STATOR FOR ROTATING ELECTRIC MACHINE

Abstract

A stator for a rotating electric machine has a stator core with a tubular yoke and teeth, coils formed by windings wound around the teeth, and insulators. Each insulator has a tubular base. The base has a first circumferential surface on one side radially aligned with the yoke, a second circumferential surface on the other side radially opposite the first, exit slots, each of which guides a connecting wire of a coil from the first side to the second side radially, and return slots, each of which guides the connecting wire, exiting through an exit slot, back from the second side to the first side radially. Each exit slot holds the connecting wire by an interference fit. Each return slot holds the connecting wire by a clearance fit.

Description

BACKGROUND 1. Area

[0001] The present disclosure relates to a stator for a rotating electrical machine. 2. Description of the state of the art

[0002] As disclosed, for example, in Japanese patent publication No. 2010-259318, a stator for a rotating electric machine has a stator core, coils, and insulators. The stator core has a tubular yoke and teeth. The teeth extend radially from a circumferential face of the yoke. The coils are formed by windings wound around the teeth. The coils have coil ends. The coil ends project from core end faces of the stator core in the axial direction of the yoke. The insulators are arranged to face the core end faces. The insulators insulate the coil ends from the core end faces. Each insulator has a tubular insulator base positioned to overlap the yoke in the axial direction.The insulator base has a first circumferential surface at a first side in the radial direction where the coil ends are located, and a second circumferential surface at a second side in the radial direction opposite to the first side.

[0003] Each coil has several wound sections formed by a winding that is tightly wound around the teeth. A winding end wire, which is a section of the winding, extends from the wound section. The beginning of the winding of each wound section is secured as a consequence of the winding around the corresponding tooth. This prevents the beginning of the winding of the wound section from loosening. Conversely, to prevent the end of the winding of the wound section from loosening, it is necessary to secure the winding end wire.

[0004] In this respect, the insulator base can have lead-out slots and return slots. The lead-out slots open at an insulator end, which is one end of the insulator base on a side opposite the stator core. Each lead-out slot has a first end that opens in the first circumferential face of the insulator base and a second end that opens in the second circumferential face of the insulator base. The lead-out slot guides the connecting wire from the first side to the second side in the radial direction of the insulator base. The return slots open at the insulator end. Each return slot has a first end that opens in the first circumferential face of the insulator base and a second end that opens in the second circumferential face of the insulator base. Each return slot is located at a position adjacent to one of the lead-out slots in the circumferential direction of the insulator base.The return groove guides the connecting wire, which is led out through the exit groove, back from the second side to the first side in the radial direction of the insulator base.

[0005] In this way, the connecting wire is guided out through the exit groove on the second side in the radial direction of the insulator base and back through the return groove on the first side in the radial direction of the insulator base. As a result, the connecting wire is wound around the insulator and fixed to it. This secures the connecting wire to the insulator, preventing the end of the winding from loosening.

[0006] However, if the connecting wire is not held by an interference fit in at least one of the feed-through and return grooves, the winding and fixing of the connecting wire to the insulator is unstable. As a consequence, there is a risk that the end of the winding of the wound section may loosen. On the other hand, for example, in a case where the return groove holds the connecting wire by an interference fit, if the connecting wire, which is fed out through the feed-through groove to the second side radially of the insulator base, is fed back to the first side radially of the insulator base via the return groove, the connecting wire can be pulled from the first side radially of the insulator base while avoiding interference with other connecting wires at the coil ends. In this case, it can be difficult to avoid interference with other connecting wires.Consequently, the process of winding and fixing the connecting wire to the insulator becomes complicated. SUMMARY

