Stator and insulator for rotating electrical machine

Abstract

The invention provides a high-quality rotating electric machine which is easy in winding operation of a winding wire. The coil is formed by winding the winding wire in multiple layers in a concentrated winding manner with respect to the teeth and the insulator extension. The insulator extension portion has an outer end surface located on the opposite side of the stator core. A first turn of a winding wire forming a first layer of the coil has a winding start portion extending along the first tooth side surface through the first innermost portion, and a portion wound around an outer end surface of the insulator extension portion. The outer end surface is provided with a protrusion that protrudes from a portion of the outer end surface that is closer to the insulator base than the first turn and that is closer to the winding start portion. A winding wire forming a specific layer of the coil is disposed on the protrusion after passing through the second innermost portion and extending along the second tooth side surface.

Description

Technical Field

[0001] The present invention relates to a stator and an insulator of a rotating electric machine. Background Art

[0002] For example, as disclosed in Japanese Patent Publication No. 2006-115565, the stator of a rotating electric machine includes a stator core, a coil, and an insulator. The stator core has a cylindrical yoke and a plurality of teeth. The plurality of teeth extend radially inward from the inner circumference of the yoke. In the stator core, grooves are defined between teeth adjacent to each other in the circumferential direction. The coil is formed by winding a winding passing through the groove on the stator core. The insulator is arranged opposite to the core end face of the stator core, which is the axial end face of the yoke. Furthermore, the insulator insulates the coil from the core end face.

[0003] The tooth has a first tooth side surface located on a first side in the circumferential direction and a second tooth side surface located on a second side in the circumferential direction. In addition, the insulator has a cylindrical insulator base and a plurality of insulator extensions. The insulator base is axially opposed to the yoke. The plurality of insulator extensions extend radially inward from the inner circumference of the insulator base and are axially opposed to the teeth, respectively. Furthermore, the coil is formed by winding the wire in multiple layers in a concentrated winding manner while reciprocating in the radial direction of the yoke relative to the teeth and the insulator extensions. The winding extends spirally in each layer of the coil. Summary of the invention

[0004] Problems to be solved by the invention

[0005] In addition, there is a case where the first layer of the coil is formed by winding the wire from the radially outer side to the inner side of the yoke. Here, the portion of the groove close to the inner peripheral surface of the yoke that is close to the first tooth side surface is called the first innermost portion, and the portion of the groove close to the inner peripheral surface of the yoke that is close to the second tooth side surface is called the second innermost portion. The first turn of the winding forming the first layer has a winding start portion and a portion extending along the second tooth side surface. The winding start portion, for example, passes through the first innermost portion and extends along the first tooth side surface. At this time, it is desired that the portion extending along the second tooth side surface passes through the second innermost portion.

[0006] The coil is formed by winding the wire in multiple layers in a concentrated winding manner with respect to the teeth and the insulator extension using a winding nozzle, for example. Here, the winding operation using the winding nozzle is performed while fixing the wire in such a manner that the winding start portion is not loose at the first innermost portion. Therefore, the winding start portion passes through the first innermost portion and extends along the first tooth side surface.

[0007] On the other hand, when the portion extending along the second tooth side surface is wound around the second tooth side surface, the winding nozzle may not reach the second innermost portion due to the trajectory of the winding nozzle. In such a case, the portion extending along the second tooth side surface passes through a position that is more separated from the inner peripheral surface of the yoke than the second innermost portion.

[0008] Therefore, an ineffective space is generated in the second innermost part of the groove, so the space factor of the winding in the groove is reduced. The reduction in the space factor of the winding becomes a cause of the reduction in the quality of the rotating electric machine. Therefore, it is desired to provide a rotating electric machine with easy winding operation and high quality.

[0009] Solutions to Solve Problems

[0010] According to one aspect of the present invention, a stator of a rotating electric machine is provided. The stator includes: a stator core having a cylindrical yoke and a plurality of teeth extending from the inner circumference of the yoke to the inner side of the yoke in the radial direction, and grooves are defined between the teeth adjacent to each other in the circumferential direction of the yoke; a coil formed by winding a winding wire passing through the grooves and wound around the stator core; and an insulator arranged to face the core end face of the stator core as the axial end face of the yoke and configured to insulate the coil from the core end face. The tooth has a first tooth side face located on a first side in the circumferential direction and a second tooth side face located on a second side in the circumferential direction. The insulator has: a cylindrical insulator base portion facing the yoke in the axial direction; and a plurality of insulator extension portions extending from the inner circumferential surface of the insulator base portion to the inner side in the radial direction and facing each of the teeth in the axial direction. The insulator extension portion has an outer end face located on the side opposite to the stator core. The coil is formed by winding the wire in multiple layers in a concentrated winding manner relative to the teeth and the insulator extension. The first layer of the coil is formed by winding the wire from the radially outer side to the radially inner side. The coil has a specific layer, which is a layer after the second layer of the coil and is formed by winding the wire from the radially inner side to the outer side. The portion of the groove close to the inner circumference of the yoke that is close to the first tooth side surface is the first innermost portion, and the portion of the groove close to the inner circumference of the yoke that is close to the second tooth side surface is the second innermost portion. The first turn of the winding forming the first layer has a winding start portion extending along the first tooth side surface through the first innermost portion, a portion extending along the second tooth side surface through a position in the groove that is farther from the inner circumference of the yoke than the second innermost portion, and a portion wound around the outer end surface of the insulator extension. A protrusion is provided on the outer end surface, protruding from a portion of the outer end surface that is closer to the insulator base than the first turn and closer to the winding starting portion, and the winding forming the specific layer is arranged on the protrusion after passing through the second innermost portion and extending along the second tooth side surface.

