Method of manufacturing an electric motor

Abstract

In a method of manufacturing an electric motor, a first operation and a second operation are performed. The first operation is to wind a wire from one end side (Y1) of a drum portion (42) in a radial direction (Y) of a yoke portion toward the other end side (Y2) while leaving a gap (G) between adjacent windings (46) in a first layer (1L). The second operation is to wind the wire to the first layer (1L) so as to be in contact with the winding (46) on the other end side (Y2) after the first operation, thereby moving at least a part of the winding (46) wound by the first operation toward the one end side (Y1) to narrow the gap (G).

Description

TECHNICAL FIELD

[0001] The present application relates to a manufacturing method of an electric motor. BACKGROUND

[0002] As an electric motor, an electric motor having a stator core, and an insulating frame provided at an end portion of the stator core, and a coil wire formed by winding a wire in a concentrated winding manner on a tooth portion of the stator core and a drum portion of the insulating frame, and having a winding portion having a plurality of layers, is known. In this electric motor, downsizing and high efficiency are achieved by increasing a space factor of the wire in the winding portion.

[0003] Patent Document 1: International Publication No. 2015 / 063877 Patent Document 2: Japanese Patent Application Publication No. 2020-127255 Patent Document 3: Japanese Patent Application Publication No. 2018-85870 SUMMARY

[0004] In the electric motor described in Patent Document 1, a surface of the drum portion of the insulating frame is flat along a radial direction of the stator core. Further, the winding portion includes a first layer formed by winding the wire along the surface of the drum portion from one end side (outer diameter side) toward the other end side (inner diameter side) in the radial direction of the stator core, and a second layer formed by winding the wire in a manner of being stacked on the first layer and from the other end side (inner diameter side) toward the one end side (outer diameter side) in the radial direction of the stator core.

[0005] Regarding this type of electric motor, the inventors of the present invention have discovered that, in order to increase the occupancy of the winding section, when the winding spacing of the first layer of windings arranged radially along the stator core is reduced (the amount of movement of the wire tip when forming one turn in the winding process using a winding machine), when the first layer of the winding section is formed, a portion of the later-wound winding sometimes overlaps with the earlier-wound winding. In this case, the later-wound winding is not positioned further to the other end (inner diameter side) than the earlier-wound winding, but rather enters a position further to one end (outer diameter side) than the earlier-wound winding. Furthermore, since the surface of the conductor's insulation film is prone to slippage, a phenomenon may occur where the earlier-wound winding is pushed towards the other end (inner diameter side) of the stator core (hereinafter also referred to as "uneven winding"). If uneven winding occurs, there is a risk that the conductor forming the winding, stretched in a manner that pushes it towards the inner diameter side, may break; or that the cross-sectional area of ​​the stretched conductor decreases, resulting in increased resistance and increased heat generation in the conductor. That is, there is a risk that the reliability of the conductor wound in the first layer of the winding section will be reduced. Furthermore, this phenomenon is not limited to the case where the winding direction of the first layer of the winding section is from the outer diameter side to the inner diameter side of the stator core in the radial direction, but can also occur even if the winding direction of the first layer of the winding section is from the inner diameter side to the outer diameter side of the stator core in the radial direction.

[0006] On the other hand, as a measure to prevent the wire in the first layer wound on the winding section from slipping, there is a structure in which grooves or the like are provided in the winding section of the insulation frame (Patent Document 2, Patent Document 3). However, in this structure, since grooves or the like that that match the outer diameter of the wire must be provided in the winding section, the insulation frame must be changed according to the outer diameter of the wire, which increases the manufacturing cost of the motor. In addition, when a wire whose outer diameter does not match the size of the grooves or the like is wound on the winding section, there are risks as follows: the wire lying on the grooves or the like is subjected to load, which reduces the reliability of the wire's energization state; in addition, as a result, gaps are generated between the grooves or the like and the wire, which reduces the occupancy rate.

[0007] The disclosed technology was developed in view of the aforementioned problems, with the aim of providing a method for manufacturing an electric motor that can improve the reliability of the wires wound in the first layer of the winding section and increase the occupancy of the winding section while avoiding an increase in the manufacturing cost of the electric motor.

[0008] One aspect of the electric motor manufacturing method disclosed in this application is a method for manufacturing an electric motor comprising: a stator core having an annular yoke and teeth extending radially from the yoke; an insulating frame having a coil portion mounted on the teeth; and a winding section having multiple layers formed by winding wires wound around the teeth with the coil portion in between. The method for manufacturing the electric motor performs a first operation and a second operation. The first operation involves winding wires from one end of the radially upward coil portion toward the other end while leaving a gap between adjacent windings in the first layer of the winding section. The second operation involves, after the first operation, winding wires in the first layer in a manner that connects them to the windings located at the other end, thereby causing at least a portion of the windings wound by the first operation to move toward one end and narrow the gap.

[0009] According to one embodiment of the electric motor manufacturing method disclosed in this application, the reliability of the wires wound in the first layer of the winding section can be improved while avoiding an increase in the manufacturing cost of the electric motor, and the occupancy rate of the winding section can be increased. Attached Figure Description

[0010] Figure 1 This is a longitudinal sectional view showing a compressor manufactured by the electric motor manufacturing method of the embodiment.

[0011] Figure 2 This is a bottom view of the stator core in an embodiment.

[0012] Figure 3 This is a perspective view schematically illustrating an embodiment of the insulating frame.

[0013] Figure 4 This is a bottom view of the stator in an embodiment.

[0014] Figure 5 This is a schematic cross-sectional view of the winding portion of an electric motor according to an embodiment.

[0015] Figure 6 It is a schematic cross-sectional view of the winding section of a motor, representing a comparative example.

[0016] Figure 7 It is a cross-sectional view used to illustrate the normal winding of the first layer of wire in the comparative winding process.

[0017] Figure 8 It is a cross-sectional view used to illustrate the situation where the winding position of the first layer of windings shifts during a comparative winding process.

[0018] Figure 9 This is a side view used to illustrate the situation where the winding position of the first layer of windings shifts during a comparative winding process.

[0019] Figure 10This is a flowchart illustrating the winding process in the method of manufacturing an electric motor according to an embodiment.

[0020] Figure 11 This is a flowchart illustrating the winding pitch of the winding process in the method for manufacturing an electric motor according to an embodiment.

[0021] Figure 12 This is a cross-sectional view used to illustrate the first and second actions performed in the winding process of the embodiment.

[0022] Figure 13 This is a cross-sectional view illustrating the situation where the first layer of winding is normally wound in the first operation of the winding process of the embodiment.

[0023] Figure 14 This is a cross-sectional view illustrating the situation where the winding position of the first layer of winding wire shifts during the first operation of the winding process in an embodiment.

[0024] Figure 15 This is a cross-sectional view used to illustrate the second action of the embodiment.

[0025] Figure 16 This is a cross-sectional view used to illustrate the first and second actions performed in the winding process of the modified example. Detailed Implementation

[0026] Hereinafter, embodiments of the method for manufacturing an electric motor disclosed in this application will be described in detail based on the accompanying drawings. Furthermore, the method for manufacturing an electric motor disclosed in this application is not limited to the following embodiments.

[0027] Example compressor Figure 1 This is a longitudinal sectional view of a compressor equipped with an electric motor manufactured using the electric motor manufacturing method described in the embodiment. (Example) Figure 1 As shown, compressor 1 is a rotary compressor, typically referred to as a compressor, comprising a container 2, a shaft 3, a compression section 5, and an electric motor 6. The container 2 is made of metal and has a sealed internal space 7. The internal space 7 is generally cylindrical. When the container 2 is placed longitudinally on a horizontal plane, the central axis of the internal space 7 is parallel to the vertical direction. An oil sump 8 is formed in the lower part of the internal space 7 of the container 2. The oil sump 8 stores lubricating oil for lubricating the compression section 5. A suction pipe 11 for drawing in refrigerant and a discharge pipe 12 for discharging compressed refrigerant are connected to the container 2. The shaft 3 is arranged vertically within the internal space 7 of the container 2, with one end immersed in the oil sump 8. The shaft 3 is supported on the container 2 in a manner that allows it to rotate about the central axis of the internal space 7. The shaft 3 supplies the lubricating oil stored in the oil sump 8 to the compression section 5 by rotating.

