Electric compressor and method of manufacturing an electric compressor

Abstract

The present application provides an electric compressor with improved operability and a manufacturing method of the electric compressor. An electric compressor includes an electric motor having a stator and a housing, the stator including a stator core having a yoke portion and a plurality of teeth, an insulating member having an insulating member base portion abutting against an end surface of the yoke portion, and three-phase windings formed by winding in a concentrated winding manner on the corresponding plurality of teeth to form a plurality of coils, the windings of each phase forming a plurality of lap wires latched to an outer circumferential surface of the insulating member base portion, each lap wire connecting adjacent coils in the corresponding phase to each other, the outer circumferential surface of the insulating member base portion having a latching surface having a receiving groove receiving the lap wires and a non-latching surface not latching the lap wires, the stator core having a fitting recess fitting with a portion of a jig at a position radially outward of the insulating member base portion in the end surface of the yoke portion and radially outward of the non-latching surface.

Description

Technical Field

[0001] This invention relates to electric compressors and methods for manufacturing electric compressors. Background Technology

[0002] For example, an electric compressor disclosed in Japanese Patent Application Publication No. 2012-144997 includes a compressor section, an electric motor, and a cylindrical housing. The compressor section compresses the fluid. The electric motor drives the compressor section. The housing houses the electric motor.

[0003] An electric motor has a stator. The stator has a ring-shaped stator core. The stator core is fixed to the inner circumferential surface of the housing. The stator core has a cylindrical yoke and multiple teeth. The yoke engages with the inner circumferential surface of the housing. The multiple teeth are spaced apart circumferentially along the yoke and extend radially from the inner circumferential surface of the yoke. The stator has U-phase, V-phase, and W-phase windings. The windings of each phase are wound in a concentrated manner around the multiple teeth to form multiple coils.

[0004] For example, to handle high voltage, coils for each phase are sometimes formed using series windings. In a series winding, first, the windings for each phase are wound around the corresponding teeth. Next, the windings for each phase are wound around the teeth corresponding to that phase. The teeth corresponding to each phase are arranged every two in the circumferential direction of the yoke. The windings for each phase are wound sequentially around the teeth corresponding to that phase in a concentrated winding manner. Thus, the coils for each phase are formed by winding the windings around the teeth corresponding to that phase in a concentrated winding manner. Furthermore, the stator has an insulating element. The insulating element has a cylindrical insulating base. The insulating base abuts against the end face of the yoke.

[0005] The windings of each phase form multiple connection wires that connect adjacent coils in the corresponding phase to each other. The connection wires terminate at the outer peripheral surface of the base of the insulator. Summary of the Invention

[0006] The problem that the invention aims to solve

[0007] The stator is assembled to the housing, for example, by heat fitting the stator core into the inner circumferential surface of the housing. In this heat fitting, after the housing is heated and expanded so that the inner diameter of the housing is larger than the outer diameter of the stator core, the stator core is inserted into a predetermined heat fitting position within the housing. Then, the inner circumferential surface of the housing comes into close contact with the outer circumferential surface of the stator core as the housing contracts towards room temperature.

[0008] When heat-fitting the stator core into the housing, a fixture is used to position the stator core relative to the housing in the circumferential direction to prevent phase shift between the stator core and the housing. After the stator core is in phase relative to the housing, it is inserted into the predetermined heat-fitting position inside the housing. However, if a connecting wire is placed at the insertion point of the fixture, interference occurs. This reduces the ease of assembly.

[0009] Solution for solving the problem

[0010] An electric compressor according to one aspect of the present invention comprises: a compression section configured to compress a fluid; an electric motor configured to drive the compression section; and a cylindrical housing housing the electric motor. The electric motor has a stator. The stator comprises: an annular stator core having a cylindrical yoke that engages with the inner circumferential surface of the housing and a plurality of teeth extending radially from the inner circumferential surface of the yoke; an annular insulating member having a cylindrical insulating member base abutting against the end face of the yoke; and U-phase, V-phase, and W-phase windings, which are windings for the U-phase, V-phase, and W-phase, respectively. Each phase winding forms a plurality of coils by being wound in a concentrated winding manner around corresponding teeth of the plurality of teeth. The windings of each phase form a plurality of contact wires that engage with the outer circumferential surface of the insulating member base, and each contact wire connects adjacent coils in the corresponding phase to each other. The outer peripheral surface of the base of the insulating member has: a locking surface having a receiving groove for receiving the lap joint; and a non-locking surface that does not have the receiving groove and does not lock the lap joint. The stator core has a locking recess in the end face of the yoke, located radially outward from the base of the insulating member, for engaging with a portion of the clamp. The locking recess is located radially outward from the non-locking surface in the end face of the yoke.

[0011] One aspect of the present invention is a method for manufacturing an electric compressor, the electric compressor comprising: a compression section configured to compress a fluid; an electric motor configured to drive the compression section; and a cylindrical housing housing the electric motor. The electric motor has a stator. The stator comprises: an annular stator core having a cylindrical yoke that engages with the inner circumferential surface of the housing and a plurality of teeth extending radially from the inner circumferential surface of the yoke; an annular insulating member having a cylindrical insulating member base abutting against the end face of the yoke; and U-phase, V-phase, and W-phase windings, which are windings for the U-phase, V-phase, and W-phase, respectively. Each phase winding forms a plurality of coils by being wound in a concentrated winding manner around corresponding teeth in the plurality of teeth. Each phase winding forms a plurality of contact wires that engage with the outer circumferential surface of the insulating member base, and each contact wire connects adjacent coils in the corresponding phase to each other. The outer peripheral surface of the base of the insulating member has: a locking surface having a receiving groove for receiving the lap joint; and a non-locking surface that does not have the receiving groove and does not lock the lap joint. The stator core has a locking recess in the end face of the yoke, located radially outward from the base of the insulating member, for engaging with a portion of a clamp. The locking recess is located radially outward from the non-locking surface in the end face of the yoke. The manufacturing method includes engaging a portion of the clamp, which faces the non-locking surface radially to the stator core, with the locking recess and performing circumferential positioning of the stator. Attached Figure Description

[0012] Figure 1 This is a side sectional view of an electric compressor illustrating an embodiment.

