Stator and motor
By designing the tooth cover and protrusion structure of the insulator component in the stator teeth, the problem of insulation wrapping cracking when the coil is bent is solved, the durability of the coil and the stability of the stator are improved, and the coil and teeth are effectively fixed.
Patent Information
- Application Number
- CN202511167423.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Priority Date
- 2024-08-23
- Filing Date
- 2025-08-20
- Publication Date
- 2026-03-03
AI Technical Summary
In the prior art, when the coil bends at the stator teeth, the insulation covering is prone to breakage due to excessive tension, and it is difficult to effectively suppress the radial movement of the coil, which affects durability.
The design employs an insulator component, including a toothed cover and a pair of protrusions. The toothed cover covers the end face of the toothed part, and the pair of protrusions protrude axially from the end of the toothed cover. The coil contacts the outer side of the protrusions, and during the winding process, the curvature of the bent part is reduced through plastic deformation to prevent the insulation sheet from breaking and the coil from falling off.
It improves the durability of the coil, suppresses the radial movement of the coil relative to the teeth, prevents the insulation from breaking, and enhances the overall structural stability of the stator.
Smart Images
Figure CN121602691A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to a stator and a motor. Background Technology
[0002] A motor is known in which an insulating member made of resin covers the axial end face of a stator core. A coil is wound around the teeth of the stator core through the insulating member. The insulating member insulates the coil from the axial end face of the stator core (e.g., Patent Document 1).
[0003] Existing technical documents
[0004] Patent documents
[0005] Patent Document 1: Chinese Utility Model No. 216981641 Specification
[0006] The coil wound around the teeth is bent to prevent radial movement by applying tension near the corners of the teeth. By bending the coil in this way, the outer side is stretched and the inner side is compressed at the bent portion of the coil. Therefore, if excessive tension is applied to the coil, the insulation covering the wires constituting the coil may break at the bent portion. Summary of the Invention
[0007] The object of the present invention is to provide a configuration in a stator in which the coil is wound around the teeth with an insulating member in between, which can improve the durability of the coil and suppress radial movement of the coil relative to the teeth.
[0008] An exemplary embodiment of the present invention provides a stator comprising: a stator core having an axially extending cylindrical back and a plurality of teeth extending radially from the back and arranged circumferentially, wherein adjacent teeth in the plurality of teeth form a plurality of circumferentially arranged slots; an insulator member covering an axial end face of the stator core; and a coil wound around each of the plurality of teeth with respect to the insulator member. The insulator member comprises: a tooth cover portion disposed on the axial end face of each of the plurality of teeth; and a pair of protrusions projecting axially from one circumferential end and the other end of the tooth cover portion, respectively. The coil contacts the outer surface of the pair of protrusions opposite to their opposing inner surfaces.
[0009] A motor according to an exemplary embodiment of the present invention has: the stator; and a rotor having magnets radially opposed to the stator.
[0010] The effects of this invention are as follows.
[0011] According to the present invention, a configuration can be provided in a stator in which the coil is wound around the teeth with an insulating member in between, which can improve the durability of the coil and suppress radial movement of the coil relative to the teeth. Attached Figure Description
[0012] Figure 1 This is a cross-sectional view showing the schematic configuration of the motor according to an embodiment.
[0013] Figure 2 It is a three-dimensional diagram showing the general structure of the stator.
[0014] Figure 3 This is a top view of the stator core.
[0015] Figure 4 It is a magnified three-dimensional view showing a portion of the stator.
[0016] Figure 5 It is a three-dimensional diagram showing the general structure of the insulator components.
[0017] Figure 6 It is a cross-sectional view obtained by cutting the insulator component and the teeth along the circumference.
[0018] Figure 7 This diagram schematically illustrates the situation where a wire is wound around a tooth.
[0019] Figure 8 This diagram schematically illustrates the situation where a wire is wound around a tooth.
[0020] Figure 9 It is a cross-sectional view obtained by radially cutting the toothed part with the wire wound around it.
[0021] Figure 10 It is a cross-sectional view obtained by circumferentially cutting the insulating component and teeth of the modified example.
[0022] In the diagram: 1—Motor, 2—Stator, 3—Rotor, 4—Shaft, 5—Stator cage, 6—Bearing, 21—Stator core, 22—Coil, 22a—Wire, 24, 124—Insulator components, 25—Insulating sheet, 25a—Sheet end, 31—Magnet, 32—Yoke, 33—Rim, 34—First wheel cover, 35—Second wheel cover, 35a—Brake drum, 51—Through hole, 211—Core back, 212—Gear, 213—Slot, 241—Core back Cover portion, 241a—rib portion, 242, 1242—tooth cover portion, 243—protrusion portion, 243a—inner side surface, 243b—outer side surface, 243c—base end portion, 243d—top end portion, 244—plastic deformation portion, 251—tooth contact portion, 252—core back contact portion, 253—bent portion, R—bent portion of coil, S—space between protrusion portion and tooth cover, L0—length of tooth portion in the circumferential direction, L1—length of protrusion side of tooth cover portion in the circumferential direction. Detailed Implementation
[0023] Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings. It should be noted that the same or equivalent parts in the drawings are labeled with the same reference numerals, and their descriptions will not be repeated. Furthermore, the dimensions of the constituent components in the drawings do not accurately represent the actual dimensions of the constituent components or the dimensional ratios of each constituent component.