[0028] The compressor unit 5 is located in the lower part of the internal space 7 and above the oil sump 8. The compressor 1 also includes an upper silencer 14 and a lower silencer 15. The upper silencer 14 is located above the compressor unit 5 in the internal space 7. An upper silencer chamber 16 is formed inside the upper silencer 14. The lower silencer 15 is located in the lower part of the compressor unit 5 in the internal space 7 and above the oil sump 8. A lower silencer chamber 17 is formed inside the lower silencer 15. The lower silencer chamber 17 communicates with the upper silencer chamber 16 via a connecting passage (not shown) formed in the compressor unit 5. A discharge port 18 for discharging compressed refrigerant is formed between the upper silencer 14 and the shaft 3, and the upper silencer chamber 16 communicates with the internal space 7 via the discharge port 18.

[0029] The compression unit 5 compresses the refrigerant supplied from the suction pipe 11 by rotating the shaft 3 driven by the electric motor 6, and supplies the compressed refrigerant to the upper silencing chamber 16 and the lower silencing chamber 17. The refrigerant is compatible with lubricating oil.

[0030] electric motor The electric motor 6 is located on the upper part of the compression section 5 within the internal space 7. The electric motor 6 is a three-phase electric motor, comprising a rotor 21 and a stator 22. The rotor 21 is fixed to the shaft 3. The stator 22 is formed into a generally cylindrical shape and is disposed on the outer periphery of the rotor 21 in a manner surrounding the rotor 21, and is fixed to the container 2. The stator 22 comprises a stator core 23, a lower insulating frame 25B serving as a first insulating frame, an upper insulating frame 25A serving as a second insulating frame, and a plurality of windings 46.

[0031] The upper insulating frame 25A is mounted on the upper end of the stator core 23 along the axial direction of the shaft 3. The lower insulating frame 25B is mounted on the lower end of the stator core 23 along the axial direction of the shaft 3. The upper insulating frame 25A and the lower insulating frame 25B are an example of insulating portions used to insulate the stator core 23 from the winding 46. In this embodiment, the upper insulating frame 25A and the lower insulating frame 25B are formed with the same shape. When provided at the upper end of the stator core 23, they are used as the upper insulating frame 25A, and when provided at the lower end of the stator core 23, they are used as the lower insulating frame 25B. Hereinafter, in this embodiment, the upper insulating frame 25A and the lower insulating frame 25B will be collectively referred to as the insulating frame 25. In addition, the upper insulating frame 25A and the lower insulating frame 25B may also be formed with different shapes.

[0032] Figure 2 This is a bottom view showing the stator core 23 of the embodiment. (See attached image.) Figure 2As shown, the stator core 23 is formed by stacking multiple metal plates, such as those made of a soft magnetic material like an electromagnetic steel plate, and includes a yoke 31 and multiple stator core teeth 32 (32-1 to 32-9). The yoke 31 is formed in a generally annular (cylindrical) shape. The first stator core tooth 32-1 among the multiple stator core teeth 32-1 to 32-9 is formed in a generally cylindrical shape extending radially along the stator core 23. The first stator core tooth 32-1 is formed by connecting one end to the inner circumferential surface of the yoke 31, that is, extending radially inward from the inner circumferential surface of the yoke 31. Of the plurality of stator core teeth 32-1 to 32-9, except for the first stator core tooth 32-1, the stator core teeth 32-2 to 32-9 are also formed in a generally cylindrical shape, similar to the first stator core tooth 32-1, and extend radially inward from the inner circumferential surface of the yoke 31. In the case of a stator 22 with 9 slots, the plurality of stator core teeth 32-1 to 32-9 are formed to be arranged at equal intervals of 40° on the inner circumferential surface of the yoke 31.

[0033] Figure 3 This is a perspective view schematically illustrating the insulating frame 25 of an embodiment. (As shown) Figure 3 As shown, the insulating frame 25 (upper insulating frame 25A and lower insulating frame 25B) is formed into a ring shape by an insulator, such as polybutylene terephthalate resin (PBT). Figure 3 As shown, the insulating frame 25 has an outer peripheral wall portion 41, a drum portion for winding the conductor (winding wire 46), i.e., a plurality of insulating frame teeth 42 (42-1 to 42-9), and a plurality of flange portions 43 (43-1 to 43-9). The outer peripheral wall portion 41 is formed in a generally cylindrical shape. In the outer peripheral wall portion 41, a plurality of slits 44 are formed at intervals along the circumference of the outer peripheral wall portion 41. These slits 44 extend from one end along the central axis of the outer peripheral wall portion 41 (the axial direction of axis 3) along the central axis. In addition, the other end of the outer peripheral wall portion 41 along the central axis is connected to the stator core 23. In other words, the plurality of slits 44 are formed from the end of the outer peripheral wall portion 41 opposite to the stator core 23 towards the stator core 23. By passing the winding wire 46 (conductor) led out from the winding section 45 (described later) through each slit 44, the winding wire 46 led out from the inner peripheral side of the outer peripheral wall section 41 to the outer peripheral side forms a jumper wire 49 that is erected along the outer peripheral surface of the outer peripheral wall section 41. Furthermore, in Figure 3 The shape and arrangement of each slit 44 in the outer peripheral wall portion 41 are schematically shown in the insulating frame 25 shown. Details of the shape and arrangement of each slit 44 will be described below.

[0034] The first insulating frame tooth 42-1 among the plurality of insulating frame teeth 42-1 to 42-9 is formed as a straight cylinder with a generally semi-circular cross-section. The first insulating frame tooth 42-1 is formed by connecting one end to the inner circumferential surface of the outer peripheral wall portion 41, that is, extending radially inward from the inner circumferential surface of the outer peripheral wall portion 41. The insulating frame teeth 42-2 to 42-9 among the plurality of insulating frame teeth 42-1 to 42-9, excluding the first insulating frame tooth 42-1, are also formed as straight cylinders with a generally semi-circular cross-section, and extend radially inward from the inner circumferential surface of the outer peripheral wall portion 41, just like the first insulating frame tooth 42-1. The plurality of insulating frame teeth 42-1 to 42-9 are formed on the inner circumferential surface of the outer peripheral wall portion 41 at equal intervals of 40 degrees in the circumferential direction. Furthermore, the insulating frame teeth 42 in the embodiment are not limited to a shape that is a straight column with a generally semi-circular cross section. For example, they can also be formed into a straight column with a generally polygonal cross section.

[0035] Multiple flange portions 43-1 to 43-9 correspond to multiple insulating frame teeth 42-1 to 42-9, and are each formed into a generally semi-circular plate shape. The first flange portion 43-1, which corresponds to the first insulating frame tooth 42-1, is continuous at the other end of the first insulating frame tooth 42-1 and is integrally formed with it. The flange portions 43-1 to 43-9 other than the first flange portion 43-1 are also continuous at the other end of the multiple insulating frame teeth 42-1 to 42-9, and are integrally formed with each of the insulating frame teeth 42-1 to 42-9, just like the first flange portion 43-1.

