Insulator, stator, rotary electric machine, method for manufacturing stator, and method for manufacturing rotary electric machine

Abstract

Since the distance between the teeth after the connection is determined in correspondence with the shape of the stator core, according to the shape of the teeth, sometimes the winding cannot be wound at high density in the winding process. Therefore, it is configured to have two arm-shaped connection portions (25a, 25b), a columnar portion (251), and a guide portion (252), the two arm-shaped connection portions (25a, 25b) protrude to both sides in the circumferential direction of the stator core (10), the columnar portion (251) is formed on one connection portion (25a), the guide portion (252) is formed on the other connection portion (25b), the columnar portion (251) of one insulator is engaged with the guide portion (252) of the adjacent other insulator in a movable manner, so that the distance between the adjacent insulators is variable, thereby the distance between the teeth (11) after the connection can be variable according to the shape of the stator core (10), and the winding can be wound at high density in the winding process regardless of the shape of the teeth (11).

Description

Technical Field

[0001] This application relates to insulators, stators, rotating electric machines, methods for manufacturing stators, and methods for manufacturing rotating electric machines. Background Technology

[0002] In the stator of a rotary electric machine, a structure has been disclosed in which iron cores (divided iron cores) divided into tooth units are flexibly connected to each other in a direction perpendicular to the axis (for example, see Patent Document 1 and Patent Document 2). Adjacent teeth in the stator are close to each other on the radially inner side, but according to the above structure, by changing the angle of the connecting portion so that the teeth are located on the outer diameter side, winding can be performed without interference with adjacent iron cores, and the duty cycle of the coil can be improved.

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2000-201458

[0006] Patent Document 2: Japanese Patent Application Publication No. 2006-254569 Summary of the Invention

[0007] The problem that the invention aims to solve

[0008] However, in Patent Document 1, the stacked steel plates of adjacent iron cores are interlocked at the connecting portion, which requires the preparation of two types of stacked steel plates and the use of riveting for connection, leading to an increase in the types of components and a more complex manufacturing process. Furthermore, in Patent Document 2, an axial insertion and removal mechanism is provided for connection and rotation, but when the teeth are oriented outwards, a retaining mechanism is needed to prevent axial displacement after connection, further complicating the manufacturing process. Moreover, in both Patent Documents 1 and 2, the distance between the teeth after connection is determined according to the shape of the stator core; therefore, depending on the shape of the teeth, it is sometimes impossible to achieve high-density winding during the winding process.

[0009] This application discloses a technique for solving the aforementioned problems, with the aim of obtaining stators and motors that can be wound with high density without increasing the number of parts and manufacturing processes.

[0010] Methods for solving problems

[0011] The insulator disclosed in this application is installed on a stator core and electrically insulates the coil from the stator core. The insulator is characterized by having a columnar portion, a guide portion, and two arm-shaped connecting portions. The two arm-shaped connecting portions protrude circumferentially to both sides of the stator core. The columnar portion is formed in one connecting portion, and the guide portion is formed in the other connecting portion and guides the columnar portion in a movable manner. The columnar portion of one insulator engages with the guide portion of an adjacent insulator in a manner that allows the distance between adjacent insulators to vary. Multiple fitting portions are formed in the guide portion, and these fitting portions can engage with the columnar portion. The guide portion has elongated holes between adjacent fitting portions in the plurality of fitting portions.

[0012] Invention Effects

[0013] In stators and motors, high-density winding can be achieved without increasing the number of parts or manufacturing processes. Attached Figure Description

[0014] Figure 1 This is a 3D diagram of the stator core.

[0015] Figure 2 This is a three-dimensional view of the stator core ring assembly.

[0016] Figure 3 This is a perspective view of the insulator according to Embodiment 1.

[0017] Figure 4 Viewed from the radial outer periphery Figure 3 Rear view of the insulator.

[0018] Figure 5 Viewed from above the axis Figure 3 A top view of an insulator.

[0019] Figure 6 This is a top view showing the state after the stator core connector of Embodiment 1 has been wound and the connector has been modified into a stator core ring assembly.

[0020] Figure 7 It's perspective. Figure 6 A three-dimensional diagram showing the interlocking state of an insulator.

[0021] Figure 8 This is a perspective view of the insulator of Embodiment 1 as viewed from the radial inner circumference side.

[0022] Figure 9 Viewed from the lower side of the axis towards the upper side Figure 8 A three-dimensional image.

[0023] Figure 10 This is a flowchart illustrating the manufacturing process of the stator in Embodiment 1.

[0024] Figure 11 This is a perspective view of the stator connector obtained by connecting the insulator of Embodiment 1.

[0025] Figure 12 This is a top view showing the state of winding the stator core connector of Embodiment 1 using a winding device in the form of a flying fork.

[0026] Figure 13 It shows the use of and Figure 12 A top view of the same winding device winding stator cores of different sizes.

[0027] Figure 14 It shows the use of and Figure 12 A top view of the state in which different winding devices are used to wind the stator core connector of Embodiment 1.

[0028] Figure 15 This is a perspective view showing the state after the stator core connector of Embodiment 1 has been wound and the connector has been modified into a stator core ring assembly.

[0029] Figure 16 yes Figure 15 Radial rear view.

[0030] Figure 17 This is a top view showing the state in which the stator core connectors of the semicircular quantity of Embodiment 1 are connected together.

[0031] Figure 18 It shows that Figure 17 A three-dimensional diagram showing the connection state of the semi-circular stator core connector.

[0032] Figure 19 This is a perspective view of the stator core ring assembly according to Embodiment 1.

[0033] Figure 20 This is a perspective view of the finished stator obtained by covering the stator core ring assembly of Embodiment 1 with molding resin.

[0034] Figure 21 This is a cross-sectional view of the motor according to Embodiment 1.

[0035] Figure 22 This is a top view of the insulator in Embodiment 2.