[0013] Figure 2 It is shown Figure 1 A cross-sectional view of an electric motor.

[0014] Figure 3 It is shown Figure 2 An exploded perspective view of the stator core and its insulating components.

[0015] Figure 4 It is Figure 3 A magnified perspective view of a portion of the insulating component.

[0016] Figure 5 This shows the various connection wires housed within. Figure 3 A three-dimensional view showing the state of each receiving slot of the insulating component.

[0017] Figure 6 This shows the winding relative to Figure 3 A schematic diagram of the stator core winding scheme.

[0018] Figure 7 It shows the cover relative to Figure 3 A three-dimensional view of the configuration of the insulating components.

[0019] Figure 8 This shows the view from the second end face of the stator core. Figure 2 The main view of the stator's state.

[0020] Figure 9 It is used for explanation Figure 2 A three-dimensional diagram showing the relationship between the stator and the fixture.

[0021] Figure 10 This is a front view showing the state of the stator of another embodiment as viewed from the second end face of the stator core. Detailed Implementation

[0022] The following is in accordance with Figures 1-9 An implementation method for embodying the electric compressor will be described.

[0023] <Overall Structure of Electric Compressor 10>

[0024] like Figure 1 As shown, the electric compressor 10 has a cylindrical housing 11. The housing 11 has a discharge housing member 12, a motor housing member 13, and an inverter housing 14. The discharge housing member 12, the motor housing member 13, and the inverter housing 14 are made of metal. For example, the discharge housing member 12, the motor housing member 13, and the inverter housing 14 are made of aluminum.

[0025] The motor housing member 13 has a plate-shaped end wall 13a and a cylindrical peripheral wall 13b extending from the outer periphery of the end wall 13a. The discharge housing member 12 is cylindrical. The discharge housing member 12 is connected to the open end of the peripheral wall 13b. The inverter housing 14 is cylindrical. The inverter housing 14 is connected to the end wall 13a of the motor housing member 13. The end wall 13a of the motor housing member 13 and the inverter housing 14 define a receiving space S1.

[0026] A cylindrical boss 13c is provided at the center of the end wall 13a of the motor housing component 13. The axis of the boss 13c is aligned with the axis of the peripheral wall 13b of the motor housing component 13. A through hole 13h is formed in the end wall 13a. The through hole 13h penetrates the end wall 13a along its thickness direction. The through hole 13h is located radially between the boss 13c and the peripheral wall 13b of the end wall 13a.

[0027] The electric compressor 10 includes a rotating shaft 15, a compression unit 16, an electric motor 20, and an inverter 17. The rotating shaft 15, the compression unit 16, and the electric motor 20 are housed within a motor housing member 13. Therefore, the housing 11 houses the electric motor 20. The direction in which the rotation axis L1 of the rotating shaft 15 extends, i.e., the axial direction, is aligned with the axial direction of the peripheral wall 13b of the motor housing member 13. The inverter 17 is housed within a housing space S1.

[0028] The compression unit 16 includes a fixed scroll 16a and a movable scroll 16b. The fixed scroll 16a is fixed to the motor housing member 13. The movable scroll 16b is arranged opposite to the fixed scroll 16a. The compression unit 16 is driven by rotating the rotating shaft 15. By driving the compression unit 16, the refrigerant, which is a fluid, is compressed. A compression chamber S2 with a variable volume is divided between the fixed scroll 16a and the movable scroll 16b. A discharge chamber S3 is divided between the fixed scroll 16a and the discharge housing member 12. The refrigerant compressed by changing the volume of the compression chamber S2 is discharged into the discharge chamber S3. The electric motor 20 drives the compression unit 16 by rotating the rotating shaft 15.

[0029] The compression unit 16 and the electric motor 20 are arranged along the axial direction of the rotation shaft 15. The electric motor 20 is disposed between the compression unit 16 and the end wall 13a. The compression unit 16, the electric motor 20, and the inverter 17 are arranged sequentially along the axial direction of the rotation shaft 15.

[0030] The electric compressor 10 includes a shaft support member 18. The shaft support member 18 is disposed between the compression section 16 and the electric motor 20. The shaft support member 18 serves as a partition between the electric motor 20 and the compression section 16. A through hole 18h is formed in the center of the shaft support member 18. The axis of the through hole 18h is aligned with the axis of the boss portion 13c. One end of a rotating shaft 15 is inserted through the through hole 18h. A radial bearing 19b is provided between the inner circumferential surface of the through hole 18h and one end of the rotating shaft 15. One end of the rotating shaft 15 is rotatably supported on the shaft support member 18 by means of the radial bearing 19b. The other end of the rotating shaft 15 is inserted into the inner side of the boss portion 13c. A radial bearing 19a is provided between the boss portion 13c and the other end of the rotating shaft 15. The other end of the rotating shaft 15 is rotatably supported on the boss portion 13c by means of the radial bearing 19a.

[0031] <Structure of Electric Motor 20>

[0032] The electric motor 20 includes a rotor 21 and a stator 22. The rotor 21 is disposed inside the stator 22. The rotor 21 has a cylindrical rotor core 21a. The rotor core 21a is fixed to the rotating shaft 15. A plurality of permanent magnets (not shown) are embedded in the rotor core 21a.

