, and the description will be mainly focused on the parts different from the above-mentioned embodiments 1 and 2.

[0157] Fig.33 It is a perspective view showing the structure of a divided core portion of a stator core of a rotating electric machine stator according to a fourth embodiment. Fig.34 It is shown Fig.33 A three-dimensional view of a fixing fixture of the split core shown in FIG. In each figure, the same reference numerals are given to the same parts as those in the above-mentioned embodiments and the description thereof is omitted. As shown in the figure, for the split core 600, the yoke 11 is formed by splitting each tooth 12 adjacent in the circumferential direction Z. The split core 600 is equivalent to the core 60 of the above-mentioned embodiments 1 and 2.

[0158] Thus, the difference between the stator core 1 of the above-mentioned embodiments 1 and 2 and the stator core 1 of the present embodiment 4 lies in that the core portions 60 adjacent to each other in the circumferential direction Z of the yoke portion 11 of the stator core 1 of each of the above-mentioned embodiments 1 and 2 are connected to each other by a rotatable connecting portion 111, whereas the split core portions 600 of the stator core 1 of the present embodiment 4 are not connected to each other and are formed independently.

[0159] The stator core 1 of the above-mentioned embodiments 1 and 2 is as follows Figure 4 As shown in the figure, two types of core plates 6A and 6B formed by punching out thin-walled magnetic steel plates are alternately stacked in the axial direction Y to form the connecting portion 111, but in the fourth embodiment, the split core portion 600 is formed by stacking a plurality of one type of core plates 6D formed by punching out thin-walled magnetic steel plates in the axial direction Y. In this way, the stator core 1 of the fourth embodiment is composed of 9 independent split core portions 600.

[0160] The stator 100 of the fourth embodiment includes the same insulating portion as in the first and second embodiments. Fig.34 As shown, all the split cores 600 are arranged and held on the fixing jig 17 in a linear arrangement with the yokes 11, and the winding is continuously performed in the same manner as in the first embodiment. Thereafter, the fixing jig 17 is removed, the yokes 11 of the split cores 600 are combined in a ring shape, and the split cores 600 adjacent to each other in the circumferential direction Z are fixed to each other, thereby forming the stator 100. The fixing method may be welding, shrink fit, etc.

[0161] According to the stator of the rotating electric machine of the fourth embodiment constructed as described above, similarly to the above embodiments, it comprises: a stator core having a yoke portion and a plurality of teeth arranged in an annular shape, wherein the plurality of teeth are formed on the inner peripheral surface of the radial inner side of the yoke portion at predetermined intervals in the circumferential direction and protrude inwardly in the radial direction; a coil formed by winding coil wires around the plurality of teeth respectively; and an insulating portion, which is arranged between the stator core and the coil and insulates the stator core from the coil.

[0162] The insulating portion has a first protrusion protruding from one side in the axial direction of the stator core.

[0163] The first protrusion has a groove portion formed of multiple stages in the axial direction and a molded concave portion that is concave toward the inside in the radial direction on the outer peripheral surface of the first protrusion in the radial direction.

[0164] The jumper wires connecting the coils of different teeth to each other are continuous wires and are held in the grooves and the formed recesses, thereby preventing poor insulation of the jumper wires and improving productivity, thereby reducing costs and improving quality.

[0165] In addition, poor insulation of the jumper wire can be prevented, so the number of wiring members can be reduced, and the manufacturing time can be shortened to improve productivity. Therefore, a stator can be obtained that can prevent pulsation and vibration while suppressing the material cost and processing cost of the wiring members and has stable electrical characteristics. In addition, low cost can be achieved due to material saving, and quality can be improved due to the strength resistance of the insulation part.

[0166] In addition, the insulating portion has a forming concave portion on one side of the axial direction for absorbing the excess length of the jumper wire and a groove portion for insulating and accommodating the jumper wire of each phase at a predetermined position. For example, the jumper wire can be implemented in the groove portions with different heights such as the upper section, the middle section, and the lower section, and the excess length of the jumper wire generated when it is deformed from a straight state to a circular state is accommodated in the forming concave portion for absorption, thereby preventing the quality of the jumper wire wound as a continuous wire in a high-voltage rotating electric machine from being poor. In addition, the slack of the coil wire when the coil is formed can be prevented, the number of wiring components can be reduced, and the manufacturing time can be shortened to improve productivity.

[0167] Moreover, according to the rotating electrical machine, the stator of the rotating electrical machine described above and the rotor arranged to face the stator with a gap therebetween are provided in the casing, so that the jumper wire can be prevented from contacting the casing and short-circuiting, and insulation failure of the jumper wire can be prevented.