[0036] Figure 23 This is a perspective view of the insulator in Embodiment 2.

[0037] Figure 24 This is a top view of the stator connector obtained by connecting the insulator of Embodiment 2 using the first fitting part.

[0038] Figure 25 This is another top view of the stator connection portion obtained by connecting the insulator of Embodiment 2 using the first fitting portion.

[0039] Figure 26 This is a top view of the stator connection portion obtained by connecting the insulator of Embodiment 2 using the second fitting portion.

[0040] Figure 27 This is a perspective view of the insulator in Embodiment 3.

[0041] Figure 28 Viewed from the axial lower side Figure 27 A bottom view of an insulator.

[0042] Figure 29 This is a perspective view showing the state after the stator core connector of Embodiment 3 has been wound and the connector has been modified into a stator core ring assembly.

[0043] Figure 30 It is a different perspective. Figure 29 A three-dimensional diagram of the state.

[0044] Figure 31 This is a cross-sectional view of the motor in embodiment 4.

[0045] Figure 32 This is a flowchart illustrating the stator manufacturing process of Embodiment 4.

[0046] Figure 33 This is a perspective view showing the stator core insulation assembly of Embodiment 5.

[0047] Figure 34 This is a top view showing the state of the stator core connector of Embodiment 6 being wound using a winding device in the form of a flying fork.

[0048] Figure 35 This is a perspective view of the insulator in embodiment 7.

[0049] Figure 36 This is a perspective view of the split connecting part in embodiment 7.

[0050] Figure 37 This is a perspective view of the stator connector obtained by connecting the insulator of Embodiment 7.

[0051] Figure 38 This is a top view of the stator connector obtained by connecting the insulator of Embodiment 7.

[0052] Figure 39This is a perspective view showing the state after the stator core connector of Embodiment 7 has been wound and the connector has been modified into a stator core ring assembly.

[0053] Figure 40 This is a perspective view of the stator core ring assembly according to embodiment 7.

[0054] Figure 41 This is a perspective view of another split connecting part in embodiment 7.

[0055] Figure 42 This is a top view of the stator connector obtained by connecting the insulator of Embodiment 7 using another separate connecting part.

[0056] Figure 43 This is a perspective view showing the state after the stator core connector obtained by connecting the insulator of Embodiment 7 using another split connector is wound, and the connector is modified into a stator core ring assembly. Detailed Implementation

[0057] Hereinafter, preferred embodiments of the insulator of this application will be described with reference to the accompanying drawings. Furthermore, identical reference numerals will be used to denote the same content and corresponding parts, and detailed descriptions thereof will be omitted. The same applies to subsequent embodiments; repeated descriptions of structures labeled with the same reference numerals will be omitted.

[0058] Implementation method 1.

[0059] First, the shapes of each component in this embodiment will be described.

[0060] Figure 1 The stator core 10 is for an internal rotor type motor (see reference). Figure 21 The stator core 10 is a ring-shaped stator divided by a number of slots, and has a toothed portion 11 and a back yoke portion 12. The dividing surface 13, which is the mating portion with the adjacent teeth, is a simple plane and does not have a mechanism for joining the individual stator core units. The stator core 10 has a simple shape, so it is easy to manufacture as long as a mold for the stator core 10 is prepared.

[0061] Figure 2 The stator core ring assembly 300, described later, is shown. In the following description, the axial (X), circumferential (θ), and radial (R) directions respectively represent... Figure 2 direction shown.

[0062] Figure 3 This is a perspective view of the insulator in Embodiment 1. Figure 4 This is the rear view as seen from the outer perimeter in the radial direction. Figure 5 This is a top view taken from the axial direction.

[0063] Figures 3 to 5 The insulator 20, which electrically insulates the coil from the stator core, has a core fitting portion 21 and a coil frame portion 22. The core fitting portion 21 fits into the stator core 10, and the coil frame portion 22 supports the wound coil. Figure 3 The insulator 20 shows the upper insulator that is axially fitted from the stator core 10 (see reference). Figure 11 The insulator 20a). The coil frame portion 22 has a portion covering the stator core 10, and an inner peripheral flange portion 23 and an outer peripheral flange portion 24 protruding in the axial direction, the inner peripheral flange portion 23 and the outer peripheral flange portion 24 so that the coil will not sag in the radial direction R (see reference). Figure 2 Support is provided by protruding.

[0064] The outer peripheral flange 24 has an inlet groove for guiding the end wire of the coil and an outlet groove for discharging the end wire of the coil. Further outward on the outer peripheral side of the outer peripheral flange 24, facing the adjacent stator core 10, there are connecting portions 25a and 25b, which protrude from the circumferential θ end face of the stator core 10.

[0065] At the end of the connecting portion 25a, there is a cylindrical columnar portion 251 extending axially. As will be described later, the connecting portion 25b has a guide portion that guides the columnar portion 251 of other insulators in a movable manner. In this embodiment, the slot-shaped opening 252 corresponds to the guide portion. The columnar portion 251 has a shape with a portion of the cylinder cut off (cut-out portion 251a). Since the diameter of the columnar portion 251 is smaller than the width of the connecting portion 25a, a step 253 is formed at the boundary between the columnar portion 251 and the connecting portion 25a. This step 253 is preferably formed around the entire circumference of the columnar portion 251, but even if it is formed in part of the entire circumference, it is sufficient as long as the step 253 is formed at a position that restricts the axial movement of the stator core 10 when it becomes the stator core connector 200 described later. In addition, a protrusion 254 is provided on the end face of the columnar portion 251, which protrudes outward from the cylindrical surface of the columnar portion 251.