[0033] The stator 22 has an annular stator core 23. The stator core 23 is fixed to the inner circumferential surface of the peripheral wall 13b of the motor housing component 13. Thus, the stator core 23 is fixed to the inner circumferential surface of the housing 11. The stator 22 is assembled to the housing 11, for example, by heat fitting the stator core 23 into the inner circumferential surface of the peripheral wall 13b.

[0034] The stator core 23 has a first end face 23a and a second end face 23b. The first end face 23a and the second end face 23b are opposite to each other in the axial direction of the stator core 23. The stator core 23 is disposed within the motor housing member 13 such that the first end face 23a is opposite to the end wall 13a of the motor housing member 13. Therefore, the first end face 23a is located closer to the inverter 17 than the second end face 23b. The second end face 23b is located closer to the compression section 16 than the first end face 23a.

[0035] like Figure 2 as well as Figure 3 As shown, the stator core 23 has a cylindrical yoke 24 and a plurality of teeth 25 extending radially inward from the inner circumferential surface 24a of the yoke 24. In this embodiment, the stator core 23 has 15 teeth 25. The yoke 24 engages with the inner circumferential surface of the housing 11.

[0036] Multiple teeth 25 are spaced apart circumferentially on the yoke 24. The yoke 24 is also circumferentially aligned with the stator core 23. Each tooth 25 extends from the inner circumferential surface 24a of the yoke 24 toward the axis of the stator core 23. Each tooth 25 has a tooth extension 26 and a tooth flange 27. The tooth extension 26 extends from the inner circumferential surface 24a of the yoke 24. The tooth flange 27 protrudes from the front end of the tooth extension 26 toward both circumferential sides of the stator core 23.

[0037] like Figure 1 as well as Figure 2As shown, the stator 22 has multiple coils 28U, 28V, and 28W for each of the U, V, and W phases. The three-phase coils 28U, 28V, and 28W are each formed by winding 29 in a concentrated manner around multiple teeth 25. Therefore, the stator 22 has windings 29 for the U, V, and W phases, and each phase winding 29 is formed by winding 29 in a concentrated manner around its corresponding multiple teeth 25 to create multiple coils 28U, 28V, and 28W. The end 28a of the first coil, which is part of each of the three-phase coils 28U, 28V, and 28W, protrudes from the first end face 23a of the stator core 23. The end 28b of the second coil, which is part of each of the three-phase coils 28U, 28V, and 28W, protrudes from the second end face 23b of the stator core 23. Therefore, each phase coil 28U, 28V, 28W has a first coil end 28a protruding from the first end face 23a of the stator core 23 and a second coil end 28b protruding from the second end face 23b of the stator core 23.

[0038] like Figure 1 As shown, the electric compressor 10 includes motor wiring 43. Motor wiring 43 is led out from the electric motor 20. Motor wiring 43 is led out from the end 28a of the first coil of each phase's coils 28U, 28V, and 28W. One motor wiring 43 is led out from the electric motor 20 corresponding to each of the three phases. Therefore, three motor wirings 43 are led out from the electric motor 20. It should be noted that in... Figure 1 The diagram shows only one motor wiring 43.

[0039] A first region R1 for arranging the end 28a of the first coil and a second region R2 for arranging the end 28b of the second coil are formed within the housing 11. The first region R1 is located within the motor housing member 13 between the first end face 23a of the stator core 23 and the end wall 13a of the motor housing member 13. The second region R2 is located within the motor housing member 13 between the second end face 23b of the stator core 23 and the shaft support member 18.

[0040] like Figure 2 As shown, slots 30 are formed between adjacent teeth 25 in the circumferential direction of the stator core 23. Each of the three-phase coils 28U, 28V, and 28W has a portion passing through the slot 30. In this embodiment, the stator 22 has 15 slots. The portions of the coils 28U, 28V, and 28W passing through each slot 30 are insulated from the stator core 23 by slot insulating sheets 31.

[0041] <Structure of Insulator 50>

[0042] like Figure 1 as well as Figure 3As shown, the stator 22 includes an annular insulating member 50. The insulating member 50 insulates the stator core 23 from the coils 28U, 28V, and 28W. The insulating member 50 is disposed on a first end face 23a and a second end face 23b of the stator core 23. Therefore, the stator 22 has two insulating members 50. Each insulating member 50 has a first surface 50a that contacts the stator core 23 and a second surface 50b located on the opposite side of the stator core 23. The first insulating member 50, being one of the two insulating members 50, is disposed relative to the stator core 23 with its first surface 50a in contact with the first end face 23a of the stator core 23. The second insulating member 50, being the other of the two insulating members 50, is disposed relative to the stator core 23 with its first surface 50a in contact with the second end face 23b of the stator core 23. The insulating member 50 is disposed between the shaft support member 18 and the motor housing member 13.

[0043] Each insulating member 50 has a cylindrical insulating member base 51, an insulating member extension 52, and an insulating member flange 53. The insulating member base 51 is positioned opposite the yoke 24 along the axial direction of the stator core 23. Each insulating member 50 is positioned relative to the stator core 23 with the axial direction of the insulating member base 51 aligned with the axial direction of the yoke 24. The insulating member base 51 abuts against the end face of the yoke 24. The outer diameter of the insulating member base 51 is smaller than the outer diameter of the yoke 24. The inner diameter of the insulating member base 51 is the same as the inner diameter of the yoke 24.

[0044] The insulating base 51 of the first insulating member 50 is disposed on the first end face 23a of the stator core 23, surrounding the end 28a of the first coil. The insulating base 51 of the second insulating member 50 is disposed on the second end face 23b of the stator core 23, surrounding the end 28b of the second coil. Therefore, the second insulating member 50 has a cylindrical insulating base 51 disposed on the second end face 23b of the stator core 23, surrounding the end 28b of the second coil.