[0036] Figure 4 This is a bottom view of the stator 22 in the embodiment, a view of the stator 22 taken from the side of the lower insulating frame 25B. (As shown) Figure 4 As shown, multiple windings 46 (U-phase windings 46-U1~46-U3, V-phase windings 46-V1~46-V3, and W-phase windings 46-W1~46-W3, described later) are respectively wound around the stator core teeth 32-1~32-9 of the stator core 23. In each stator core tooth 32-1~32-9, as... Figure 4 As shown, each phase's winding 46 (conductor) forms a winding section (coil) 45. In each winding section 45, the winding 46 has multiple layers, for example, approximately six to eight layers. The winding 46 is formed by winding the conductor onto the stator core teeth 32 through the insulating frame teeth 42. For each winding section 45 forming nine teeth, according to... Figure 4 The nine winding sections 45 are indicated by the clockwise sequence symbols 1 to 9. They are arranged in a three-phase, repeating cycle along the circumference of the stator core 23. Figure 4The phases are arranged in a clockwise direction, repeating in the order of U phase, V phase, W phase.

[0037] The motor 6 in this embodiment is a six-pole, nine-slot concentrated winding type motor. The plurality of windings (conductors) 46 include a plurality of U-phase windings 46-U1 to 46-U3 forming the U-phase winding portion 45, a plurality of V-phase windings 46-V1 to 46-V3 forming the V-phase winding portion 45, and a plurality of W-phase windings 46-W1 to 46-W3 forming the W-phase winding portion 45.

[0038] Furthermore, the motor 6 in the embodiment is configured with nine slots, but the number of slots, i.e. the number of winding portions 45 (or the number of stator core teeth 32), is not limited.

[0039] Furthermore, in the stator core 23 of the embodiment, the annular yoke 31 is integrally formed, but it can also be formed by assembling multiple arc-shaped yoke components (not shown) into an annular shape. Additionally, the stator core teeth 32 of the stator core 23 of the embodiment extend radially inward from the inner circumferential surface of the yoke 31, but can also extend radially outward from the outer circumferential surface of the yoke 31. Similarly, the insulating frame teeth 42 of the insulating frame 25 are not limited to a shape extending radially inward from the inner circumferential surface of the outer circumferential wall 41, but can also extend radially outward from the outer circumferential surface of the outer circumferential wall 41.

[0040] The winding section of the electric motor Figure 5 This is a schematic cross-sectional view of the winding portion (coil) 45 in the electric motor 6 of the embodiment. Figure 5 In order to distinguish the winding method of the first layer 1L of the winding section 45, the characters "F" and "S" are used to indicate the winding method. "F" indicates the winding 46 wound by the first operation described later, and "S" indicates the winding 46 wound by the second operation described later. Furthermore, Figure 5 In the text, the numbers “2~8” marked on the windings 46 of each layer of the winding section 45 represent the second layer 2L to the eighth layer 8L.

[0041] like Figure 5As shown, in the winding section 45 of this embodiment, the wire supplied from the wire nozzle N is arranged in a radial direction Y of the yoke 31 (which also corresponds to the radial direction Y of the outer peripheral wall 41, hereinafter simply referred to as radial Y) and wound at a predetermined winding pitch (the amount of movement of the wire nozzle N along radial Y when one turn is formed). The winding 46, which is wound as the first layer 1L of the winding section 45, is wound along radial Y in a manner that it contacts the surface of the first layer 1L of the winding section 45, i.e., the surface of the insulating frame tooth 42 where the wire is wound (hereinafter referred to as the surface of the insulating frame tooth 42). In the winding section 45 of this embodiment, the winding 46 of the first layer 1L does not become unevenly wound, and the occupancy of the winding section 45 is increased, as will be explained in detail below.

[0042] The winding pitch mentioned here refers to the amount of movement of the wire nozzle N along the radial Y direction when one turn (one loop) of the conductor (winding wire 46) wound around the insulating frame teeth 42 and stator core teeth 32 is formed. This is different from the spacing between adjacent winding wires 46 along the radial Y direction. For convenience, the winding pitch is also represented as a spacing dimension in the accompanying drawings, but in the following description, the winding pitch refers to the amount of movement of the wire nozzle N along the radial Y direction when one turn is formed. Furthermore, the amount of movement of the wire nozzle N refers to the change in the relative position of the wire nozzle N and the insulating frame teeth 42. That is, when changing the relative position of the wire nozzle N with respect to the insulating frame teeth 42, the insulating frame teeth 42 can be fixed and the wire nozzle N can be moved, the wire nozzle N can be fixed and the insulating frame teeth 42 can be moved, or both the insulating frame teeth 42 and the wire nozzle N can be moved.

[0043] Electric motor manufacturing method The method for manufacturing the electric motor in this embodiment includes a winding process in which a wire is wound around the stator core teeth 32 through the insulating frame teeth 42 to form a winding portion (coil) 45. For example... Figure 5 As shown, in the winding process of this embodiment, a winding machine (not shown) is used to wind the conductor, the winding machine having a feed nozzle N for supplying the conductor. The method for manufacturing an electric motor in this embodiment includes: in the winding process, controlling the operation of winding the conductor onto the first layer 1L of the winding section 45 by the control unit C of the winding machine, and controlling the movement amount (winding pitch) of the feed nozzle N for supplying the conductor to be wound onto the first layer 1L.

[0044] In the winding step, the winding wire 46 is supplied from a nozzle N that moves in the radial direction Y of the stator core 23, the winding wire 46 is wound around the stator core teeth 32 of the stator core 23 and the insulator teeth 42 of the insulator 25 mounted to overlap the stator core teeth 32, and the jumper wire 49 led out from the winding part 45 is wound along the outer peripheral wall part 41 of the insulator 25. In the embodiment, when a winding machine is used to form each of the three-phase winding parts 45, for example, the so-called three-nozzle winding method is applied, that is, by using three nozzles N, the winding part 45 is formed for each phase respectively, and the winding parts 45 of the respective phases are formed in sequence, thereby forming the three-phase winding parts 45.

[0045] Winding Step of Comparative Example First, in order to compare with the winding step in the method for manufacturing the electric motor of the embodiment, the winding step in the method for manufacturing the electric motor of the comparative example will be described. In the winding step of the comparative example, in order to increase the space factor of the winding part, the conductor is wound in the following manner: when the outer diameter of the conductor in the state before winding is defined as B, and the winding pitch of the winding wire in the first layer 1L of the winding part (the movement amount of the nozzle N in the radial direction Y per turn formed) is defined as P, P < B is satisfied (for example, P = 0.8B). In addition, regarding the outer diameter B of the conductor, the tension applied when the conductor is wound around the stator core teeth 32 via the insulator teeth 42 elongates the conductor in the longitudinal direction, so the outer diameter of the winding wire wound in the winding part tends to decrease slightly.

[0046] Figure 6 is a schematic cross-sectional view of the winding part 145 in a case where the winding wire of the first layer 1L is normally wound in the electric motor of the comparative example. Figure 6 in which the numbers "1 to 8" marked on the winding wires 46 of the respective layers of the winding part 145 represent the first layer 1L to the eighth layer 8L. As shown in Figure 6 , in the winding part 145 of the comparative example, for example, the conductor is wound in such a manner that 8 layers of winding wires 46 are formed, and the winding pitch P of all layers from the first layer 1L to the eighth layer 8L satisfies P < B. Therefore, the first layer 1L to the eighth layer 8L of the winding part 145 are wound such that the winding wires 46 adjacent to each other in the radial direction Y are in close contact with each other.

[0047] Winding Step of Comparative Example Figure 7 is a cross-sectional view for illustrating a case where the winding wire of the first layer 1L is normally wound in the winding step of the comparative example. As shown in Figure 7As shown, in the comparative example, in the first layer 1L, the winding 46 of the second turn 2T slides along the outer peripheral surface of the winding 46 of the first turn 1T to the other end side Y2 in the radial direction Y (the inner side of the radial direction Y, i.e., the inner diameter side), whereby the wire is wound in such a manner that following the winding 46 of the first turn 1T, the winding 46 of the second turn 2T and the winding 46 of the third turn 3T are brought into adjacent contact in sequence. From the fourth turn 4T onward, by setting the winding pitch P to satisfy P<B, the wire is wound in a neatly arranged manner such that the adjacent windings 46 in the radial direction Y are in contact with each other. That is, when the respective windings 46 (wires) forming the first layer 1L are normally wound, the respective windings 46 of the first layer 1L are tightly wound without gaps therebetween.