[0066] The structure is configured such that a first arcuate portion 252a, with the same diameter as the columnar portion 251, is provided on the inlet side of the slot-shaped opening 252 of the connecting portion 25b. This first arcuate portion 252a fits into the columnar portion 251 and can rotate freely around the columnar portion 251. That is, the columnar portion 251 is rotatably fitted into the first arcuate portion 252a, which is the fitting portion farthest from each other among the insulators 20. A second arcuate portion 252b of the same diameter is also provided on the end side of the opening 252. With the stator core 10's dividing surfaces 13 aligned, the columnar portion 251 is positioned to fit into the second arcuate portion 252b.

[0067] The first arc portion 252a and the second arc portion 252b are connected by an elongated hole portion 252c. The width of the elongated hole portion 252c is the same as or larger than the diameter of the columnar portion 251. The width of the opening 252 formed by the first arc portion 252a, the elongated hole portion 252c, and the second arc portion 252b is approximately the same as the diameter of the columnar portion 251, but... Figure 5 As shown in (a) and (b), the first arc portion 252a and the second arc portion 252b have a protrusion 252d, which is used to form a portion with a width smaller than the diameter of the columnar portion 251.

[0068] The insulator 20 uses an elastic insulating material such as resin, rubber, paper, or wood. Therefore, even if the width of the opening 252 is locally smaller than that of the columnar portion 251, the columnar portion 251 can be moved to the second arcuate portion 252b through the first arcuate portion 252a and the elongated hole 252c by the temporary elastic deformation of the insulator 20. The second arcuate portion 252b has a surface on its opening side that engages with the cutout 251a of the columnar portion 251. This surface is perpendicular to the direction in which the columnar portion 251 is removed from the second arcuate portion 252b (the direction of the opening).

[0069] A protrusion 255 is provided on the root side of the connecting portion 25a, which has a columnar portion 251. This will be described in detail later. Figure 6 , Figure 7 The image shows the stator core connector 200 formed by connecting the insulator 20, and the connector modified into a stator core ring assembly 300. In this configuration, the side of the first arcuate portion 252a of the protrusion 255 is positioned to contact the end face of the first arcuate portion 252a of the elongated hole 252c when the columnar portion 251 and the second arcuate portion 252b are engaged. The protrusion 255 has a guiding slope such that its height decreases towards the columnar portion 251. This shape enhances the holding force of the connection.

[0070] Through these mechanisms, the columnar portion 251 can fix adjacent insulators 20 and stator core 10 at a predetermined angle in the second arcuate portion 252b, which is the closest fitting portion between the insulators 20. The fitting of the columnar portion 251 with the first arcuate portion 252a or the second arcuate portion 252b is formed into a snap-fit ​​shape utilizing the elastic deformation of the insulator, thereby enabling simple assembly. The snap-fit ​​can be installed and removed in a plane perpendicular to the axial direction. In addition, to illustrate the fitting state, Figure 7 The document describes the process of examining an insulator.

[0071] like Figure 8As shown from the radial inner circumferential side of the insulator 20, the circumferential end face of the inner circumferential flange portion 23 has inner circumferential flange fitting portions 23a and 23b, which fit into adjacent insulators 20. Viewed from the inner circumferential side, the inner circumferential flange fitting portions 23a and 23b form a hook-like shape that opens axially, and the inner circumferential flange fitting portions 23a and 23b do not restrict the radial movement of the insulator 20.

[0072] Figure 9 Viewed from the lower side of the axis towards the upper side Figure 8 The diagram shows that the coil frame portion 22, obtained by dividing the insulator 20 into two along the axial direction, has overlapping portions 22a and 22b where the insulators overlap each other. The overlapping portions 22a and 22b function to increase the insulation distance between the stator core 10 and the coil 30. The overlapping portions 22a and 22b are stepped, with the steps of one side of the overlapping portion 22a and the other side of the overlapping portion 22b facing the same direction. That is, the steps on one axial end of the insulator 20 and the steps on the other axial end are interlocked on one or the other side of the circumferential direction.

[0073] Next, for Figure 10 The assembly method of the stator in this embodiment will be described.

[0074] <Stator core insulation process S1>

[0075] like Figure 11 As shown, in Figure 1 The stator core 10 shown is assembled with two Figure 3 The insulators 20 shown (insulators 20a and 20b) serve as the stator core insulation assembly 100. The axially opposite side of the columnar portion 251 of one insulator 20a is opposite to the opening portion 252 (first arc portion 252a) of the other insulator 20b, allowing insulators 20a and 20b of the same shape to be assembled into a stator core 10 to form the stator core insulation assembly 100.

[0076] Alternatively, depending on the stator specifications, the shape of a portion of an insulator (e.g., insulator 20a) can be changed by altering a part of the mold component of insulators 20a and 20b. However, to minimize the amount of mold change, it is preferable to arrange the columnar portion 251 and the opening portion 252 in an axially opposed configuration.

[0077] By aligning the stepped shapes of the overlapping portions 22a and 22b of the insulators 20 on the same side of the circumference, the insulators 20a and 20b are rotationally symmetrical to each other. Therefore, it is possible to form an opposite insulator 20b with the same shape as one insulator 20a, and the stator core insulation assembly 100 can be constructed from insulators 20 of the same shape. Depending on the insulation specifications of the stator, the overlapping portions 22a and 22b are sometimes necessary and sometimes not. When the overlapping portions 22a and 22b are not necessary, it is sufficient to satisfy the conditions of the connecting portions 25a and 25b or the inner circumferential flange fitting portions 23a and 23b described above.

[0078] <Insulator Connection Process S2>

[0079] like Figure 11 As shown, multiple stator core insulation assemblies 100 are connected together by fitting the columnar portions 251 of insulators 20a and 20b with the first arcuate portion 252a, forming a stator core connector 200. The stator core connector 200 is connected by the first arcuate portion 252a and the columnar portion 251, thus, as described above, it can rotate freely around the columnar portion 251. The step 253 formed by the columnar portion 251 and the connecting portion 25a enters the axial gap between the adjacent stator core 10 and the opening 252, thereby restricting the axial movement of the opening 252. The protrusion 254 provided on the end face of the columnar portion 251 restricts movement in the direction opposite to the restriction achieved based on the step 253.