[0024] In the following description, the direction parallel to the central axis P of the motor 1 is called the axial direction, the direction orthogonal to the central axis P is called the radial direction, and the direction along the arc centered on the central axis P is called the circumferential direction. However, it is not intended that the orientation of the motor 1 of the present invention be limited by the definition of these directions. It should be noted that in the figures, A represents the axial direction, B represents the radial direction, and C represents the circumferential direction. In the radial direction B, B1 represents the direction in which the tooth portion 212 is located relative to the back surface 211 of the core, and B2 represents the direction in which the back surface 211 of the core is located relative to the tooth portion 212.
[0025] Furthermore, in the following explanation, the expressions "fixed," "connected," and "installed" (hereinafter, "fixed, etc.") include not only cases where components are directly fixed to each other, but also cases where they are fixed via other components. That is, in the following explanation, the expressions "fixed, etc." include both direct and indirect fixing of components to each other.
[0026] (The composition of a motor)
[0027] Reference Figure 1 The motor 1 of an exemplary embodiment of the present invention will be described. Figure 1This is a cross-sectional view showing the general configuration of motor 1. In this embodiment, motor 1 is, for example, an in-wheel motor disposed on the rear wheel of an electric motorcycle. It should be noted that the motor can also be disposed on the front wheel of an electric motorcycle.
[0028] like Figure 1 As shown, motor 1 has a stator 2 and a rotor 3. Motor 1 also has a shaft 4, a stator cage 5, and a bearing 6.
[0029] Shaft 4 is a column extending along axis A with central axis P as its center. Shaft 4 is mounted to the main body of the electric motorcycle in a manner that prevents it from rotating relative to the main body of the electric motorcycle.
[0030] The stator cage 5 is a disk-shaped structure centered on the central axis P. The stator cage 5 has a through hole 51 extending axially along axis A at its center. The shaft 4 is inserted into the through hole 51 and protrudes from both axial ends of the through hole 51. For example, the shaft 4 can be directly pressed into the through hole 51, or indirectly pressed into the through hole 51 by installing a sleeve component, thereby fixing the stator cage 5 to the shaft 4.
[0031] Stator 2 is the armature of motor 1. Stator 2 is a cylindrical shape extending along axis A. Stator 2 is located radially outside stator cage 5. Stator 2 is fixed to stator cage 5. That is, stator 2 is fixed to shaft 4 in a manner that prevents it from rotating relative to shaft 4. Details about stator 2 will be described later.
[0032] The rotor 3 has a magnet 31, a yoke 32, a rim 33, a first wheel cover 34, and a second wheel cover 35. The magnet 31 of the rotor 3 is opposite to the stator 2 in the radial direction B. In this embodiment, the magnet 31 is located radially outside the stator 2 with a gap. Multiple magnets 31 are arranged at equal intervals in the circumferential direction. It should be noted that the magnet may not be multiple, but may be a single ring-shaped magnet.
[0033] The magnetic yoke 32 is a cylindrical shape extending along the axial direction A with the central axis P as the center. The magnet 31 is fixed to the inner circumferential surface of the magnetic yoke 32.
[0034] The rim 33 is annular with the central axis P as its center. The rim 33 is located radially outside the magnetic yoke 32. The rim 33 is fixed to the magnetic yoke 32. The rear tire is mounted on the radially outer side of the rim 33.
[0035] The first wheel cover 34 is located on one side of the axial direction and radially inward relative to the magnetic yoke 32. The first wheel cover 34 is mounted on the shaft 4 in a rotatable manner relative to the shaft 4 via bearings 6 such as ball bearings. The outer periphery of the first wheel cover 34 is fixed to the magnetic yoke 32 by screws or the like. Therefore, the first wheel cover 34, together with the magnetic yoke 32 and the wheel rim 33, rotates about the central axis P.
[0036] The second wheel cover 35 is located on the opposite side of the axial direction and radially inward relative to the magnetic yoke 32. The second wheel cover 35 is mounted on the shaft 4 in a rotatable manner relative to the shaft 4 via bearings 6 such as ball bearings. The outer periphery of the second wheel cover 35 is fixed to the magnetic yoke 32. Therefore, the second wheel cover 35, together with the magnetic yoke 32, the wheel rim 33, and the first wheel cover 34, rotates around the central axis P.