[0048] Figure 8 is a cross-sectional view for explaining a situation in which the winding position of the winding 46 of the first layer 1L is displaced in the winding process of the comparative example. Figure 9 is a side view for explaining a situation in which the winding position of the winding 46 is displaced in the winding process of the comparative example.

[0049] As shown in Figure 8 , in the winding process of the comparative example, in the first layer 1L wound around the insulator tooth portion 42, for example, there is a situation where the winding 46 of the second turn 2T wound after the winding 46 of the first turn 1T slides to a position further toward the other end side Y2 in the radial direction Y (the inner side of the radial direction Y, i.e., the inner diameter side) than the position adjacent to the winding 46 of the first turn 1T, so that the winding position of the winding 46 of the second turn 2T is far from the winding 46 of the first turn 1T.

[0050] At this time, in the comparative example, the winding pitch (the movement amount of the nozzle N in the radial direction Y each time one turn is formed) P satisfies P<B (P=0.8B), so the winding 46 of the third turn 3T is fed by an amount of 0.8B away from the winding position where the winding 46 of the third turn 3T should normally be wound relative to the winding 46 of the second turn 2T. Therefore, the winding 46 of the third turn 3T cannot pass over the winding 46 of the second turn 2T toward the other end side Y2 in the radial direction Y (the inner side of the radial direction Y, i.e., the inner diameter side), but is wound to a position closer to the winding 46 side of the first turn 1T (the one end side Y1 of the radial direction Y, i.e., the outer diameter side) than the position of the winding 46 of the second turn 2T. As a result, the winding 46 of the third turn 3T enters between the winding 46 of the first turn 1T and the winding 46 of the second turn 2T, such that a part of the winding 46 of the third turn 3T is wound while riding on the winding 46 of the second turn 2T, thereby causing winding irregularity.

[0051] Next, starting from the winding position of the winding wire 46 of the second turn 2T at the winding position where the winding wire 46 of the third turn 3T should normally be wound, the winding wire 46 of the fourth turn 4T is fed by an amount of 0.8B, which is smaller than the outer diameter B of the conductor in the state before winding. As a result, the winding wire 46 of the fourth turn 4T is wound so as to be adjacent in the radial direction Y to the side of the winding wire 46 of the second turn 2T opposite to the winding wire 46 side of the third turn 3T (one end side Y1 in the radial direction Y).

[0052] In addition, as Figure 9 shown, for example, when the respective winding wires 46 of the third turn 3T and the fourth turn 4T enter between the winding wire 46 of the first turn 1T and the winding wire 46 of the second turn 2T, the winding wire 46 of the second turn 2T continuously shifts in position in the radial direction Y in the direction away from the winding wire 46 of the first turn 1T (the direction approaching the flange portion 43, that is, the other end side Y2), which results in irregular winding, and at the same time causes the following problem: in particular, the winding wire 46 of the second turn 2T is pulled toward the other end side Y2 in the radial direction Y (the inner side in the radial direction Y, that is, the inner diameter side), so that the cross-sectional area is reduced, the resistance is increased, and the heat generation of the winding wire 46 is increased. In addition, when irregular winding occurs in the first layer 1L, there is a problem that since the conductor wound in the second layer 2L is laid on the winding wire 46 where irregular winding has occurred, the winding portion 45 bulges significantly in the lamination direction (the winding diameter direction, for example, the axial direction of the shaft 3), causing the winding portion 45 to deform and increase in size.

[0053] As described above, in the case where the conductor is wound such that the winding pitch P of the winding wire 46 (conductor) wound in the first layer 1L satisfies P < B in order to increase the space factor of the winding portion 145, there is a problem that the winding wire 46 wound in the first layer 1L is prone to irregular winding. In addition, as an example, the case where irregular winding starts to occur due to the sliding of the winding wire 46 of the second turn 2T in the first layer 1L on the insulator tooth portion 42 is shown here, but in the first layer 1L where the winding wire 46 is wound in contact with the surface of the insulator tooth portion 42, the same irregular winding may occur at any position in the radial direction Y.

[0054] Winding step of the embodiment In the winding step in the method for manufacturing the electric motor of the embodiment, when one conductor is continuously wound to form the first layer 1L, a first action of winding the conductor and a second action of winding the conductor after the first action are performed. Figure 10 is a flowchart for explaining the winding step in the method for manufacturing the electric motor of the embodiment.

[0055] As Figure 10As shown, in the first operation, in the first layer 1L of the winding section 45, while leaving a gap G between adjacent windings 46, the wire is wound from the outer peripheral wall 41 side of the insulating frame tooth section 42, which is one end side Y1 in the radial direction, toward the flange 43 side, which is the other end side Y2 in the radial direction (step S1). In the second operation, after the first operation, the next wire is wound in the first layer 1L in such a way that it is connected to the winding 46 located on the flange 43 side (the other end side Y2 in the radial direction) that was wound in the first operation, thereby causing at least a portion of the winding 46 wound in the first operation to move toward the outer peripheral wall 41 side (one end side Y1 in the radial direction) and narrowing the gap G (step S2).

[0056] In the second operation, the wire is wound in such a way that it connects with the winding 46 located on the other end side Y2 (inner diameter side) of the insulating frame tooth portion 42 in the first operation (hereinafter also referred to as the other end winding 46), thereby narrowing the gap G from the other end side Y2 (inner diameter side) in the radial Y, which is therefore preferable. The invention is not limited to this; in the second operation, the wire may also be wound in such a way that it enters between and connects with the winding 46 adjacent to the outer peripheral wall portion 41 side of the other end winding 46, which can push the adjacent winding 46 towards the outer peripheral wall portion 41 side (one end side Y1). Furthermore, in the second operation, it is preferable that the wire is wound in such a way that it connects with the outer peripheral surface of the flange portion 43 side (the other end side Y2 in the radial Y) of the outer peripheral surface of the other end winding 46. As described later... Figure 15 As shown, the winding 46(S) wound by the second operation contacts the outer peripheral surface of the other end of the winding 46(F) wound by the first operation, on the side of the flange portion 43. Thus, the other end of the winding 46(S) wound by the first operation is subjected to a force f1 toward the radial Y-side Y1 (outer diameter side) and a force f2 toward the stator core 23 in the direction of the central axis of the outer peripheral wall portion 41. Then, the force f1 from the winding 46(S) wound by the second operation, toward the radial Y-side Y1 (outer diameter side), pushes the other end of the winding 46(F) wound by the first operation toward the outer peripheral wall portion 41 (the radial Y-side Y1, i.e., the outer diameter side).

[0057] Furthermore, in the second operation, when the wire is wound in such a way that it is in contact with the outer peripheral wall 41 side (one end Y1 of the radial Y) of the outer peripheral surface of the other end of the winding 46(F), the winding 46(S) wound by the second operation enters between the other end of the winding 46(F) wound by the first operation and the winding 46(F) adjacent to the outer peripheral wall 41 side (one end Y1 of the radial Y) of the other end of the winding 46, and pushes the adjacent winding 46(F) towards the outer peripheral wall 41 side (one end Y1 of the radial Y). In this case, a portion of the winding 46(S) wound by the second operation overlaps the other end of the winding 46(F) wound by the first operation, resulting in slight winding irregularities on the other end Y2 of the radial Y in the first layer 1L. However, this uneven winding only occurs at the other end Y2 of the radial Y in the first layer 1L after the winding of the winding 46 in the first layer 1L is basically completed, and it has little impact on the winding state of the winding section 45 and the reliability of the wire, so it is within the allowable range.