[0080] <Winding process S3>

[0081] like Figure 12 As shown, the stator core connector 200 is mounted on the core holding mechanism 51 of the winding device 50 for winding. Since the stator core connector 200 can rotate freely around the columnar portion 251, the stator core 10b adjacent to the stator core 10a to be wound can be rotated to a configuration that does not interfere with the fly fork 52, and then held by the core holding mechanism 51 of the winding device 50. Furthermore, as... Figure 13 As shown, even stator cores 10c of different sizes can be wound using the same winding device 50 as long as the columnar portions 251 of the insulator are aligned.

[0082] like Figure 14 As shown in (a), even when the winding is performed by bringing the nozzle 53 close to the stator cores 10a and 10b and moving it on a rectangular track, without using the flying fork mechanism, it is as follows: Figure 14As shown in (b), a stator core 10c, which has a different size than the stator core 10a, can be wound using a shared core holding mechanism. Furthermore, in this case, the space between the teeth of the stator core can be increased, thus increasing the diameter of the nozzle 53 and increasing the curvature of the rounded corner shape connecting the outlet from the inner circumference of the nozzle 53, thereby suppressing the deterioration of the coil coating.

[0083] <Circular ring assembly process S4>

[0084] like Figure 15 , Figure 16 As shown, the connecting part of the wound stator core connector 200 is positioned to assemble into a stator core ring assembly 300, as follows. Figure 17 As shown, they are connected in a ring shape to form the stator core ring assembly 300. At this time, as... Figure 18 As shown, by sliding the columnar portion 251 in the direction of arrow A to the second arc portion 252b, thus achieving the desired effect. Figure 19 It becomes a ring shape as shown. At this time, since the connecting parts 25a and 25b of the insulator 20 are housed in a structure that is inside the outer diameter of the stator core 10, the wall thickness of the molding resin described later can be ensured.

[0085] At this time, Figure 3 As explained in the text, the cutout 251a of the columnar portion 251 fits into the surface of the second arc portion 252b. This surface is perpendicular to the direction (opening direction) from which the columnar portion 251 is removed from the second arc portion 252b. Therefore, even if a load is applied to disassemble the stator core connector 200, no component force will be generated to open the opening portion 252, making it difficult to disassemble.

[0086] In addition, Figure 8 As described above, the inner circumferential flange fitting portions 23a and 23b, located on the inner circumferential flange portion 23, engage and hook with the adjacent insulator 20, thus assisting in preventing the disassembly of the stator core ring assembly 300. This enhances the holding force after the stator core 10 is assembled into a ring. The inner circumferential flange fitting portions 23a and 23b are shaped to not restrict the radial movement of the insulator (having the same cross-sectional shape in the radial direction), therefore they do not hinder the radial alignment of the outer circumferential connecting portions 25a and 25b.

[0087] Furthermore, the stator core ring assembly 300 does not require welding or pressing equipment and can be easily assembled. Because it is not easily disassembled, it does not require special fixtures for conveying it to subsequent processes.

[0088] <Wire Wiring Procedure S5>

[0089] The ends of coil 30 are wire-connected according to the stator specifications.

[0090] <Molding process S6>

[0091] The stator core ring assembly 300, after winding and wiring, is placed in a resin molding mold for molding. This completes the process as follows: Figure 20 The stator shown is a molded resin specimen depicted in perspective, showing only its outline. For example... Figure 21 As shown, the pressure of the resin 400 during molding is used to press the stator core 10 towards the inner circumference in the radial direction, thereby connecting the segmented surfaces 13 of the stator core to form a magnetic circuit.

[0092] The rotor 60, with bearings mounted on both sides of the axial direction, is assembled into the stator manufactured through the above processes, and the brackets are fitted together, thereby forming a structure as shown above. Figure 21 The motor 70 shown.

[0093] Based on the above structure, stator cores of different shapes can be wound without modifying or altering the winding machine. Separated stator cores can be easily connected and assembled into a ring shape, and some or all of the axially separated insulators can be formed into a common shape. Furthermore, in existing insulator constructions, it is necessary to prepare the tooth-holding mechanism according to the tooth shape and install it into the manufacturing apparatus. However, in this embodiment, the distance between adjacent insulators can be variably adjusted using the columnar portion and opening portion of the insulator's connecting part. This allows for the winding of various stator cores without changing the manufacturing equipment, resulting in high-performance stators and motors. Therefore, in stators and motors, high-density winding can be achieved without increasing the number of parts or manufacturing processes.

[0094] Furthermore, in Patent Document 2, the connecting portion is positioned outside the outer diameter of the stator core, requiring a portion of the yoke to be thinned, thus reducing motor efficiency, in order to prevent interference between adjacent yoke portions of the stator core during winding. On the other hand, in this embodiment, a stator and motor capable of ensuring the magnetic circuit of the stator core can be obtained.

[0095] Implementation method 2.

[0096] exist Figure 22 , Figure 23The structure of the connecting portion 25b, which has the same guiding function as the slot-shaped opening 252 in Embodiment 1, will be described. The connecting portion 25b can also be formed by connecting two parallel arm-shaped portions 25b1 and 25b2 using a connecting portion 25b3. Furthermore, protrusions 252d are formed in the arm-shaped portions 25b1 and 25b, and first fitting portions 25b4 and second fitting portions 25b5 have the same function as the first arcuate portion 252a and second arcuate portion 252b described in Embodiment 1. The connecting portion 25b3 can also be formed between the first fitting portion 25b4 and the second fitting portion 25b5 at the bottom of the two arm-shaped portions 25b1 and 25b2 in a manner that does not impede the movement of the columnar portion 251. Additionally, as... Figure 11 As explained in the text, since insulators 20a and 20b of the same shape are assembled on opposite sides of the axial direction to form a stator core insulator, the positional relationship between the columnar portion 251 and the first fitting portion 25b4, and between the columnar portion 251 and the second fitting portion 25b5 in the insulators 20a and 20b are opposite to each other, so the positions of the bottom are also opposite. In other words, the connecting portion 25b3 is formed on the upper part of the two arm-shaped portions 25b1 and 25b2.

