Stator, motor, compressor, refrigeration cycle device, and method for manufacturing stator

Abstract

The stator is provided with: a cylindrical stator core (34); a first covering wire rod having a first lead wire harder than the second lead wire among the first lead wire and the second lead wire having different hardness, and an insulating coating film covering the periphery of the first lead wire; and a second covering wire having a second conductive wire and an insulating coating that covers the periphery of the second conductive wire and that is thicker than the thickness of the insulating coating that covers the periphery of the first conductive wire, the first covering wire and the second covering wire being mixed and wound around a plurality of teeth (36) provided along the circumferential direction of the stator core (34). Therefore, the occurrence of short circuit and burning loss in the coil (35) can be suppressed.

Description

Technical Field

[0001] The present disclosure relates to a stator, a motor, a compressor, a refrigeration cycle device, and a method for manufacturing the stator. Background Art

[0002] Generally speaking, in an electric motor, a coated wire is wound around a plurality of teeth provided along the circumferential direction of a cylindrical stator core to form a coil. For example, the coated wire includes a copper wire composed of a copper conductor and an insulating film covering the periphery of the copper conductor, an aluminum wire composed of an aluminum conductor and an insulating film covering the periphery of the aluminum conductor, and the like.

[0003] For example, Patent Document 1 forms a coil by winding a copper wire and an aluminum wire around each tooth portion in a concentrated winding manner. In this case, it is not necessary to hold the two copper wires and the aluminum wire at the same time by the holding part of the winding machine.

[0004] Patent Document 1: WO2014 / 188466

[0005] However, when forming a coil by winding a mixture of copper wires and aluminum wires around each tooth portion, although the two copper wires and the aluminum wire are simultaneously held by a holding portion of the winding machine, generally speaking, by making the wire diameters of the copper conductor wire and the aluminum conductor wire and the thickness of the insulating film covering the periphery of each wire the same, no gap is generated between each wire and the holding portion due to the difference in wire diameters of the copper wire and the aluminum wire.

[0006] However, since the hardness of each wire is different, the deformation amount of each wire caused by the holding force of the holding portion is different, and the contact between each wire and the holding portion is also different. For this reason, each wire may easily fall off from the holding portion, causing winding disorder.

[0007] Therefore, there is a problem that if the holding force of the holding portion is increased in order to prevent winding disorder, the aluminum wire, which is softer than the copper wire, is indented due to the holding force of the holding portion, and a stress greater than that of the cross section of the aluminum wire without the indentation is generated in the cross section of the aluminum wire. Therefore, the aluminum wire is more likely to break than in the case where no indentation is generated.

[0008] As described above, in addition to the problem of easy wire breakage of aluminum wires, when the holding force of the holding part is increased, the contact area between the holding part and the insulating film of each wire is larger at the surface of the insulating film covering the aluminum wire than at the surface of the insulating film covering the copper wire. Therefore, the insulating film covering the aluminum wire is affected by the holding force of the holding part in a wider range than the insulating film covering the copper wire. Therefore, there is a problem that the surface of the insulating film is affected by the holding force of the holding part due to the contact of the holding part, so that deformation and scratches occur on the surface, which becomes an important factor causing indentation and cracks, and it is difficult to ensure the insulation resistance of the insulating film covering the aluminum wire.

[0009] As described above, if the aluminum conductive wire is easily disconnected, it is difficult to ensure the dielectric strength of the insulating film covering the periphery of the aluminum conductive wire, and there is a problem that a short circuit or burnout is likely to occur in the coil. Summary of the invention

[0010] The present disclosure has been made to solve the above-mentioned problems, and an object of the present disclosure is to provide a coil capable of suppressing occurrence of short circuit and burnout.

[0011] The stator of the present disclosure comprises: a cylindrical stator core; a first covered wire having: a first conductive wire having different hardnesses and a first conductive wire which is harder than the second conductive wire among a first conductive wire and a second conductive wire, and an insulating film covering the first conductive wire; and a second covered wire having: a second conductive wire and an insulating film which is thicker than the insulating film covering the first conductive wire and covers the second conductive wire, wherein the first covered wire and the second covered wire are mixedly wound around a plurality of teeth provided along the circumferential direction of the stator core.

[0012] The electric motor disclosed herein includes a stator and a rotor, wherein the stator includes: a cylindrical stator core; a first covered wire having: a first conductor having different hardnesses and a first conductor being harder than the second conductor among a first conductor and a second conductor, and an insulating film covering the first conductor; and a second covered wire having: a second conductor and an insulating film covering the second conductor that is thicker than the insulating film covering the first conductor, wherein the first covered wire and the second covered wire are mixedly wound around a plurality of teeth arranged along the circumferential direction of the stator core, and the rotor rotates using a magnetic field generated by the stator.

[0013] The compressor disclosed in the present invention comprises: an electric motor having a stator and a rotor, wherein the stator comprises a cylindrical stator core; a first coated wire having a first wire having different hardnesses and a first wire harder than the second wire, and an insulating film covering the periphery of the first wire; a second coated wire having a second wire and an insulating film covering the periphery of the second wire which is thicker than the insulating film covering the periphery of the first wire, wherein the first coated wire and the second coated wire are mixedly wound around a plurality of teeth arranged along the circumferential direction of the stator core, and the rotor is rotated using a magnetic field generated by the stator; a sealed container having a suction pipe for sucking in a fluid and a discharge pipe for discharging the fluid; and a compression element which is driven by the electric motor, compresses the fluid sucked in through the suction pipe, and discharges the compressed fluid through the discharge pipe.

[0014] The refrigeration cycle device disclosed in the present invention includes: a compressor, a condenser, a decompression device, and an evaporator. The compressor includes: an electric motor including a stator and a rotor, the stator including: a cylindrical stator core; a first coated wire including: a first wire harder than the second wire among a first wire and a second wire having different hardnesses, and an insulating film covering the periphery of the first wire; a second coated wire including: a second wire and an insulating film covering the periphery of the second wire thicker than the insulating film covering the periphery of the first wire, the first coated wire and the second coated wire being mixedly wound around a plurality of teeth arranged along the circumferential direction of the stator core, the rotor being rotated using a magnetic field generated by the stator; a sealed container including a suction pipe for sucking in a fluid and a discharge pipe for discharging the fluid; and a compression element driven by the electric motor to compress the fluid sucked in through the suction pipe and discharge the compressed fluid through the discharge pipe, the condenser liquefies the fluid, the decompression device reduces the pressure of the compressed fluid, and the evaporator gasifies the fluid.

