Annular temporarily assembled stator

Abstract

A motor (1) according to an embodiment includes a stator (2). The stator (2) is provided with a plurality of coupling cores (23). The connecting iron core (23) is provided with a plurality of assemblies (23a) which are connected through connecting parts (23b). The plurality of assemblies (23a) are arranged in an arc shape. The plurality of connecting iron cores (23) are arranged in a ring shape.

Description

[0001] This application is a divisional application of an application filed on May 31, 2019, with application number 2019 8 0056 301.7 (PCT / JP2019 / 021748) and invention name “MOTOR AND METHOD FOR MANUFACTURING MOTOR” Technical Field

[0002] The present invention relates to temporary assembly. Background Art

[0003] Conventionally, there is known a motor in which a stator is formed of three divided bodies and the total number of windings and the number of salient poles of each divided body are adjusted to prevent noise associated with vibration.

[0004] Prior Art Literature

[0005] Patent Literature

[0006] Patent Document 1: Japanese Patent Application Publication No. 2000-152529 Summary of the invention

[0007] Problems to be solved by the invention

[0008] However, in a conventional stator formed of a plurality of divided bodies, since the divided bodies are formed in an arc shape, for example, the space around the teeth is narrow, which makes it difficult to wind the coil and fails to improve productivity.

[0009] The present invention takes the above-mentioned problem as an example, and an object of the present invention is to reduce the vibration of the stator and improve the productivity.

[0010] Solutions to Solve Problems

[0011] A stator temporarily assembled in an annular shape according to one embodiment of the present invention, wherein the motor includes a stator, the stator includes a plurality of connecting cores, a plurality of insulating members, and a plurality of coils, the connecting core includes a plurality of components connected via a connecting portion, the plurality of insulating members are mounted on the plurality of components, the plurality of coils are wound around the plurality of insulating members, the plurality of components are arranged in an arc shape, the plurality of connecting cores are arranged in an annular shape, and the plurality of insulating members include two insulating members connected in the circumferential direction by a connecting member and two insulating members separated from each other in the circumferential direction. .

[0012] According to one aspect of the present invention, it is possible to reduce vibration of the stator and improve productivity. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 It is a perspective view showing a configuration example of a stator according to the first embodiment.

[0014] Figure 2It is a plan view showing an example of the shape of a steel plate as a magnetic body constituting the connection core.

[0015] Figure 3A It is a perspective view showing an example of the shape of the connection core.

[0016] Figure 3B It is a plan view showing an example of the shape of the connection core.

[0017] Figure 4A This is a diagram (part 1) showing an example in which a plurality of connected cores are formed in a ring shape.

[0018] Figure 4B This is a diagram (part 2) showing an example in which a plurality of connected cores are formed into a ring shape.

[0019] Figure 5 The diagram shows an example of an upper insulator, a lower insulator, and a terminal applied to a connecting core.

[0020] Figure 6 It is a diagram showing an example of winding of a coil.

[0021] Figure 7 1 is a diagram showing an example of phases allocated to the respective coils of the three divided bodies.

[0022] Figure 8 It is a diagram showing another example of winding of the coil.

[0023] Fig. 9A This is a perspective view (part 1) showing a configuration example of a motor.

[0024] Fig. 9B This is a perspective view showing an example of the configuration of a motor (part 2).

[0025] Fig.10 This is a diagram (part 1) showing a configuration example of a connection core according to a second embodiment.

[0026] Fig.11 This is a diagram (part 2) showing a configuration example of a connection core according to the second embodiment.

[0027] Fig.12 It is a diagram showing an example of a grain-oriented electromagnetic steel sheet according to a third embodiment.

[0028] Fig.13 It is a diagram showing an example of a connection core according to a third embodiment.

[0029] Fig.14A This is a diagram (part 1) showing an example of press-fitting of a stator according to a fourth embodiment.

[0030] Fig. 14BThis is a diagram (part 2) showing an example of press-fitting of the stator according to the fourth embodiment.

[0031] Fig. 14C This is a diagram (part 3) showing an example of press-fitting of the stator according to the fourth embodiment.

[0032] Fig.15 It is a plan view showing an example of the shape of a connection core according to the fifth embodiment.

[0033] Fig.16A It is a diagram (part 1) showing an example of insertion of an elastic member according to the sixth embodiment.

[0034] Fig. 16B This is a diagram (part 2) showing an example of insertion of the elastic member according to the sixth embodiment.

[0035] Fig.17A This is a diagram (part 1) showing an example of a protrusion according to the seventh embodiment.

[0036] Fig. 17B This is a diagram (part 2) showing an example of the protrusion according to the seventh embodiment.

[0037] Fig. 17C This is a diagram (part 3) showing an example of a protrusion according to the seventh embodiment.

[0038] Fig.18 It is a diagram showing an example of a bulging portion according to the eighth embodiment.

[0039] Fig.19 This is a diagram showing an example of a state in which the connection core according to the ninth embodiment is assembled in a ring shape.

[0040] Fig. 20 This is a diagram showing a situation where a plurality of connection cores are assembled in a ring shape.

[0041] Fig.21A This is a diagram (part 1) showing an example of provisional assembly of a stator according to the tenth embodiment.

[0042] Fig.21B This is a diagram (part 2) showing an example of provisional assembly of the stator according to the tenth embodiment.

[0043] Fig.22A This is a diagram (part 1) showing an example of provisional assembly of a stator according to the eleventh embodiment.

[0044] Fig. 22B This is a diagram (part 2) showing an example of provisional assembly of the stator according to the eleventh embodiment.

[0045] Fig.23 It is a perspective view showing an example of a terminal according to the twelfth embodiment.

[0046] Fig.24 It is a perspective view showing an example of a common terminal of a comparative example.

[0047] Fig.25 It is a perspective view showing an example of a terminal according to a thirteenth embodiment.

[0048] Fig.26 It is a perspective view showing an example of a terminal according to a fourteenth embodiment.

[0049] Fig. 27 It is a perspective view showing an example of an upper insulating member according to the fifteenth embodiment.

[0050] Fig.28A This is a diagram (part 1) showing an example of insertion of a partition plate according to the sixteenth embodiment.

[0051] Fig.28B This is a diagram (part 2) showing an example of insertion of a partition plate according to the sixteenth embodiment.

[0052] Fig.29 It is a diagram showing an example of a countermeasure against a temperature rise according to the seventeenth embodiment.

[0053] Fig.30 It is a plan view showing a state where a sheet-shaped resin member is inserted between adjacent coils.

[0054] Fig.31 This is a diagram showing a state where the connection core is bent with a sheet-shaped resin member inserted. DETAILED DESCRIPTION

[0055] Hereinafter, the motor and the method for manufacturing the motor according to the embodiment will be described with reference to the accompanying drawings. It should be noted that the present invention is not limited to the embodiment. In addition, the dimensional relationship of the elements in the drawings, the proportion of the elements, etc. may sometimes be different from the actual ones. The figures may sometimes contain parts with different dimensional relationships and proportions. In addition, the contents described in one embodiment or modification example are also applicable to other embodiments and modifications in principle.

[0056] (First Embodiment)

[0057] Figure 1 2 is a perspective view showing a configuration example of the stator 2 according to the first embodiment. Figure 1In the figure, a stator 21 and an annular substrate (hereinafter referred to as a connecting plate) 28 provided on the stator 21 are shown. The stator 21 is formed as follows: an upper insulating member 24 and a lower insulating member 25 are assembled on each component of a connecting core 23 formed by connecting a plurality of (for example, four) components (pieces) via a bendable connecting portion, and a coil 26 is wound on this basis, and then the connecting portion is bent, and the stator 21 is formed in an annular shape by a plurality of (for example, three) connecting cores 23. Here, the insulating member includes an upper insulating member 24 and a lower insulating member 25. Each connecting core 23 is respectively used as a split body to form an iron core as a whole stator. When three connecting cores 23 are used, the number of split bodies is 3. As for the number of split bodies, 3 is preferred in terms of improving the rigidity relative to the secondary / fourth annular vibration mode, but it can also be an odd number greater than 3. In addition, the number of components of the plurality of connecting cores 23 may be an even number, and the number of the plurality of connecting cores 23 may be an odd number or a prime number. Even if the number of components is an even number, by setting the number of connecting cores 23 to an odd number or a prime number greater than 3, the vibration of the motor and the noise associated with the vibration can be suppressed.