[0037] The second wheel cover 35 has a brake drum 35a that protrudes axially. The brake drum 35a is integrally formed with the second wheel cover. For example, a braking mechanism for the motorcycle body side of an electric motorcycle is disposed on the inner circumferential side of the brake drum 35a.
[0038] The rotor 3 rotates around the central axis P using the circumferential torque generated by supplying drive current to the stator 2.
[0039] (Details of the stator)
[0040] Reference Figures 1 to 4 The stator 2 of this embodiment will be described. Figure 2 This is a three-dimensional view showing the general structure of stator 2. Figure 3 This is a top view of stator core 21. Figure 4 This is a magnified perspective view showing a portion of the stator 2 before the winding coil 22. It should be noted that... Figure 2 In addition to showing the stator 2, the stator cage 5 is also shown.
[0041] like Figure 2 As shown, the stator 2 has a stator core 21, a coil 22, an insulator component 24, and an insulating sheet 25.
[0042] like Figure 1 As shown, the stator core 21 is disposed radially inside the magnet 31, with a gap between it and the magnet 31. The stator core 21 is a magnetic material. In this embodiment, the stator core 21 is constructed by stacking electromagnetic steel sheets.
[0043] like Figure 3 As shown, the stator core 21 has a core back 211 and a plurality of teeth 212. The core back 211 is cylindrical and extends along the axial direction A. The teeth 212 extend radially B from the core back 211. In this embodiment, the teeth 212 extend radially outward from the core back 211.
[0044] Multiple teeth 212 are arranged circumferentially C. Grooves 213 are formed between adjacent teeth 212 in the circumferential direction C. Multiple grooves 213 are arranged circumferentially C.
[0045] like Figure 2 As shown, coil 22 is wound around tooth 212. In detail, coil 22 is formed by winding wire 22a covered by an insulator around tooth 212.
[0046] When a driving current is supplied to the coil 22, a radial magnetic flux is generated in the tooth section 212. As a result, a circumferential torque is generated in the rotor 3, which has the magnet 31, and the rotor 3 rotates about the central axis P.
[0047] The coil 22 is wound around each of the teeth 212, with the insulator member 24 and the insulating sheet 25 in between. The insulator member 24 and the insulating sheet 25 are insulators. In this embodiment, the insulator member 24 and the insulating sheet 25 are made of resin.
[0048] like Figure 4 As shown, the insulator member 24 is disposed on one axial end face and the other axial end face of the stator core 21. That is, the insulator member 24 covers at least a portion of the axial A end face of the stator core 21. In this embodiment, the insulator member 24 disposed on one axial end face of the stator core 21 has the same configuration as the insulator member 24 disposed on the other axial end face. Details regarding the insulator member 24 will be described later.
[0049] like Figure 4 As shown, an insulating sheet 25 is disposed within a groove 213. One insulating sheet 25 is disposed on each of the inner circumferential surfaces of the plurality of grooves 213. The insulating sheet 25 has a shape that runs along the inner circumferential surface of the groove 213.
[0050] Specifically, the insulating sheet 25 has a pair of toothed contact portions 251 extending radially B and a core-back contact portion 252 extending circumferentially. The pair of toothed contact portions 251 contact a pair of opposing side surfaces of adjacent teeth 212 in the circumferential direction. The core-back contact portion 252 contacts a portion of the outer peripheral surface of the core back 211 located between the pair of side surfaces. Viewed along the axial direction A, the insulating sheet 25 has a bend 253 between the core-back contact portion 252 and each of the pair of toothed contact portions 251.
[0051] The insulating sheet 25 has a sheet end portion 25a protruding from the groove 213 in the axial direction A. In this embodiment, the length of the sheet end portion 25a in the axial direction A is less than the length of the insulating member 24 in the axial direction A. Therefore, the sheet end portion 25a covers at least a portion of the end face of the insulating member 24 in the circumferential direction C.
[0052] like Figure 2 As shown, the coil 22 is wound around the tooth 212 via an insulator member 24 and an insulating sheet 25. That is, the insulator member 24 is located between the tooth 212 and the coil 22 in the axial direction A. The insulating sheet 25 is located between the tooth 212 and the coil 22 in the circumferential direction C. The stator core 21 and the coil 22 are insulated by the insulator member 24 and the insulating sheet 25.
[0053] When an outward force is applied to the insulating sheet 25, the bent portion 253 may break. That is, the end portion 25a of the sheet may break when it is pressed outward by the coil 22 wound around the tooth portion 212.
[0054] In this embodiment, an insulating member 24 is present on the circumferential C of the end piece 25a. Therefore, the end piece 25a will not expand outward even if pressed by the coil 22. Thus, breakage of the insulating sheet 25 can be prevented.