[0011] According to another aspect of the present invention, an insulator is provided, which constitutes a part of a stator of a rotating electric machine. The stator includes: a stator core having a cylindrical yoke and a plurality of teeth extending from the inner circumference of the yoke to the inner side of the yoke in the radial direction, and grooves are defined between teeth adjacent to each other in the circumferential direction of the yoke; and a coil formed by winding a wire passing through the grooves and wound around the stator core. The insulator is arranged to face an end face of the stator core, which is an end face located in the axial direction of the yoke, and is configured to insulate the coil from the end face of the core. The insulator includes: a cylindrical insulator base, which faces the yoke in the axial direction; and a plurality of insulator extensions, which extend from the inner circumference of the insulator base to the inner side of the radial direction and face the teeth in the axial direction. The insulator extension has an outer end face located on the side opposite to the stator core. A protrusion located at the outer end of the outer end face in the radial direction and on the first side in the circumferential direction is provided on the outer end face. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 It is a cross-sectional view for explaining the rotating electrical machine in the embodiment.

[0013] Figure 2 It is shown Figure 1 An exploded perspective view of a stator core and a pair of insulators included in a rotating electrical machine.

[0014] Figure 3 It is used to describe the settings Figure 2 A three-dimensional view of the protrusion of the insulator.

[0015] Figure 4 It is used to illustrate Figure 3 A cross-sectional view of a protrusion.

[0016] Figure 5 It is used to illustrate Figure 2 FIG. 1 is a diagram showing the operation of winding wire around a stator core and a pair of insulators.

[0017] Figure 6 It is used to illustrate Figure 2 FIG. 1 is a diagram showing the operation of winding wire around a stator core and a pair of insulators.

[0018] Figure 7 It is used to illustrate Figure 2 FIG. 1 is a diagram showing the operation of winding wire around a stator core and a pair of insulators.

[0019] Figure 8 It is used to illustrate Figure 2 FIG. 1 is a diagram showing the operation of winding wire around a stator core and a pair of insulators.

[0020] Fig. 9It is used to illustrate Figure 2 FIG. 1 is a diagram showing the operation of winding wire around a stator core and a pair of insulators.

[0021] Fig.10 It is used to illustrate Figure 2 FIG. 1 is a diagram showing the operation of winding wire around a stator core and a pair of insulators. DETAILED DESCRIPTION

[0022] Below, according to Figures 1 to 10 An embodiment in which a stator and an insulator of a rotating electrical machine are embodied will be described.

[0023] <General structure of rotating electrical machines>

[0024] like Figure 1 As shown, the rotary electric machine 10 includes a rotor 21 and a stator 22. The stator 22 is cylindrical. The rotor 21 is arranged inside the stator 22. The rotor 21 has a cylindrical rotor core 21a and a plurality of permanent magnets (not shown) embedded in the rotor core 21a. The rotor core 21a is fixed to the rotating shaft 15. The rotor core 21a is configured to be rotatable integrally with the rotating shaft 15.

[0025] <Stator core>

[0026] The stator 22 includes a stator core 23. The stator core 23 includes a yoke 24 and a plurality of teeth 25. The yoke 24 is cylindrical. It should be noted that the axial direction of the yoke 24 is also the axial direction of the stator core 23. The circumferential direction of the yoke 24 is also the circumferential direction of the stator core 23. The radial direction of the yoke 24 is also the radial direction of the stator core 23. Hereinafter, the axial direction of the yoke 24 is sometimes referred to as the axial direction, the radial direction of the yoke 24 is sometimes referred to as the radial direction, and the circumferential direction of the yoke 24 is sometimes referred to as the circumferential direction.

[0027] A plurality of teeth 25 extend radially inward from the inner circumferential surface 24a of the yoke 24. The plurality of teeth 25 are arranged at intervals in the circumferential direction. The plurality of teeth 25 are arranged at equal intervals in the circumferential direction. Each tooth 25 extends from the inner circumferential surface 24a of the yoke 24 toward the axis of the stator core 23. In the present embodiment, the stator core 23 has 15 teeth 25. It should be noted that the number of teeth 25 is not particularly limited, but the number of teeth 25 is a multiple of 3.

[0028] like Figure 2 As shown in the figure, the end faces on both sides of the yoke 24 in the axial direction have a flat shape. The end faces on both sides of the yoke 24 in the axial direction have a flat shape. The length of the yoke 24 in the axial direction is the same as the length of each tooth 25 in the axial direction. The first end face on the first side of the yoke 24 in the axial direction and the first end face on the first side of the yoke 24 in the axial direction are located on the same plane. The second end face on the second side of the yoke 24 in the axial direction and the second end face on the second side of the yoke 24 in the axial direction are located on the same plane.