[0058] The connecting plate 28 is a member for wiring the terminals 27 provided on the upper part of the upper insulating member 24 uniformly for each component (for each slot) of the connecting core 23, and is formed by a printed circuit board or a substrate in which a printed circuit board or a flexible substrate is provided on a predetermined substrate. It should be noted that there is also a case where the connecting plate 28 is connected to the terminal 27 after the connecting core 23, which is temporarily assembled in a ring shape and wound with the coil 26, is inserted into the housing of the motor. The electrical connection of the coil 26 of each slot is uniformly performed through the connecting plate 28 via the terminal 27, thereby avoiding the crossing of the connecting wires. In addition, since a guide portion for guiding the connecting wire is not required on the insulating member, the size of the stator in the direction of the rotating axis can be shortened, and the useless space of the motor can be reduced. In the example shown in the figure, the end 27-a of the terminal 27 is respectively inserted into the plurality of hole portions 28a formed in the connecting plate 28, and a part of the end 27-a of the terminal 27 protrudes outward from the surface of the connecting plate 28. The end 27-a of the terminal 27 is electrically connected to a part of the wiring formed on the connecting plate 28. The protrusions 27 - b and 27 - c fixed to the insulating member are connected to the end portion 27 - a.

[0059] Figure 2 FIG. 2 is a plan view showing an example of the shape of the steel plate 22 as a magnetic body constituting the connection core 23. Figure 2 In the embodiment, the steel plate 22 is formed by punching out an electromagnetic steel plate using a die etc. In addition, a plurality of steel plates 22 are stacked to form the connection core 23 .

[0060] Figure 3A 2 is a perspective view showing an example of the shape of the connecting core 23. Figure 3BFIG. 2 is a top view showing an example of the shape of the connecting core 23. Figure 3B In FIG. 1 , an enlarged view of both ends of the connecting core 23 is attached. The connecting core 23 is formed by Figure 2 The steel plate 22 as a magnetic body is formed by laminating a plurality of sheets. Figure 3A In the figure, the illustration of the transverse stripes on the end surface due to the lamination of the electromagnetic steel sheets is omitted. In the example shown in the figure, four components 23a having a substantially T-shaped plane shape are connected via a connecting portion 23b. A tooth 23e is formed on each component 23a. One end 23e1 of the tooth 23e (the end facing the rotor 3 in the radial direction) becomes a magnetic pole portion. The connecting portion 23b is formed thinly between the planar edge 23b-a located on the outer circumference and the curved concave portion 23b-b located on the inner circumference, and can be easily bent in a direction to close the curved concave portion 23b-b. In other words, the concave portion 23b-b is provided on the side of the connecting portion 23b. The planar contact portion 23b-c is connected to the curved concave portion 23b-b, and the contact portions 23b-c of the adjacent components 23a contact when the connecting core 23 is bent. The left and right ends of the connection core 23 are formed as contact portions 23c and 23d, and the contact portions 23d and 23c of the adjacent connection cores 23 are in contact and fit with each other in a state of being annularly bent.

[0061] The surface of the contact portion 23c includes a first surface 23c1 extending in the direction along the side surface 23e2 of the tooth 23e and a second surface 23c2 inclined relative to the first surface 23c1. In the radial direction, the first surface 23c1 is arranged on the outside (the side of the cylinder 11) relative to the second surface 23c2. The first surface 23c1 extends in a direction perpendicular to the direction in which the components 23a are arranged when the components 23a are opened and the connecting core 23 is in a straight line. In addition, the first surface 23c1 and the second surface 23c2 are respectively formed to intersect with the surface extending radially from the contact portion 23c and passing through the center of the shaft (the center position of the motor) when the connecting core 23 is bent into a ring shape. On the other hand, the contact portion 23d has a surface corresponding to the contact portion 23c of the other connecting cores 23, including a second surface 23d2 extending in the direction along the side surface 23e3 of the tooth 23e and a first surface 23d1 inclined relative to the second surface 23d2. The first surface 23d1 is opposite to the first surface 23c1 of the contact portion 23c, and the second surface 23d2 is opposite to the second surface 23c2. In the radial direction, the first surface 23d1 is arranged on the outside (the side of the cylinder 11) relative to the second surface 23d2. The second surface 23d2 extends in a direction perpendicular to the direction in which the components 23a are arranged when the components 23a are opened and the connecting cores 23 are in a straight line. In addition, the first surface 23d1 and the second surface 23d2 become surfaces that intersect with a surface along the radial direction extending from the contact portion 23d and passing through the center of the shaft (the center position of the motor) when the connecting core 23 is bent into a ring shape. In this way, two connecting cores 23 that are in contact with each other among the plurality of connecting cores 23 respectively have contact portions 23c and 23d, and surfaces that intersect with a surface extending along the radial direction and passing through the center of the shaft are provided on the contact portions 23c and 23d of the two connecting cores 23 (refer to Fig. 14C ), thereby enabling the contact portions 23c to mesh with each other, preventing radial misalignment, and thus improving the roundness of the stator. It should be noted that the contact portions 23c and 23d are not limited to being configured as a convex shape in the circumferential direction and a concave shape in the circumferential direction on one side and a flat end surface on the other side through the above-mentioned structure. In addition, the first surfaces 23c1 and 23d1 may also extend in a direction perpendicular to the side surface 23e4 of the tooth.

[0062] Figure 4A and Figure 4B 2 is a diagram showing an example of forming a plurality of connected cores 23 in a ring shape. It should be noted that this is a diagram conceptually showing the formation of a ring-shaped core. In reality, as described above, the upper insulating member 24 and the lower insulating member 25 are assembled on each component of the connected core 23, and the coil is wound and then bent. Figure 4A In the embodiment, the three connecting cores 23 are respectively bent into arc shapes and then combined to form Figure 4B An annular core as shown.

[0063] In the conventional stator of the type in which a whole strip of iron core is bent into a ring shape, the ring shape is bent in a single operation within a range of 360° in one circle. Therefore, there is a situation in which an excessive force acts on a part of the connecting portion, resulting in deterioration of the roundness, and vibration caused by the excitation force in the radial direction corresponding to the number of magnetic poles of the magnet is generated. In contrast, in the present embodiment, after a plurality of (for example, three) connecting iron cores 23 are bent into arc shapes, the plurality of connecting iron cores 23 are combined, so that the roundness is improved. As a result, it can be expected that the vibration and noise caused by the excitation force in the radial direction corresponding to the number of magnetic poles of the magnet can be reduced.

[0064] In addition, in the conventional stator of the type in which a whole strip-shaped iron core is bent into a ring shape, the end is connected at one point in one circle, so the rigidity is reduced with respect to the secondary and fourth annular vibration modes, and vibration and noise are also generated from this point. In contrast, in the present embodiment, the number of such segmented bodies, for example, three, is an odd number, so the connection parts of the segmented bodies are not opposed to each other across the center of the circle, and the rigidity is high with respect to the secondary and fourth annular vibration modes. As a result, it can be expected that vibration and noise will be reduced.

[0065] then, Figure 5 2 is a diagram showing an example of an upper insulating member 24, a lower insulating member 25, and a terminal 27 applied to the connecting core 23. Figure 5 In the embodiment, the upper insulating member 24 and the lower insulating member 25 are formed in a shape that the coil skeleton having a longitudinal length (long in the direction of stacking the steel sheets) can be divided upward and downward near the center, and the upper insulating member 24 and the lower insulating member 25 are assembled in a manner that the teeth 23e are accommodated in the state where the connecting core 23 is opened (in a state where it is not bent). In addition, a hole 24-a for the terminal 27 is provided at the upper part of the upper insulating member 24 (the end part on the side of the cover part 12 described later) for inserting the terminal 27. Specifically, two protrusions 27-b and 27-c extending toward the upper insulating member 24 are provided on the terminal 27, and these two protrusions 27-b and 27-c are inserted into the hole 24-a of the upper insulating member 24 to fix the terminal 27 to the upper insulating member 24. In addition, the terminal 27 is provided with an end 27-a connected to the connecting plate 28 and a hook 27n for connecting a wire.