[0055] (Details of the insulating components)
[0056] Next, refer to Figures 4 to 6 The insulating component 24 is described in detail. Figure 5 This is a perspective view showing the general structure of the insulator component 24. Figure 6 This is a cross-sectional view obtained by cutting the insulator component 24 and the tooth 212 along the circumferential direction C. For example... Figure 5 As shown, the insulator member 24 is plate-shaped. The insulator member 24 has an annular core back cover portion 241, multiple toothed cover portions 242, and multiple protrusions 243.
[0057] The core back cover 241 is annular with the central axis P as its center. For example... Figure 4 As shown, the core back cover portion 241 is disposed on the axial A end face of the core back cover 211. The core back cover portion 241 covers at least a portion of the axial A end face of the core back cover 211. The thickness of the core back cover portion 241 is equal to the thickness of the tooth cover portion 242 described later. The core back cover portion 241 insulates the coil 22 from the core back cover 211 of the stator core 21.
[0058] like Figure 4 As shown, the core back cover portion 241 has a plurality of ribs 241a protruding axially A on the surface opposite to the surface of the core back cover 211. The plurality of ribs 241a improve the rigidity of the core back cover portion 241.
[0059] In this embodiment, a plurality of ribs 241a extend radially along B. Specifically, viewed along the axial direction A, the plurality of ribs 241a extend radially along B at positions corresponding to the circumferential positions of the protrusions 243 of the insulator member 24, which will be described later. In this embodiment, the plurality of ribs 241a are connected to the protrusions 243 radially along B.
[0060] It should be noted that each rib may extend radially along B at a position different from the circumferential position of the protrusion, or it may extend in a direction other than radially along B. As in this embodiment, by aligning the circumferential position of the rib 241a with the circumferential position of the protrusion 243, the shape of the resin molding die for molding the insulator member 24 can be simplified.
[0061] like Figure 5 As shown, a plurality of toothed covers 242 extend in the stator core 21 in the direction in which the toothed portion 212 extends from the back of the core 211. That is, in this embodiment, the toothed covers 242 extend radially outward from the back of the core 211.
[0062] like Figure 4 As shown, a plurality of toothed covers 242 are disposed on the end faces of a plurality of teeth 212 along the axial direction A. The number of toothed covers 242 is the same as the number of teeth 212. The plurality of toothed covers 242 respectively cover at least a portion of the end face of each tooth 212 along the axial direction A.
[0063] Multiple pairs of protrusions 243 protrude axially A from multiple toothed cover portions 242. Specifically, one pair of protrusions 243 protrudes axially A from one toothed cover portion. In this embodiment, the multiple toothed cover portions 242 have identical configurations. Furthermore, the pair of protrusions 243 protruding from each toothed cover portion 242 have identical configurations. Therefore, the following description will focus on the pair of protrusions 243 protruding from one toothed cover portion.
[0064] like Figure 6 As shown, a pair of protrusions 243 protrude axially from one end of the toothed cover portion 242 in the circumferential direction C and the other end of the toothed cover portion 242, respectively. The pair of protrusions 243 have opposing inner surfaces 243a and outer surfaces 243b on the opposite side. The coil 22 contacts the outer surfaces 243b of the pair of protrusions 243.
[0065] In this embodiment, a pair of protrusions 243 protrude axially from the top of one and the top of the other on the circumferential C of the toothed cover portion 242. Here, the top on the circumferential C refers to the outermost end on the circumferential C. That is, there is no step between the outer surface 243b of the pair of protrusions 243 and the end face on the circumferential C of the toothed cover portion 242.
[0066] It should be noted that the pair of protrusions only need to protrude axially from one end of the toothed cover portion in the circumferential direction C and the other end of the toothed cover portion, respectively. Here, the end in the circumferential direction C refers to a certain range including the top point in the circumferential direction C. That is, the pair of protrusions can be located at the top point in the circumferential direction C, viewed radially B, or they can be located on the central side of the toothed cover portion in the circumferential direction C, closer to the top point. The outer surfaces of the pair of protrusions and the end faces in the circumferential direction C of the toothed cover portion may also have a step.
[0067] In this embodiment, when the gear cover portion 242 is viewed radially along B, a pair of protrusions 243 are located symmetrically with respect to a left-right symmetry line. The left-right symmetry line is a line extending axially along A at the center of the circumferential direction C of the gear cover portion 242 when viewed radially along B. The shapes of the pair of protrusions 243 are symmetrical with respect to the left-right symmetry line.
[0068] In this embodiment, the pair of protrusions 243 are plate-shaped and inclined toward each other as they move away from the toothed cover portion 242. The insulator member 24 has a space S between the inner surface 243a of the pair of protrusions 243 and the toothed cover portion 242.