[0015] The manufacturing method of the stator disclosed in the present invention comprises the following steps: the steps of generating a first covered wire having: a first conductive wire having different hardnesses and a first conductive wire harder than the second conductive wire, and an insulating film covering the periphery of the first conductive wire, and the second covered wire having: a second conductive wire and an insulating film covering the periphery of the second conductive wire having a thickness thicker than that of the insulating film covering the periphery of the first conductive wire; and the steps of mixing and winding the first covered wire and the second covered wire around a plurality of teeth provided along the circumferential direction of a cylindrical stator core.

[0016] Effects of the Invention

[0017] According to the present disclosure, it is possible to suppress the occurrence of short circuit and burnout in the coil. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1This is a diagram showing the refrigeration cycle device according to Embodiment 1.

[0019] Figure 2 This is a diagram showing the refrigeration cycle device according to Embodiment 1.

[0020] Figure 3 It is a longitudinal sectional view of the compressor in Embodiment 1.

[0021] Figure 4 This is a schematic diagram showing a stator according to the first embodiment.

[0022] Figure 5 This is a cross-sectional view showing the stator according to the first embodiment.

[0023] Figure 6 This is a connection diagram of the coils of the stator according to the first embodiment.

[0024] Figure 7 It is a cross-sectional view showing the cross-sectional structure of the winding according to the first embodiment.

[0025] Figure 8 This is a flowchart showing the method for manufacturing the stator according to the first embodiment.

[0026] Fig. 9 This is a schematic diagram showing a gripping portion according to the first embodiment.

[0027] Fig.10 It is a cross-sectional view showing the cross-sectional structure of a winding wire according to a conventional example.

[0028] Fig.11 It is a cross-sectional view showing the cross-sectional structure of the winding according to the second embodiment.

[0029] Fig.12 It is a cross-sectional view showing the cross-sectional structure of the winding according to the third embodiment. DETAILED DESCRIPTION

[0030] Hereinafter, the embodiments of the present disclosure will be described with reference to the accompanying drawings. In addition, the accompanying drawings are schematic representations, and the mutual relationship between the dimensions and positions respectively represented by different accompanying drawings is not necessarily accurately recorded, but can be appropriately changed. In addition, in the following description, the same components are marked with the same reference numerals for illustration, and these names and functions are also the same or similar. Therefore, their detailed description is sometimes omitted.

[0031] Implementation method 1.

[0032] A refrigeration cycle device 1 in the present embodiment will be described. The refrigeration cycle device 1 includes a compressor 2 , a condenser 3 , a decompression device 4 , an evaporator 5 , a four-way valve 6 , a refrigerant circuit 7 , and a control unit 8 .

[0033] use Figure 1 as well as Figure 2 The configuration and operation of the refrigeration cycle device 1 will be described when the refrigeration cycle device 1 is an air conditioner.

[0034] The compressor 2, condenser 3, pressure reducing device 4, evaporator 5 and four-way valve 6 are connected by refrigerant piping to form a refrigeration cycle, and the refrigerant circulates in the order of the compressor 2, four-way valve 6, condenser 3, pressure reducing device 4 and evaporator 5.

[0035] The compressor 2 compresses the refrigerant sucked from the refrigerant circuit 7 to a high temperature and high pressure, and discharges the compressed refrigerant to the four-way valve 6 .

[0036] The four-way valve 6 switches the flow of the refrigerant between the heating operation and the cooling operation.

[0037] The condenser 3 exchanges heat with the refrigerant compressed by the compressor 2 to dissipate heat from the compressed refrigerant, thereby liquefying the refrigerant.

[0038] The decompression device 4 expands the refrigerant that has released heat in the condenser 3 .

[0039] The evaporator 5 exchanges heat with the refrigerant expanded in the decompression device 4 to heat the expanded refrigerant and vaporize the refrigerant.

[0040] The control unit 8 controls the entire refrigeration cycle device 1 based on instructions from an input device such as a remote controller, thereby controlling the flow of the refrigerant. The control unit 8 controls the frequency of the compressor 2 and the four-way valve 6, for example. The control unit 8 is composed of, for example, an analog circuit, a digital circuit, a CPU (Central Processing Unit) and a memory, or a combination of two or more thereof, and can be provided in the refrigeration cycle device 1 or in another housing.

[0041] The refrigerant used may include, for example, HFC (Hydro Fluoro Carbon) refrigerants such as R32, R125, R134a, R407C, and R410A, HFO (Hydro Fluoro Olefin) refrigerants such as R1123, R1132(E), R1132(Z), R1132a, R1141, R1234yf, R1234ze(E), and R1234ze(Z), and natural refrigerants such as R290 (propane), R600a (isobutane), R744 (carbon dioxide), and R717 (ammonia). At least one refrigerant is used.

[0042] The operation of the refrigeration cycle device 1 will be described. Figure 1The arrows shown indicate the direction of refrigerant flow during cooling operation. Figure 2 The arrows shown indicate the direction of refrigerant flow during heating operation. Figure 1 as well as Figure 2 In the figure, the flow of the refrigerant in the cooling operation and the flow of the refrigerant in the heating operation in the four-way valve 6 are shown by solid lines.

[0043] The operation of the refrigeration cycle device 1 during the cooling operation will be described.

[0044] By driving the compressor 2, the compressed refrigerant is discharged from the compressor 2. The refrigerant discharged from the compressor 2 flows into the first heat exchanger 9, which functions as the condenser 3, via the four-way valve 6. In the first heat exchanger 9, heat exchange is performed with the inflowing refrigerant, so that the refrigerant dissipates heat. The refrigerant sent out from the first heat exchanger 9 is expanded by the decompression device 4. The refrigerant expanded by the decompression device 4 flows into the second heat exchanger 10, which functions as the evaporator 5. In the second heat exchanger 10, heat exchange is performed with the inflowing refrigerant, so that the refrigerant is heated. The refrigerant sent out from the second heat exchanger 10 flows into the compressor 2 via the four-way valve 6, becomes the compressed refrigerant, and is discharged from the compressor 2 again, and this cycle is repeated.