[0058] Furthermore, in the second action, it is not limited to winding the wire only once (one turn). Depending on the size of the gap G between the windings 46(F) wound in the first action, multiple turns (number of turns) can be repeatedly wound, for example, about two to four turns. By increasing the number of turns in this way, the effect of narrowing the gap G can be enhanced, and the number of windings 46(F, S) wound on the first layer 1L can be increased, thereby increasing the occupancy rate.

[0059] In the winding process of this embodiment, the first action is an action to prevent uneven winding of the winding 46 in the first layer 1L, which is prone to occur. The second action is an action to narrow the gap G left between the windings 46(F) wound in the first action. The second action may also be an action to reduce (narrow) at least one of the multiple gaps G. According to the second action, the number of turns of the winding 46 in the first layer 1L can be increased, and the arrangement of the windings 46 in the subsequent layers after the second layer 2L, which overlap with the first layer 1L where the gap G between the windings 46 has been narrowed, can be improved.

[0060] winding spacing Figure 11 This is a flowchart illustrating the winding pitch of the winding process in the method for manufacturing an electric motor according to an embodiment. Figure 12 This is a cross-sectional view illustrating the first and second actions performed in the winding process of an embodiment. Hereinafter, refer to... Figure 11 , Figure 12 and Figure 5 Let me explain. Figure 12 middle, and Figure 5Similarly, in the first layer 1L of the winding portion 45, the winding wire 46 wound by the first operation is denoted by "F", and the winding wire 46 wound by the second operation is denoted by "S".

[0061] While the winding pitch P of the comparative example described above (the movement amount of the nozzle N in the radial direction Y every time one turn is formed) satisfies P<B (P=0.8B), in the first operation of the winding process of the embodiment, as Figure 5 and Figure 11 shown, when the first pitch, which is the winding pitch for winding the conductor by the first operation, is set to P1, and the outer diameter of the conductor in the state before winding is set to B, the conductor is wound such that the first pitch P1 satisfies P1>B in the first layer 1L of the winding portion 45 (step S3). Accordingly, the winding wire 46(F) can be wound in the first layer 1L in a manner that winding disorder does not occur (see Figure 14 ). In the first operation, when winding the conductor in the first layer 1L, the nozzle N moves along the radial direction Y from the outer peripheral wall portion 41 side which is the one end side Y1 in the radial direction Y of the insulator tooth portion 42 toward the flange portion 43 side which is the other end side Y2 in the radial direction Y. The first pitch P1, which is the movement amount of the nozzle N, is controlled by the control portion C included in the winding machine.

[0062] When the second pitch, which is the winding pitch for winding the conductor by the second operation after the first operation, is set to P2, in the second operation, the conductor is wound such that the second pitch P2 satisfies P2<P1 in the first layer 1L of the winding portion 45 (step S4). Accordingly, the gap G between the winding wires 46(F) wound by the first operation can be narrowed by the winding wire 46(S) wound by the second operation (see Figure 15 ). In the second operation, the second pitch P2, which is the movement amount of the nozzle N, is also controlled by the control portion C included in the winding machine.

[0063] When the third pitch, which is the winding pitch of the conductor wound in the second layer 2L and subsequent layers of the winding portion 45, is set to P3, after the second operation following the completion of winding the winding wire 46 in the first layer 1L, the conductor is wound in the second layer 2L and subsequent layers such that the third pitch P3 satisfies P3<P1 (step S5). Accordingly, the number of turns in each of the second layer 2L and subsequent layers can be increased, so that the space factor of the winding portion 45 can be improved. The third pitch P3, which is the movement amount of the nozzle N, is also controlled by the control portion C included in the winding machine. In the embodiment, the third pitch P3 is set to a value satisfying P2<P3<P1.

[0064] As described above, the wire nozzle N winds the conductor while moving back and forth along the radial direction Y. That is, during the outward movement of the wire nozzle N, it winds the conductor in the first layer 1L through a first action and a second action; during the return movement, it winds the conductor in the second layer 2L; and from the third layer 3L onwards, it repeats the back-and-forth movement a predetermined number of times while winding the conductor. Furthermore, in the winding process of this embodiment, by coordinating with the movement of the wire nozzle N, the stator core 23 and the insulating frame 25 rotate around the radial direction Y, and the conductor is wound around the stator core teeth 32 through the insulating frame teeth 42. Furthermore, in the first layer 1L, the direction in which the winding 46 (conductor) is wound along the radial Y, that is, the direction in which the wire nozzle N moves in the first layer 1L, is not limited to the direction from the outer peripheral wall 41 side toward the flange 43 side (from one end Y1 (outer side) of the radial Y to the other end Y2 (inner side), but can also be the direction from the flange 43 side toward the outer peripheral wall 41 side (from the other end Y2 (inner side) of the radial Y to one end Y1 (outer side).

[0065] In the first operation, it is preferable to wind the wire with a first pitch P1 such that P1 < 2B. When the first pitch P1 is 2B or more, the gap G between adjacent windings 46 will increase, and it may not be possible to properly narrow the gap G through the second operation. In addition, when the first pitch P1 is 2B or more, the number of turns in the first layer 1L decreases, and the windings 46 of the second layer 2L can easily enter the gap G between the windings 46 of the first layer 1L, which may lead to a decrease in the arrangement of the windings 45. By ensuring that the first pitch P1 satisfies P1 < 2B, these problems can be avoided.

[0066] In the second action, multiple turns of the conductor are wound. In one embodiment, as an example, two turns of wire 46 (conductor) are wound in the second action, but the number of turns of wire 46 in the second action is not limited. The number of turns of wire 46 in the second action may be set to approximately one to four turns. In the second action, relative to the first turn of wire 46 (S), the second turn of wire 46 (S) is fed and wound with a second spacing P2, but the second spacing P2 may also be different in each turn. In the second action, the conductor may also be wound in a manner in which the second spacing P2 gradually decreases, for example, from the first turn to the last turn.

[0067] Furthermore, in the second operation, the wire is wound in such a way that the second spacing P2 satisfies 0 ≤ P2 < (B / 2). This allows for the appropriate narrowing of the gap G between the windings 46 wound in the first operation.

[0068] When the second spacing P2 satisfies P2=0, the wire is wound around the insulating frame tooth 42 at the same position in the radial Y direction. In other words, when the second spacing P2 satisfies P2=0, the wire wound by the second action is wound relative to the winding 46(F) located at the other end (flange 43 side) by the first action, and is connected to either the flange 43 side (the other end side Y2 in the radial Y direction) or the outer peripheral wall side 41 side (the one end side Y1 in the radial Y direction) in the outer peripheral surface of the winding 46 at the other end.

[0069] In this case, from the viewpoint of narrowing the gap G by moving the other end of the winding 46 towards the outer peripheral wall 41 side using the wire wound by the second action, it is ideal to contact the flange 43 side in the outer peripheral surface of the other end of the winding 46, but it is also possible to contact the outer peripheral wall 41 side in the outer peripheral surface of the other end of the winding 46. When the wire wound by the second action is wound into contact with the outer peripheral wall 41 side in the outer peripheral surface of the other end of the winding 46, the wire enters between the other end of the winding 46 and the winding 46 adjacent to it, and can push the adjacent winding 46 towards the outer peripheral wall 41 side (one end Y1 in the radial Y direction) to narrow the gap G. At this time, a part of the winding 46 wound by the second action overlaps the other end of the winding 46, so that a slight winding irregularity occurs on the other end Y2 in the radial Y direction in the first layer 1L. However, this uneven winding only occurs at the other end Y2 of the radial Y in the first layer 1L after the winding of the wire 46 in the first layer 1L is basically completed, and its impact on the winding state of the winding section 45 and the reliability of the wire is small, so it is within an acceptable range. When the second gap P2 is (B / 2) or greater, the wire wound by the second operation will not connect with the wire 46 located at the other end (flange 43 side) wound by the first operation, but will be wound separately from the wire 46 at the other end, which may prevent the gap G from being narrowed.