[0069] In this embodiment, the pair of protrusions 243 have traces of plastic deformation at their base ends 243c, which serve as the connection portion with the gear cover portion 242. Specifically, the pair of protrusions 243 have traces of plastic deformation at their base ends 243c, changing from a state extending perpendicularly relative to the gear cover portion 242 to a state inclined relative to the gear cover portion 242. That is, the pair of protrusions 243 have plastically deformed portions 244 at their base ends 243c.
[0070] Next, the relationship between the pair of protrusions 243 of the insulator member 24 having the above-described configuration and the coil 22 will be explained. In this embodiment, as... Figure 7 and Figure 8 As shown, a pair of protrusions 243 are tilted during the winding process of the coil 22 during manufacturing.
[0071] Specifically, in the process described above, the wires 22a constituting the coil 22 are directed towards... Figure 8 Tension is applied in the direction of the hollow arrowhead, and the wire 22a is wound around the tooth portion 212. The wire 22a, under tension in the direction of the hollow arrowhead, generates a force in the direction of the winding center. The force of the wire 22a in the direction of the winding center presses a pair of protrusions 243 toward the tooth cover portion 242. As a result, the pair of protrusions 243 tilt. Consequently, a plastic deformation portion 244 is formed at the base end portion 243c of the pair of protrusions 243.
[0072] like Figure 6 As shown, the coil 22 wound around the tooth 212 has a bend R between the portion extending axially along the side of the tooth 212 along the axial direction A and the portion extending circumferentially along the end face of the tooth 212 along the axial direction A. The bend R is formed by bending the wire 22a constituting the coil 22 during the winding process.
[0073] In this embodiment, during the winding process of the coil 22, a pair of protrusions 243 are pressed and tilted by the coil 22. That is, the pair of protrusions 243 reduce the curvature of the bend R of the coil 22. Therefore, by winding the coil 22 onto the toothed portion 212 through the insulating member 24 configured as described above, the rupture of the wire 22a can be suppressed. As a result, the durability of the coil 22 can be improved.
[0074] Furthermore, during the winding process of coil 22, the wire 22a comes into contact with the tip 243d of the protrusion 243. That is, in this embodiment, during this process, the surface pressure acting on the tip 243d of the protrusion 243 is high. Therefore, as... Figure 9 As shown, the wire 22a can be inserted into the tip portion 243d of the protrusion 243. Therefore, radial movement of the wire 22a relative to the insulator member 24 along the radial direction B can be suppressed. Therefore, the coil 22 composed of the wire 22a can be prevented from falling off the tooth portion 212.
[0075] Therefore, a stator 2 can be provided that can improve the durability of the coil 22 and suppress the movement of the coil 22 relative to the tooth portion 212 in the radial direction B.
[0076] As described above, the exemplary stator 2 of this embodiment includes: a stator core 21 having a cylindrical core back 211 extending along an axial direction A and a plurality of teeth 212 extending radially from the core back 211 and arranged circumferentially along a direction C, wherein a plurality of grooves 213 arranged circumferentially along a direction C are formed between adjacent teeth 212 in the plurality of teeth 212; an insulator member 24 covering the end face of the stator core 21 in the axial direction A; and a coil 22 wound around each of the plurality of teeth 212 with respect to the insulator member 24. The insulator member 24 includes: a tooth cover portion 242 disposed on the end face of the plurality of teeth 212 in the axial direction A; and a pair of protrusions 243 protruding axially from one end and the other end of the tooth cover portion 242 in the circumferential direction C. The coil 22 contacts the outer surface 243b of a pair of protrusions 243, which is opposite to the inner surface 243a of the two protrusions. It should be noted that, here, the end in the circumferential direction C refers to a certain range including the top point in the circumferential direction C.
[0077] The coil 22 wound around the tooth 212 has a bend R between the portion extending axially along the side of the tooth 212 along the axial direction A and the portion extending circumferentially along the end face of the tooth 212 along the axial direction A. The bend R is formed during the winding process of the coil 22 by bending the wire 22a constituting the coil 22.
[0078] In the above configuration, the coil 22 contacts the outer surfaces 243b of a pair of protrusions 243. During the manufacturing process of winding the coil 22 around the teeth 212, tension is applied to the coil 22 by the protrusions 243, and the force exerted on the coil 22 towards the winding center is pressed towards each other. The outer surfaces 243b of the pair of protrusions 243 can withstand the force exerted on the coil 22 towards the winding center by their inclined surfaces. This reduces the curvature of the bend R in the coil 22. Therefore, by winding the coil 22 around the teeth 212 through the insulating member 24 with the above configuration, the rupture of the wire 22a's sheath can be suppressed. This improves the durability of the coil 22.
[0079] Furthermore, during the winding process of the coil 22, the wire 22a contacts the tip 243d of the protrusion 243. That is, during this process, the surface pressure acting on the tip 243d of the protrusion 243 is high. As a result, the wire 22a can be embedded into the tip 243d of the protrusion 243. Therefore, radial movement of the wire 22a relative to the insulator member 24 along the radial direction B can be suppressed. Therefore, the coil 22 composed of the wire 22a can be prevented from falling off the teeth 212.