[0045] The operation of the refrigeration cycle device 1 during the heating operation will be described.

[0046] By driving the compressor 2, the compressed refrigerant is discharged from the compressor 2. The refrigerant discharged from the compressor 2 flows into the second heat exchanger 10, which functions as the condenser 3, via the four-way valve 6. In the second heat exchanger 10, heat exchange is performed with the inflowing refrigerant, so that the refrigerant dissipates heat. The refrigerant sent out from the second heat exchanger 10 is expanded by the decompression device 4. The refrigerant expanded by the decompression device 4 flows into the first heat exchanger 9, which functions as the evaporator 5. In the first heat exchanger 9, heat exchange is performed with the inflowing refrigerant, so that the refrigerant is heated. The refrigerant sent out from the first heat exchanger 9 flows into the compressor 2 via the four-way valve 6, becomes the compressed refrigerant, and is discharged from the compressor 2 again, and this cycle is repeated.

[0047] In addition, in the present embodiment, an example is shown in which the refrigeration cycle device 1 is an air conditioner, but the refrigeration cycle device 1 may be a refrigeration cycle device other than an air conditioner. The refrigeration cycle device 1 is, for example, a heat pump cycle device or the like.

[0048] The compressor 2 in this embodiment is described. The compressor 2 includes a closed container 11, a motor 12, a crankshaft 13, a suction muffler 14, and a compression element 15. Figure 3The configuration of the compressor 2 will be described when the compressor 2 is a single-cylinder rotary compressor. Figure 3 as well as Figure 4 In the description, the direction of the axis of the stator 30 and the rotor 31 indicated by A1 is referred to as the “axial direction”, the circumferential direction centered on the axis indicated by arrow C1 is referred to as the “circumferential direction”, and the radial direction centered on the axis indicated by arrow R1 is referred to as the “radial direction”.

[0049] The sealed container 11 is provided with a suction pipe 16 for sucking in the refrigerant and a discharge pipe 17 for discharging the refrigerant. The upper portion of the sealed container 11 is provided with a terminal 19 for connecting an external power source to a lead wire 18. The bottom of the sealed container 11 stores a refrigeration oil 20 for lubricating the sliding portion of the compression element 15. The refrigeration oil 20 is, for example, POE (polyol ester), PVE (polyvinyl ether), AB (alkylbenzene), etc.

[0050] The motor 12 is provided inside the closed container 11 and above the compression element 15, and drives the compression element 15 via the crankshaft 13. The refrigerant compressed by the compression element 15 is discharged to the outside of the closed container 11 via the motor 12.

[0051] The suction muffler 14 is disposed outside the closed container 11 and is connected to the suction pipe 16. The suction muffler 14 supplies the refrigerant to the cylinder 21 through the suction pipe 16 from the refrigerant circuit 7 of the refrigeration cycle.

[0052] The compression element 15 includes a cylinder 21, a rotary piston 22, a blade (not shown), a main bearing 23, and a sub-bearing 24. The compression element 15 is provided inside the closed container 11, the rotary piston 22 is arranged in a cylinder chamber described later, and the blade is arranged in the cylinder 21, and is stacked from the bottom in the order of the sub-bearing 24, the cylinder 21, and the main bearing 23. In addition, the compression element 15 compresses the refrigerant sucked from the suction muffler 14 through the suction pipe 16, and discharges the compressed refrigerant from the discharge valve described later, through the discharge muffler 25 described later and the motor 12, and from the discharge pipe 17.

[0053] The cylinder 21 is a hollow cylindrical shape, and has a cylinder chamber in the hollow part of the cylinder. In addition, the cylinder 21 has: a suction port 26 that penetrates from the outer peripheral surface of the cylinder 21 to the cylinder chamber in order to be able to inhale refrigerant, and a discharge port (not shown) formed by cutting the upper end of the cylinder 21 in order to be able to discharge refrigerant.

[0054] The rolling piston 22 is hollow and cylindrical, and is slidably mounted on the eccentric shaft portion 27 of the crankshaft 13. The rolling piston 22 performs eccentric rotational motion in the cylinder chamber due to the rotation of the crankshaft 13 driven by the motor 12. The refrigerant is thereby sucked in, and the sucked refrigerant is compressed and discharged.

[0055] The vane is a rectangular parallelepiped, is slidably disposed in a vane groove (not shown), and is pressed against the rotary piston 22 by a vane spring (not shown) provided in a vane back pressure chamber (not shown).

[0056] Here, the vane groove is provided in the cylinder 21 so as to extend in the radial direction so as to communicate with the cylinder chamber and further penetrate the cylinder 21 in the axial direction. The vane back pressure chamber is a circular space provided between the vane groove and the outer peripheral surface of the cylinder 21.

[0057] When the compressor 2 is started, there is no difference in pressure between the inside of the sealed container 11 and the cylinder chamber, so the vane is pressed against the rotary piston 22 by the vane spring. During the operation of the compressor 2, the pressure inside the sealed container 11 is higher than the pressure in the cylinder chamber, so the force pressing the vane against the rotary piston 22 acts.

[0058] The main bearing 23 rotatably supports a main shaft portion 28 which is a portion of the crankshaft 13 above the eccentric shaft portion 27 and closes the cylinder chamber, the vane groove, and the upper side of the vane back pressure chamber. The main bearing 23 includes a discharge valve (not shown).

[0059] The auxiliary bearing 24 rotatably supports the auxiliary shaft portion 29 which is a portion of the crankshaft 13 below the eccentric shaft portion 27 and closes the lower side of the cylinder chamber, the vane groove, and the vane back pressure chamber.

[0060] The discharge muffler 25 is disposed outside the main bearing 23 and releases the refrigerant from the cylinder chamber into the interior of the closed container 11 via the discharge valve.

[0061] The cylinder body 21, main bearing 23 and auxiliary bearing 24 are made of gray cast iron, sintered steel, carbon steel, etc., the rotary piston 22 is made of alloy steel containing chromium, etc., and the blade is made of high-speed tool steel, etc.