[0066] Figure 6 2 is a diagram showing an example of winding of the coil 26 in the connection core 23, wherein the upper portion shows a top view and the lower portion shows a front view. Figure 6For example, point P1 is set as the winding start point of the wire W, and the wire W is passed through the hook portion 27n-1 of the terminal 27-1 of the component 23a-1 and then the wire W is wound counterclockwise (CCW) to form the coil 26-1. Next, the wire W is continuously wound clockwise (CW) on the component 23a-2 from the winding end point of the coil 26-1 to form the coil 26-2, and the wire W is passed through the hook portion 27n-2 of the terminal 27-2 from the winding end point of the coil 26-2. Next, the wire W is passed through the hook portion 27n-3 of the terminal 27-3 of the component 23a-3 and then wound clockwise (CW) to form the coil 26-3. Next, the wire W is continuously wound counterclockwise (CCW) around the assembly 23a-4 from the winding end of the coil 26-3 to form the coil 26-4, and the wire W passes through the hook 27n-4 of the terminal 27-4 and reaches the point P2 where the winding ends. After the wire W at the hooks 27n-1 to 27n-4 of the terminals 27-1 to 27-4 is fixed (riveted, welded, etc.), the wire W between the point P1 and the hook 27n-1 of the terminal 27-1, between the hook 27n-2 of the terminal 27-2 and the hook 27n-3 of the terminal 27-3, and between the hook 27n-4 of the terminal 27-4 and the point P2 is cut.

[0067] It should be noted that the point P1 where the winding starts and the point P2 where the winding ends can be swapped. In addition, the clockwise (CW) and counterclockwise (CCW) winding can also be swapped, but it is required that the first coil 26-1 and the second coil 26-2 are in opposite directions, the second coil 26-2 and the third coil 26-3 are in the same direction, and the third coil 26-3 and the fourth coil 26-4 are in opposite directions, that is, the winding is performed in a so-called one-stroke manner. In other words, when the connecting core 23 has four components 23a-1 to 23a-4, in the circumferential direction, the winding directions of the coils 26-1 and 26-4 of the two components 23a-1 and 23a-4 located at the two ends of the plurality of components are in one direction, and the winding directions of the coils 26-2 and 26-3 of the two components 23a-2 and 23a-3 located between the two components 23a-1 and 23a-4 at the two ends are in the opposite direction.

[0068] In addition, Figure 6 In the embodiment, the first coil 26-1 is set to U reverse phase, the second coil 26-2 is set to U phase, the third coil 26-3 is set to V phase, and the fourth coil 26-4 is set to V reverse phase, but the winding of the connecting core 23 constituting each split body is the same, which is directly applicable to other phases. Figure 7 This is a diagram showing an example of phases assigned to each coil of three split bodies, where the first split body is assigned U reverse phase, U phase, V phase, and V reverse phase, the second split body is assigned W reverse phase, W phase, U phase, and U reverse phase, and the third split body is assigned V reverse phase, V phase, W phase, and W reverse phase.

[0069] It should be noted that the surfaces 23c1 and 23d2 of the contact portions 23c and 23d of the two components located on both sides of the connecting core 23 may be arranged in a direction perpendicular to the direction in which the plurality of components are arranged, and coils may be wound around the components of the connecting core 23. By providing the surfaces 23c1 and 23d2 on the contact portions 23c and 23d when the components 23a are opened and the connecting core 23 is in a straight line, the holding force relative to the clamp of the winding machine can be improved, and the connecting core 23 can be maintained in a straight line even if an external force (tension) continues to act on the connecting core during the winding of the wire by the winding machine. As a result, the coils can be wound around the components of the connecting core 23 at a predetermined tension, and the occupancy rate of the coils can be increased.

[0070] In this embodiment, when the connecting core 23 is Figure 6 Since the coil 26 is wound in a state where the components 23a are opened and the connecting cores 23 are in a straight line as shown, the wire W can be easily wound even in a small motor with a small space around the teeth. In addition, the coil 26 can be wound around a plurality of connecting cores 23 in parallel, which contributes to a significant improvement in productivity.

[0071] Figure 8 2 is a diagram showing another example of the winding of the coil 26. Figure 8 In the process, the conductor W is wound around the first column (hereinafter referred to as the winding start column) 401 provided on the clamp, and the coil 26-1 of the component 23a-1, the coil 26-2 of the component 23a-2, the coil 26-3 of the component 23a-3 and the coil 26-4 of the component 23a-4 are wound in sequence to reach the second column (hereinafter referred to as the winding end column) 402 provided on the clamp.

[0072] exist Figure 8In the embodiment, the hook 27n-1 of the terminal 27-1 faces the winding start column 401, the hook 27n-2 of the terminal 27-2 faces the hook 27n-3 of the terminal 27-3, and the hook 27n-4 of the terminal 27-4 faces the winding end column 402. In addition, in the direction in which the plurality of modules are arranged, protrusions 24a-1 and 24a-2 are provided on the insulating member above the portion in which the module 23a-1 faces the module 23a-2, and similarly, in the direction in which the plurality of modules are arranged, protrusions 24a-3 and 24a-4 are provided on the insulating member above the portion in which the module 23a-3 faces the module 23a-4. The above-mentioned structure can realize the natural arrangement of the wire W, and can prevent the wire W from being loosened and protruding at the front end side of the module, the rear end side of the module (the outer peripheral side of the stator 21), or the terminal side. It should be noted that after the wire W is fixed at the hooks 27n-1 to 27n-4 of the terminals 27-1 to 27-4, the wire W between the winding start post 401 and the hook 27n-1 of the terminal 27-1, between the hook 27n-2 of the terminal 27-2 and the hook 27n-3 of the terminal 27-3, and between the hook 27n-4 of the terminal 27-4 and the winding end post 402 is cut. It should be noted that the relationship between the winding start point / winding end point and the winding direction are the same as Figure 6 The structure shown is the same.

[0073] Fig. 9A and Fig. 9B is a perspective view showing a configuration example of a motor 1 to which the above-mentioned stator 2 is applied. Fig. 9A Show appearance, Fig. 9B The main components are shown. Fig. 9A In the embodiment, the motor 1 includes a cylinder 11, covers 12 and 13, and a shaft 32. The cylinder 11, covers 12 and 13 form a housing. Fig. 9B In the embodiment, the stator 2 is inserted (pressed) into the cylindrical barrel 11, and the rotor 3 is arranged in the space inside the stator 2, and the shaft 32 of the rotor 3 is supported rotatably by the upper and lower covers 12 and 13 that hold the bearing. A plurality of holes 12b are provided on the surface 12a of the cover 12 that faces the stator 2 in the longitudinal direction of the rotor 3, and a plurality of holes 12d are provided on the outer peripheral portion 12c of the cover 12. Similarly, a plurality of holes 13b are provided on the surface 13a of the cover 13 that faces the stator 2 in the longitudinal direction of the rotor 3, and a plurality of holes 13d are provided on the outer peripheral portion 13c of the cover 13. The holes 12d and 13d provided in the outer peripheral portions 12c and 13c of the covers 12 and 13 and the holes 11a and 11b provided in the outer peripheral portion of the barrel 11 can be fixed by inserting screws or the like into the holes 12d and 13d provided in the outer peripheral portions 12c and 13c of the covers 12 and 13 and the holes 11a and 11b provided in the outer peripheral portion of the barrel 11. In the example shown in the figure, the rotor 3 includes a rotor yoke 3 a which is a magnetic body provided on a shaft 32 , and an annular magnet 3 b is provided on the outer peripheral surface of the rotor yoke 3 a .