[0029] The first end surface of the yoke 24 and the first end surface of each tooth 25 form a first core end surface 23a, which is an end surface located on the first side in the axial direction of the stator core 23. The second end surface of the yoke 24 and the second end surface of each tooth 25 form a second core end surface 23b, which is an end surface located on the second side in the axial direction of the stator core 23. Therefore, the stator core 23 has a first core end surface 23a and a second core end surface 23b.

[0030] like Figure 1 as well as Figure 2 As shown, each tooth 25 has a tooth extension portion 26 and a tooth flange portion 27. The tooth extension portion 26 is a thin plate extending from the inner peripheral surface 24a of the yoke 24. The tooth extension portion 26 extends axially from the first core end surface 23a of the stator core 23 to the second core end surface 23b. Each tooth extension portion 26 has a first tooth side surface 261 and a second tooth side surface 262. The first tooth side surface 261 is a side surface of the tooth extension portion 26 located on the first side in the circumferential direction. The second tooth side surface 262 is a side surface of the tooth extension portion 26 located on the second side in the circumferential direction. Therefore, the tooth 25 has a first tooth side surface 261 located on the first side in the circumferential direction and a second tooth side surface 262 located on the second side in the circumferential direction. The first tooth side surface 261 and the second tooth side surface 262 are continuous with the inner peripheral surface 24a of the yoke 24. The tooth flange portion 27 protrudes in the circumferential direction from the radially inner end of each of the first tooth side surface 261 and the second tooth side surface 262. Therefore, the tooth flange portion 27 protrudes from the radially inner end portion of the tooth extending portion 26 to both sides in the circumferential direction.

[0031] The stator core 23 is defined with a groove 30. The groove 30 is defined between teeth 25 adjacent in the circumferential direction. The groove 30 is a space defined by the inner circumferential surface 24a of the yoke 24, the first tooth side surface 261 and the second tooth side surface 262 opposite in the circumferential direction, and the radially outer surface of the tooth flange portion 27. Sometimes, the portion of the groove 30 close to the inner circumferential surface 24a of the yoke 24 that is close to the first tooth side surface 261 is called the first innermost portion 30a, and the portion of the groove 30 close to the inner circumferential surface 24a of the yoke 24 that is close to the second tooth side surface 262 is called the second innermost portion 30b. In addition, the stator core 23 has a groove opening 31. The groove opening 31 is a gap between tooth flange portions 27 adjacent in the circumferential direction. The groove opening 31 is connected to the groove 30.

[0032] <Insulator>

[0033] like Figure 2 As shown, the stator 22 includes a pair of insulators 50. Therefore, the insulators 50 constitute a part of the stator 22. Each insulator 50 is cylindrical. Each insulator 50 is made of, for example, a resin material.

[0034] Each insulator 50 has an insulator base 51 and a plurality of insulator teeth 52. The insulator base 51 is cylindrical. Each insulator 50 is arranged relative to the stator core 23 in a state where the axis of the insulator base 51 is aligned with the axis of the yoke 24. Each insulator base 51 is axially opposed to the yoke 24. The axial direction of each insulator base 51 is also the axial direction of the yoke 24. The circumferential direction of each insulator base 51 is also the circumferential direction of the yoke 24. The radial direction of each insulator base 51 is also the radial direction of the yoke 24.

[0035] Sometimes one of the pair of insulators 50 is referred to as the first insulator 50A, and the other of the pair of insulators 50 is referred to as the second insulator 50B. The first insulator 50A is arranged opposite to the first core end face 23a of the stator core 23 in a state of contacting the first core end face 23a. The second insulator 50B is arranged opposite to the second core end face 23b of the stator core 23 in a state of contacting the second core end face 23b of the stator core 23. Therefore, the insulator 50 is arranged opposite to the core end face that is the axial end face of the stator core 23. The outer diameter of the insulator base 51 is smaller than the outer diameter of the yoke 24. The inner diameter of the insulator base 51 is the same as the inner diameter of the yoke 24.

[0036] Each insulator tooth 52 extends radially inward from the inner circumferential surface 51a of the insulator base 51. A plurality of insulator teeth 52 are arranged at intervals in the circumferential direction. A plurality of insulator teeth 52 are arranged at equal intervals in the circumferential direction. Each insulator tooth 52 extends from the inner circumferential surface 51a of the insulator base 51 toward the axis of the insulator base 51. In the present embodiment, each insulator 50 has 15 insulator teeth 52. The number of insulator teeth 52 is the same as the number of teeth 25 of the stator core 23.