[0007] This summary is intended to present, in a simplified form, a selection of concepts that are further described in detail below. It is not intended to identify key features or essential characteristics of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0008] In general terms, a stator for a rotating electric machine has a stator core, several coils, and an insulator. The stator core has a tubular yoke and several teeth extending radially from a circumferential face of the yoke. The coils are formed by windings wound around the teeth. The coils have coil ends projecting from a core end face. The core end face is an end face of the stator core in an axial direction of the yoke. The insulator is positioned to face the core end face. The insulator isolates the coil ends and the core end face from each other. Each coil has a wound section formed by the winding that is concentrated around one of the teeth, and a winding end wire, which is a section of the winding that extends from the wound section.The insulator has a tubular insulator base positioned axially overlapping the yoke. The insulator base has a first circumferential surface on the radial side where the coil ends are located, a second circumferential surface on the radial side opposite the first, an insulator end opposite the stator core, a lead-out groove opening at the insulator end, and a return groove at the insulator end. The lead-out groove has a first end opening in the first circumferential surface and a second end opening in the second circumferential surface. The lead-out groove guides the connecting wire radially from the first side to the second side. The return groove has a first end opening in the first circumferential surface and a second end opening in the second circumferential surface.The return groove is located in a position adjacent to the exit groove in a circumferential direction of the insulator base and guides the connecting wire, which exits through the exit groove, back radially from the second side to the first side. The exit groove holds the connecting wire by an interference fit. The return groove holds the connecting wire by a clearance fit.

[0009] In a more general sense, a stator for a rotating electric machine has a stator core, several coils, and an insulator. The stator core has a tubular yoke and several teeth extending radially from a circumferential face of the yoke. The coils are formed by windings wound around the teeth. The coils have coil ends projecting from a core end face. The core end face is an end face of the stator core in an axial direction of the yoke. The insulator is positioned to face the core end face. The insulator isolates the coil ends and the core end face from each other. Each coil has a wound section formed by the winding that is concentrated around one of the teeth, and a winding end wire, which is a section of the winding that extends out from the wound section.The insulator has a tubular insulator base positioned axially overlapping the yoke. The insulator base has a first circumferential surface on the radial side where the coil ends are located, a second circumferential surface on the radial side opposite the first, an insulator end opposite the stator core, a lead-out groove opening at the insulator end, and a return groove opening at the insulator end. The lead-out groove has a first end opening in the first circumferential surface and a second end opening in the second circumferential surface. The lead-out groove guides the connecting wire radially from the first side to the second side. The return groove has a first end opening in the first circumferential surface and a second end opening in the second circumferential surface.The return groove is located at a position adjacent to the exit groove in one circumferential direction of the insulator base and guides the connecting wire, which exits through the exit groove, back radially from the second side to the first side. The return groove has two return groove-forming surfaces located on opposite sides of the connecting wire in the circumferential direction. When viewed axially, the two return groove-forming surfaces are inclined to gradually separate from the exit groove, extending from the second circumferential surface to the first. The width between the two return groove-forming surfaces is less than the outer diameter of the original connecting wire shape.

[0010] Other features and aspects will become apparent from the following detailed description, drawings, and claims. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 is a cross-sectional view of a stator and a rotor of a rotating electrical machine according to a first embodiment. Fig. Figure 2 is a perspective exploded view of a stator core and two insulators of the stator, which is in Fig. 1 is shown. Fig. 3 is a perspective view of the stator, which is located in Fig. 1 is shown. Fig. Figure 4 is another perspective view of the stator, which is located in Fig. 1 is shown. Fig. 5 is an enlarged side view of a section of the stator located in Fig. 1 is shown. Fig. 6 is an enlarged cross-sectional view of a section of the stator located in Fig. 1 is shown. Fig. Figure 7 is an explanatory diagram illustrating the process of winding and fixing a connecting wire of the stator, which is located in Fig. Figure 1 shows an insulator. Fig. Figure 8 is an explanatory diagram illustrating the process of winding and fixing a stator connection wire, which is located in Fig. Figure 1 shows an insulator. Fig. Figure 9 is an explanatory diagram illustrating the process of winding and fixing a stator connection wire, which is located in Fig. Figure 1 shows an insulator. Fig. Figure 10 is an explanatory diagram illustrating the process of winding and fixing a stator connection wire, which is located in Fig. Figure 1 shows an insulator. Fig. Figure 11 is an enlarged perspective view showing part of a stator according to a second embodiment. Fig. Figure 12 is an enlarged front view of the part of the stator that is located in Fig. 11 is shown. Fig. Figure 13 is an enlarged side view of part of a stator according to a modification. Fig. Figure 14 is an enlarged front view of part of a stator according to a further modification.