[0074] It should be noted that the rotor 3 may also include a rotor yoke 3a formed in an annular shape by stacking electromagnetic steel plates as magnetic components, and a shaft 32 is provided in the central portion of the rotor yoke 3a so as to penetrate the rotor yoke 3a. For example, the rotor yoke 3a is formed into an annular shape by bending four roughly fan-shaped components connected by connecting portions so as to sandwich the rod-shaped shaft 32, and the connecting portion connecting the end of the core is connected by laser welding along the axial direction or the like. In addition, a hole portion for generating a magnetic resistance torque is provided in the rotor yoke 3a, and a magnet is arranged in the hole portion as required. It should be noted that the illustration of the terminal 27 and the connecting plate 28 of the stator 2 is omitted.

[0075] (Second Embodiment)

[0076] Fig.10 and Fig.11 FIG. 2 is a diagram showing a configuration example of the connection core 23 according to the second embodiment, and shows an example of the connection core 23 applied to the outer rotor type motor 1. Fig.10 In the embodiment, six (six-part) connection cores 23 are connected in a ring shape to form the stator 2 . Fig.11 A connecting core 23 is shown, on which six components are arranged and bent in an arc shape. It should be noted that the thickness of the connecting portion between the components is uniform, but it can also be set to Figure 3A A thin connection as shown.

[0077] (Third Embodiment)

[0078] In such Figure 3A In the connecting core 23 constructed as described above, when the connecting core 23 is bent into a ring shape, a magnetic circuit is formed by the portion (contact portion) where the two contact portions 23b-c are in contact and the connecting portion 23b which is a part of the steel plate. The connecting portion 23b has a large magnetic permeability. In contrast, since a tiny gap is generated in the contact portion, the magnetic permeability becomes equal to that of air, and the difference in magnetic resistance between the contact portion and the connecting portion 23b becomes large. Therefore, there is a situation where the magnetic flux is concentrated in the connecting portion 23b, causing magnetic saturation, unnecessary heat generation and other disadvantages. In this embodiment, by using a directional electromagnetic steel sheet in the manufacture of the connecting core 23, the difference in magnetic resistance between the connecting portion 23b and the contact portion can be reduced, magnetic saturation is not easily caused, and unnecessary heat generation and other disadvantages can be prevented.

[0079] Fig.12 : is a diagram showing an example of a directional electromagnetic steel sheet 9 according to the third embodiment. A directional electromagnetic steel sheet is an electromagnetic steel sheet that has magnetic properties biased by magnetizing in a specific direction by aligning the direction of the crystal axis when rolling the steel sheet, and usually the easy magnetization axis is orthogonal to the hard magnetization axis in the left and right directions. Fig.12In the figure, the up and down direction is the easy magnetization axis, and the left and right direction is the difficult magnetization direction.

[0080] Fig.13 is a diagram showing an example of a connection core 23 of the third embodiment, which is obtained by Fig.12 The example of the connection core 23 formed by laminating steel sheets formed by punching out the directional electromagnetic steel sheet 9 is shown in FIG. That is, the connection core 23 is formed by the directional electromagnetic steel sheet, and the hard magnetization axial direction of the directional electromagnetic steel sheet is the direction from one of the multiple connection parts of the connection core 23 toward another connection part. As a result, the direction in which the magnetic flux flows in the connection part 23b (the left-right direction in the figure) becomes the hard magnetization axial direction.

[0081] In a grain-oriented electromagnetic steel sheet, the magnetic permeability of the easy magnetization axis and the hard magnetization axis differs by, for example, more than 100 times. The magnetic permeability of the easy magnetization axis is, for example, 10,000 to 100,000, but the magnetic permeability of the hard magnetization axis is, for example, only 100 to 1,000. Therefore, when the hard magnetization axis is set in the direction of the flow of the magnetic flux in the connection portion 23b, the magnetic permeability of the contact portion is the same as the magnetic permeability of the air, which is 1. Assuming that the magnetic permeability of the connection portion 23b is, for example, "100" and the cross-sectional area of ​​the magnetic path of the connection portion 23b is one-tenth of the cross-sectional area of ​​the contact portion, the difference in magnetic resistance is reduced compared to the case where the easy magnetization axis is set in the direction of the flow of the magnetic flux in the connection portion 23b. As a result, the magnetic flux is difficult to flow not only in the connection portion 23b, but also in the contact portion, and magnetic saturation can be suppressed at the connection portion 23b, magnetic loss is reduced, and unnecessary heat generation can be suppressed.

[0082] (Fourth Embodiment)

[0083] exist Fig. 9A and Fig. 9B In the fourth embodiment, the configuration of the stator 2 in the motor 1 is described. If the stator 2 in which the three connected iron cores 23 are arranged in a ring shape can be assembled by pressing it into the housing, a high-precision stator 2 can be manufactured in a short time. Thus, by pressing the three connected iron cores 23 into the housing while maintaining the state of being arranged in a ring shape, the assembly can be simple. Therefore, in the fourth embodiment, a method of pressing the stator 2 using a clamp is described.

[0084] Figures 14A to 14C 2 is a diagram showing an example of press-fitting of the stator 2 according to the fourth embodiment. Fig.14A In the embodiment, the cylindrical portion 11 of the housing is fitted into the lower fixture 41. The lower fixture 41 has a bottom 41a, an inner surface in close contact with the outer peripheral surface of the cylindrical portion 11, and a convex portion 41c fitted into the central hollow portion 41b of the stator 2 (equivalent to the space of the rotor 3).

[0085] On the other hand, the stator 2 including, for example, three connected iron cores 23 wound with coils and bent in an arc shape is inserted into the stator holding fixture 42. The stator holding fixture 42 has a contact portion 43 of a predetermined width protruding toward the center side by a predetermined distance at a position corresponding to the contact portion of the three connected iron cores 23. Fig. 14B As shown, at the lower end of the stator holding jig 42 , an end portion (hereinafter referred to as a guide piece) 43 a extends downward from the contact portion 43 , and the guide piece 43 a of the contact portion 43 is inserted into the inner periphery of the cylinder portion 11 . Fig. 14C The state after three connecting cores 23 are inserted into the stator holding fixture 42 is shown, and the contact parts 23d and 23c of the connecting cores 23 are pressed toward the center by the contact part 43 of the stator holding fixture 42 to maintain the ring shape. At this time, the two mutually meshing surfaces of the contact parts 23c and 23d of the adjacent connecting cores 23 are surfaces intersecting with the surface extending from the contact parts 23c and 23d in the radial direction and passing through the center of the shaft 32 that is the center of the rotor yoke 3a and the magnet 3b as shown in the enlarged figure. Therefore, the contact parts 23c can be meshed with each other to prevent the radial deviation, thereby improving the roundness of the stator.

[0086] Back to Fig.14A In a state where the stator holding fixture 42 with the stator 2 inserted therein is arranged on the barrel 11 and the guide piece 43a at the lower end side of the contact portion 43 is inserted into the inner surface of the barrel 11, the upper fixture 44 is pressed from the upper part of the stator 2. The upper fixture 44 has an inner surface 44a that is in close contact with the outer peripheral surface of the stator 2, a convex portion 44b that fits into the hollow portion (equivalent to the space of the rotor 3) located inside the stator 2, and a top portion 44c that is in contact with the upper surface of the stator 2. In addition, by pressing downward with the upper fixture 44 while the contact portions 23c and 23d of each connecting core 23 of the stator 2 are held by the contact portion 43 of the stator holding fixture 42, the stator 2 can be pressed into the barrel 11 while maintaining a high roundness. In this way, a high-precision stator 2 can be manufactured in a short time.

[0087] (Fifth Embodiment)

[0088] In targeting Figure 3A , Figure 3B The connecting core 23 shown in the figure is Figure 6In the process of winding the coils 26 (coils 26-1 to 26-4), it is difficult to firmly fix the connecting cores 23 with a clamp in each straight connecting core 23 before being bent into a ring shape. However, in most cases, the straight connecting core 23 requires winding of a thick wire diameter to effectively utilize the advantage of the opening slot width. During the winding of the thick wire diameter, a very high tension is applied to the wire, so it becomes more difficult to fix the connecting core 23. Therefore, the fifth embodiment proposes a modified example that can firmly fix the connecting core 23.