[0080] Therefore, a stator 2 can be provided that can improve the durability of the coil 22 and suppress the movement of the coil 22 relative to the tooth portion 212 in the radial direction B.
[0081] In this embodiment, a pair of protrusions 243 protrude axially from the top end of one and the top end of the other on the circumferential C of the toothed cover portion 242. Here, the top end on the circumferential C refers to the outermost end on the circumferential C.
[0082] Therefore, during the manufacturing process of winding the coil 22 onto the toothed portion 212, the coil 22 can be bent along the pair of protrusions 243. As a result, the curvature of the bent portion R of the coil 22 can be reduced more reliably.
[0083] The insulator member 24 has a core back cover portion 241 disposed on the end face of the core back 211 along the axial direction A. The core back cover portion 241 has a plurality of ribs 241a protruding from a face opposite to the face of the core back 211.
[0084] Thus, the core back cover portion 241 of the insulator member 24 can be configured to insulate the coil 22 from the core back cover 211. Furthermore, the multiple ribs 241a of the core back cover 211 can improve the rigidity of the core back cover 211.
[0085] In this embodiment, the pair of protrusions 243 are plate-shaped and inclined toward each other as they move away from the toothed cover portion 242. The insulator member 24 has a space S between the inner surface 243a of the pair of protrusions 243 and the surface of the toothed cover portion 242 on the side of the protrusions 243.
[0086] In the above configuration, the outer surfaces 243b of the pair of protrusions 243 that are inclined toward each other are inclined surfaces that are inclined toward each other as they approach the top portion. Therefore, the curvature of the bent portion R of the coil 22 can be reduced more reliably.
[0087] Furthermore, through the space S between the pair of protrusions 243 and the toothed cover portion 242, the top end portion 243d of the protrusions 243 can be easily pressed towards the toothed cover portion 242 during the winding process of the coil 22. Therefore, during the winding process of the coil 22, the tension applied to the coil 22 can be easily adjusted, and the coil 22 can be more reliably embedded in the top end portion 243d of the pair of protrusions 243. Thus, a stator 2 can be provided that improves the durability of the coil 22 and suppresses radial movement of the coil 22 relative to the toothed portion 212.
[0088] Furthermore, in this embodiment, a pair of protrusions 243 have a plastically deformable portion 244 at the base end portion 243c.
[0089] In this embodiment, the pair of protrusions 243 are inclined through plastic deformation. That is, when tension is applied to the coil 22 during the winding process, the coil 22 causes the tip portions 243d of the pair of protrusions 243 to move closer to the tooth cover portion 242. Therefore, with this configuration, the coil 22 can be more reliably embedded in the tip portions 243d of the pair of protrusions 243. Thus, a stator 2 can be provided that further suppresses radial B movement of the coil 22 relative to the tooth portion 212.
[0090] Furthermore, in this embodiment, the stator 2 also has insulating sheets 25 disposed on the inner surfaces of a plurality of slots 213. The insulating sheets 25 have sheet ends 25a protruding from the slots 213 in the axial direction A. The length of the sheet ends 25a in the axial direction A is less than the length of the insulating member 24 in the axial direction A.
[0091] When viewed along the axial direction A, the insulating sheet 25 disposed on the inner surface of the groove 213 has a bend 253 between the portion along the side of the tooth 212 and the portion along the outer peripheral surface of the core back 211. Therefore, the insulating sheet 25 may break when an outwardly expanding force is applied.
[0092] In contrast, in the above configuration, the insulating member 24 is located outside the end portion 25a protruding from the groove 213 of the insulating sheet 25. Therefore, the end portion 25a will not expand outward even when pressed by the coil 22. Thus, breakage of the insulating sheet 25 can be prevented.
[0093] Furthermore, the motor 1 of this embodiment has a stator 2 and a rotor 3 having a magnet 31 that is radially opposite the stator 2 at a distance B.
[0094] Thus, a motor 1 having a stator 2 can be provided, which can improve the durability of the coil 22 and suppress the movement of the coil 22 relative to the tooth 212 in the radial direction B.
[0095] (Modified Example)
[0096] Next, refer to Figure 10 The modified insulator member 124 will be described below. In this modified example, the shape of the toothed cover portion 1242 of the insulator member 124 is different from the shape of the toothed cover portion 242 of the insulator member 24 in Embodiment 1. Figure 10 It is a cross-sectional view obtained by circumferentially cutting the tooth 212 and the insulator member 124.
[0097] like Figure 10 As shown, in this modified example, the further away the tooth cover portion 1242 is from the tooth portion 212, the greater its length in the circumferential direction C. That is, in this modified example, the length of the protrusion 243 side of the tooth cover portion 1242 in the circumferential direction C is greater than the length of the tooth portion 212 side of the tooth cover portion 1242 in the circumferential direction C.