[0045] Each insulating member extension 52 extends radially from the inner peripheral surface 51a of the insulating member base 51. The circumferential width of each insulating member extension 52 in the insulating member base 51 is the same as the circumferential width of each tooth extension 26 in the stator core 23. Each insulating member extension 52 contacts the corresponding tooth 25. An insulating member flange 53 protrudes from the front end of each insulating member extension 52 in a direction intersecting the extending direction of the insulating member extension 52.

[0046] like Figure 3 , Figure 4 as well as Figure 5As shown, the insulating base 51 of the second insulating member 50 has a thick-walled portion 55 and a thin-walled portion 56. The thick-walled portion 55 is the part of the insulating base 51 adjacent to the second surface 50b of the second insulating member 50. The thick-walled portion 55 is continuous with the second surface 50b. The thick-walled portion 55 extends circumferentially along the insulating base 51 with a portion missing in the circumferential direction. The thick-walled portion 55 is not an endless ring. A plurality of through grooves 60U, 60V, and 60W are formed in the thick-walled portion 55. The number of through grooves 60U, 60V, and 60W is five in each phase. The through grooves 60U, 60V, and 60W extend from the second surface 50b of the second insulating member 50 along the axial direction of the insulating base 51 and penetrate the insulating base 51 radially.

[0047] Three receiving grooves 61U, 61V, and 61W are formed on the outer peripheral surface of the thick-walled portion 55. The three receiving grooves 61U, 61V, and 61W extend circumferentially on the outer peripheral surface of the thick-walled portion 55. The three receiving grooves 61U, 61V, and 61W are arranged along the axial direction of the insulating base 51 on the outer peripheral surface of the thick-walled portion 55. The three receiving grooves 61U, 61V, and 61W are not through-holes relative to the thick-walled portion 55.

[0048] The thin-walled portion 56 does not have receiving grooves 61U, 61V, and 61W, and its thickness is smaller than that of the thick-walled portion 55. The thin-walled portion 56 has a first thin-walled portion 57 and a second thin-walled portion 58. The first thin-walled portion 57 is a portion of the insulating base 51 located closer to the first surface 50a of the second insulating member 50 than the thick-walled portion 55, and extends throughout the entire circumferential direction of the insulating base 51. The first thin-walled portion 57 is continuous with the first surface 50a. The second thin-walled portion 58 is a portion of the insulating base 51 located closer to the second surface 50b of the second insulating member 50 than the first thin-walled portion 57, and is sandwiched between the thick-walled portion 55 in the circumferential direction of the insulating base 51. The second thin-walled portion 58 is continuous with the second surface 50b. The second thin-walled portion 58 is continuous with a portion of the first thin-walled portion 57. The first thin-walled portion 57 and the second thin-walled portion 58 have the same thickness.

[0049] <Structure of winding 29>

[0050] like Figure 5 as well as Figure 6As shown, the coils 28U, 28V, and 28W of each phase are formed by series windings. In the series windings, first, the windings 29 of each phase are wound around the corresponding tooth extensions 26. Then, the windings 29 of each phase are sequentially wound around the corresponding multiple tooth extensions 26 arranged every two circumferentially in the stator core 23 in a concentrated winding manner. Thus, the coils 28U, 28V, and 28W of each phase are arranged every two circumferentially in the stator core 23. It should be noted that the windings 29 are wound around the portion including each tooth extension 26 and the two insulating extensions 52 arranged on both sides of each tooth extension 26. In this embodiment, five coils 28U, 28V, and 28W are arranged for each of the three phases. The coils 28U, 28V, and 28W of the three phases are arranged adjacent to each other in the circumferential direction of the stator core 23 in each slot 30 with different phases.

[0051] In the U-phase coils 28U, adjacent coils 28U in the circumferential direction of the stator core 23 are connected to each other by a connecting wire 281U. The connecting wire 281U is led out from the end 28b of the second coil and is located in a portion of the winding 29 in the second region R2. The connecting wire 281U extends circumferentially along the stator core 23 at the portion facing the second end face 23b of the stator core 23. In the V-phase coils 28V, adjacent coils 28V in the circumferential direction of the stator core 23 are connected to each other by a connecting wire 281V. The connecting wire 281V is led out from the end 28b of the second coil and is located in a portion of the winding 29 in the second region R2. The connecting wire 281V extends circumferentially along the stator core 23 at the portion facing the second end face 23b of the stator core 23. In the W-phase coils 28W, adjacent coils 28W in the circumferential direction of the stator core 23 are connected to each other by a connecting wire 281W. The bridging wire 281W is a portion of the winding 29 that originates from the end 28b of the second coil and is located in the second region R2. The bridging wire 281W extends circumferentially along the stator core 23 at the portion facing the second end face 23b of the stator core 23. Thus, for each phase, adjacent coils 28U, 28V, and 28W in the circumferential direction of the stator core 23 are connected to each other via bridging wires 281U, 281V, and 281W. The bridging wires 281U, 281V, and 281W for each phase are located in the second region R2 and are thus housed in the annular space between the shaft support member 18 and the motor housing member 13.

[0052] like Figure 6 As shown, after the coils 28U, 28V, and 28W of each phase are wound around any one tooth 25, the connecting lines 281U, 281V, and 281W extending from the coils 28U, 28V, and 28W are wound in the circumferential direction of the stator core 23 towards the next tooth 25, which is arranged every two teeth. Figure 6The three-phase contact wires 281U, 281V, and 281W extend in the same direction (winding direction) toward the next tooth 25. Thus, the three-phase coils 28U, 28V, and 28W are formed sequentially in the same winding direction.