[0062] In addition, in the present embodiment, an example is shown in which the discharge valve and the discharge muffler 25 are arranged on the main bearing 23 and on the outer side of the main bearing 23 , but they may be provided on at least one of the main bearing 23 and the auxiliary bearing 24 .

[0063] The operation of the compressor 2 will be described.

[0064] First, by supplying power to the motor 12 from the terminal 19 via the lead 18, the crankshaft 13 rotates, and the rotary piston 22 rotates eccentrically inside the cylinder 21. The interior of the cylinder chamber is divided into two spaces by the rotary piston 22 and the vanes. The volumes of the two spaces change as the crankshaft 13 rotates. In one space, the volume gradually expands, and the refrigerant is sucked in from the suction muffler 14 via the suction pipe 16 and the suction port 26. In the other space, the volume gradually decreases, and the refrigerant in the space is compressed and discharged from the discharge muffler 25 via the discharge valve and the discharge muffler 25 to the inside of the closed container 11. The refrigerant discharged to the inside of the closed container 11 is discharged from the discharge pipe 17 to the outside of the closed container 11 via the motor 12.

[0065] In the present embodiment, the compressor 2 is an example of a single-cylinder rotary compressor, but the compressor 2 may be a compressor other than a single-cylinder rotary compressor 2. The compressor 2 is, for example, a multi-cylinder rotary compressor, a scroll compressor, or the like.

[0066] The motor 12 in this embodiment is described. The motor 12 includes a stator 30 and a rotor 31 that has a certain gap with the stator 30 and is located on the same axis. The motor 12 generates a rotating magnetic field by supplying an AC power supply to the coil 35 of the stator 30, and the rotor 31 rotates due to the interaction between the AC current and the rotating magnetic field. Figure 3 to Figure 6 The configuration of the motor 12 will be described when the motor 12 is a cage induction motor.

[0067] In the present embodiment, a case where the rotor 31 is a rotor 31 constituting a squirrel-cage induction motor will be described.

[0068] like Figure 3 As shown, the rotor 31 includes a rotor core 32 , a rotor bar (not shown), and an end ring 33 .

[0069] The rotor core 32 is cylindrical and has grooves (not shown) at equal intervals along the circumferential direction. The rotor core 32 is manufactured by stacking a plurality of electromagnetic steel plates punched into a predetermined shape and having a thickness of 0.1 to 1.5 mm in the axial direction and fixing them by riveting, welding, etc. A through hole (not shown) is formed in the rotor core 32 in the axial direction, which serves as a passage for the gas refrigerant discharged from the discharge muffler 25 to the inner side of the closed container 11.

[0070] The rotor bar is an electric inductor, has a length in the axial direction, a width in the circumferential direction, and a thickness in the radial direction, and is filled or inserted in the groove. The rotor bar is formed of, for example, aluminum.

[0071] The end rings 33 short-circuit the two ends of the rotor bar.

[0072] In this embodiment, the rotor 31 is an example of a rotor 31 constituting a cage induction motor, but the rotor 31 may be a rotor 31 constituting a motor 12 other than a cage induction motor. The rotor 31 is, for example, a rotor 31 constituting a DC motor, a brushless DC motor, an AC motor, or the like.

[0073] like Figures 4 to 6 As shown, the stator 30 includes a stator core 34 and a coil 35 .

[0074] The stator core 34 is a hollow cylindrical shape, and teeth 36 are provided at equal intervals along the circumferential direction. The stator core 34 is manufactured by stacking a plurality of electromagnetic steel plates with a thickness of 0.1 to 1.5 mm punched into a predetermined shape in an axial direction and fixed by riveting, welding, etc. On the outer periphery of the stator core 34, not shown cutouts are formed at equal intervals along the circumferential direction, which serve as a passage for the gas refrigerant discharged from the discharge muffler 25 to the inside of the sealed container 11, and a passage for the refrigeration oil 20 returned from the motor 12 to the bottom of the sealed container 11.

[0075] The coil 35 includes a U-phase coil portion 41, a V-phase coil portion 42, and a W-phase coil portion 43. The coil is connected to a lead wire 18 that supplies electric power from a power source to the motor 12.

[0076] like Figure 6 As shown, the U-phase coil portion 41 is composed of a U-phase copper wire coil portion 44 and a U-phase aluminum wire coil portion 45, the V-phase coil portion 42 is composed of a V-phase copper wire coil portion 46 and a V-phase aluminum wire coil portion 47, and the W-phase coil portion 43 is composed of a W-phase copper wire coil portion 48 and a W-phase aluminum wire coil portion 49.

[0077] The U-phase copper wire coil portion 44 is composed of four U-phase copper wire coils 44a, 44b, 44c, and 44d, the U-phase aluminum wire coil portion 45 is composed of four U-phase aluminum wire coils 45a, 45b, 45c, and 45d, the V-phase copper wire coil portion 46 is composed of four V-phase copper wire coils 46a, 46b, 46c, and 46d, the V-phase aluminum wire coil portion 47 is composed of four V-phase aluminum wire coils 47a, 47b, 47c, and 47d, the W-phase copper wire coil portion 48 is composed of four W-phase copper wire coils 48a, 48b, 48c, and 48d, and the W-phase aluminum wire coil portion 49 is composed of four W-phase aluminum wire coils 49a, 49b, 49c, and 49d.

[0078] The U-phase copper wire terminal wire 44e, which is one of the terminals of the U-phase copper wire coils 44a, 44b, 44c, and 44d, and the U-phase aluminum wire terminal wire 45e, which is one of the terminals of the U-phase aluminum wire coils 45a, 45b, 45c, and 45d, are connected to the neutral point 50. Similarly, the V-phase copper wire terminal wire 46e, which is one of the terminals of the V-phase copper wire coils 46a, 46b, 46c, and 46d, and the V-phase aluminum wire terminal wire 47e, which is one of the terminals of the V-phase aluminum wire coils 47a, 47b, 47c, and 47d, are connected to the neutral point 50. The W-phase copper wire terminal wire 48e, which is one of the terminals of the W-phase copper wire coils 48a, 48b, 48c, and 48d, and the W-phase aluminum wire terminal wire 49e, which is one of the terminals of the W-phase aluminum wire coils 49a, 49b, 49c, and 49d, are connected to the neutral point 50.