[0037] Each insulator tooth portion 52 has an insulator extension portion 53. Therefore, each insulator 50 has a plurality of insulator extension portions 53. Each insulator extension portion 53 is a columnar shape extending radially inward from the inner circumferential surface 51a of the insulator base portion 51. The circumferential width of each insulator extension portion 53 is the same as the circumferential width of each tooth extension portion 26. Each insulator extension portion 53 contacts the corresponding tooth 25. Each insulator extension portion 53 is arranged at a position overlapping with the corresponding tooth extension portion 26 in the axial direction. Therefore, each insulator extension portion 53 is opposite to the corresponding tooth 25 in the axial direction.

[0038] The insulator extension portion 53 has a first insulator side surface 531 and a second insulator side surface 532. The first insulator side surface 531 is a side surface of the insulator extension portion 53 located on a first side in the circumferential direction. The first insulator side surface 531 is continuous with the first tooth side surface 261. The second insulator side surface 532 is a side surface of the insulator extension portion 53 located on a second side in the circumferential direction. The second insulator side surface 532 is continuous with the second tooth side surface 262.

[0039] Each insulator tooth portion 52 has an insulator inner wall 54. Therefore, each insulator 50 has a plurality of insulator inner walls 54. The insulator inner wall 54 protrudes from the radially inner end of the insulator extension portion 53 along the insulator base 51. The insulator inner wall 54 protrudes from the insulator extension portion 53 to both sides in the circumferential direction and to the side opposite to the stator core 23 in the axial direction. In this way, the insulator inner wall 54 protrudes from the insulator extension portion 53. Each insulator inner wall 54 is arranged at a position overlapping with the tooth flange portion 27 in the axial direction. Therefore, each insulator inner wall 54 is opposed to the corresponding tooth flange portion 27 in the axial direction.

[0040] The radially inner surface 52a of each insulator tooth portion 52 is located on the same plane as the radially inner surface 25a of the corresponding tooth 25. The radially inner surface of each insulator inner wall 54 forms the radially inner surface 52a of the corresponding insulator tooth portion 52. The radially inner surface of each tooth flange portion 27 forms the radially inner surface 25a of the corresponding tooth 25. The thickness of the insulator inner wall 54 is thicker than the thickness of the tooth flange portion 27.

[0041] The insulator extension 53 has an outer end surface 55 located on the side opposite to the stator core 23. The outer end surface 55 has a flat shape. The outer end surface 55 is continuous with the inner circumferential surface 51a of the insulator base 51. The outer end surface 55 is continuous with the surface located on the outer side in the radial direction of the insulator inner wall 54. The outer end surface 55 connects the inner circumferential surface 51a of the insulator base 51 and the surface located on the outer side in the radial direction of the insulator inner wall 54.

[0042] <Coil>

[0043] like Figure 1 As shown, the stator 22 has a plurality of coils 28. The stator 22 has coils 28 of U phase, V phase and W phase. Therefore, the stator 22 has multi-phase coils 28. A portion of the coil 28 extends through the groove 30. In addition, another portion of the coil 28 protrudes from the first core end face 23a and the second core end face 23b. The first insulator 50A insulates the coil 28 from the first core end face 23a. The second insulator 50B insulates the coil 28 from the second core end face 23b. It should be noted that a portion of the coil 28 passing through the groove 30 is insulated from the stator core 23 by the groove insulation paper 36.

[0044] <Protrusion>

[0045] like Figure 3 as well as Figure 4As shown in the figure, a protrusion 56 is provided on the outer end surface 55 of each insulator extension portion 53 of the first insulator 50A. The protrusion 56 is provided at the end portion located on the outer side in the radial direction of the outer end surface 55. The protrusion 56 has a top 57, an inclined surface 58, and a protrusion side surface 59. The top 57 has a flat shape. The top 57 extends parallel to the outer end surface 55.

[0046] like Figure 4 As shown in FIG. 1 , the height from the outer end surface 55 to the top 57 of the protrusion 56, that is, the protrusion height H1, is the same as the outer diameter D1 of the winding wire 29 forming the coil 28. Figure 3 as well as Figure 4 As shown, the top 57 of the protrusion 56 is located at the radially outer end of the outer end surface 55 and close to the first insulator side surface 531. Therefore, the outer end surface 55 is provided with a protrusion 56 located at the radially outer end of the outer end surface 55 and on the first side in the circumferential direction.

[0047] The inclined surface 58 has a flat shape. The inclined surface 58 extends obliquely with respect to the outer end surface 55. The inclined surface 58 is continuous with the topmost point 57 of the protrusion 56. The end portion of the inclined surface 58 located on the side opposite to the topmost point 57 is continuous with the outer end surface 55. The protruding height of the inclined surface 58 with respect to the outer end surface 55 gradually increases from the portion of the outer end surface 55 close to the second insulator side surface 532 toward the topmost point 57. Therefore, the inclined surface 58 is continuous with the topmost point 57 of the protrusion 56, and the protruding height with respect to the outer end surface 55 gradually increases from the second side in the circumferential direction of the outer end surface 55 toward the topmost point 57.

[0048] The protrusion side surface 59 is a side surface of the protrusion 56 located on the opposite side to the insulator base 51. That is, the protrusion side surface 59 is a side surface of the protrusion 56 located on the inner side in the radial direction. The protrusion side surface 59 has a flat shape. The protrusion side surface 59 stands from the outer end surface 55. The protrusion side surface 59 is orthogonal to the outer end surface 55 and extends in a direction orthogonal to the radial direction.