[0053] The first coil formed among the multiple coils 28U, 28V, and 28W of each phase is called the starting coil 282U, 282V, and 282W, and the last coil formed is called the ending coil 283U, 283V, and 283W. That is, each phase's coils 28U, 28V, and 28W have starting coils 282U, 282V, and 282W that form the beginning of a series winding, and ending coils 283U, 283V, and 283W that form the end of a series winding. The starting coils 282U, 282V, and 282W of the three phases are adjacent to each other in the circumferential direction of the stator core 23. The ending coils 283U, 283V, and 283W of the three phases are adjacent to each other in the circumferential direction of the stator core 23. In this embodiment, the starting coil 282W of phase W and the ending coil 283U of phase U are adjacent to each other in the circumferential direction of the stator core 23. In the circumferential direction of the stator core 23, there are no connecting wires 281U, 281V, and 281W between the starting coil 282W of phase W and the terminal coil 283U of phase U.

[0054] like Figure 5 as well as Figure 6 As shown, the contact wires 281U, 281V, and 281W are led out from the end 28b of the second coil and pass through their respective through slots 60U, 60V, and 60W. Furthermore, the contact wires 281U, 281V, and 281W are respectively housed in their corresponding receiving slots 61U, 61V, and 61W and are secured to the outer peripheral surface of the thick-walled portion 55. This prevents the three-phase contact wires 281U, 281V, and 281W from contacting each other. The outer peripheral surface of the thick-walled portion 55 in the outer peripheral surface 51b of the insulating base 51 has securing surfaces X1 with receiving slots 61U, 61V, and 61W for accommodating the contact wires 281U, 281V, and 281W respectively.

[0055] The U-phase winding 29 forms multiple coils 28U and multiple connecting wires 281U that connect adjacent coils 28U to each other and are secured to the outer peripheral surface 51b of the insulating base 51. The V-phase winding 29 forms multiple coils 28V and multiple connecting wires 281V that connect adjacent coils 28V to each other and are secured to the outer peripheral surface 51b of the insulating base 51. The W-phase winding 29 forms multiple coils 28W and multiple connecting wires 281W that connect adjacent coils 28W to each other and are secured to the outer peripheral surface 51b of the insulating base 51.

[0056] Connecting wire 281U has a starting connecting wire 284U connected to the starting coil 282U and a ending connecting wire 285U connected to the ending coil 283U. Connecting wire 281V has a starting connecting wire 284V connected to the starting coil 282V and a ending connecting wire 285V connected to the ending coil 283V. Connecting wire 281W has a starting connecting wire 284W connected to the starting coil 282W and a ending connecting wire 285W connected to the ending coil 283W.

[0057] The contact wires 281U, 281V, and 281W extend circumferentially along the stator core 23, respectively housed in their corresponding receiving slots 61U, 61V, and 61W. The outer peripheral surface of the second thin-walled portion 58 is a non-locking surface X2, which does not have receiving slots 61U, 61V, and 61W and therefore does not lock any of the contact wires 281U, 281V, and 281W. The non-locking surface X2 is located circumferentially between the starting contact wire 284W connected to the starting coil 282W and the terminal contact wire 285U connected to the terminal coil 283U in the insulating base 51.

[0058] <About the 23c card slot>

[0059] like Figure 7 as well as Figure 8 As shown, the stator core 23 has an engagement groove 23c that serves as an engagement recess. The engagement groove 23c is formed on the outer peripheral surface of the stator core 23. The engagement groove 23c extends along the axial direction of the stator core 23. One end of the engagement groove 23c opens at the first end face 23a of the stator core 23. The other end of the engagement groove 23c opens at the second end face 23b of the stator core 23. When the stator 22 is viewed in the axial direction of the stator core 23 facing the second end face 23b, the engagement groove 23c is positioned within the phase range A1 where the non-locking surface X2 exists. Therefore, when the stator 22 is viewed in the axial direction of the stator core 23 facing the second end face 23b, a portion of the thin-walled portion 56 and the engagement groove 23c are positioned within the phase range A1. Therefore, when viewing the second end face 23b of the stator core 23 from the axial direction, the circumferential engagement groove 23c is located between the starting connection line 284W and the ending connection line 285U. Furthermore, when viewing the stator 22 from the axial direction of the stator core 23 facing the second end face 23b, the engagement groove 23c is located radially outward of the stator core 23 compared to the non-engaging surface X2.

[0060] <Structure of Cover 70>

[0061] The stator 22 also has an insulating cylindrical cover 70. The cover 70 has an end wall 70a and a cylindrical peripheral wall 70b extending from the outer periphery of the end wall 70a. The cover 70 is disposed relative to the insulating member 50 with the peripheral wall 70b surrounding the insulating member base 51. The peripheral wall 70b of the cover 70 is sandwiched between the connecting wires 281U, 281V, 281W and the peripheral wall 13b of the motor housing member 13. Thus, the cover 70 is sandwiched between the connecting wires 281U, 281V, 281W and the housing 11 and surrounds the insulating member base 51.

[0062] The cover 70 has a notch 71. The notch 71 is formed on the outer peripheral surface 70c of the cover 70. The notch 71 is configured to penetrate the cover 70 along its axial direction. Therefore, the cover 70 has a through-hole notch 71 on its outer peripheral surface 70c. The cover 70 is arranged such that the notch 71 overlaps with the phase range A1 in the axial direction of the stator core 23. Therefore, the notch 71 and a portion of the thin-walled portion 56 are arranged radially along the stator core 23. Furthermore, when the stator 22 is viewed in the axial direction of the stator core 23 facing the second end face 23b, the engaging groove 23c is located inside the notch 71. Therefore, when the second end face 23b of the stator core 23 is viewed in the axial direction of the stator core 23, at least a portion of the engaging groove 23c is located inside the notch 71.