[0097] In this embodiment, the columnar portion 251 of the connecting portion 25a is not cylindrical as in Embodiment 1, but is formed as a polygon, such as a hexagonal prism. Furthermore, the first fitting portion 25b4 and the second fitting portion 25b5 are formed along the outer periphery of the columnar portion 251. Figure 22 As can be understood from the top view, the shape of the first fitting part 25b4 is based on a shape that is identical or similar to the shape of the columnar part 251, and a triangular groove 25b7 can be formed to engage with the polygonal corner to lock the rotation, so that they fit at a predetermined number of angles.

[0098] Furthermore, the columnar portion 251 can fix adjacent insulators 20 and stator core 10 at a predetermined angle in the second fitting portion 25b5 where the insulators 20 are closest to each other. The fitting of the columnar portion 251 with the first fitting portion 25b4 or the second fitting portion 25b5 is formed into a snap-fit ​​shape utilizing the elastic deformation of the insulator, thereby enabling simple assembly. The snap-fit ​​can be installed and removed in a plane perpendicular to the axial direction.

[0099] Figure 24 Compared with implementation method 1 Figure 11 , Figure 12Similarly, the situation described above refers to the state after the multiple stator core insulation assemblies 100 are connected by engaging the columnar portion 251 with the first engaging portion 25b4 in the insulator connection process of this embodiment, and then mounted on the core holding mechanism 51 as a stator core connector 200 and wound during the winding process. When the insulator 20 is rotated while the polygonal shape of the columnar portion 251 is engaged with the first engaging portion 25b4, the opening of the first engaging portion 25b4 can be elastically deformed and rotated under a certain or greater rotational load. Thus, it functions as an auxiliary mechanism that selectively maintains the angle of the core during the winding process.

[0100] Compared with implementation method 1 Figure 15 and Figure 16 Similarly, in this embodiment, the situation described above is also present. Figure 25 , Figure 26 The diagram illustrates the process of forming the connecting portion of the wound stator core connector 200 into a stator core annular assembly 300. The columnar portion 251, which engages with the first engaging portion 25b4, is shown... Figure 24 The state changes and becomes Figure 25 After reaching this state, the columnar portion 251 is moved toward the second fitting portion 25b5, thereby, as... Figure 26 As shown, the columnar portion 251 passes over the protrusion 252d and engages with the second engaging portion 25b5.

[0101] By forming the connecting portions 25a and 25b as in this embodiment, the deformation that occurs when the first fitting portion 25b4, where the insulators 20 are furthest apart, and the second fitting portion 25b5, where the insulators 20 are closest together, are engaged is the same. Furthermore, similar to Embodiment 1, since the connecting portions 25a and 25b of the insulators 20 are housed in a structure that is closer to the outer diameter of the stator core 10, the wall thickness of the molding resin described later can be ensured.

[0102] Implementation method 3.

[0103] like Figure 27 , Figure 28 As shown, the long side of the elongated hole 252c of the insulator 20 is tangent to the arc of the second arc portion 252b, and it does not have a retaining mechanism that restricts circumferential movement using the second arc portion 252b when it becomes the stator core connector 200. Therefore, a tethering portion 256 is provided on the side of the connector portions 25a and 25b. Figure 29 When combined with adjacent stator cores 10a and 10b as shown, Figure 30 This is a view showing the tie portion 256 through the stator core. The tie portion 256, which hooks onto the adjacent insulator, is positioned to restrict circumferential movement of the insulator and stator core insulation assembly. (See diagram for example.) Figure 27As shown, the tethering portion 256 of adjacent insulators has a portion that protrudes relative to the connecting portions 25a and 25b. The opposite side of the protruding portion of one or both of the tethering portions 256 is cut out to facilitate elastic deformation during insertion.

[0104] The connecting portions 25a and 25b have elastically deformable tethering portions 256 on their sides, thereby restricting the circumferential movement of the stator cores 10a and 10b, and the elongated hole portion 252c restricts the radial movement of the stator cores 10a and 10b. In the case of Embodiment 1, there is a constraint that the size of the second arc portion 252b is the same as the size of the first arc portion 252a, but in this embodiment, there is no size constraint on the tethering portion 256, and it can be configured according to the required strength. Furthermore, the tethering portion 256 of this embodiment can also be added to the shape of Embodiment 1. By forming such a tethering portion 256, the holding force after the stator core 10 is assembled into a ring is enhanced.

[0105] Implementation method 4.

[0106] like Figure 31 Similar to motor 70, the final fixation of the stator core 10 does not use resin 400, but rather a frame 80. The frame 80 is made of materials such as metals like iron or aluminum, or structural materials like reinforced plastics. The frame 80 is cylindrical, and its inner diameter is smaller than the outer diameter of the stator core connector. This inner diameter is the dimension by which a preload is applied to the inner circumference of the stator core in the radial direction when the frame 80 is assembled with the stator core 10. Figure 19 or Figure 26 As shown, the connecting portions 25a and 25b of the insulator 20 are housed at a position closer to the inner side than the outer diameter of the stator core 10, thus preventing interference between the insulator and the frame during frame assembly.

[0107] There are methods for assembling frame 80 onto the stator. Figure 32 In the frame pressing or hot pressing process S7, the frame 80 is heated to expand its diameter and fit together through thermal expansion, and then the frame 80 is cooled to shrink and fix it. Alternatively, the frame 80 can be pressed in without heating it. Furthermore, there are also methods where the frame 80 is constructed as multiple segments and fastened using screws, welding, or adhesive.