[0089] Fig.15 FIG. 2 is a plan view showing an example of the shape of the connection core 23 according to the fifth embodiment. Fig.15 In the figure, grooves 23i are provided along a direction perpendicular to the paper surface of the figure (in the case where the connecting core 23 is formed by stacking steel plates), on the back of the magnetic pole (the portion that becomes the outer peripheral side when the connecting core 23 is bent in an arc shape) of each component 23a constituting the connecting core 23. In the case where it is formed by stacking steel plates, the grooves 23i are formed by providing cuts corresponding to the grooves 23i on the steel plates and stacking the steel plates. The grooves 23i have a shape that opens inwardly in a roughly rectangular shape and is connected to the narrow opening on the back side of the magnetic pole. It should be noted that the connecting core 23 shown in the figure is composed of three components 23a, but it may also be as follows. Figure 3A In addition, the two ends of the connecting core 23 may also be provided with Figure 3A The contact parts 23c and 23d have the shapes shown in FIG.

[0090] In targeting Fig.15 In the process of winding the coil using the connecting core 23 of the structure, the connecting core 23 is firmly fixed by engaging a part of the clamp with the slot 23i of the connecting core 23. Even if a very high tension is applied to the wire during the winding of a thick wire diameter, it can be stably fixed, thereby increasing the reliability of the winding.

[0091] (Sixth Embodiment)

[0092] exist Figure 3A In the connecting core 23 of the structure described in the above, each connecting core 23 is divided into a plurality of components 23a, and the annular stator 2 is formed by a plurality of connecting cores 23, so it is sometimes difficult to maintain good roundness when assembling in an annular shape. In addition, since the connecting cores 23 are assembled in a state where they are divided, the connecting portion 23b is easily subjected to stress caused by vibration, and the connecting portion 23b is sometimes deformed unexpectedly. Therefore, in the sixth embodiment, a method for improving the above point is proposed.

[0093] Fig.16A and Fig. 16B 2 is a diagram showing an example of insertion of the elastic member 291 according to the sixth embodiment. Fig.16A FIG. 2 shows a state before the connecting portion 23b of the connecting core 23 is bent. Fig. 16B The connecting portion 23b is shown in a bent state.

[0094] First, in Fig.16A In the embodiment, each connecting portion 23b of the connecting core 23 is provided with a curved recess 23b-b. The recess 23b-b is provided in the connecting portion 23b on the side where the connecting portion 23b is bent to narrow the space located inside the connecting portion 23b. An elastic member 291 such as a rod-shaped rubber is inserted into the curved recess 23b-b. It should be noted that the size of the outer shape of the elastic member 291 (hereinafter referred to as the diameter) is set to be larger than the size of the gap (hereinafter referred to as the inner diameter) formed when the recess 23b-b is bent. Therefore, the elastic member 291 generates a repulsive force on the inner surface of the recess 23b-b in the direction from the inside to the outside. In addition, the timing of inserting the elastic member 291 is preferably after the coil is wound around the connecting core 23 from the point of preventing the elastic member 291 from falling off. It should be noted that the elastic member 291 may be inserted into all the recesses 23 b - b , or one elastic member 291 may be inserted into every several recesses 23 b - b within a range in which the symmetry of the stator 2 is ensured.

[0095] Fig. 16B The figure shows the state after the connecting portion 23b of the connecting core 23 is bent to form the connecting core 23 into an arc shape. The diameter of the elastic member 291 is set to be larger than the inner diameter of the curved recessed portion 23b-b of the connecting portion 23b when it is bent. Due to the compression of the elastic member 291, a repulsive force acts from the inside, so that the connecting portion 23b is not completely bent. In this state, for example, three connecting cores 23 are combined and temporarily assembled in a ring shape, and then pressed into the shell (cylindrical portion 11). Pressing can be performed without using a special clamp, and can also be performed using Fig.14A and Fig. 14B This is done using a fixture as described in the description.

[0096] When a plurality of connected cores 23 (hereinafter sometimes referred to as temporary assembly stators) in a state of being temporarily assembled in a ring shape are pressed into the housing, a force inward is applied to the temporary assembly stator due to the contact between the temporary assembly stator and the inner surface of the housing, but the repulsive force generated by the elastic member 291 and the force received from the inner surface of the housing cancel each other out. The outer peripheral surface of the temporary assembly stator in this mutually canceling state is close to the true roundness of the inner surface of the housing. Therefore, by fixing the temporary assembly stator with an adhesive or the like in this mutually canceling state, good true roundness can be maintained.

[0097] In this way, the elastic member 291 generates a force to press the connecting core 23 itself against the housing, so it is easy to obtain a true roundness that matches the true roundness of the inner surface of the housing. In addition, since the elastic member 291 attenuates the vibration, it is possible to prevent the unexpected deformation of the connecting portion 23b, and the generation of noise can be suppressed by attenuating the vibration.

[0098] (Seventh Embodiment)

[0099] In the seventh embodiment, a method of maintaining good roundness when assembling a plurality of connection cores 23 in a ring shape by a method different from the above-mentioned embodiments is proposed.

[0100] Figures 17A to 17C It is a figure which shows an example of the protrusion 23g of 7th Embodiment. Fig.17A The figure shows a strip-shaped connecting core 23 before the connecting cores 23 are bent. A protrusion 23g is provided on the component 23a serving as the left and right ends of the strip-shaped connecting core 23. The protrusion 23g is provided on the curved portion forming the outer periphery of the component 23a. In the example shown in the figure, the curved portion of the component 23a is an arc portion 23f, and a protrusion 23g is provided at one end of the arc portion 23f. When the connecting cores 23 are bent in a ring shape, the protrusion 23g is located at the outermost side of the connecting cores 23, forming the outermost periphery of the connecting cores 23 bent in a ring shape. Thus, at least the protrusion 23g and a portion of the connecting cores 23 are in contact with the inner surface of the cylindrical portion 11 of the shell.

[0101] Fig. 17B The figure shows a state where three connecting cores 23 are pressed into the barrel 11, and the protrusion 23g is in contact with the inner surface of the barrel 11. In the case where the protrusion 23g is not provided, when a plurality of (for example, three) connecting cores 23 are temporarily assembled and then pressed into the housing, the entire surface of the outer circumference of the connecting core 23 or only a few unexpected places on the outer circumference of the connecting core 23 due to dimensional tolerance will be subjected to the reaction force generated by the pressing, so that the contact parts 23c and 23d at the ends of the connecting core 23 of the temporarily assembled stator 2 are separated when pressed, resulting in the disintegration of the connecting core 23.

[0102] In this regard, in the case where the protrusion 23g is provided, Fig. 17CAs shown, the protrusion 23g receives a reaction force as indicated by the arrow from the shell side, which acts to press the contact portion 23c and the contact portion 23d in the circumferential direction, thereby making the connecting cores 23 more firmly connected. In addition, the contact portions 23c and 23d at the ends of the connecting core 23 have convex and concave shapes in the circumferential direction, respectively, and the circumferential clamping force is stabilized by fitting with each other. Even if the contact portions 23c and 23d are flat end faces, sufficient clamping force can be ensured due to the friction force. It should be noted that the press-in can be performed without using a special clamp, and can also be performed using a special clamp. Fig.14A and Fig. 14B It can also be used in conjunction with the clamp described above. Fig.16A and Fig. 16B The elastic member 291 is shown.

[0103] In this way, since the protrusion 23g generates a force to press the connection core 23 itself against the case, it is easy to obtain a roundness that matches the roundness of the inner surface of the case.