[0063] <Structure of the airtight terminal 40>

[0064] like Figure 1 As shown, the electric compressor 10 includes a hermetically sealed terminal 40. The hermetically sealed terminal 40 is housed within the housing 11. The hermetically sealed terminal 40 has three conductive members 41 corresponding to the three-phase coils 28U, 28V, and 28W, respectively. It should be noted that... Figure 1 Only one conductive member 41 is shown in the diagram. Each conductive member 41 is a cylindrical metal terminal extending in a straight line. One end of each conductive member 41 is electrically connected to the inverter 17 within the housing space S1. The other end of each conductive member 41 protrudes from the housing space S1 into the motor housing member 13 through a through hole 13h. The hermetic terminal 40 has a support plate 42. The support plate 42 supports the three conductive members 41 in a mutually insulated manner. The support plate 42 is fixed within the housing space S1 around the through hole 13h on the outer surface of the end wall 13a.

[0065] <Structure of Connector 44>

[0066] A connector 44 is housed within the motor housing component 13. The connector 44 is located in the first region R1. The connector 44 has three connection terminals 45 corresponding to the three-phase coils 28U, 28V, and 28W respectively, and an insulated wire harness block 46 housing the three connection terminals 45. Therefore, the wire harness block 46 is located in the first region R1.

[0067] The wiring harness block 46 has three conductive component insertion holes 47 and three motor wiring insertion holes 48. It should be noted that... Figure 1 Only one conductive component insertion hole 47 and only one motor wiring insertion hole 48 are shown in the diagram. A conductive component 41 is inserted into each conductive component insertion hole 47. A motor wiring 43 is inserted into each motor wiring insertion hole 48. Each connection terminal 45 electrically connects the corresponding conductive component 41 to the corresponding motor wiring 43. The wiring harness block 46 is disposed within the motor housing component 13 such that the conductive component insertion holes 47 extend along the axial direction of the rotation shaft 15.

[0068] Power from inverter 17 is supplied to electric motor 20 via conductive components 41, connection terminals 45, and motor wiring 43. This drives electric motor 20. Therefore, inverter 17 drives electric motor 20. Driven by electric motor 20, compression unit 16 is driven, compressing the refrigerant.

[0069] <Relationship between the engaging groove 23c and the engaging protrusion 83 of the clamp 80>

[0070] like Figure 9 As shown, when the stator core 23 is heat-fitted into the motor housing component 13, a clamp 80 is used for circumferential positioning of the stator core 23 relative to the motor housing component 13. The clamp 80 has a cylindrical main body 81, a plate-shaped mounting portion 82, and an elongated plate-shaped engaging protrusion 83. The mounting portion 82 protrudes from a portion of the outer periphery of one end face of the main body 81. The engaging protrusion 83 is an engaging portion protruding from the front end of the mounting portion 82. The engaging protrusion 83 can engage with the engaging groove 23c of the stator core 23. Therefore, the stator core 23 has an engaging groove 23c in the region of the end face of the yoke 24 that is radially outer than the insulating base 51, which engages with the engaging protrusion 83 of the clamp 80 that inserts the stator 22 into the housing 11.

[0071] The clamp 80 is installed on the stator 22 with the axis of the main body 81 aligned with the axis of the stator core 23. At this time, the mounting part 82 is installed along the notch 71 of the cover 70. The length of the engaging protrusion 83 is set to a length that allows the engaging protrusion 83 to engage with the engaging groove 23c of the stator core 23 when the mounting part 82 is installed in the notch 71.

[0072] <Function>

[0073] Next, the manufacturing method of the electric compressor 10 according to this embodiment will be described, and the operation of this embodiment will also be explained. Here, as the manufacturing method of the electric compressor 10, the assembly method of the stator 22 relative to the motor housing member 13 will be described.

[0074] The stator 22 is assembled to the housing 11, for example, by heat fitting the stator core 23 into the inner circumferential surface of the motor housing component 13. In this heat fitting, after heating and expanding the motor housing component 13 so that the inner diameter of the motor housing component 13 is larger than the outer diameter of the stator core 23, the stator core 23 is inserted into a predetermined heat fitting position within the motor housing component 13. Then, the inner circumferential surface of the motor housing component 13 is brought into close contact with the outer circumferential surface of the stator core 23 as the motor housing component 13 contracts towards room temperature.

[0075] When the stator core 23 is heat-fitted into the motor housing component 13, a clamp 80 is used for circumferential relative positioning to prevent phase shift of the stator core 23 relative to the motor housing component 13. The engaging protrusion 83, located on the clamp 80 opposite the non-locking surface X2 in the radial direction of the stator core 23, engages with the engaging groove 23c, and the clamp 80 presses the stator 22 into the interior of the housing 11, thereby achieving circumferential relative positioning of the stator 22 relative to the housing 11.

[0076] When the stator 22 is viewed along the axial direction of the stator core 23 facing the second end face 23b of the stator core 23, the engaging groove 23c is positioned within the phase range A1 of the non-locking surface X2. Furthermore, the engaging groove 23c is located radially outward of the stator core 23 than the non-locking surface X2. This prevents interference between the contact lines 281U, 281V, and 281W and the engaging protrusion 83 of the clamp 80.

[0077] Furthermore, the cover 70 surrounds the base 51 of the insulating component. Therefore, for example, even when the connecting wires 281U, 281V, 281W extend from their corresponding receiving slots 61U, 61V, 61W, contact between the connecting wires 281U, 281V, 281W and the housing 11 is avoided. As a result, insulation between the housing 11 and the connecting wires 281U, 281V, 281W is ensured.