[0098] Resin components are molded using resin molding molds. Therefore, resin components typically have a draft angle formed on the end face extending along the thickness direction for easy removal from the resin molding mold. Consequently, in resin components, either a corner of the face on one side of the thickness direction or a corner of the face on the other side of the thickness direction protrudes relative to the direction in which the other face extends.
[0099] In this modified example, the side of the toothed cover portion 1242 opposite to the toothed portion 212 protrudes circumferentially C. Therefore, when the coil 22 is wound around the toothed cover portion 1242, the coil 22 can be positioned in a circumferential position that does not make angular contact with the toothed portion 212. This prevents the coil 22 from making angular contact with the toothed portion 212 when it is wound around the toothed portion. Therefore, peeling of the coil 22's coating can be further suppressed.
[0100] Furthermore, in this modified example, the length L1 of the protrusion 243 side of the tooth cover portion 1242 in the circumferential direction C is equal to or less than the length L0 of the tooth portion 212 in the circumferential direction C.
[0101] That is, the toothed cover portion 1242 does not protrude into the groove 213. Therefore, the coil 22 can be wound along the side of the toothed portion 212. As a result, compared with the configuration where the toothed cover portion protrudes into the groove when viewed along the axial direction A, the duty cycle of the coil in the groove can be increased.
[0102] (Other implementation methods)
[0103] The embodiments of the present invention have been described above, but these embodiments are merely examples for implementing the present invention. Therefore, the present invention is not limited to the above embodiments, and the above embodiments can be appropriately modified and implemented without departing from its spirit.
[0104] In the described embodiment, the configuration of motor 1 is illustrated as an in-wheel motor disposed on the rear wheel of an electric motorcycle. However, the motor may not be for electric motorcycles. It may also be a general motor having a stator and a rotor.
[0105] In the described embodiment, motor 1 is a so-called external rotor type motor in which the magnet 31 of rotor 3 is arranged radially outside stator 2. However, the motor may also be a so-called internal rotor type motor in which the magnet of rotor is arranged radially inside stator.
[0106] In the figures, the radial B end face of the core back 211 of stator 2 appears circular when viewed along the axial direction A. However, the radial B end face of the core back of stator can also appear polygonal when viewed along the axial direction A.
[0107] In the described embodiment, the rotor 3 has a magnet 31, a yoke 32, and a rim 33. The magnet 31 and the yoke 32 for fixing the magnet 31 are separate. However, the rotor may also not have a yoke. In this case, the rotor may have annular magnets that function as a yoke. The magnets may also be fixed to the rim or other components.
[0108] In the described embodiment, the plurality of toothed covers 242, 1242 have the same configuration. However, the configuration of some of the toothed covers may differ from that of the other toothed covers.
[0109] In the described embodiment, a pair of protrusions 243 are located symmetrically with respect to a left-right line of symmetry. The shapes of the pair of protrusions 243 are symmetrical with respect to the left-right line of symmetry. However, the pair of protrusions may not be located symmetrically with respect to the left-right line of symmetry. The shapes of the pair of protrusions may also not be symmetrical with respect to the left-right line of symmetry. For example, the axial length A of one pair of protrusions may be different from that of the other. The circumferential length C of one pair of protrusions may also be different from that of the other. The inclination angles of one pair of protrusions may also be different from those of the other.
[0110] In the described embodiment, the pair of protrusions 243 are plate-shaped with a length in the circumferential direction C that is less than the length in the protruding direction. However, the pair of protrusions may also be column-shaped with a length in the circumferential direction C that is equal to or greater than the length in the protruding direction.
[0111] In the embodiment described, the pair of protrusions 243 are plate-shaped with equal lengths in the circumferential direction C, extending from the base end portion 243c to the top end portion 243d. However, the pair of protrusions may also be triangular shapes, with the length in the circumferential direction C decreasing as they move further away from the tooth cover portion, or they may be dome-shaped.
[0112] In the figures of the embodiments described, the inner surfaces 243a of a pair of protrusions 243 are circumferentially separated from each other. However, the inner surfaces of a pair of protrusions may not be circumferentially separated from each other as shown in the figures. It should be noted that, preferably, the distance between the inner surfaces of a pair of protrusions in the circumferential direction is greater than the combined length of the length of one protrusion in the circumferential direction and the length of the other protrusion in the circumferential direction.
[0113] In the described embodiment, the pair of protrusions 243 are inclined. However, the pair of protrusions may not be inclined.
[0114] In the embodiment described, a pair of protrusions 243 extend axially along A before the coil 22 is wound around the tooth 212, and are inclined by the winding of the coil 22. However, the pair of protrusions may also be inclined before the coil is wound around the tooth.