[0104] (Eighth Embodiment)

[0105] In the eighth embodiment, a method is proposed to maintain good roundness when assembling a plurality of connecting cores 23 in a ring shape by a method different from the above-mentioned embodiments. That is, in the above-mentioned seventh embodiment, the diameter of the outermost peripheral surface of the connecting core 23 when it is bent in an arc shape is increased by the protrusion 23g, but in the eighth embodiment, the outer shape of the outermost peripheral portion is increased compared to other parts by reducing the curvature of the outer peripheral surface of the assembly 23a.

[0106] Fig.18 FIG. 2 is a diagram showing an example of a bulging portion 23h according to the eighth embodiment, and shows a strip-shaped connection core 23 before being bent. Fig.18 In the embodiment, an arc portion 23f is formed as a curved portion at the upper portion of the component 23a that becomes the left and right ends of the connecting core 23, and the arc portion 23f becomes a bulging portion 23h that bulges toward the cylindrical portion of the shell. The curvature of the bulging portion 23h is changed in a manner that becomes smaller. The dotted line represents the arc portion 23f when the curvature is not changed. The benefits brought by the bulging portion 23h are similar to those of the embodiment of the embodiment of the invention. Figures 17A to 17C The same is true for the protrusion 23g in the middle. In addition, the plurality of connection cores 23 may include a component 23a having an arc portion and a component 23a having a bulging portion having a curvature different from that of the arc portion.

[0107] (Ninth Embodiment)

[0108] In the ninth embodiment, a method of maintaining good roundness when assembling a plurality of connection cores 23 in a ring shape by a method different from the above-mentioned embodiments is proposed.

[0109] Fig.19 2 is a diagram showing an example of a state where the connecting core 23 of the ninth embodiment is assembled in a ring shape. It should be noted that, in the illustrated connecting core 23, a case where the connecting core 23 is composed of three components 23a is used as an example, but it may also be Figure 3A The ring-shaped assembly is performed after the coil is wound, but the coil is not shown in the figure for simplicity.

[0110] exist Fig.19 In the embodiment, flat portions 23e5 are provided at both ends of the end portions 23e1 of the teeth 23e of each assembly 23a constituting the connecting core 23, which are in contact with the wedge-shaped protrusions of the clamp during assembly. In addition, the angle between the flat portions 23e5 of the adjacent assemblies 23a is open relative to the central axis side, and if this angle is referred to as the magnetic pole angle θ, the magnetic pole angle θ is preferably greater than 30 degrees and less than 120 degrees, and further limited to 60 degrees and less than 100 degrees.

[0111] Fig. 20 2 is a diagram showing a situation where a plurality of connecting cores 23 are assembled in a ring shape. Fig. 20 In. A plurality of connecting cores 23 are combined on the outer periphery of the shaft rod 7 with a plurality of wedge-shaped protrusions 7a arranged at equal intervals on the outer periphery as the center. The apex angle of the wedge shape of the protrusion 7a of the shaft rod 7 matches the aforementioned magnetic pole angle θ, and the flat portion 23e5 of each component 23a is arranged in a manner that is in contact with the inclined surface of the wedge shape of the protrusion 7a of the shaft rod 7. In addition, by applying a radial tightening force as indicated by arrow F to the outer peripheral surface of the connecting core 23 using a mold not shown in the figure, the flat portion 23e5 of each component 23a is attracted by the wedge-shaped protrusion 7a of the shaft rod 7, thereby improving the roundness of the annular core formed by the plurality of connecting cores 23. On this basis, the three connecting cores 23 are fixed integrally by resin molding or the like.

[0112] (Tenth Embodiment)

[0113] In the tenth embodiment, a method of maintaining good roundness when assembling a plurality of connection cores 23 in a ring shape by a method different from the above-mentioned embodiments is proposed.

[0114] Fig.21A and Fig.21B It is a diagram showing an example of provisional assembly of the stator 2 according to the tenth embodiment. Fig.21AThe upper insulating member 24 is shown, and in the rotation axis direction, holes (hereinafter referred to as connecting fitting insertion holes) 24b for inserting connecting fittings 45 as connecting members are provided on the left and right sides of the upper part of the upper insulating member 24. It should be noted that the illustration of the hole for the terminal 27 is omitted. In addition, although the illustration of the lower insulating member 25 is omitted, a connecting fitting insertion hole for inserting the connecting fitting 45 is also provided at the lower part of the lower insulating member 25. In addition, the connecting fitting insertion hole 24b only needs to be provided for the component 23a as the end of the connecting iron core 23, but from the perspective of productivity, the upper insulating member 24 and the lower insulating member 25 are uniformly provided with the same structure. However, if it is allowed to prepare two types of upper insulating member 24 and lower insulating member 25 respectively, it is also possible to provide the upper insulating member 24 and the lower insulating member 25 with the connecting fitting insertion hole 24b formed only for the component at the end of the connecting iron core 23.

[0115] During the temporary assembly of the stator 2, if Fig.21B As shown, the connection metal fitting 45 is inserted across the upper insulator 24 and the lower insulator 25 of two connection cores 23 whose ends are connected to connect the plurality of connection cores 23. The connection metal fitting 45 is press-fitted into the case to arrange the stator 2, and then removed.

[0116] In this way, when the plurality of connection cores 23 are temporarily assembled in an annular shape, they are fixed by the connection fittings 45 , thereby ensuring the circularity.

[0117] (Eleventh Embodiment)

[0118] In the eleventh embodiment, a method of maintaining good roundness when assembling a plurality of connection cores 23 in a ring shape by a method different from the above-mentioned embodiments is proposed.

[0119] Fig.22A and Fig. 22B It is a diagram showing an example of provisional assembly of the stator 2 according to the eleventh embodiment. Fig.22A The upper insulating member 24 is shown, and a groove portion (hereinafter referred to as an adhesive filling groove) 24c is provided on the upper portion of the upper insulating member 24, which is open at one end in the direction of the rotation axis. The groove portion extends along the circumferential direction. It should be noted that the hole portion for the terminal is omitted in the figure. In addition, the lower insulating member 25 is Figure 5 The structure shown is the same.

[0120] like Fig. 22B As shown, after the stator 2 is temporarily assembled, a thermosetting adhesive or a two-component adhesive is poured into the annular groove portion formed by the plurality of adhesive filling grooves 24 c , and the plurality of connection cores 23 are cured while maintaining the annular shape.

[0121] In this way, by curing the adhesive while maintaining the circularity when temporarily assembling the plurality of connection cores 23 in an annular shape, the plurality of connection cores 23 bent in an annular shape can be fixed and the circularity can be ensured.

[0122] (Twelfth Embodiment)

[0123] exist Figure 5 In the description, an example of the terminal 27 mounted on the upper insulating member 24 has been described, but the requirements for the terminal vary depending on the application. For example, there is a case where a hook portion for wiring is required in the terminal for wiring the start or end of the winding of the coil of each component, and a wiring hook portion is further required for winding back the connection wire connecting the coils of each component. If two hook portions are required, the space used for the terminal needs to be large, and there is a disadvantage that it cannot be completely accommodated in the narrow space in the housing.

[0124] Fig.23 1 is a perspective view showing an example of a terminal 27 according to the twelfth embodiment, in which hook portions 27b and 27c are provided in two upper and lower stages on one side of one end portion 27a of the terminal extending along the rotation axis direction. Fig.24 2 is a perspective view showing an example of a conventional terminal 27' of a comparative example, in which hooks 27e and 27f are provided at the upper part of one end 27d of the terminal extending along the rotation axis and at both ends extending along the circumferential direction. Fig.23 In the present embodiment, since the hook portions 27b and 27c are provided in two stages in the upper and lower parts on the same side of the terminal 27, the winding can be wound in a small space in the housing, thereby effectively utilizing the space in the housing.

[0125] (Thirteenth embodiment)

[0126] Terminals of this type that use a hook to wrap the end of the conductor sometimes require a locking portion (hereinafter referred to as a release pin) (Japanese original: アズケピン) for hooking the conductor at the start / end of winding. Usually, the release pin is provided outside the core (including the connecting core 23) for winding, for example, on an outer frame fixture. In special examples, the release pin is also provided on a portion of the insulating member covering the core. However, when the release pin is provided outside the core, the outer frame fixture is required until the welding process for wiring, and a dedicated winding outer frame fixture needs to be applied to each core. In addition, when the release pin is provided on the insulating member, there is almost no space around the release pin in most cases, which restricts the winding itself and makes it difficult to carry out the winding. The present embodiment proposes a solution thereto.