[0049] The protrusion 56 has a protruding end face 60 located at the front end of the protruding direction from the outer end face 55. The protruding end face 60 is composed of the topmost part 57 and the inclined surface 58. The radially inner edge of the topmost part 57 and the radially inner edge of the inclined surface 58 are continuous with each other. The radially inner edge of the topmost part 57 and the radially inner edge of the inclined surface 58 constitute the radially inner edge 61 of the protruding end face 60. The radially inner edge of the topmost part 57 is chamfered into an arc shape. The radially inner edge of the inclined surface 58 is chamfered into an arc shape. Therefore, the radially inner edge 61 of the protruding end face 60, that is, the edge 61 on the side opposite to the insulator base 51, is chamfered into an arc shape.

[0050] <Winding>

[0051] Next, the structure of the coil 28 will be described in conjunction with the description of the winding operation of the winding wire 29 .

[0052] like Figure 5 As shown in the figure, the coil 28 is formed by winding the winding wire 29 passing through the groove 30 on the stator core 23. The coil 28 is formed by winding the winding wire 29 in multiple layers in a concentrated winding manner while reciprocating in the radial direction of the yoke 24 with respect to the teeth 25 and the insulator extension 53. The coil 28 is formed by winding the winding wire 29 in four layers, for example. The winding wire 29 extends in a spiral shape in each layer of the coil 28. The winding operation of the winding wire 29 is performed, for example, using a winding nozzle not shown in the figure.

[0053] like Figure 5 , Figure 6 , Figure 7 , Figure 8 , Fig. 9 as well as Fig.10 As shown, the first layer of the coil 28 is formed by winding the wire 29 from the radially outer side toward the inner side of the yoke 24. The second layer of the coil 28 is formed by winding the wire 29 from the radially inner side toward the outer side of the yoke 24. The third layer of the coil 28 is formed by winding the wire 29 from the radially outer side toward the inner side of the yoke 24. The fourth layer of the coil 28 is formed by winding the wire 29 from the radially inner side toward the outer side of the yoke 24. In this way, the second layer and the fourth layer of the coil 28 are specific layers 62 formed by winding the wire 29 from the radially inner side toward the outer side of the yoke 24. Therefore, the coil 28 has a specific layer 62, which is formed after the second layer of the coil 28 and by winding from the radially inner side toward the outer side of the yoke 24. It should be noted that in Figure 5 , Figure 6 , Figure 7 , Figure 8 , Fig. 9 as well as Fig.10 In FIG. 1 , the third layer and the fourth layer of the coil 28 are omitted from illustration.

[0054] like Figure 5 As shown in the figure, the winding 29 has a lead portion 63. The lead portion 63 passes through the end surface of the insulator base 51 of the first insulator 50A and is led out to the radially outer side. The winding 29 also has a winding start portion 29s that forms the first layer of the coil 28. The winding start portion 29s is continuous with the lead portion 63. The winding start portion 29s is inserted into the groove 30 through the first insulator 50A. And the winding start portion 29s passes through the first innermost portion 30a in the groove 30 and extends along the first tooth side surface 261. The winding operation of the winding 29 using the winding nozzle is performed while fixing the winding 29 in a manner that the winding start portion 29s is not loose at the first innermost portion 30a.

[0055] like Figure 6 as well as Figure 7 As shown, the first turn of the winding 29 forming the first layer of the coil 28, in addition to the above-mentioned winding starting portion 29s, also includes a first portion wound around the outer end surface 55 of the insulator extension portion 53 of the second insulator 50B, a second portion extending along the second tooth side surface 262, and a third portion wound around the outer end surface 55 of the insulator extension portion 53 of the first insulator 50A.

[0056] exist Figure 6 In FIG. 1 , a first portion of a first turn of the winding 29 is shown by a dotted line. Figure 6 As shown in the figure, the first part of the first turn of the winding 29 extends in a manner approaching the radial inner side as it moves from the first insulator side surface 531 to the second insulator side surface 532. In addition, the second part of the first turn of the winding 29 is arranged at a position separated from the inner peripheral surface 24a of the yoke 24 than the second innermost portion 30b in the groove 30.

[0057] When the second part of the first turn of the winding 29 is wound around the second tooth side surface 262, the winding nozzle cannot reach the second innermost portion 30b due to the trajectory of the winding nozzle. Therefore, the second part of the first turn of the winding 29 is arranged at a position separated from the inner peripheral surface 24a of the yoke 24 than the second innermost portion 30b.

[0058] like Figure 7 As shown in FIG. 1 , the third portion of the first turn of the winding 29 corresponds to the immediately preceding portion of the second turn of the winding 29. The third portion of the first turn of the winding 29 extends in a direction orthogonal to the radial direction. The third portion of the first turn of the winding 29 extends along the protrusion side surface 59 of the protrusion 56. Furthermore, the starting portion of the second turn of the winding 29 forming the first layer of the coil 28 extends along the first tooth side surface 261 while being arranged radially inward relative to the winding starting portion 29s.