[0115] In the described embodiment, the length of the end portion 25a of the insulating sheet 25 in the axial direction A is less than the length of the insulating member 24 in the axial direction A. However, the length of the end portion of the insulating sheet in the axial direction A may also be equal to or greater than the length of the insulating member in the axial direction A.
[0116] (Example of composition)
[0117] It should be noted that this technology can also be configured as follows.
[0118] (1) A stator comprising: a stator core having an axially extending cylindrical back and a plurality of teeth extending radially from the back and arranged circumferentially C, wherein a plurality of grooves arranged circumferentially C are formed between adjacent teeth in the plurality of teeth; an insulator member covering an axial end face of the stator core; and a coil wound around each of the plurality of teeth through the insulator member. The insulator member comprises: toothed covers disposed on the axial end faces of the plurality of teeth; and a pair of protrusions projecting axially from one end and the other end of the toothed covers in the circumferential direction C. The coil contacts an outer surface of the pair of protrusions opposite to their opposing inner surfaces.
[0119] (2) In the stator described in (1), the pair of protrusions are plate-shaped and inclined toward each other as they move away from the toothed cover portion. The insulator member has a space between the inner surfaces of the pair of protrusions and the protrusion-side surface of the toothed cover portion.
[0120] (3) In the stator described in (1) or (2), the pair of protrusions are plate-shaped and inclined toward each other as they move away from the toothed portion, and have plastically deformable portions at the base ends.
[0121] (4) In any one of (1) to (3) the stator, the pair of protruding portions protrude axially from the top end of one and the top end of the other on the circumferential C of the toothed portion.
[0122] (5) In the stator described in (4),
[0123] The stator also has insulating sheets disposed on the inner surfaces of the plurality of slots. Each insulating sheet has an end portion projecting axially from the slot. The axial length of the end portion is less than the axial length of the insulating member.
[0124] (6) In any one of (1) to (5) the stator, the insulator member has a core back cover portion disposed on an axially upward end face of the core back. The core back cover portion has a plurality of ribs protruding on a face opposite to the face of the core back.
[0125] (7) In any one of (1) to (6) the stator, the length of the protruding side of the tooth cover portion in the circumferential direction is greater than the length of the tooth side of the tooth cover portion in the circumferential direction.
[0126] (8) In the stator described in (7),
[0127] The length of the protruding part of the toothed cover in the circumferential direction is equal to or less than the length of the tooth in the circumferential direction.
[0128] (9) The motor has a stator according to any one of (1) to (8); and a rotor having a magnet that is radially opposed to the stator.
[0129] The industrial applicability is as follows.
[0130] This invention can be used for insulating components of stators.
Claims
1. A stator, said stator having: The stator core has an axially extending cylindrical back and a plurality of teeth extending radially from the back and arranged circumferentially, wherein a plurality of grooves are formed between adjacent teeth in the circumferential direction. An insulating component that covers the axial end face of the stator core; as well as A coil, the coil being wound around each of the plurality of teeth via the insulating member. The insulating component has the following characteristics: A toothed cover portion, wherein the toothed cover portion is respectively disposed on the axial end face of the plurality of teeth portions; as well as A pair of protrusions, each protruding axially from one end of the toothed cover portion in the circumferential direction and the other end, respectively. The coil contacts the outer side of the pair of protrusions on the side opposite to the inner side of each other.
2. The stator according to claim 1, wherein, The pair of protrusions are plate-shaped and tilted toward each other as they move away from the gear cover. The insulating member has a space between the inner surfaces of the pair of protrusions and the protrusion-side surface of the toothed cover.
3. The stator according to claim 2, wherein, The pair of protrusions are plate-shaped and tilted toward each other as they move away from the toothed portion, with plastically deformable portions at their base ends.
4. The stator according to claim 1, wherein, The pair of protruding portions protrude axially from the top of one side and the top of the other side of the toothed cover portion.
5. The stator according to claim 4, wherein, The stator also has insulating sheets disposed on the inner surfaces of the plurality of slots. The insulating sheet has a sheet end that protrudes axially from the groove. The length of the end piece in the axial direction is less than the length of the insulator member in the axial direction.
6. The stator according to claim 1, wherein, The insulator member has a core back cover portion disposed on an axially upward end face of the core back. The core back cover portion has multiple ribs protruding from a surface opposite to the back side of the core.
7. The stator according to claim 1, wherein, The length of the protruding side of the toothed cover in the circumferential direction is greater than the length of the toothed side of the toothed cover in the circumferential direction.
8. The stator according to claim 7, wherein, The length of the protruding part of the toothed cover in the circumferential direction is equal to or less than the length of the tooth in the circumferential direction.
9. A motor, said motor having: The stator according to any one of claims 1 to 8; and The rotor has magnets that are radially opposed to the stator.