[0079] With the above configuration, the U-phase copper wire coil portion 44 , the V-phase copper wire coil portion 46 , the W-phase copper wire coil portion 48 , the U-phase aluminum wire coil portion 45 , the V-phase aluminum wire coil portion 47 , and the W-phase aluminum wire coil portion 49 are gathered at one point to form a neutral point 50 .

[0080] The winding 60 in this embodiment will be described. The winding 60 is a general term for two covered wires described later, and is wound around the teeth 36 of the stator 30 to form the coil 35 .

[0081] Figure 7 The cross-sectional structure of the winding 60 in this embodiment is shown. The winding 60 includes two coated wires, and the coated wires include conductors with different hardness and an insulating film covering the conductors with different hardness. The wire diameters of the soft conductor and the hard conductor of the conductors with different hardness are the same, and the thickness of the insulating film covering the soft conductor is thicker than the thickness of the insulating film covering the conductor with different hardness. The following is a detailed description.

[0082] The cross-sectional shapes of the coated wire and the conductive wire are both circular, and the wire diameters of the coated wire and the conductive wire are defined by the diameter of the circle.

[0083] The conductor is made of copper or aluminum. Copper and aluminum have different hardnesses. When the hardness is measured as Vickers hardness, copper is about 50 to 60 HV and aluminum is about 20 to 30 HV. In other words, the harder conductor among the conductors with different hardnesses is the copper conductor, and the softer conductor among the conductors with different hardnesses is the aluminum conductor.

[0084] In the description of the winding in this embodiment, the copper wire is referred to as the wire 61C, the aluminum wire is referred to as the wire 61A, the insulating film covering the periphery of the wire 61C is referred to as the insulating film 62C, the insulating film covering the periphery of the wire 61A is referred to as the insulating film 62A, the covered wire having the wire 61C and the insulating film 62C is referred to as the covered wire 63C, and the covered wire having the wire 61A and the insulating film 62A is referred to as the covered wire 63A.

[0085] The wire diameter 64C of the conductor 61C and the wire diameter 64A of the conductor 61A are, for example, 1.0 mm. The thickness 65C of the insulating film 62C is, for example, 0.04 mm, and the thickness 65A of the insulating film 62A is, for example, 0.052 mm. The insulating film 62C and the insulating film 62A are made of a material having electrical insulation properties, such as polyamide-imide, polyester-imide, polyester, polyurethane, methylal, etc. In this case, the wire diameter 66C of the coated wire 63C is the sum of the wire diameter 64C of the conductor 61C and twice the thickness 65C of the insulating film 62C, and is therefore 1.08 mm, and the wire diameter 66A of the coated wire 63A is also 1.104 mm.

[0086] In addition, in the present embodiment, an example in which the coated wire 63C and the coated wire 63A are 0.04 mm and 0.52 mm is shown, but the coated wire 63C and the coated wire 63A are selected according to the sizes of each wire specified in the JIS (Japanese Industrial Standards) standard so that the wire diameter 64C of the conductor 61C is the same as the wire diameter 64A of the conductor 61A, and the thickness 65A of the insulating film 62A is thicker than the thickness 65C of the insulating film 62C.

[0087] In addition, in the present embodiment, an example is shown in which the covered wire 63C and the covered wire 63A are round wires, but they may be rectangular wires.

[0088] use Figure 8 A method for manufacturing the stator 30 in this embodiment will be described.

[0089] In step S1, the conductive wire 61C, the conductive wire 61A, and a material having electrical insulation properties are prepared. In the following description, the material having electrical insulation properties is described as polyamide-imide.

[0090] Then, in step S2 , the wire 61C and the wire 61A are annealed.

[0091] Then, in step S3 , the wire 61C and the wire 61A annealed in step S2 are softened.

[0092] Then, in step S4 , polyamide-imide is applied to the conductive wire 61C and the conductive wire 61A softened in step S3 .

[0093] Then, in step S5 , the conductive wire 61C and the conductive wire 61A coated with polyamide-imide in step S4 are sintered to form the insulating film 62C and the insulating film 62A, thereby forming the covered wire 63C and the covered wire 63A.

[0094] Here, wire diameter 64A of conductive wire 61A and wire diameter 64C of conductive wire 61C are the same, and insulating film 62C and insulating film 62A are formed so that thickness 65A of insulating film 62A is thicker than thickness 65C of insulating film 62C.

[0095] Then, in step S6 , the covered wire material 63C and the covered wire material 63A manufactured in step S5 are simultaneously grasped by the grasping unit 51 described later.

[0096] Then, in step S7, the gripping portion 51 is driven to wind the coated wire 63C and the coated wire 63A around the teeth portion 36 in a predetermined winding method. The winding method may be, for example, concentrated winding, concentric winding, overlap winding, or wave winding.

[0097] Through steps S1 to S7 , the coil 35 in this embodiment is completed. Figure 4 The coil 35 shown is formed by winding the coated wire 63C and the coated wire 63A around the teeth portion 36 in a concentrically wound manner.

[0098] Here, the gripping portion 51 will be described. Fig. 9 As shown, the holding portion 51 includes a fixed portion 52 and a movable portion 53. The holding portion 51 is one of the components of a machine, i.e., a winding machine, which manufactures the coil 35 by winding the wire 60. The winding machine drives the holding portion 51 that clamps the coated wire 63C and the coated wire 63A by the fixed portion 52 and the movable portion 53, and winds the coated wire 63C and the coated wire 63A around the tooth portion 36, thereby manufacturing the coil 35 from the coated wire 63C and the coated wire 63A.

[0099] In addition, in this embodiment, an example is shown in which the motor 12 is arranged inside the closed container 11 of the compressor 2 to drive the compression element 15 built into the compressor 2, but the motor 12 can also drive a machine other than the compression element 15 built into the compressor 2.