[0059] like Figure 8 As shown, the winding wire 29 is also wound spirally from the outside to the inside in the radial direction of the yoke 24 in the second and subsequent turns, similarly to the first turn. Thus, the first layer of the coil 28 is formed.

[0060] like Fig. 9 As shown, the second layer of coil 28 is wound around the outer periphery of the first layer of coil 28. The second layer of coil 28 is formed by spirally winding the winding wire 29 from the inside to the outside in the radial direction of the yoke 24 with respect to the first layer.

[0061] like Fig.10As shown in the figure, the winding 29 forming the second layer is wound from the radial inner side to the outer side of the yoke 24. When the winding 29 of the second layer is wound around the second tooth side 262, the winding 29 of the first layer that has been wound around the second tooth side 262 is wound around the second tooth side 262. Fig.10 A portion of the winding 29 of the second layer indicated by the double-dotted line is guided toward the second innermost portion 30b as indicated by the arrow A1. Thus, the winding 29 forming the second layer is arranged at the second innermost portion 30b. And, after the winding 29 forming the second layer passes through the second innermost portion 30b and extends along the second tooth side surface 262, it is arranged on the protrusion 56. Thus, the winding 29 forming the second layer is guided by the protrusion 56 to be farther away from the first tooth side surface 261 than the winding 29 forming the first layer. The winding 29 arranged on the protrusion 56 extends along the inclined surface 58. Therefore, the winding 29 arranged on the protrusion 56 gradually moves away from the outer end surface 55 as it moves from the portion of the outer end surface 55 on the side opposite to the winding start portion 29s toward the top 57.

[0062] In this way, the first turn of the winding wire 29 is wound around the outer end surface 55 of the insulator extension portion 53 of the first insulator 50A. The outer end surface 55 of the insulator extension portion 53 of the first insulator 50A is provided with a protrusion 56 protruding from a portion of the outer end surface 55 closer to the insulator base 51 than the first turn of the winding wire 29 and closer to the winding start portion 29s. In other words, the outer end surface 55 of the insulator extension portion 53 of the first insulator 50A is provided with a protrusion 56 protruding from a portion of the outer end surface 55 closer to the insulator base 51 than the first turn of the winding wire 29 and closer to the winding start portion 29s. And the winding wire 29 forming the second layer passes through the second innermost portion 30b and extends along the second tooth side surface 262, and is arranged on the protrusion 56. Therefore, the winding wire 29 forming the specific layer 62 passes through the second innermost portion 30b and extends along the second tooth side surface 262, and is arranged on the protrusion 56. In the present embodiment, the windings 29 forming the specific layer 62 and extending along the second tooth side surface 262 through the second innermost portion 30 b are the windings 29 forming the second layer.

[0063] The protrusion 56 guides the winding wire 29 that has passed through the second innermost portion 30b and extended along the second tooth side surface 262 so that the winding wire 29 passes through the second innermost portion 30b and extends along the second tooth side surface 262 and then is wound around the winding wire 29 that forms the first layer. Thereafter, in the third and fourth layers, the winding wire 29 is wound in a concentrated winding manner while reciprocating in the radial direction of the yoke 24 with respect to the teeth 25 and the insulator extension portion 53, similarly to the first and second layers, to form the coil 28. In this way, the winding wire 29 is wound in a concentrated winding manner in multiple layers while reciprocating in the radial direction of the yoke 24 with respect to the teeth 25 and the insulator extension portion 53, to form the coil 28. The winding operation of the winding wire 29 is performed as described above to form the coil 28.

[0064] [Effects of implementation methods]

[0065] Next, the operation of this embodiment will be described.

[0066] The third portion of the first turn of the winding 29 wound around the outer end surface 55 contacts the protrusion 56, thereby preventing the winding 29 forming the first layer from shifting to the radially outer side of the yoke 24. Therefore, the winding 29 forming the first layer is stabilized, so that the neat arrangement of the winding 29 becomes good. After the winding 29 forming the second layer passes through the second innermost portion 30b and extends along the second tooth side surface 262, it is arranged on the protrusion 56 and guided by the protrusion 56 to be farther away from the first tooth side surface 261 than the winding 29 forming the first layer. Therefore, even if the winding 29 forming the second layer passes through the second innermost portion 30b and extends along the second tooth side surface 262, the subsequent winding operation of the winding 29 is smoothly performed.

[0067] [Effects of implementation methods]

[0068] The following effects can be obtained in the above-mentioned embodiment.