[0127] Fig.252 is a perspective view showing an example of a terminal 27 of the thirteenth embodiment, in which a release pin 27h is provided at the central part of the upper part of one end 27g of the terminal extending in the longitudinal direction (from the insulating member toward the cover), and hooks 27i and 27j are provided at the two wings of the upper part. In this embodiment, since the release pin 27h is provided on the terminal 27, the release and winding of the winding can be completed in a small space on the terminal 27. That is, by positioning the release pin 27h at the start / end of winding at the terminal 27 when winding, a winding fixture is not required. In addition, since there is no need to provide a release pin on the insulating member, the utilization of the space occupied by the insulating member in the housing is improved.

[0128] (Fourteenth Embodiment)

[0129] The fourteenth embodiment shows another example of the terminal 27 including the latching and releasing pin. Fig.26 2 is a perspective view showing an example of the terminal 27 of the fourteenth embodiment, in which a release pin 271 is provided on one side of the end portion 27k extending in the longitudinal direction (direction from the insulating member toward the cover), and a hook portion 27m is provided on the other side. In this embodiment, since the release pin 271 is provided on the terminal 27, the release and winding of the winding can be completed in a small space on the terminal 27. That is, by positioning the release pin 271 at the start / end of winding at the terminal 27 when winding, a winding fixture is not required. In addition, since there is no need to provide a release pin on the insulating member, the utilization of the space occupied by the insulating member in the housing is improved.

[0130] (Fifteenth embodiment)

[0131] Figure 3A The connecting core 23 of the structure described above needs to be temporarily assembled in a ring shape after winding coils around each component, and then the coils of each component need to be connected to the desired circuit. This connection needs to be carried out through a printed circuit board or busbar, etc., which is a costly method. This embodiment proposes a solution to this problem.

[0132] Fig. 27 15 is a perspective view showing an example of the upper insulating member 24 according to the fifteenth embodiment. Fig. 27 In the embodiment, hooks 24d and 24e for assisting the connection wire to the teeth side of the stator are provided in the upper part of the upper insulating member 24 in the form of extending in the longitudinal direction (direction from the insulating member toward the cover). In addition, a plurality of grooves 24f and 24g for winding the connection wire are provided on both sides of the upper part of the upper insulating member 24.

[0133] When in use, in the connection after the coils of each assembly are wound, for example, the connection wires from the circumferentially opposed assemblies of the same phase are passed through the groove 24f of the outer circumference and clamped on (wrapped around) the hook 24d or the hook 24e, so as to be connected to the terminal 27 (not shown) arranged on the upper part of the upper insulating member 24. By such a method, it is unnecessary to use components such as a printed circuit board and a bus bar, and the connection wires can be stored more smoothly, thereby fully utilizing the advantages of the connection core.

[0134] (Sixteenth Embodiment)

[0135] Figure 3A The connecting core 23 of the structure described in the above description can be used to wind the coil when the assembly 23a is open, so there is also a situation where the coil is required to be wound as much as possible. Although it is an advantage of the connecting core 23 that this requirement can be achieved, if multiple connecting cores 23 are bent and assembled in a ring shape after the coil is wound, the coils that are wound to the limit will be squeezed against each other, and there is also a concern that the coating layer of the coil will be damaged and cause a short circuit. This embodiment proposes a solution to this problem.

[0136] Fig.28A and Fig.28B 1 is a diagram showing an example of insertion of a plate (hereinafter referred to as a partition plate) 292 according to the sixteenth embodiment. Fig.28A The partition plate 292 is formed of an elastic member such as rubber, and is integrally formed with a rod-shaped portion 292 a extending in the longitudinal direction and a rectangular flat plate portion 292 b.

[0137] When in use, the rod-shaped portion 292 a of the partition plate 292 is inserted into the curved recessed portion ( 23 b - b ) of the connection portion 23 b of the connection core 23 around which the coil 26 is wound, and the flat plate portion 292 b is disposed between the side surfaces of adjacent coils 26 . Fig.28B The state where the partition plate 292 is arranged in the stator 2 is shown. Therefore, even if the plurality of connection cores 23 are bent and assembled in a ring shape, the coils 26 do not come into direct contact with each other, and short circuits can be prevented, thereby fully demonstrating the advantages of the connection cores.

[0138] (Seventeenth Embodiment)

[0139] As a countermeasure for the temperature rise caused by the current of the stator coil, there are methods such as impregnating the stator with varnish (for example, see Japanese Patent Publication No. 2018-74827) or resin molding the stator (for example, see Japanese Patent Publication No. 2009-50048), but both methods have the problem of consuming equipment and man-hours. In the seventeenth embodiment, a countermeasure for the temperature rise is proposed without consuming equipment and man-hours.

[0140] Fig.29FIG. 1 is a diagram showing an example of a countermeasure for a temperature rise according to the seventeenth embodiment. Fig.29 , the following state is shown: in a state where the upper insulating member 24, the lower insulating member 25 and the terminal 27 are assembled on each component 23a of the straight connecting core 23 before bending and the coil 26 is wound, a sheet-like resin member is sandwiched between each coil 26. The sheet-like (plate-like) resin member is a member (sheet) 8 formed of a gel having a high thermal conductivity. The gel may be, for example, a viscous gel, a jelly-like gel, or a gel with low fluidity, and an example is an example formed of a resin material such as silicone. Fig.30 It is a plan view showing a state where the sheet-shaped resin member 8 is inserted between adjacent coils 26 .

[0141] Fig.31 This is a diagram showing a state where the connecting core 23 is bent with a sheet-like resin member 8 inserted therein. When the connecting core 23 is bent in an arc shape, the sheet-like resin member 8 sandwiched between the coils 26 is flattened, and the coils 26 are in close contact with the sheet-like resin member 8. By setting it in this way, the air area between the coils 26 with low thermal conductivity is filled with the sheet-like resin member 8, thereby improving the heat dissipation. It should be noted that the sheet-like resin member 8 can also be set between the coils 26 at the ends of the adjacent connecting cores 23 combined in an annular shape, thereby flattening the sheet-like resin member 8 when forming an annular shape.

[0142] As mentioned above, although embodiment of this invention was described, this invention is not limited to the said embodiment, Various changes can be made as long as they do not deviate from the summary.

[0143] For example, you can also use Figure 1 The connecting plate 28 shown in the figure is used to connect the plurality of coils 26 in parallel. By using the connecting plate 28, parallel connection can be easily performed, and even if thick windings are not used for operation with large currents, equivalent thick wires can be achieved by connecting the windings in parallel, and the reduction in the winding duty factor, increase in winding resistance, increase in thermal resistance, and increase in coil end size caused by the use of thick windings can be suppressed.

[0144] The motor of the embodiment includes a stator, the stator includes a plurality of connecting cores, and the connecting core includes a plurality of components connected via a connecting portion. In addition, the plurality of components are arranged in an arc shape, and the plurality of connecting cores are arranged in a ring shape. Thus, the vibration of the stator can be reduced and productivity can be improved.

[0145] In addition, the stator includes three connection cores, and the connection core includes four components. This can provide a more specific structure.

[0146] In addition, the motor is provided with a connection plate for electrically connecting the coil wound on the assembly. Thus, wiring can be easily performed, and a guide portion for guiding the connection wire is not required, thereby reducing the useless space of the motor. In addition, equivalent thick wires can be achieved by connecting the windings in parallel, and operation under large current can be handled.

[0147] In addition, in the circumferential direction, the winding directions of the coils wound on two of the plurality of assemblies are the same direction. Thus, the coils can be wound on the plurality of connected cores in parallel, thus contributing to a significant improvement in productivity.