[0070] Details of the first action Figure 13 This is a cross-sectional view illustrating the normal winding of the first layer 1L winding 46 in the first operation of the winding process in the embodiment. (See attached image.) Figure 13 As shown, in the first operation of the winding process in this embodiment, the wire is wound in the first layer 1L in such a way that, after the first turn 1T of the winding 46, the second turn 2T of the winding 46 and the third turn 3T of the winding 46 are wound sequentially with a gap G between them. After the fourth turn 4T, the wire is wound in such a way that the first spacing P1 satisfies P1>B, thereby winding the wire in a neat arrangement while leaving a gap G between adjacent windings 46 in the radial Y direction.

[0071] Figure 14This is a cross-sectional view illustrating the situation where the winding position of the first layer 1L winding 46 shifts during the first operation of the winding process in an embodiment. (See attached image.) Figure 14 As shown, in the first operation of the winding process in this embodiment, the winding process is also similar to the one described above (see...). Figure 8 Similarly, in the first layer 1L, for example, the second turn 2T winding 46 wound after the first turn 1T winding 46, sometimes slides radially Y on the insulating frame tooth 42 from the winding position where the second turn 2T winding 46 should have been wound normally, so that the winding position of the second turn 2T winding 46 is far away from the first turn 1T winding 46.

[0072] Even in this case, in the first operation of the winding process of the embodiment, by winding the wire with the first spacing P1 of the first layer 1L satisfying P1>B, the amount of movement of the wire nozzle N is properly ensured. Therefore, the subsequent winding 46 of the third turn 3T can also smoothly pass over the winding 46 of the second turn 2T, whose winding position has shifted. The winding 46 of the third turn 3T is wound on the surface of the insulating frame tooth 42, for example, while contacting the flange 43 side of the outer peripheral surface of the winding 46 of the second turn 2T. Therefore, the winding 46 of the third turn 3T does not enter between the winding 46 of the first turn 1T and the winding 46 of the second turn 2T as in the comparative example described above, but is properly wound on the side opposite to the winding 46 of the first turn 1T relative to the winding 46 of the second turn 2T.

[0073] In other words, the first spacing P1 (movement amount of the wire tip N) of the first layer 1L in the first operation is preferably set to a value that is, a predetermined value corresponding to the maximum positional offset of the assumed winding position of the winding 46 in the first layer 1L, i.e., the maximum sliding amount of the winding 46, plus the outer diameter B (upper limit of dimensional tolerance) of the wire. Furthermore, the first spacing P1 of the first layer 1L in the first operation only needs to be set to a value that allows the next winding 46 to be wound in a manner that connects with the outer peripheral surface (the flange 43 side, i.e., the other end Y2 side) of the winding 46 whose winding position has shifted. Thus, in the first operation of the winding process in this embodiment, the next winding 46 can pass over the winding 46 whose winding position has shifted. Therefore, in the first operation of the winding process in this embodiment, the order of the windings 46 wound in the first layer 1L is not disordered; instead, the windings 46 of each turn are wound in the correct order, thus preventing uneven winding in the first layer 1L.

[0074] Regarding the windings 46 after the fourth turn 4T in the first operation, similarly to the above, even when the winding position of the previously wound winding 46 is displaced, the subsequent winding 46 can be smoothly wound so as to ride over the previously wound winding 46, thereby preventing winding misalignment in the first layer 1L.

[0075] Details of the Second Operation Figure 15 is a cross-sectional view for illustrating the second operation of the embodiment. Figure 15 wherein, in the first layer 1L of the winding portion 45, the windings 46 wound by the first operation are denoted by marking "F", and the windings 46 wound by the second operation are denoted by marking "S".

[0076] As shown in Figure 15 , in the second operation, the conductor is wound such that the second pitch P2 satisfies P2<P1, whereby the conductor (S) is wound so as to be in contact with the winding 46(F) located at the other end in the radial direction Y among the windings 46(F) wound by the first operation. When the conductor (S) is wound by the second operation, the conductor (S) is wound around the surface of the insulator tooth portion 42 while being in contact with the outer peripheral surface on the flange portion 43 side (the other end side Y2 in the radial direction Y) of the outer peripheral surfaces of the winding 46(F) at the other end in the radial direction Y, whereby a force f1 directed to one end side Y1 (outer diameter side) in the radial direction Y is applied from the winding 46(S) wound by the second operation to the winding 46(F) at the other end wound by the first operation. By this force f1 directed to one end side Y1 (outer diameter side) in the radial direction Y, the winding 46(F) at the other end is pressed toward one end side Y1 (outer diameter side) in the radial direction Y and moved toward the outer peripheral wall portion 41 side (one end side Y1 in the radial direction Y). As a result, the gap G between the winding 46(F) at the other end and the winding 46(F) adjacent to the winding 46(F) at the other end is narrowed, and the two windings 46(F) are brought into contact with each other.

[0077] Next, in the second operation, the conductor (S) to be wound subsequently is wound such that the second pitch P2 satisfies P2<P1, so as to be wound around the surface of the insulator tooth portion 42 in contact with the outer peripheral surface on the flange portion 43 side (the other end side Y2 in the radial direction Y) of the winding 46(S) previously wound by the second operation, thereby pressing the winding 46(S) previously wound by the second operation to move it toward the outer peripheral wall portion 41 side (one end side Y1 in the radial direction Y). As a result, the gap G between the windings 46(F) located closer to the outer peripheral wall portion 41 side than the winding 46(S) previously wound by the second operation is narrowed. Thereafter, the same applies to the case where the conductor is further wound by the second operation, and the gap G between the windings 46(F) wound on the outer peripheral wall portion 41 side is further narrowed.

[0078] Furthermore, regarding the insulating frame tooth portion 42 of the embodiment, when viewed in a cross-section along the radial Y direction, the surface of the insulating frame tooth portion 42 around which the wire is wound has a flat surface 42a extending radially Y, and an inclined surface, i.e., an arc-shaped curved surface 42b, inclined relative to the flat surface 42a. The flat surface 42a extends from the inner peripheral surface of the outer peripheral wall portion 41. The curved surface 42b extends from the side of the flange portion 43 facing the outer peripheral wall portion 41, and is smoothly and continuously formed with the flange portion 43 side (the other end side Y2 of the radial Y) of the flat surface 42a.

[0079] In the second action, the winding 46 wound on the curved surface 42b of the insulating frame tooth 42 can also be moved towards the outer peripheral wall 41 (one end of the radial Y, Y1) by sliding the winding 46 wound on the flange 43 side (the other end of the radial Y, Y2) of the insulating frame tooth 42 wound in the radial Y direction towards the flat surface 42a side. By utilizing the force of the winding 46 wound on the curved surface 42b sliding in this way, the gap G between the windings 46(F) wound in the first action can be smoothly narrowed.

[0080] Furthermore, the inclined surface formed on the insulating frame tooth portion 42 is not limited to a curved surface (R surface) 42b formed by a single curvature. For example, it can also be a C surface, a surface formed by continuously forming multiple C surfaces with different inclination angles, or a surface formed by continuously forming multiple R surfaces with different curvatures. In order to facilitate the sliding of the winding 46 wound on the inclined surface, a surface processing such as a coating to reduce the static friction coefficient can also be performed on the flange portion 43 side of the insulating frame tooth portion 42.

[0081] The relationship related to the outer diameter B of the wire used in the winding process of the embodiment is preferably valid even when the outer diameter B is set as the upper limit of the dimensional tolerance of the outer diameter of the wire (maximum processed outer diameter). Therefore, the winding spacing (first spacing P1, second spacing P2, etc.) can be optimally set, thus most appropriately achieving the following effects: preventing uneven winding of the winding 46 wound on the first layer 1L by the first action, and narrowing the gap G between the windings 46 by the second action. Figure 5 As shown, the wire (wound 46) here has a conductor 46a and an insulating film 46b covering the conductor 46a, and the outer diameter B of the wire is a dimension including the thickness of the insulating film 46b. In this embodiment, for example, the outer diameter of the conductor 46a is set to 0.8 mm, and the upper limit of the dimensional tolerance of the outer diameter B of the wire covered by the insulating film 46b is 0.88 mm.