[0069] (1) The winding 29 forming the second layer is wound from the radially inner side to the outer side. When the winding 29 of the second layer is wound around the second tooth side surface 262, the winding 29 that has been wound around the second tooth side surface 262 guides a part of the winding 29 of the second layer to the second innermost part 30b. Thus, the winding 29 forming the second layer is arranged at the second innermost part 30b. Therefore, the winding 29 passes through the second innermost part 30b and extends along the second tooth side surface 262, so that no dead space is generated in the second innermost part 30b in the groove 30. Therefore, the space factor of the winding 29 in the groove 30 can be improved. In addition, for example, it is not necessary to forcibly push the second part of the first turn of the winding 29 extending along the second tooth side surface 262 toward the second innermost part 30b so that the winding 29 passes through the second innermost part 30b and extends along the second tooth side surface 262. Therefore, the winding can be performed while maintaining the neat arrangement of the winding 29, and the quality of the winding 29 can be improved. In addition, the third portion of the first turn of the winding 29 wound around the outer end surface 55 contacts the protrusion 56, thereby preventing the winding 29 forming the first layer from shifting outward in the radial direction of the yoke 24. Therefore, the winding 29 of the first layer is stable, so that the winding 29 can be wound while maintaining the neat arrangement, and the quality of the winding 29 can be improved. In addition, after the winding 29 forming the second layer passes through the second innermost portion 30b and extends along the second tooth side surface 262, it is arranged on the protrusion 56 and guided by the protrusion 56 to be farther from the first tooth side surface 261 than the winding 29 forming the first layer. According to this, even if the winding 29 forming the second layer passes through the second innermost portion 30b and extends along the second tooth side surface 262, the subsequent winding operation of the winding 29 can be smoothly performed. With the above, it is possible to provide a rotating electric machine 10 in which the winding operation of the winding 29 is easy and high quality. In addition, by improving the space factor, it is possible to reduce the size of the rotating electric machine 10 or improve the output of the rotating electric machine 10.

[0070] (2) The protruding height H1 of the top 57 of the protrusion 56 relative to the outer end surface 55 is the same as the outer diameter D1 of the winding wire 29. Therefore, the winding wire 29 after passing through the second innermost portion 30b and extending along the second tooth side surface 262 is easily aligned with the position of the winding wire 29 forming the second layer. Therefore, the protrusion 56 can be easily used to guide the winding wire 29 in a manner such that the winding wire 29 passes through the second innermost portion 30b and extends along the second tooth side surface 262 and then is wound around the winding wire 29 forming the first layer. As a result, the winding operation of the winding wire 29 can be further facilitated.

[0071] (3) The windings 29 that form the specific layer 62 and extend along the second tooth side surface 262 through the second innermost portion 30b are the windings 29 that form the second layer. Thus, for example, compared with the case where the windings 29 that extend along the second tooth side surface 262 through the second innermost portion 30b are the windings 29 that form the fourth layer, the windings 29 can be arranged in a better order. Therefore, a rotating electrical machine 10 of higher quality can be provided.

[0072] (4) The protrusion 56 has an inclined surface 58 continuous with the top 57 of the protrusion 56, and the protrusion height of the inclined surface 58 relative to the outer end surface 55 gradually increases as it goes from the portion of the outer end surface 55 on the side opposite to the winding start portion 29s toward the top 57. According to this, the winding 29 arranged on the protrusion 56 can be extended along the inclined surface 58. Therefore, it is possible to suppress the winding 29 from being partially bent, so that the durability of the winding 29 can be prevented from being damaged. Therefore, it is possible to provide a rotating electric machine 10 of higher quality.

[0073] (5) The edge 61 of the protruding end surface 60 located on the side opposite to the insulator base 51 is chamfered into an arc shape. Thus, even if the winding 29 arranged on the protrusion 56 is pressed against the edge 61, the load applied to the winding 29 can be reduced, thereby preventing the durability of the winding 29 from being damaged. Therefore, a higher quality rotating electrical machine 10 can be provided.

[0074] (6) The outer end surface 55 is provided with the protrusion 56 located at the radially outer end portion of the outer end surface 55 and on the first side in the circumferential direction. Thus, the winding operation of the winding wire 29 is easy and high-quality rotating electrical machine 10 can be provided.

[0075] [Change example]

[0076] It should be noted that the above-mentioned embodiment can be implemented by modification as follows. The above-mentioned embodiment and the following modification examples can be implemented in combination with each other within the scope of no technical contradiction.

[0077] In the embodiment, the protrusion height H1 of the topmost portion 57 of the protrusion 56 relative to the outer end surface 55 may be larger or smaller than the dimension of the outer diameter D1 of the winding 29 .

[0078] In the embodiment, the winding 29 passing through the second innermost portion 30b and extending along the second tooth side surface 262 may be, for example, the winding 29 forming the fourth layer. In short, the winding 29 passing through the second innermost portion 30b and extending along the second tooth side surface 262 may be the winding 29 forming the specific layer 62.

[0079] In the embodiment, the winding 29 extending along the second tooth side surface 262 through the second innermost portion 30b may be, for example, the winding 29 forming the fourth layer. Furthermore, the winding 29 may be guided by the protrusion 56 in such a manner that, after the winding 29 passes through the second innermost portion 30b and extends along the second tooth side surface 262, it is wound around the winding 29 forming the third layer. In such a case, it is preferable that the protruding height H1 of the top 57 of the protrusion 56 relative to the outer end surface 55 is set to a dimension that is three times the outer diameter D1 of the winding 29.