[0168] Moreover, according to the manufacturing method of the stator of a rotating electric machine, after the yoke is deformed into a straight shape or a reverse warping shape in the opposite direction of the radial protrusion of the teeth and the coil wire is wound on the teeth to form the coil, the yoke is deformed into a ring shape in such a manner that the teeth protrude radially inward, and the jumper wire is inserted into the groove portion of the first protrusion, and the jumper wire is pressed into and accommodated in the forming recess, so that when the excess length of the jumper wire is formed in the forming recess, the jumper wire is maintained in different multi-level grooves, thereby preventing interference of multiple jumper wires.

[0169] Moreover, according to the manufacturing method of the rotating electric machine, a rotor is arranged in a housing with a gap between the stator manufactured by the manufacturing method of the stator of the rotating electric machine described above, so that the jumper wire is accommodated and held in the groove portion and the formed recessed portion formed in the insulating portion, thereby preventing a short circuit with the housing due to the extension of the jumper wire.

[0170] Moreover, according to the stator of the rotating electrical machine, the molded recess has an inner bottom on the radially inner side, and the jumper wire is held separately from the inner bottom of the molded recess, so that overload on the jumper wire can be reduced and quality can be improved.

[0171] Moreover, according to the stator of the rotating electric machine, the insulating portion has a second protrusion protruding from the other side of the axial direction of the stator core, and the second protrusion has a bundling portion of the coil wire for bundling the winding end portion of each of the coils. Therefore, it is possible to prevent the jumper wires between the coils from loosening, prevent the winding disorder of the coils, and achieve uniformity of the coils.

[0172] Furthermore, according to the stator of the rotating electrical machine, the yoke portion is divided and formed for each of the teeth adjacent to each other in the circumferential direction, and therefore the yoke portion can be easily changed to a linear shape.

[0173] Furthermore, according to the stator of the rotating electrical machine, the yoke is formed to be deformable into a straight shape or a reversely warped shape in which the radially protruding direction of the teeth is reversed, so that the coil wire can be easily wound around the teeth of the stator core.

[0174] The present disclosure describes various exemplary embodiments and examples, but various features, methods, and functions described in one or more embodiments are not limited to application in specific embodiments and can be applied to the embodiments alone or in various combinations.

[0175] Therefore, numerous modifications not shown in the examples are conceivable within the scope of the technology disclosed in the present specification, including, for example, modification, addition, or omission of at least one component, and extraction of at least one component and combination with components of other embodiments.

[0176] Description of Reference Numerals

[0177] 1 stator core, 100 stator, 101 housing, 102 rotor, 11 yoke, 111 connection part, 112 inner peripheral surface, 113 outer peripheral surface, 114 first recess, 115 second recess, 12 teeth, 121 first side surface, 122 top surface, 13 shoe, 131 second side surface, 14 groove, 152 thin-wall connection part, 17 fixing fixture, 2 first winding frame, 200 rotating electric machine, 21 first protrusion, 211 bearing, 22 first leg, 221 shaft, 222 permanent magnet, 223 rotor core, 230 membrane, 231 first side surface, 232 second side surface , 233 third side, 3 second winding frame, 31 second protrusion, 310 bundling portion, 32 second leg, 40 chuck mechanism, 400 winding machine, 41 chuck, 42 ​​chuck, 43 chuck, 44 chuck, 45 chuck, 46 chuck, 47 pressing portion, 48 forming portion, 411 claw, 412 claw, 413 claw, 414 claw, 415 convex portion, 421 claw, 422 claw, 423 claw, 424 claw, 425 convex portion, 51 winding nozzle, 511 arrow, 52 winding nozzle, 521 arrow, 53 winding nozzle, 531 arrow, 54 winding nozzle, 55 winding nozzle, 56 winding nozzle, 6A core plate, 6B core plate, 6C core plate, 6D core plate, 60 core, 600 split core, 61 first core, 62 second core, 63 third core, 64 fourth core, 65 fifth core, 66 sixth core, 67 seventh core, 68 eighth core, 69 ninth core, 7 coil, 70 coil wire, 71 first coil wire, 711 first winding start wire, 712 first winding end wire, 713 first power supply wire, 72 second coil wire, 721 second winding start wire, 722 second winding end wire, 723 second power supply line, 73 third coil line, 731 third winding start line, 732 third winding end line, 733 third power supply line, 8 jumper line, 81 first jumper line, 82 second jumper line, 83 third jumper line, 84 fourth jumper line, 85 fifth jumper line, 86 sixth jumper line, 91 first groove portion, 92 second groove portion, 93 third groove portion, 94 import groove portion, 95 export groove portion, 96 forming recessed portion, 960 inner bottom, G gap, H depth, T rotation axis, M rotation axis, N rotation axis, X radial direction, X1 outer side, X2 inner side, Y axial direction, Z circumferential direction.