[0082] Furthermore, the jumper wire 49 extending from the winding portion 45 is less prone to elongation due to tension, unlike the winding wire 46. Therefore, its outer diameter is larger than that of the portion of the conductor forming the winding wire 46, and is close to the outer diameter B of the conductor in its pre-winding state. Thus, the outer diameter B of the conductor in its pre-winding state can approximate the outer diameter of the conductor extending from the winding portion 45 to the outer peripheral wall portion 41 as the jumper wire 49. Therefore, in this embodiment, the outer diameter of the conductor extending from the winding portion 45 to the outer peripheral wall portion 41 as the outer diameter B of the conductor in its pre-winding state is considered.

[0083] The insulating film 46b, for example, contains polyamide-imide, and its static friction coefficient is 0.12 or less. The insulating film 46b in this embodiment has high lubricity and a static friction coefficient of approximately 0.05. Therefore, by utilizing the winding 46 wound in the second operation, the winding 46 wound in the first operation can easily slide radially Y along the surface of the insulating frame teeth 42, thereby smoothly narrowing the gap G between the windings 46. Furthermore, as described above, while the wire (winding 46) with a low static friction coefficient on the surface of the insulating film 46b can suppress wire jamming during the winding process, it is prone to slippage in the first layer 1L in contact with the surface of the insulating frame teeth 42, and the winding position of the winding 46 is prone to shift. Therefore, when using a wire with a low static friction coefficient of the insulating film 46b as described above, by ensuring that the first spacing P1 of the first layer 1L in the first operation satisfies P1>B as in the embodiment, the effect of preventing uneven winding of the first layer 1L is higher.

[0084] Furthermore, the insulating frame 25 of the embodiment contains 15% to 45% by weight of glass fiber, which increases the coefficient of dynamic friction of the surface of the insulating frame teeth 42. When the amount added is less than 15% by weight, the molding shrinkage rate of the resin material containing glass fiber increases, and the formability of the insulating frame 25 decreases, which is undesirable. When the amount added exceeds 45% by weight, the increase in the coefficient of dynamic friction is insufficient, and it only leads to an increase in manufacturing cost, which is also undesirable. By adding glass fiber in this way, the insulating frame 25 can suppress the slippage of the winding 46 wound on the surface of the insulating frame teeth 42, thereby improving the effect of preventing the first layer 1L from winding unevenly during the first operation and improving the reliability of the wire wound on the first layer 1L.

[0085] In addition, the winding process of the embodiment uses a winding machine with a wire nozzle N to wind the wire, so that the movement amount of the wire nozzle N (first spacing P1 and second spacing P2) is controlled by the control unit C of the winding machine. Thus, in the first operation, a winding portion 45 without winding irregularities can be easily formed at the required first spacing P1, and in the second operation, the gap G between the windings 46 can be appropriately narrowed at the required second spacing P2.

[0086] Variations In the winding step of the modified example, the number of turns of the winding wire 46 wound by the second operation is four turns, which is different from the winding step of the embodiment in which the number of turns of the winding wire 46 in the second operation is two turns. Figure 16 is a cross-sectional view for illustrating the first operation and the second operation performed in the winding step of the modified example. Figure 16 in the first layer 1L of the winding portion 45, the winding wire 46 wound by the first operation is denoted by "F", and the winding wire 46 wound by the second operation is denoted by "S".

[0087] As shown in Figure 16 , in the first operation of the winding step of the modified example, similarly to the embodiment, the conductive wire is wound in the first layer 1L of the winding portion 55 such that the first pitch P1 satisfies P1>B, whereby the winding wire 46 is wound in the first layer 1L in a manner that winding misalignment does not occur. In the second operation of the winding step of the modified example, the conductive wire is wound such that the second pitch P2 satisfies P2<P1, whereby the gap G on the flange portion 43 side (the other end side Y2 in the radial direction Y) between the winding wires 46 wound by the first operation is narrowed.

[0088] Further, in the second operation of the modified example, by repeatedly winding the conductive wire for multiple turns up to four turns at the second pitch P2, a plurality of gaps G between the winding wires 46 wound by the first operation are sequentially narrowed from the flange portion 43 side, and all the gaps G are completely narrowed so that the winding wires 56 in the first layer 1L are in close contact with each other. In the winding step of the modified example, similarly to the embodiment, the conductive wire is wound in the second layer 2L and subsequent layers such that the third pitch P3 satisfies P3<P1, thereby forming the winding portion 55.

[0089] Effects of the Embodiment As described above, the method for manufacturing the electric motor in the embodiment performs a first operation and a second operation. The first operation is to wind a wire from the outer peripheral wall 41 side (one end Y1 side of radial Y) of the insulating frame tooth 42 in the first layer 1L of the winding portion 45, leaving a gap G between adjacent windings 46, towards the flange 43 side (the other end Y2 side of radial Y). The second operation is to wind the wire in the first layer 1L after the first operation, so as to connect with the winding 46 located on the flange 43 side (the other end Y2 side of radial Y), thereby causing at least a portion of the winding 46 wound by the first operation to move towards the outer peripheral wall 41 side (one end Y1 side of radial Y) and narrow the gap G. By winding the wire while leaving a gap G between the windings 46 in the first layer 1L through the first action, even if the windings 46 wound in the first layer 1L slip on the surface of the insulating frame teeth 42, the subsequent windings 46 can be smoothly passed over the windings 46 whose winding positions have shifted and properly wound, thus preventing uneven winding in the first layer 1L. Furthermore, by winding the wire in the first layer 1L through the second action to narrow the gap G between the windings 46, the number of turns of the windings 46 in the first layer 1L can be increased, and the alignment of the windings 46 in the second layer 2L and beyond, which overlap with the first layer 1L with the narrowed gap G between the windings 46, can be improved. Therefore, according to the embodiment, for example, it is not necessary to change the insulating frame with grooves to prevent winding slippage according to the outer diameter of the wire, thus avoiding an increase in the manufacturing cost of the motor 6. In addition, according to the embodiment, the winding 46 of the first layer 1L of the winding portion 45 can be prevented from elongating due to uneven winding, thereby suppressing the increase in resistance and heat generation of the winding 46 and improving the reliability of the wire wound on the first layer 1L.

[0090] Furthermore, in the method for manufacturing the electric motor in this embodiment, during the first operation, the conductor is wound with a first spacing P1 such that P1>B. Therefore, even if the winding 46 wound on the first layer 1L slides on the surface of the insulating frame teeth 42, the subsequent winding 46 can be smoothly wound past the winding 46 whose winding position has shifted and wound appropriately. Thus, the winding 46 can be wound in the first layer 1L without causing uneven winding.

[0091] Further, in the method for manufacturing a motor according to the embodiment, in the first operation, the wire is wound such that the first pitch P1 satisfies P1<2B. In other words, the outer diameter B of the winding wire 46 wound in the first layer 1L of the winding portion 45 and the winding pitch P satisfy 2B>P. When the first pitch P1 is 2B or more, the gap G between adjacent winding wires 46 becomes large, and there is a possibility that the gap G cannot be appropriately narrowed by the second operation. In addition, when the first pitch P1 is 2B or more, the number of turns in the first layer 1L decreases, and the winding wire 46 of the second layer 2L easily enters the gap G between the winding wires 46 of the first layer 1L, which may lead to deterioration of the arrangement performance of the winding portion 45. These problems can be avoided by making the first pitch P1 satisfy P1<2B.