[0078] The cover 70 has a notch 71. Furthermore, the notch 71 and the non-locking surface X2 are arranged radially along the stator core 23, and when the stator 22 is viewed in the axial direction of the stator core 23 facing the second end face 23b of the stator core 23, the engaging groove 23c is located inside the notch 71. Therefore, even if the stator 22 has a structure that also includes the cover 70 surrounding the insulating base 51, the cover 70 is prevented from blocking the engaging groove 23c. Thus, while viewing the stator 22 in the axial direction of the stator core 23 facing the second end face 23b, it is easy for the engaging protrusion 83 of the clamp 80 to engage with the engaging groove 23c.

[0079] The following effects can be obtained from the above embodiments.

[0080] (1) The non-locking surface X2 of the insulating base 51 does not have receiving grooves 61U, 61V, and 61W, and the lap joints 281U, 281V, and 281W are not locked on the non-locking surface X2. Therefore, when the clamp 80 is engaged with the engaging groove 23c, interference between the clamp 80 and the lap joints 281U, 281V, and 281W is avoided. Thus, while viewing the stator 22 in the axial direction of the stator core 23 facing the second end face 23b, it is easier to engage the engaging protrusion 83 of the clamp 80 with the engaging groove 23c. As a result, operability is improved.

[0081] (2) When viewed from the axial direction on the second end face 23b of the stator core 23, the circumferential engagement groove 23c is located between the starting connection line 284W and the ending connection line 285U. Therefore, it is not necessary to provide a non-locking surface X2 outside the area between the starting connection line 284W and the ending connection line 285U. Thus, the non-locking surface X2 can be appropriately provided at the base 51 of the insulating member.

[0082] (3) The cover 70 surrounds the base 51 of the insulating component. Therefore, for example, even when the connecting wires 281U, 281V, 281W extend from the receiving grooves 61U, 61V, 61W, contact between the connecting wires 281U, 281V, 281W and the housing 11 can be avoided. As a result, reliability is improved because insulation between the housing 11 and the connecting wires 281U, 281V, 281W can be ensured.

[0083] The cover 70 has a notch 71. Furthermore, the notch 71 and a portion of the non-locking surface X2 are arranged radially along the stator core 23. Moreover, when the stator 22 is viewed in the axial direction of the stator core 23 facing the second end face 23b, the engaging groove 23c is located inside the notch 71. Therefore, even if the stator 22 has a structure that also includes a cover 70 surrounding the insulating base 51, the cover 70 is prevented from blocking the engaging groove 23c. Consequently, it becomes easier for the engaging protrusion 83 of the clamp 80 to engage with the engaging groove 23c. As a result, reliability and operability are improved.

[0084] (4) According to this embodiment, even if the depth of each receiving groove 61U, 61V, and 61W is increased, the thickness of the portion where the non-locking surface X2 is provided will not increase, nor will the base 51 of the insulating member block the engaging groove 23c. Therefore, it is easy to ensure the depth of the receiving grooves 61U, 61V, and 61W so that the connecting wires 281U, 281V, and 281W will not protrude from their respective receiving grooves 61U, 61V, and 61W. Therefore, it is easy to ensure the reliability of the electric compressor 10.

[0085] (5)According to the present embodiment, when the stator core 23 is shrink-fitted to the motor housing member 13, generation of a phase shift of the stator core 23 with respect to the motor housing member 13 is suppressed. Thus, for example, when connecting the conductive member 41 to the corresponding connection terminal 45 in the harness block 46, excessive stretching or excessive bending of each motor wiring 43 is avoided. As a result, application of an excessive load to each motor wiring 43 is suppressed.

[0086] (6)For example, even when the jumper wires 281U, 281V, 281W protrude from the accommodation grooves 61U, 61V, 61W, the jumper wires 281U, 281V, 281W can be prevented from contacting the housing 11 by the cover 70. Thus, by setting the depth of the accommodation grooves 61U, 61V, 61W to a depth that can accommodate the jumper wires 281U, 281V, 281W at a minimum, the thickness of the thick wall portion 55 can be made as thin as possible.

[0087] (7)An annular space is formed between the shaft support member 18 having a tapered portion and the motor housing member 13. For miniaturization of the electric compressor 10, the insulating member 50 for engaging the jumper wires 281U, 281V, 281W is disposed in this annular space. On the other hand, since the motor housing member 13 before joining the shaft support member 18 has an opening, it is easy to insert the jig 80. For the above reasons, the engaging convex portion 83 of the jig 80 easily interferes with the jumper wires 281U, 281V, 281W. By providing the non-engaging surface X2 on the insulating member base 51, this interference is avoided.

[0088] <Modification example>

[0089] It should be noted that the above embodiment can be modified as follows. The above embodiment and the following modification examples can be implemented in combination with each other within a range without technical contradictions.

[0090] ο As Figure 10 shown, the stator 22 may not have the cover 70. In short, when observing the stator 22 in a direction facing the second end face 23b in the axial direction of the stator core 23, it is sufficient that the engaging groove 23c is located at a position radially outside the stator core 23 with respect to the non-engaging surface X2. It should be noted that, in this case where the stator 22 does not have the cover 70, the depth of the accommodation grooves 61U, 61V, 61W needs to be set such that the jumper wires 281U, 281V, 281W can be reliably accommodated therein.

[0091] In this embodiment, the insulating base 51 has a thick-walled portion 55 and a thin-walled portion 56, but is not limited to this. For example, the insulating base 51 may have a constant thickness. In short, the outer peripheral surface 51b of the insulating base 51 may have a locking surface X1 and a non-locking surface X2.

[0092] In the implementation, the number of slots in the stator core 23 can also be changed appropriately.

[0093] In an embodiment, the stator core 23 may also replace the engaging groove 23c, for example, by having a recess provided in the second end face 23b of the stator core 23 as the engaging recess.