[0100] For comparison with this embodiment, Fig.10The cross-sectional structure of the winding 70 in the conventional example is shown. The winding 70 has two coated wires, and the coated wires have conductors of different hardness and insulating films covering the conductors of different hardness. The wire diameters of the soft conductor and the hard conductor of the conductors of different hardness are the same, and the thicknesses of the insulating films covering the soft conductor and the insulating films covering the hard conductor are also the same. In other words, the winding 70 in the conventional example is different from the winding 60 in the first embodiment in that the thicknesses of the insulating films covering the soft conductor and the insulating films covering the hard conductor are the same. The following is a detailed description.

[0101] In the description of the winding wire 70 in the conventional example, the copper wire is the wire 71C, the aluminum wire is the wire 71A, the insulating film covering the periphery of the wire 71C is the insulating film 72C, the insulating film covering the periphery of the wire 71A is the insulating film 72A, the covered wire having the wire 71C and the insulating film 72C is the covered wire 73C, and the covered wire having the wire 71A and the insulating film 72A is the covered wire 73A. In addition, the cross-sectional shapes of the covered wire and the wire are both circular, and the wire diameters of the covered wire and the wire are defined by the diameter of the circle.

[0102] The wire diameter 74C of the conductor 71C and the wire diameter 74A of the conductor 71A are, for example, 1.0 mm. The thickness 75C of the insulating film 72C and the thickness 75A of the insulating film 72A are, for example, 0.04 mm. In this case, the wire diameter 76C of the coated wire 73C is the sum of the wire diameter 74C of the conductor 71C and the thickness 75C of the insulating film 72C twice, and is therefore 1.08 mm, and the wire diameter 76A of the coated wire 73A is also 1.08 mm.

[0103] In the conventional coil formed by mixedly winding the coated wire 73C and the coated wire 73A around each tooth portion 36, although the two coated wires 73C and the coated wire 73A are simultaneously held by the holding portion 51, generally speaking, since the wire diameter 74C of the conductor 71C and the wire diameter 74A of the conductor 71A, and the thickness of the insulating film covering the surroundings of each wire are the same, a gap caused by the difference in wire diameter 76C of the coated wire 73C and the wire diameter 76A of the coated wire 73A is avoided between each wire and the holding portion 51.

[0104] However, since the hardness of each wire is different, the deformation amount of each wire caused by the holding force of the holding portion 51 is different, and the contact between each wire and the holding portion 51 is also different. For this reason, each wire may easily fall off from the holding portion 51, causing winding disorder.

[0105] Therefore, if the holding force of the holding portion 51 is increased in order to prevent winding disorder, an indentation is generated in the conductor 71A which is softer than the conductor 71C due to the holding force of the holding portion 51, and a stress greater than that in the cross-section of the conductor 71A where the indentation is generated is generated. Therefore, compared with the case where no indentation is generated, the conductor 71A is more likely to break.

[0106] As described above, in addition to the problem that the wire 71A is easily disconnected, when the holding force of the holding portion 51 is increased, the area where the holding portion 51 of the holding portion 51 contacts the insulation film of each wire becomes larger at the surface of the insulation film 72A than at the surface of the insulation film 72C, so that the insulation film 72A is affected by the holding force of the holding portion 51 in a wider range than the insulation film 72C. Therefore, at the surface of the insulation film, the holding portion 51 of the holding portion 51 contacts and is affected by the holding force of the holding portion 51, so that deformation, scratches, etc. are generated on the surface, which becomes a major factor causing indentations and cracks, and it is difficult to ensure the insulation resistance of the insulation film 72A.

[0107] In the stator 30 of the first embodiment, the thickness 65A of the insulating film 62A is thicker than the thickness 65C of the insulating film 62C, so there is a difference between the thickness 65A of the insulating film 62A and the thickness 65C of the insulating film 62C. On the other hand, since the wire 61A is softer than the wire 61C, when the coated wire 63C and the coated wire 63A are held simultaneously, the deformation amount of the wire 61A is larger than the deformation amount of the wire 61C, resulting in a difference in the deformation amount of the wire 61C and the wire 61A. Here, the difference in the deformation amount is compensated by the difference in the thickness, so that it is less likely to produce a difference in the contact between each wire and the holding portion 51 compared to the conventional example, and as a result, each wire is less likely to fall off from the holding portion 51, and winding disorder can be suppressed. In addition, since each wire is not easily dislodged from the holding portion 51, it is not necessary to increase the holding force of the holding portion 51, and the generation of an indentation in the conductor 61A accompanying the increase in the holding force of the holding portion 51 can be suppressed, and as a result, the conductor 61A is not easily disconnected. In addition, the generation of an indentation or crack in the insulating film covering the periphery of each conductor accompanying the increase in the holding force of the holding portion 51 is suppressed, and as a result, the reduction in insulation resistance can be suppressed.

[0108] In order to further prevent winding disorder, the stator 30 of the first embodiment also has an effect when the holding force of the holding portion 51 is increased. When the holding force of the holding portion 51 is increased, the area of ​​the holding portion 51 in contact with the holding portion 51 becomes larger at the surface of the insulating film 62A than at the surface of the insulating film 62C, so that the insulating film 62A is affected by the holding force of the holding portion 51 in a wider range than the insulating film 62C. Therefore, since the holding portion 51 contacts the holding portion 51 at the surface of the insulating film and is affected by the holding force of the holding portion 51, deformation and scratches are generated on the surface, which becomes an important factor causing indentation and cracking, and as a result, there is a possibility that the insulation resistance of the insulating film 62A is reduced.

[0109] Here, since the insulating film 62A is thickened by the difference in thickness, compared with the conventional example, even when deformation, scratches, etc. occur on the surface of the insulating film 62A, causing indentations or cracks, the insulating resistance of the insulating film 62A is maintained. In this way, the conductive wire 61A of the coil 35 is not easily disconnected, and the insulating resistance of the insulating film 62A is maintained, so that the occurrence of short circuits and burnouts in the coil 35 can be suppressed.

[0110] The stator 30 of the first embodiment includes: a cylindrical stator core 34; a first covered wire having a first conductive wire having different hardnesses and a first conductive wire harder than the second conductive wire among the second conductive wires, and an insulating film covering the first conductive wire; and a second covered wire having a second conductive wire and an insulating film covering the second conductive wire having a thickness thicker than the insulating film covering the first conductive wire, wherein the first covered wire and the second covered wire are mixedly wound around a plurality of teeth 36 arranged along the circumferential direction of the stator core 34, thereby being able to suppress the occurrence of short circuits and burnouts in the coils 35.