[0092] Further, in the method for manufacturing a motor according to the embodiment, in the second operation, the wire is wound such that the second pitch P2 satisfies P2<P1. Thereby, the winding wire 46 wound through the second operation can narrow the gap G between the winding wires 46 wound through the first operation.

[0093] Further, in the method for manufacturing a motor according to the embodiment, in the second operation, the wire is wound such that the second pitch P2 and the outer diameter B of the wire satisfy 0≤P2<(B / 2). Thereby, the gap G between the winding wires 46 wound through the first operation can be appropriately narrowed.

[0094] Further, in the method for manufacturing a motor according to the embodiment, the wire is repeatedly wound for a plurality of turns in the second operation. By increasing the number of turns in this manner, the effect of narrowing the gap G can be enhanced, and the number of winding wires 46 wound around the first layer 1L can be increased.

[0095] Further, in the method for manufacturing a motor according to the embodiment, the wire is wound such that the third pitch P3 of the winding wires 46 wound in the second layer 2L and subsequent layers of the winding portion 45 satisfies P3<P1. Thereby, the number of turns in each of the second layer 2L and subsequent layers can be increased, so that the space factor of the winding portion 45 can be improved.

[0096] Further, the outer diameter B of the wire used in the method for manufacturing a motor according to the embodiment is the upper limit value of the dimensional tolerance. Thereby, the winding pitches (the first pitch P1, the second pitch P2, etc.) can be optimally set, so that the following effects can be obtained most appropriately: preventing winding disorder of the winding wires 46 wound on the first layer 1L in the first operation, and narrowing the gap G between the winding wires 46 through the second operation.

[0097] Furthermore, in the method of manufacturing the electric motor of the embodiment, the insulating frame tooth 42 of the insulating frame 25, when viewed in a cross-section along the radial Y direction, has a flat surface 42a extending radially Y, and a curved surface 42b continuously formed with respect to the radial Y on the flange 43 side (the other end Y2 side of the radial Y). Then, in the second operation, by sliding the winding 46 wound on the curved surface 42b toward the flat surface 42a side along the curved surface 42b, the winding 46 wound on the flange 43 side is moved toward the outer peripheral wall 41 side (the other end Y1 side of the radial Y). By utilizing the force of the sliding of the winding 46 wound on the curved surface 42b in this way, the gap G between the windings 46 wound in the first operation can be smoothly narrowed.

[0098] Furthermore, the insulating film 46b of the wire (winding 46) used in the motor manufacturing method of the embodiment contains polyamide-imide. Therefore, the insulating film 46b has high lubricity, and thus, using the winding 46 wound in the second operation, the winding 46 wound in the first operation can easily slide radially Y along the surface of the insulating frame teeth 42, thereby smoothly narrowing the gap G between the windings 46. Moreover, because the insulating film 46b has high lubricity, although it can suppress wire jamming during the winding process, slippage easily occurs in the first layer 1L in contact with the surface of the insulating frame teeth 42, and the winding position of the winding 46 is prone to deviation. Therefore, by ensuring that the first spacing P1 of the first layer 1L in the first operation satisfies P1>B, as in the embodiment, the effect of preventing uneven winding of the first layer 1L is higher.

[0099] Furthermore, the insulating frame 25 used in the electric motor manufacturing method of the embodiment contains 15% to 45% glass fiber. As a result, the coefficient of dynamic friction of the surface of the insulating frame teeth 42 is increased, which can suppress the slippage of the winding 46 wound on the surface of the insulating frame teeth 42. Therefore, it can improve the effect of preventing the first layer 1L from being wound unevenly by the first action and improve the reliability of the wire wound on the first layer 1L.

[0100] Furthermore, the method for manufacturing the electric motor in this embodiment uses a winding machine to wind the conductor, the winding machine having a wire nozzle N for supplying the conductor. Thus, the control unit C of the winding machine controls the amount of movement of the wire nozzle N (first pitch P1, second pitch P2), thereby easily forming a winding section 45 without uneven winding at the desired first pitch P1 in the first operation, and appropriately narrowing the gap G between the windings 46 at the desired second pitch P2 in the second operation.

[0101] Symbol Explanation 6 Electric motors 23 Stator core 25 (25A, 25B) Insulating Frame 31 Yoke 32 (32-1~32-9) Stator core teeth (teeth) 41 Peripheral wall portion 42 (42-1~42-9) Insulation frame tooth section (drum section) 42a Flat surface 45, 55 winding sections 46 winding 46a conductor 46b Insulating Film 49. Jumper wire B. Outer diameter of the conductor G gap P1 First Spacing (Wrapping Spacing in the First Action) P2 Second Spacing (Wrapping Spacing in the Second Action) P3 Wrapping spacing after the second layer 1L First Floor 2L~8L Second to Eighth Floors M length N-line nozzle Y represents radial direction.

Claims

1. A method for manufacturing an electric motor, the electric motor comprising: a stator core having an annular yoke portion, and teeth portions extending from the yoke portion in a radial direction of the yoke portion; an insulating bobbin having a drum portion attached to the teeth portion; and a winding portion formed with multiple layers by a winding wire formed by winding a conductor wire around the teeth portion with the drum portion interposed therebetween, the method for manufacturing the electric motor is characterized by performing a first operation and a second operation, the first operation is to wind the conductor wire from one end side of the drum portion in the radial direction toward the other end side while leaving a gap between adjacent winding wires in the first layer of the winding portion, the second operation is, after the first operation, winding the conductor wire around the first layer in a manner to be in contact with the winding wire located on the other end side, thereby moving at least a part of the winding wire wound by the first operation toward the one end side to narrow the gap.

2. The method for manufacturing an electric motor according to claim 1, characterized in that in the first operation, when a winding pitch in the first operation, i.e., a first pitch, is defined as P1, and an outer diameter of the conductor wire is defined as B, the conductor wire is wound in a manner satisfying P1>B.

3. The method for manufacturing an electric motor according to claim 2, characterized in that in the first operation, the conductor wire is wound in a manner satisfying P1<2B.

4. The method for manufacturing an electric motor according to claim 2, characterized in that in the second operation, when a winding pitch in the second operation, i.e., a second pitch, is defined as P2, the conductor wire is wound in a manner satisfying P2<P1.

5. The method for manufacturing an electric motor according to claim 4, characterized in that in the second operation, the conductor wire is wound in a manner satisfying 0≤P2<(B / 2).

6. The method for manufacturing an electric motor according to claim 1, characterized in that in the second operation, the conductor wire is wound for a plurality of turns repeatedly.

7. The method for manufacturing an electric motor according to claim 1, characterized in that when a winding pitch of the conductor wire wound on the second and subsequent layers of the winding portion, i.e., a third pitch, is defined as P3, the conductor wire is wound in a manner satisfying P3<P1.

8. The method for manufacturing an electric motor according to any one of claims 2 to 5, characterized in that the outer diameter B of the conductor wire is the upper limit value of the dimensional tolerance of the outer diameter.

9. The method for manufacturing an electric motor according to claim 1, characterized in that the drum portion of the insulating bobbin, when viewed in a cross section of the drum portion along the radial direction, has a flat surface extending in the radial direction, and an inclined surface formed continuously with the other end side of the flat surface and inclined relative to the radial direction, in the second operation, the winding wire wound on the other end side is moved toward the one end side by causing the winding wire wound on the inclined surface to slide along the inclined surface toward the flat surface side.

10. The method for manufacturing an electric motor according to claim 1, characterized in that the conductor wire has a conductor, and an insulating film covering the conductor, The insulating film contains polyamide imide.

11. The method for manufacturing an electric motor according to claim 1, characterized in that, The insulating frame contains 15% to 45% glass fiber.

12. The method for manufacturing an electric motor according to claim 1, characterized in that, A winding machine is used to wind the conductor, the winding machine having a nozzle for supplying the conductor.

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