Claims

1. A stator of a rotating electric machine, comprising: a stator core, the stator core having a yoke portion arranged in an annular shape and a plurality of teeth, the plurality of teeth being formed on an inner circumferential surface of the yoke portion on the radial inner side thereof at predetermined intervals in the circumferential direction and protruding inward in the radial direction; a coil, the coil being formed by winding coil wires around the plurality of teeth respectively; and an insulating portion, the insulating portion being arranged between the stator core and the coil and insulating the stator core from the coil, wherein: The insulating portion has a first protrusion protruding from one side in the axial direction of the stator core. The first protrusion has a groove portion formed of multiple stages in the axial direction and a molded concave portion that is concave toward the inside in the radial direction on the outer peripheral surface of the first protrusion in the radial direction. The jumper wires connecting the coils of different teeth to each other are continuous wires and are held within the grooves and the shaped recesses, The excess length of the jumper wire is received in the forming recess. The molded recess opens radially outward from one end of the excess length portion of the jumper wire received in the molded recess to the other end.

2. The stator of a rotating electrical machine according to claim 1, wherein: The yoke is formed to be deformable into a straight shape or a reversely warped shape that reverses the radial protrusion direction of the teeth. The extra length of the jumper wire is generated in the jumper wire when the stator core wound in a linear state is deformed into a circular ring state.

3. The stator of a rotating electrical machine according to claim 2, wherein: Among the plurality of teeth in a linear state, the jumper wire is not housed in each of the forming recessed portions in the insulating portion of the teeth mounted at both ends in the circumferential direction.

4. The stator of a rotating electrical machine according to claim 3, wherein: Among the plurality of teeth in a linear state, one jumper wire is housed in each of the forming recessed portions in the insulating portion mounted on the second tooth from both ends in the circumferential direction.

5. The stator of a rotating electrical machine according to any one of claims 1 to 4, wherein: Two of the jumper wires are housed in one of the forming recesses.

6. The stator of a rotating electrical machine according to any one of claims 1 to 4, wherein: The formed recess has an inner bottom on the inner side in the radial direction, The jumper wire is held separately from the inner bottom of the shaped recess.

7. The stator of a rotating electrical machine according to claim 6, wherein: When the excess length is defined as S, the depth H of the molding recessed portion to the inner bottom portion is formed to be greater than or equal to H=S×1 / 2.

8. The stator of a rotating electrical machine according to any one of claims 1 to 4, wherein: The insulating portion includes: a second protrusion protruding from the other end side of the stator core in the axial direction; as well as A diaphragm portion is connected to the first protrusion portion and the second protrusion portion in the axial direction and covers the axial side surface of the tooth and the axial side surface on the radial inner side of the yoke portion.

9. The stator of a rotating electrical machine according to any one of claims 1 to 4, wherein: The insulating portion includes a second protruding portion that protrudes from the other side in the axial direction of the stator core, and the second protruding portion includes a binding portion that binds the coil wires at winding end portions of the coils.

10. The stator of a rotating electrical machine according to any one of claims 1 to 4, wherein: The yoke portion includes a thin-walled connection portion between the teeth adjacent to each other in the circumferential direction.

11. The stator of a rotating electrical machine according to any one of claims 1 to 4, wherein: The yoke portion is formed by dividing into sections corresponding to each of the teeth adjacent to each other in the circumferential direction.

12. A rotating electrical machine, wherein: The rotating electrical machine includes the stator of the rotating electrical machine according to any one of claims 1 to 11 and a rotor disposed facing the stator with a gap therebetween in a casing.

13. A method for manufacturing a stator of a rotating electrical machine, wherein the stator of the rotating electrical machine is the stator of the rotating electrical machine according to any one of claims 1 to 11, wherein: After the yoke is deformed into a straight shape or a reversely warped shape in which the radially protruding direction of the teeth is reversed and the coil wire is wound around the teeth to form the coil, The yoke is deformed into an annular shape so that the teeth protrude radially inward, the jumper wire is inserted into the groove of the first protrusion, and the jumper wire is pressed into the molding recess to be accommodated.

14. The method for manufacturing a stator of a rotating electrical machine according to claim 13, wherein: The jumper wire is held in the groove of the first protrusion by the pressing portion and the forming portion is moved radially inward from the pressing portion in the forming recessed portion, thereby forming and housing the jumper wire.

15. The method for manufacturing a stator of a rotating electrical machine according to claim 13 or 14, wherein: The yoke is formed to be deformable into a straight shape or a reversely warped shape that reverses the radial protrusion direction of the teeth. In the case where the core portion of the yoke portion including the teeth at one circumferential end among the plurality of teeth and the teeth at one circumferential end protrudes is set as the first core portion, When the yoke is formed into a straight line, the yoke of the first core is deformed into a ring shape, and the jumper wire is pressed into and accommodated in the forming recess of the first core. Then, among the remaining cores, the yokes are deformed into a ring shape in sequence starting from the core adjacent to the first core, and the jumper wire is pressed into and accommodated in the forming recess.

16. A method for manufacturing a rotating electrical machine, wherein: A rotor is provided in the housing with a gap between the stator manufactured by the method for manufacturing a stator of a rotating electrical machine according to any one of claims 13 to 15 and the stator.

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