[0111] The electric motor 12 of the first embodiment includes a stator 30 and a rotor 31, and the stator 30 includes: a cylindrical stator core 34; a first covered wire having a first conductor having different hardnesses and a first conductor among the second conductors which is harder than the second conductor, and an insulating film covering the first conductor; and a second covered wire having a second conductor and an insulating film covering the second conductor which is thicker than the insulating film covering the first conductor, wherein the first covered wire and the second covered wire are mixedly wound on a plurality of teeth 36 arranged along the circumferential direction of the stator core 34, and the rotor 31 rotates using the magnetic field generated by the stator 30, thereby being able to suppress the occurrence of short circuits and burnouts in the coils 35.

[0112] The compressor 2 of the first embodiment includes an electric motor 12, a sealed container 11, and a compression element 15. The electric motor 12 includes a stator 30 and a rotor 31. The stator 30 includes: a cylindrical stator core 34; a first coated wire having a first conductive wire having different hardnesses and a first conductive wire harder than the second conductive wire among the second conductive wires, and an insulating film covering the periphery of the first conductive wire; and a second coated wire having a second conductive wire and an insulating film covering the periphery of the second conductive wire with a thickness thicker than the insulating film covering the periphery of the first conductive wire. The first coated wire and the second coated wire are mixedly wound on a plurality of teeth 36 arranged along the circumferential direction of the stator core 34. The rotor 31 rotates using a magnetic field generated by the stator 30. The sealed container 11 includes a suction pipe 16 for sucking in a fluid and a discharge pipe 17 for discharging the fluid. The compression element 15 is driven by the electric motor 12 to compress the fluid sucked in through the suction pipe 16 and discharge the compressed fluid through the discharge pipe 17. Therefore, the occurrence of short circuit and burning in the coil 35 can be suppressed.

[0113] The refrigeration cycle device 1 of the first embodiment includes a compressor 2, a condenser 3 for liquefying a fluid, a decompression device 4 for reducing the pressure of the compressed fluid, and an evaporator 5 for gasifying the fluid. The compressor 2 includes a motor 12, a closed container 11, and a compression element 15. The motor 12 includes a stator 30 and a rotor 31. The stator 30 includes: a cylindrical stator core 34; a first coated wire having a first conductor with different hardness and a first conductor harder than the second conductor among the second conductors, and an insulating film covering the periphery of the first conductor; and a second coated wire having a second conductor and a thick The insulating film covering the second conductive wire is thicker than the insulating film covering the first conductive wire, the first coated wire and the second coated wire are mixed and wound on a plurality of teeth 36 arranged along the circumferential direction of the stator core 34, the rotor 31 rotates using the magnetic field generated by the stator 30, the sealed container 11 has a suction pipe 16 for sucking in the fluid and a discharge pipe 17 for discharging the fluid, the compression element 15 is driven by the motor 12, compresses the fluid sucked in through the suction pipe 16, and discharges the compressed fluid through the discharge pipe 17, thereby being able to suppress the occurrence of short circuits and burning in the coil 35.

[0114] The manufacturing method of the stator 30 of the first embodiment includes the following steps: generating a first covered wire and a second covered wire, wherein the first covered wire has a first conductor having different hardnesses and a first conductor harder than the second conductor among the second conductors, and an insulating film covering the first conductor, and the second covered wire has a second conductor and an insulating film covering the second conductor with a thickness thicker than the insulating film covering the first conductor; and mixing and winding the first covered wire and the second covered wire on a plurality of teeth 36 arranged along the circumferential direction of a cylindrical stator core 34, thereby being able to suppress the occurrence of short circuits and burnouts in the coils 35.

[0115] Implementation method 2.

[0116] like Fig.11 As shown, the winding 80 includes two coated wires, and the coated wires include conductors of different hardness and an insulating film covering the conductors of different hardness. Among the conductors of different hardness, the diameter of the soft conductor is larger than that of the hard conductor, and the thickness of the insulating film covering the soft conductor is thicker than that of the hard conductor. In other words, the winding 80 in the second embodiment is different from the winding 60 in the first embodiment in that among the conductors of different hardness, the diameter of the soft conductor is larger than that of the hard conductor.

[0117] In the description of the winding wire 80 in the present embodiment, the copper wire is the wire 81C, the aluminum wire is the wire 81A, the insulating film covering the periphery of the wire 81C is the insulating film 82C, the insulating film covering the periphery of the wire 81A is the insulating film 82A, the coated wire having the wire 81C and the insulating film 82C is the coated wire 83C, and the coated wire having the wire 81A and the insulating film 82A is the coated wire 83A. In addition, the cross-sectional shapes of the coated wire and the wire are both circular, and the wire diameters of the coated wire and the wire are defined by the diameter of the circle.

[0118] The wire diameter 84C of the conductor 81C is, for example, 1.0 mm, and the wire diameter 84A of the conductor 81A is, for example, 1.05 mm. The thickness 85C of the insulating film 82C is, for example, 0.04 mm, and the thickness 85A of the insulating film 82A is, for example, 0.052 mm. In this case, the wire diameter 88C of the coated wire 83C is 1.08 mm, and the wire diameter 88A of the coated wire 83A is also 1.154 mm.

[0119] In addition to the effects of the first embodiment, the stator (not shown) of the second embodiment further prevents the conductive wire 81A from being easily disconnected even when the holding force of the holding portion 51 is increased, thereby preventing winding disorder.

[0120] In order to prevent winding disorder, when the holding force of the holding portion 51 is increased, the holding force of the holding portion 51 generates an indentation in the conductor 81A which is softer than the conductor 81C, and generates a stress greater than that in the cross section of the conductor 81A where the indentation is generated. Here, compared with the wire diameter 64A of the conductor 61A in the first embodiment, the wire diameter 84A of the conductor 81A in the present embodiment is larger, so the cross-sectional area of ​​the conductor 81A where the indentation is generated is larger. In other words, compared with the first embodiment, the stress generated in the cross section of the conductor 81A becomes smaller, and as a result, the conductor 81A is not easily broken. In this way, the conductor 81A of the coil of the present embodiment is not easily broken, and the insulation resistance of the insulating film 82A is guaranteed, so that the occurrence of short circuit and burning in the coil of the present embodiment can be suppressed.