[0094] In this embodiment, the shape of the cover 70 can also be modified appropriately. For example, the cover 70 can also be composed only of the peripheral wall 70b. In short, the cover 70 can ensure the insulation between the housing 11 and the bonding wires 281U, 281V, and 281W by surrounding the base 51 of the insulating member.

[0095] In one embodiment, the first region R1 may be located between the second end face 23b of the stator core 23 and the shaft support member 18, and the second region R2 may be located between the first end face 23a of the stator core 23 and the end wall 13a of the motor housing member 13.

[0096] In one embodiment, the thin-walled portion 56 may not have a first thin-walled portion 57, and the second thin-walled portion 58 may extend from the first surface 50a of the insulating member 50 to the second surface 50b. That is, it may also be a structure in which, when the stator 22 is viewed in the axial direction of the stator core 23 facing the second end surface 23b in the base portion 51 of the insulating member, only the portion disposed within the phase range A1 is the thin-walled portion 56.

[0097] In one embodiment, when the stator core 23 is heat-fitted onto the motor housing component 13, the clamp 80 is engaged with the engagement groove 23c to prevent a phase shift of the stator core 23 relative to the motor housing component 13, but this is not a limitation. For example, in the assembly line of the stator 22, when the winding 29 is wound around the stator core 23, the clamp 80 is engaged with the engagement groove 23c to perform circumferential positioning of the stator 22. In short, when manufacturing the electric compressor 10 and the electric motor 20, it is sufficient to engage a portion of the clamp 80, which is located radially opposite the non-locking surface X2 of the stator core 23, with the engagement groove 23c, and to achieve circumferential positioning of the stator 22 using the clamp 80; the purpose of the clamp 80 is not particularly limited.

[0098] As used in this specification, the term "ring-shaped" can refer to any construction that forms a ring shape as a whole. The shape of "ring-shaped" includes circles, ellipses, and polygons with sharp or rounded corners, but is not limited to these. Similarly, the term "cylindrical" can refer to any construction with a cross-sectional shape of circles, ellipses, and polygons with sharp or rounded corners, but is not limited to these.

Claims

1. An electric compressor, comprising: The compression section is configured to compress fluid; An electric motor configured to drive the compression unit; and A cylindrical outer casing that houses the electric motor. The electric motor has a stator. The stator comprises: The annular stator core has a cylindrical yoke that engages with the inner circumferential surface of the housing and a plurality of teeth extending radially from the inner circumferential surface of the yoke. An annular insulating member having a cylindrical insulating base that abuts against the end face of the yoke; and The U-phase, V-phase, and W-phase windings are formed by winding each phase winding onto the corresponding teeth of the multiple teeth in a concentrated winding manner, thereby creating multiple coils. The windings of each phase form multiple contact wires that are locked onto the outer peripheral surface of the base of the insulator. Each contact wire connects adjacent coils in the corresponding phase to each other. in, The outer peripheral surface of the base of the insulating component has: A locking surface having a receiving groove for receiving the lap joint; and The non-locking surface, which does not have the aforementioned receiving groove, does not lock the connecting line. The stator core has a locking recess in the end face of the yoke that is radially outer than the base of the insulator, which engages with a portion of the clamp. The engaging recess is located radially outside the non-engaging surface in the end face of the yoke.

2. The electric compressor according to claim 1, wherein, The plurality of coils in each phase have: The starting coil, which becomes the winding start of the series winding; and The terminating coil becomes the end of the series winding. The plurality of contact wires of each phase have: The starting connection wire is connected to the starting coil; and The terminal connection cable is connected to the terminal coil. When viewed from the axial direction, the engagement recess is located between the starting end connection line and the ending end connection line in the circumferential direction.

3. The electric compressor according to claim 1, wherein, The base of the insulating component includes: The thick-walled portion has the aforementioned locking surface; and The thin-walled portion has the non-locking surface and is thinner than the thick-walled portion.

4. The electric compressor according to any one of claims 1 to 3, wherein, The stator also has an insulating cylindrical cover sandwiched between the bonding wire and the housing and surrounding the base of the insulating element. The cover has a notch on its outer peripheral surface that extends through the cover along its axial direction. The notch and the non-locking surface are arranged radially along the stator core. When the end face of the stator core is viewed along the axial direction of the stator core, at least a portion of the engaging recess is located inside the notch.

5. A method for manufacturing an electric compressor, wherein, The electric compressor has the following features: The compression section is configured to compress fluid; An electric motor configured to drive the compression unit; and A cylindrical outer casing that houses the electric motor. The electric motor has a stator. The stator comprises: The annular stator core has a cylindrical yoke that engages with the inner circumferential surface of the housing and a plurality of teeth extending radially from the inner circumferential surface of the yoke. An annular insulating member having a cylindrical insulating member base that abuts against the end face of the yoke; as well as The U-phase, V-phase, and W-phase windings are formed by winding each phase winding onto the corresponding teeth of the multiple teeth in a concentrated winding manner, thereby creating multiple coils. The windings of each phase form multiple contact wires that are locked onto the outer peripheral surface of the base of the insulator. Each contact wire connects adjacent coils in the corresponding phase to each other. The outer peripheral surface of the base of the insulating component has: A locking surface having a receiving groove for receiving the lap joint; and The non-locking surface, which does not have the aforementioned receiving groove, does not lock the connecting line. The stator core has a locking recess in the end face of the yoke that is radially outer than the base of the insulator, which engages with a portion of the clamp. The engaging recess is located radially outside the non-engaging surface in the end face of the yoke. The manufacturing method includes a process of engaging a portion of the clamp, which faces the non-locking face radially on the stator core, with the engaging recess and positioning the stator circumferentially.

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