[0080] In the embodiment, the protrusion 56 may not have the inclined surface 58. The protrusion 56 may be provided so as to protrude from a portion of the outer end surface 55 closer to the insulator base 51 than the first turn of the winding 29 forming the first layer and closer to the winding start portion 29s. In other words, the protrusion 56 may be provided at a portion of the outer end surface 55 located at the end portion located on the outer side in the radial direction and located on the first side in the circumferential direction.

[0081] In the embodiment, the edge 61 does not need to be chamfered into an arc shape.

[0082] In the embodiment, the number of layers of the winding wire 29 forming the coil 28 is not particularly limited.

Claims

1. A stator of a rotating electrical machine, comprising: A stator core having a cylindrical yoke and a plurality of teeth extending from an inner peripheral surface of the yoke toward the radial inner side of the yoke, wherein grooves are defined between teeth adjacent to each other in the circumferential direction of the yoke; A coil formed by winding a winding wire passing through the groove around the stator core; as well as an insulator disposed opposite to an iron core end face of the stator iron core, which is an axial end face of the yoke, and configured to insulate between the coil and the iron core end face, in, The tooth has a first tooth flank located on a first side of the circumference and a second tooth flank located on a second side of the circumference, The insulator has: a cylindrical insulator base which is opposed to the yoke in the axial direction; and a plurality of insulator extensions extending from the inner circumferential surface of the insulator base toward the inner side in the radial direction and respectively facing the teeth in the axial direction, The insulator extension portion has an outer end surface located on a side opposite to the stator core, The coil is formed by winding the winding wire in multiple layers around the teeth and the insulator extension portion in a concentrated winding manner. The first layer of the coil is formed by winding the winding wire from the outer side to the inner side in the radial direction. The coil has a specific layer, the specific layer is a layer after the second layer of the coil, and is formed by winding the winding wire from the inside to the outside in the radial direction, The portion of the groove close to the inner circumferential surface of the yoke that is close to the first tooth side surface is a first innermost portion, and the portion of the groove close to the inner circumferential surface of the yoke that is close to the second tooth side surface is a second innermost portion. The first turn of the winding forming the first layer includes a winding start portion passing through the first innermost portion and extending along the first tooth side surface, a portion passing through a position in the groove farther from the inner peripheral surface of the yoke than the second innermost portion and extending along the second tooth side surface, and a portion wound around the outer end surface of the insulator extension portion. The outer end surface is provided with a protrusion protruding from a portion of the outer end surface closer to the insulator base than the first turn and closer to the winding start portion, The winding forming the specific layer passes through the second innermost portion, extends along the second tooth side surface, and is then arranged on the protrusion.

2. The stator of a rotating electrical machine according to claim 1, wherein: The protruding height of the top of the protrusion relative to the outer end surface is the same as the outer diameter of the winding, The protrusion is configured to guide the winding wire that passes through the second innermost portion and extends along the second tooth side surface so that the winding wire is wound around the winding wire forming the first layer after passing through the second innermost portion and extending along the second tooth side surface.

3. The stator of a rotating electrical machine according to claim 1 or 2, wherein: The windings that pass through the second innermost portion and extend along the second tooth side surface are windings that form the second layer.

4. The stator of a rotating electrical machine according to claim 1, wherein: The protrusion has an inclined surface continuous with the top of the protrusion, and a protrusion height of the inclined surface relative to the outer end surface gradually increases from a portion of the outer end surface on the side opposite to the winding start portion toward the top.

5. The stator of a rotating electrical machine according to claim 1, wherein: The protrusion has a protruding end surface located at the front end of the protruding direction from the outer end surface, An edge portion of the protruding end surface located on the opposite side to the insulator base is chamfered in an arc shape.

6. An insulator constituting a part of a stator of a rotating electrical machine, wherein: The stator has: a stator core having a cylindrical yoke and a plurality of teeth extending from an inner peripheral surface of the yoke toward the radial inner side of the yoke, wherein grooves are defined between teeth adjacent to each other in the circumferential direction of the yoke; and a coil formed by winding a winding wire passing through the groove around the stator core, The insulator is disposed opposite to an end face of the stator core, which is an end face located in the axial direction of the yoke, and is configured to insulate between the coil and the end face of the core. The insulator has: a cylindrical insulator base which is opposed to the yoke in the axial direction; and a plurality of insulator extensions extending from the inner circumferential surface of the insulator base toward the inner side in the radial direction and respectively facing the teeth in the axial direction, The insulator extension portion has an outer end surface located on a side opposite to the stator core, The outer end surface is provided with a protrusion located at an end portion of the outer end surface in the radial direction and on a first side in the circumferential direction.

7. The insulator according to claim 6, wherein: The protrusion has an inclined surface continuous with a topmost portion of the protrusion, and a protrusion height of the inclined surface relative to the outer end surface gradually increases as it approaches the topmost portion from the second side in the circumferential direction of the outer end surface.

8. The insulator according to claim 6 or 7, wherein: The protrusion has a protruding end surface located at the front end of the protruding direction from the outer end surface, An edge portion of the protruding end surface located on the opposite side to the insulator base is chamfered in an arc shape.

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