[0121] Implementation method 3.

[0122] like Fig.12 As shown, the winding 90 has two coated wires, and the coated wires have conductors with different hardness and an insulating film covering the conductors with different hardness. The wire diameter of the soft conductor among the conductors with different hardness is smaller than the wire diameter of the hard conductor, the thickness of the insulating film covering the soft conductor is thicker than the thickness of the insulating film covering the hard conductor, and the wire diameters of the two coated wires are the same. In other words, the winding 90 in the third embodiment is different from the winding 60 in the first embodiment in that the wire diameters of the two coated wires are the same.

[0123] In the description of the winding wire 90 in the present embodiment, the copper wire is the wire 91C, the aluminum wire is the wire 91A, the insulating film covering the periphery of the wire 91C is the insulating film 92C, the insulating film covering the periphery of the wire 91A is the insulating film 92A, the covered wire having the wire 91C and the insulating film 92C is the covered wire 93C, and the covered wire having the wire 91A and the insulating film 92A is the covered wire 93A. In addition, the cross-sectional shapes of the covered wire and the wire are both circular, and the wire diameters of the covered wire and the wire are defined by the diameter of the circle.

[0124] The wire diameter 94C of the conductor 91C is, for example, 1.0 mm, and the wire diameter 94A of the conductor 91A is, for example, 0.976 mm. The thickness 95C of the insulating film 92C is, for example, 0.04 mm, and the thickness 95A of the insulating film 92A is, for example, 0.052 mm. In this case, the wire diameter 99C of the coated wire 93C is 1.08 mm, and the wire diameter 99A of the coated wire 93A is also 1.08 mm.

[0125] In the stator of the third embodiment, the thickness 95A of the insulating film 92A is thicker than the thickness 95C of the insulating film 92C, so there is a difference between the thickness 95A of the insulating film 92A and the thickness 95C of the insulating film 92C. In order to prevent winding disorder, when the holding force of the holding portion 51 is increased, the area of ​​the holding portion 51 in contact with the holding portion 51 becomes larger at the surface of the insulating film 92A than at the surface of the insulating film 92C, so that the insulating film 92A is affected by the holding force of the holding portion 51 in a wider range than the insulating film 92C. Therefore, at the surface of the insulating film, the holding portion 51 of the holding portion 51 contacts the holding portion 51 and is affected by the holding force of the holding portion 51, so that deformation, scratches, etc. are generated on the surface, which becomes an important factor for causing indentations and cracks, and as a result, there is a possibility that the insulation resistance of the insulating film is reduced.

[0126] Here, the insulating film 92A is thickened by the difference in thickness, so compared with the conventional example, even when deformation, scratches, etc. occur on the surface of the insulating film 92A, causing indentations or cracks, the insulating resistance of the insulating film 92A is ensured. In this way, the coil of the present embodiment ensures the insulating resistance of the insulating film 92A, so that the occurrence of short circuits and burnout in the coil of the present embodiment can be suppressed.

[0127] In addition, in the above-mentioned embodiments described in this specification, there are cases where the material, material, size, shape, relative configuration relationship or implementation conditions of each component are recorded, but these are illustrative in all aspects and are not limited to the contents recorded in each embodiment. Therefore, countless unillustrated variations are envisioned within the scope of each embodiment. For example, there are cases where any component is deformed, added or omitted, or even at least one component in at least one embodiment is extracted and combined with components of other embodiments.

[0128] Description of Reference Numerals

[0129] 1…refrigeration cycle device, 2…compressor, 12…motor, 30…stator, 35…coil, 60…winding.

Claims

1. A stator, characterized in that: have: A cylindrical stator core; A first covered wire having: a first conductive wire and a second conductive wire having different hardnesses, the first conductive wire being harder than the second conductive wire, and an insulating film covering the periphery of the first conductive wire; as well as a second covered wire having: the second conductive wire and an insulating film covering the second conductive wire which is thicker than the insulating film covering the first conductive wire; The first covered wire and the second covered wire are mixedly wound around a plurality of teeth provided along the circumferential direction of the stator core.

2. The stator according to claim 1, characterized in that: The cross-sectional area of ​​the second conductive line is larger than the cross-sectional area of ​​the first conductive line.

3. The stator according to claim 1, characterized in that: The cross-sectional areas of the first coated wire and the second coated wire are equal.

4. The stator according to any one of claims 1 to 3, characterized in that: The first conductive wire is made of copper, the second conductive wire is made of aluminum, and the insulating film covering the first conductive wire and the insulating film covering the second conductive wire are made of any one of polyamideimide, polyesterimide, polyester, polyurethane, and methylal.

5. The stator according to any one of claims 1 to 4, characterized in that: The cross-sectional shape of the first covered wire and the second covered wire is either a circle or a quadrilateral.

6. An electric motor, characterized in that: have: The stator according to any one of claims 1 to 5; and A rotor is rotated using a magnetic field generated by the stator.

7. A compressor, characterized in that: have: The electric motor according to claim 6; A closed container having: a suction pipe for sucking in a fluid, and a discharge pipe for discharging the fluid; and The compression element is driven by the motor to compress the fluid sucked through the suction pipe and discharge the compressed fluid through the discharge pipe.

8. A refrigeration cycle device, characterized in that: have: The compressor according to claim 7; a condenser, which liquefies the fluid; a pressure reducing device that reduces the pressure of the compressed fluid; and An evaporator, which vaporizes the fluid.

9. A method for manufacturing a stator, characterized in that: The following steps are required: The step of generating a first covered wire and a second covered wire, wherein the first covered wire comprises: a first conductive wire having different hardnesses and a first conductive wire which is harder than the second conductive wire, and an insulating film covering the first conductive wire, and the second covered wire comprises: the second conductive wire and an insulating film which is thicker than the insulating film covering the first conductive wire and covers the second conductive wire; as well as The step of winding the first covered wire and the second covered wire mixedly around a plurality of teeth provided along the circumferential direction of a cylindrical stator core.

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