[0148] In addition, the connecting core has four components, and in the circumferential direction, the winding direction of the coils wound on the two components located at the two ends of the plurality of components is one direction, and the winding direction of the coils wound on the two components located between the two ends is the opposite direction to the one direction. Thus, a more specific structure can be provided.

[0149] In addition, the connecting core is formed of a grain-oriented electromagnetic steel sheet, and the hard-magnetized axial direction of the grain-oriented electromagnetic steel sheet is the direction from one connecting part of the multiple connecting parts of the connecting core toward another connecting part. This can prevent magnetic saturation of the connecting part and suppress unnecessary heat generation caused by magnetic loss.

[0150] In addition, two of the plurality of connecting cores that are in contact with each other are provided with contact portions, and the contact portions of the two connecting cores are provided with a surface that intersects with a surface that extends in the radial direction and passes through the center of the shaft. Thus, the contact portions can be meshed with each other to prevent radial deviation, thereby improving the roundness of the stator.

[0151] Furthermore, the number of components included in the plurality of connection cores is an even number, and the number of the plurality of connection cores is an odd number or a prime number. This facilitates assembly.

[0152] The motor manufacturing method of the embodiment is designed to arrange the connection core including a plurality of components connected via a connection portion in an arc shape and to arrange a plurality of connection cores including the connection core in an annular shape, thereby reducing vibration and noise of the stator and improving productivity.

[0153] In addition, the ends of the plurality of connected cores arranged in a ring are held by the contact portion of the clamp, and the held plurality of connected cores are pressed into the housing. More specifically, the plurality of connected cores are pressed into the housing while the front end of the contact portion is inserted into the housing. Thus, a high-precision stator can be manufactured in a short time.

[0154] In addition, the surfaces of the contact parts of the two components on both sides of the connecting core are arranged in a direction perpendicular to the direction in which the multiple components are arranged, and the coil is wound around the connecting core. Thus, the coil can be wound around each component of the connecting core with a predetermined tension using a winding machine, which can increase the occupancy rate of the coil.

[0155] In addition, the motor includes a stator, the stator includes a plurality of connecting cores, the connecting cores include a plurality of components connected via a connecting portion, and the side of the connecting portion includes a recess. Furthermore, the plurality of connecting cores are arranged in a ring shape, and an elastic member is arranged in the recess. Thus, the vibration and noise of the stator can be reduced and productivity can be improved. That is, the elastic member acts to exert a force to expand the components, and the plurality of connecting cores are pressed against the inner circumferential surface of the housing. Thus, the stator has a true roundness equivalent to the true roundness of the inner circumference of the housing.

[0156] In addition, the elastic members are arranged in the recessed portions of the plurality of connecting cores. Thus, the elastic members can be arranged uniformly, and roundness can be achieved.

[0157] In addition, the elastic member is disposed in a part of the recessed portion of the plurality of connection cores. Thus, the elastic member to be used can be minimized to achieve roundness.

[0158] In addition, the motor includes a housing, and the outer peripheral portions of the plurality of components are in contact with the inner surface of the housing. Thus, a stator having a circularity equivalent to that of the inner periphery of the housing can be realized.

[0159] In addition, the outer peripheries of two components located at both ends of the connection core among the plurality of components are provided with protrusions, thereby preventing the connection core from being disassembled during assembly, and maintaining the roundness.

[0160] In addition, an elastic member is arranged inside the concave portion of the connection portion, and a plurality of connection cores including a plurality of assemblies connected by the connection portion are arranged in an arc shape. This can reduce vibration and noise of the stator and improve productivity.

[0161] In addition, the plurality of connection cores arranged in an annular shape are press-fitted into the housing. This makes it possible to easily mount the stator.

[0162] In addition, the motor includes a stator, the stator includes a plurality of connecting cores, the connecting cores include a plurality of components connected via a connecting portion, and a protrusion is provided on the outer periphery of two components located at both ends of the connecting core among the plurality of components. Furthermore, the plurality of connecting cores are arranged in a ring shape. The protrusion 23g and the bulging portion 23h are examples of protrusions, respectively. Thus, the vibration and noise of the stator can be reduced and the productivity can be improved. That is, by utilizing the protrusion to more firmly connect the connecting cores to each other, the connecting cores will not disintegrate, and the roundness can be improved.

[0163] In addition, the protrusion is a bulging portion that bulges out from the outer peripheral portion of the assembly. Thus, the protrusion can be easily configured.

[0164] In addition, the motor includes a housing, and the protrusion is in contact with the inner surface of the housing. Thus, a strong contact between the connecting cores can be achieved.

[0165] In addition, the side portion of the connection portion is provided with a recessed portion, and an elastic member is disposed inside the recessed portion. This can improve the circularity of the stator.

[0166] In addition, in a connection core having a plurality of components connected via a connection portion, in a connection core having a plurality of components connected via connection portions at both ends of the connection core, protrusions are provided on the outer peripheries of two components located at both ends of the connection core among the plurality of components, and the plurality of connection cores including the connection core are arranged in a ring shape. Thus, vibration and noise of the stator can be reduced and productivity can be improved.

[0167] In addition, the present invention is not limited by the above-mentioned embodiment. The scheme obtained by appropriately combining the above-mentioned various constituent elements is also included in the present invention. In addition, further effects and modifications can be easily derived by those skilled in the art. Thus, the scheme of the wider scope of the present invention is not limited by the above-mentioned embodiment and can be variously changed.

[0168] The present application enjoys the priority of Tokugan Application No. 2018-157659 filed in Japan on August 24, 2018, Tokugan Application No. 2018-157660 filed in Japan on August 24, 2018, and Tokugan Application No. 2018-157661 filed in Japan on August 24, 2018.

[0169] Description of Reference Numerals

[0170] 1 motor, 11 cylinder, 2, 21 stator, 23 connecting core, 23a assembly, 23b connecting portion, 23b-b recess, 23e5 flat portion, 23g protrusion, 23h bulging portion, 23i slot, 26 coil, 28 connecting plate, 291 elastic member, 3 rotor, 32 shaft, 42 stator holding fixture, 43 contact portion, 8 sheet-shaped resin member, 9 oriented electromagnetic steel sheet, W conductor, θ magnetic pole angle

Claims

1. A stator temporarily assembled in a ring shape, wherein: It has a plurality of connecting cores, a plurality of insulating members and a plurality of coils. The connecting core includes a plurality of components connected via a connecting portion. The plurality of insulating members are assembled on the plurality of components, The plurality of coils are wound around the plurality of insulating members, The multiple components are arranged in an arc shape, The plurality of connecting cores are arranged in a ring shape, The plurality of insulating members include two insulating members connected in the circumferential direction by a connecting member and two insulating members separated from each other in the circumferential direction.

2. The stator temporarily assembled in an annular shape according to claim 1, wherein: The number of the plurality of connecting cores is an odd number or a prime number, The number of components included in the link core is an even number.

3. The stator temporarily assembled in an annular shape according to claim 1 or 2, wherein: In the circumferential direction, the coils wound around two of the plurality of components are wound in the same direction.

4. The stator temporarily assembled in an annular shape according to claim 3, wherein: The number of components of the connecting core is four, In the circumferential direction, the coils wound on two components located at both ends of the plurality of components are wound in one direction, and the coils wound on two components located between the two ends are wound in a direction opposite to the one direction.

5. The stator temporarily assembled in an annular shape according to any one of claims 1 to 4, wherein: The connecting core is formed of a grain-oriented electromagnetic steel sheet. The hard-magnetization axial direction of the grain-oriented electromagnetic steel sheet is a direction from one of the plurality of connection parts included in the connection core toward another connection part.

6. The stator temporarily assembled in an annular shape according to claim 1, wherein: Two of the plurality of connecting cores that are in contact with each other each have a contact portion, A surface intersecting with a surface extending in the radial direction and passing through the axis is provided at the contact portion of the two connection cores.

7. The stator temporarily assembled in an annular shape according to claim 1, wherein: The number of components of the connecting core is four, The number of the plurality of connecting cores is three.

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