[0108] According to this structure, no mold or molding machine is needed for molding, and the stator can be manufactured with simpler manufacturing equipment.

[0109] Implementation method 5.

[0110] like Figure 33As shown, the insulator 20 is not segmented along the axial direction; instead, the stator core 10 is inserted into a resin molding die for embedding. This ensures the insulation distance without considering the step of the overlapping portion. In the case of a step with an overlapping portion, the thin-walled side of the step portion needs to be set as the minimum thickness for resin molding, and the wall thickness of the insulator where there is no overlapping portion is twice the minimum thickness. On the other hand, in this embodiment, there is no overlapping portion, so the wall thickness of the insulator can be set to the minimum thickness for resin molding, increasing the space for accommodating the coil and reducing the copper loss of the stator.

[0111] Implementation method 6.

[0112] like Figure 34 As shown, a number of stator core insulation assemblies 100 corresponding to one stator are connected as stator core connectors 200. By installing these assemblies on multiple core holding mechanisms 51, multiple forks 52 are used to continuously wind the coils of each phase without cutting the wire midway. This shortens the wire cutting time in the winding device's cycle time and improves the winding device's operating efficiency. Furthermore, the stator core insulation assemblies 100 can be supplied one by one during the winding process, eliminating the waiting time for workpiece supply and improving operating efficiency.

[0113] The stator core that has completed winding is in Figure 34 Moving in the direction of the arrow, the stator cores are pre-assembled into a ring shape during discharge. When all the stator cores for one stator are ready, they are cut from the stator core connector 200 during the winding process, forming a stator core ring assembly 300. This saves labor and time in rearranging the stator cores of each phase. Furthermore, Figure 34 The diagram shows a structure with two non-phase coils arranged between in-phase coils, such as a 9-pole 12-slot coil. However, even in cases such as a 10-pole 12-slot coil, where two in-phase coils are adjacent and two pairs of non-phase coils are inserted between each pair of in-phase coils, it is possible to wind the coils in the same structure by changing the number of stator cores between different fly forks to an appropriate amount.

[0114] Implementation method 7.

[0115] The connecting portions 25a and 25b in embodiments 1 to 5 are present in the insulator 20, but in this embodiment, a separate connecting portion is provided separately from the insulator. Figure 35 This is a perspective view of the insulator 20 in this embodiment. Figure 36 This is a perspective view of the split connecting portion 25c. The insulator 20 has protrusions 27a and 27b, which form columnar portions 26a and 26b. Openings 252e and 252f are formed in the split connecting portion 25c, as shown... Figure 37As shown, the columnar portion 26b of the protrusion 27b formed on the insulator 20a fits into the opening 252e of the split connecting portion 25c, and the columnar portion 26a of the protrusion 27a of the insulator 20b adjacent to the insulator 20a fits into the opening 252f of the split connecting portion 25c, thereby connecting them in a rotatable manner.

[0116] Therefore, as Figure 38 As shown, with Figure 11 Similarly, a stator core connector 200 is formed that can rotate freely around the columnar portions 26a and 26b. Through this structure, it connects with... Figure 12 or Figure 34 Similarly, the structure shown allows the stator core adjacent to the stator core to be wound to be rotated into a configuration that does not interfere with the fly fork 52, and can be held by the core holding mechanism 51 of the winding device 50, enabling winding using the winding device 50. Then, as... Figure 39 As shown, the connecting part of the wound stator core connector 200 is positioned to assemble into a stator core ring assembly 300, and as... Figure 40 They are connected in a ring shape as shown. At this time, the split connecting part 25c of the insulator 20 can also be configured to be housed in a position that is closer to the outer diameter of the stator core 10. With such a structure, the wall thickness of the molding resin can be ensured, just like in Embodiment 1.

[0117] In addition, in the above structure, there is an opening in the split connection part 25c and two columnar parts in the insulator 20, but the same effect can be achieved by providing columnar parts in the split connection part 25c and opening parts in the insulator 20.

[0118] Furthermore, the split connecting part 25c is connected in a rotatable manner to the two columnar parts 26a and 26b, but it can also be a structure in which only one part is connected in a rotatable manner.

[0119] In addition, such as Figure 41 As shown, the openings 252e and 252f formed in the split connecting portion 25c may also have a third arc portion 252g and a fourth arc portion 252h. With this configuration, as... Figure 42 , Figure 43 As shown, by adjusting the length of the split connection part according to the machine type, the distance between adjacent stator cores during winding can be made common, and manufacturing can be carried out without production change adjustments using common manufacturing equipment.

[0120] As described above, the insulator 20 is connected by the split connecting portion 25c, so that the split connecting portion 25c is housed within the outer diameter of the core in the stator core ring assembly 300 state. Therefore, high-density winding can be performed using the same assembly method as in Embodiments 1 and 3. Furthermore, the fitting portion, which rotatably connects the columnar portions 26a and 26b of the insulator 20 to the openings 252e and 252f of the split connecting portion 25c, can be arranged at any position relative to the insulator and the stator core. Therefore, similar to Embodiment 1, various stator cores can be wound without changing the manufacturing equipment, resulting in high-performance stators and motors. Thus, in stators and motors, high-density winding can be achieved without increasing the number of parts or manufacturing processes.

[0121] The stator assembled in this way can also be used to manufacture the motor 70 as a rotary electric motor by the method described in Embodiment 1 or Embodiment 3.

[0122] This application describes various exemplary embodiments and examples, but the various features, methods and functions described in one or more embodiments are not limited to application in a specific embodiment, and can be applied to the embodiment alone or in various combinations.

[0123] Therefore, numerous variations not illustrated can be conceived within the scope of the technology disclosed in this application. These include variations of at least one constituent element, additions, omissions, and extraction of at least one constituent element combined with constituent elements of other embodiments.

[0124] Label Explanation

[0125] 10: Stator core; 11: Tooth; 12: Back yoke; 13: Segmentation surface; 20: Insulator; 21: Core mating part; 22: Coil frame part; 23: Inner peripheral flange part; 23a, 23b: Inner peripheral flange mating part; 24: Outer peripheral flange part; 25a, 25b: Connecting part; 25b3: Connecting part; 25b4: First mating part; 25b5: Second mating part; 25c: Separate connecting part; 26a, 26b: Columnar part; 30: Coil; 50: Winding device; 51: Core holding mechanism Components; 52: Flying fork; 53: Nozzle; 60: Rotor; 70: Motor; 80: Frame; 100: Stator core insulation assembly; 200: Stator core connector; 251: Columnar part; 252, 252e, 252f: Opening part; 252a: First arc part; 252b: Second arc part; 252c: Long hole part; 252g: Third arc part; 252h: Fourth arc part; 253: Step; 254, 255: Protrusion; 300: Stator core ring assembly; 400: Resin.

Claims

1. An insulator mounted on a stator core and electrically insulating a coil from the stator core, characterized in that, The insulator includes a columnar portion, a guide portion, and two arm-shaped connecting portions protruding circumferentially to both sides of the stator core. The columnar portion is formed in one connecting portion, and the guide portion is formed in the other connecting portion and guides the columnar portion in a movable manner. The columnar portion of one insulator engages with the guide portion of an adjacent insulator in a manner that allows the distance between adjacent insulators to be variable. The guide portion has multiple fitting portions that can engage with the columnar portion. The guide portion has elongated holes between adjacent fitting portions in the plurality of fitting portions. The guide portion has multiple fitting portions between two components that have a spacing that allows the columnar portion to move and extend circumferentially. A connecting portion is formed in the elongated hole between the fitting portions at a location that does not impede the movement of the columnar portion, and the connecting portion connects the two components.

2. The insulator according to claim 1, characterized in that, The guide portion has protrusions at both ends of the elongated hole portion, and the protrusions form portions with a width smaller than the width of the elongated hole portion.

3. The insulator according to claim 1, characterized in that, The columnar portion is rotatably fitted into the first fitting portion in which the insulators are furthest apart from each other.

4. The insulator according to claim 2, characterized in that, The columnar portion is rotatably fitted into the first fitting portion in which the insulators are furthest apart from each other.

5. The insulator according to any one of claims 1 to 4, characterized in that, The columnar portion is fixed at a predetermined angle in the second fitting portion where the insulators are closest to each other.

6. The insulator according to any one of claims 1 to 4, characterized in that, The columnar portion and the fitting portion are in the shape of snap-fit ​​that can be attached and detached.

7. The insulator according to claim 5, characterized in that, The columnar portion and the fitting portion are in the shape of snap-fit ​​that can be attached and detached.

8. The insulator according to any one of claims 1 to 4, characterized in that, The insulator has a flange portion formed on the inner and outer peripheral sides of the insulator for limiting the coil. A cutout portion that fits into an adjacent insulator is formed on the circumferential side of the flange portion on the inner peripheral side.

9. The insulator according to claim 5, characterized in that, The insulator has a flange portion formed on the inner and outer peripheral sides of the insulator for limiting the coil. A cutout portion that fits into an adjacent insulator is formed on the circumferential side of the flange portion on the inner peripheral side.

10. The insulator according to claim 6, characterized in that, The insulator has a flange portion formed on the inner and outer peripheral sides of the insulator for limiting the coil. A cutout portion that fits into an adjacent insulator is formed on the circumferential side of the flange portion on the inner peripheral side.

11. The insulator according to claim 7, characterized in that, The insulator has a flange portion formed on the inner and outer peripheral sides of the insulator for limiting the coil. A cutout portion that fits into an adjacent insulator is formed on the circumferential side of the flange portion on the inner peripheral side.

12. A stator, characterized in that, The coil is wound on an insulator as described in any one of claims 1 to 11 and mounted on a stator core, the stator core being connected into a ring shape and molded using resin.

13. A stator, characterized in that, The coil is wound on an insulator as described in any one of claims 1 to 11 and mounted on a stator core, the stator core being connected in a ring shape, the outer periphery of the stator core being covered by a frame and preloaded radially.

14. The stator according to claim 12 or 13, characterized in that, The connecting part is housed at a position that is inside the outer periphery of the stator core.

15. The stator according to claim 12 or 13, characterized in that, Two insulators are assembled axially on the teeth of the stator core, and a guide portion is disposed on the other insulator on the opposite side of the axial direction, corresponding to the columnar portion of one of the insulators.

16. The stator according to claim 15, characterized in that, In the assembled and fitted two insulators, the core fitting portion of one insulator has two first overlapping portions on the left and right in the circumferential direction, and the core fitting portion of the other insulator on the opposite axial side has two second overlapping portions on the left and right in the circumferential direction. The first overlapping portions and the second overlapping portions are formed by steps, and the steps are oriented in the same direction on the left and right.

17. A rotary electric motor, wherein, The rotary motor includes: The stator according to any one of claims 12 to 16; and the rotor, which is radially opposed to the stator.

18. An insulator mounted on a stator core and electrically insulating a coil from the stator core, characterized in that, The insulator has a columnar portion, a guide portion, and two arm-shaped connecting portions, which protrude circumferentially to both sides of the stator core. The columnar portion is formed in one connecting portion, and the guide portion is formed in the other connecting portion and guides the columnar portion in a movable manner. The columnar portion of one insulator engages in a manner that allows it to move within the guide portion of an adjacent insulator, so that the distance between adjacent insulators is variable. The guide portion is a slotted portion, which has multiple fitting portions that can fit into the columnar portion. A slit is formed in the columnar portion, and a protrusion is formed in the closest mating portion of the insulators, the protrusion fitting into the slit. The guide portion has multiple fitting portions between two components that have a spacing that allows the columnar portion to move and extend circumferentially. A connecting portion is formed between the fitting portions at a location that does not impede the movement of the columnar portion, and the connecting portion connects the two components.

19. The insulator according to claim 18, characterized in that, The insulator has a flange portion formed on the inner and outer peripheral sides of the insulator for limiting the coil. A cutout portion that fits into an adjacent insulator is formed on the circumferential side of the flange portion on the inner peripheral side.

20. A stator, characterized in that, The coil is wound on the insulator as described in claim 18 or 19 and mounted on the stator core, which is connected into a ring and molded using resin.

21. A stator, characterized in that, The coil is wound on the insulator as described in claim 18 or 19 and mounted on the stator core, the stator core being connected in a ring shape, the outer periphery of the stator core being covered by a frame and preloaded radially.

22. The stator according to claim 20 or 21, characterized in that, The connecting part is housed at a position that is inside the outer periphery of the stator core.

23. The stator according to claim 20 or 21, characterized in that, Two insulators are assembled axially on the teeth of the stator core, and a guide portion is disposed on the other insulator on the opposite side of the axial direction, corresponding to the columnar portion of one of the insulators.

24. The stator according to claim 23, characterized in that, In the assembled and fitted two insulators, the core fitting portion of one insulator has two first overlapping portions on the left and right in the circumferential direction, and the core fitting portion of the other insulator on the opposite axial side has two second overlapping portions on the left and right in the circumferential direction. The first overlapping portions and the second overlapping portions are formed by steps, and the steps are oriented in the same direction on the left and right.

25. A rotary electric motor, wherein, The rotary motor includes: The stator according to any one of claims 20 to 24; and the rotor, which is radially opposed to the stator.

26. An insulator mounted on a stator core and electrically insulating a coil from the stator core, characterized in that, The insulator has a columnar portion, a guide portion, and two arm-shaped connecting portions, which protrude circumferentially to both sides of the stator core. The columnar portion is formed in one connecting portion, and the guide portion is formed in the other connecting portion and guides the columnar portion in a movable manner. The columnar portion of one insulator engages in a manner that allows it to move within the guide portion of an adjacent insulator, so that the distance between adjacent insulators is variable. The guide portion has multiple fitting portions between two components that have a spacing that allows the columnar portion to move and extend circumferentially. A connecting portion is formed between the fitting portions at a location that does not impede the movement of the columnar portion, and the connecting portion connects the two components. The columnar portion is a polygonal prism that is rotatably fitted into the first fitting portion of the insulator that is furthest from it. A groove is formed in the first fitting portion, which engages with the corner of the prism to lock the rotation of the columnar portion.

27. The insulator according to claim 26, characterized in that, The insulator has a flange portion formed on the inner and outer peripheral sides of the insulator for limiting the coil. A cutout portion that fits into an adjacent insulator is formed on the circumferential side of the flange portion on the inner peripheral side.

28. A stator, characterized in that, The coil is wound on the insulator as described in claim 26 or 27 and mounted on the stator core, which is connected into a ring and molded using resin.

29. A stator, characterized in that, The coil is wound on the insulator as described in claim 26 or 27 and mounted on the stator core, the stator core being connected in a ring shape, the outer periphery of the stator core being covered by a frame and preloaded radially.

30. The stator according to claim 28 or 29, characterized in that, The connecting part is housed at a position that is inside the outer periphery of the stator core.

31. The stator according to claim 28 or 29, characterized in that, Two insulators are assembled axially on the teeth of the stator core, and a guide portion is disposed on the other insulator on the opposite side of the axial direction, corresponding to the columnar portion of one of the insulators.

32. The stator according to claim 31, characterized in that, In the assembled and fitted two insulators, the core fitting portion of one insulator has two first overlapping portions on the left and right in the circumferential direction, and the core fitting portion of the other insulator on the opposite axial side has two second overlapping portions on the left and right in the circumferential direction. The first overlapping portions and the second overlapping portions are formed by steps, and the steps are oriented in the same direction on the left and right.

33. A rotary electric motor, wherein, The rotary motor includes: The stator according to any one of claims 28 to 32; and the rotor, which is radially opposed to the stator.

34. A method for manufacturing a stator, the stator comprising an insulator, the insulator being mounted on a stator core and electrically insulating the coils from the stator core, the method being characterized in that... The insulator includes a columnar portion, a guide portion, and two arm-shaped connecting portions protruding circumferentially from both sides of the stator core. The columnar portion is formed in one connecting portion, and the guide portion is formed in the other connecting portion. The columnar portion of one insulator engages with the guide portion of an adjacent insulator in a movable manner, allowing the distance between adjacent insulators to be variable. Furthermore, multiple fitting portions are formed in the guide portion, which can engage with the columnar portion. The guide portion has an elongated hole between adjacent fitting portions. The insulator is mounted on a winding device in a state where the columnar portion is moved according to the size of the stator core and engaged with one of the multiple fitting portions. The guide portion forms multiple fitting portions between two components that have a spacing that allows the columnar portion to move and extend circumferentially. A connecting portion is formed in the elongated hole between the fitting portions at a location that does not impede the movement of the columnar portion, and the connecting portion connects the two components.

35. The method for manufacturing a stator according to claim 34, characterized in that, By using arm-shaped connecting parts that protrude circumferentially towards the stator core, the insulator is engaged with another adjacent insulator in a rotatable state, and more than one stator corresponding to the number of stator cores are connected to each other for winding.

36. A method for manufacturing a rotary electric motor, characterized in that, Based on the stator manufacturing method of claim 34 or 35, rotors are arranged opposite each other in the radial direction of the manufactured stator.

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