[0011] In the drawings and the detailed description, the same reference symbols refer to the same elements. The drawings need not be to scale, and the relative size, proportions, and depiction of elements in the drawings may be exaggerated for clarity, illustration, and convenience. DETAILED DESCRIPTION

[0012] This description assumes a comprehensive understanding of the processes, devices, and / or systems described. Modifications and equivalents of the described processes, devices, and / or systems are obvious to a person skilled in the art. Sequences of operations are exemplary and may be modified as is obvious to a person skilled in the art, with the exception of operations that necessarily occur in a certain order. Descriptions of functions and constructions that are well known to a person skilled in the art may be omitted.

[0013] Exemplary embodiments can take various forms and are not limited to the examples described. However, the examples described are complete and comprehensive, conveying the full scope of the disclosure to the person skilled in the art.

[0014] In this application, “at least one of A and B” should be understood to mean “only A, only B or both A and B”. First embodiment

[0015] A stator 11 for a rotating electric machine 10 according to a first embodiment is now described with reference to Fig. 1, Fig. 2, Fig. 3, Fig. 4, Fig. 5, Fig. 6, Fig. 7, Fig. 8, Fig. 9 to Fig. 10 described. Basic structure of the rotating electric machine

[0016] As in Fig. As shown in Figure 1, the rotating electric machine 10 has a stator 11 and a rotor 12. The stator 11 is tubular. The rotor 12 is located on the inner side of the stator 11. The rotor 12 has a cylindrical rotor core 13 and permanent magnets (not shown) embedded in the rotor core 13. The rotor core 13 is fixed to a rotating shaft 14. The rotor core 13 is designed to rotate in unison with the rotating shaft 14.

[0017] As in Fig. 1 and Fig. As shown in Figure 2, the stator 11 has a stator core 23. The stator core 23 has a yoke 24 and several teeth 25. The yoke 24 is cylindrical. The teeth 25 extend radially from an inner circumferential surface 24a, which is a circumferential surface of the yoke 24. The teeth 25 are spaced apart along the circumferential direction of the yoke 24. The circumferential direction of the yoke 24 corresponds to the circumferential direction of the stator core 23. Each tooth 25 extends from the inner circumferential surface 24a of the yoke 24 towards the axis of the stator core 23. In the present embodiment, the stator core 23 has twelve teeth 25. Although the number of teeth 25 is not particularly limited, the number of teeth 25 is a multiple of three.

[0018] As in Fig. As shown in Figure 2, opposite end faces of the yoke 24 are flat in the axial direction. Opposite end faces of each tooth 25 in the axial direction of the yoke 24 are flat. The length of the yoke 24 in the axial direction is equal to the length of each tooth 25 in the axial direction of the yoke 24. An end face of the yoke 24 located at a first side in the axial direction lies in the same plane as an end face of each tooth 25 located at the first side in the axial direction of the yoke 24. An end face of the yoke 24 located at a second side in the axial direction lies in the same plane as an end face of each tooth 25 located at the second side in the axial direction of the yoke 24.

[0019] The end face of the yoke 24, which is located in the axial direction on the first side, and the end faces of the teeth 25, which are located in the axial direction of the yoke 24 on the first side, form a first core end face 23a, which is an end face of the stator core 23 located in the axial direction of the yoke 24 on the first side. The end face of the yoke 24, which is located in the axial direction on the second side, and the end faces of the teeth 25, which are located in the axial direction of the yoke 24 on the second side, form a second core end face 23b, which is an end face of the stator core 23 located in the axial direction of the yoke 24 on the second side. The first core end face 23a and the second core end face 23b are core end faces of the stator core 23 in the axial direction of the yoke 24.

[0020] As in Fig. 1 and Fig. As shown in Figure 2, each tooth 25 has a tooth extension 26 and two tooth flanges 27. The tooth extension 26 is a thin plate extending from the inner circumferential surface 24a of the yoke 24. The tooth extension 26 extends from the first core end face 23a to the second core end face 23b of the stator core 23. The tooth flanges 27 project from the end of the tooth extension 26 on the side opposite to the end connected to the yoke 24 and on the opposite sides in the circumferential direction of the yoke 24.

[0021] As in Fig. As shown in Figure 2, the stator 11 has two insulators 50. Each insulator 50 is tubular. Each insulator 50 is made of, for example, plastic. Each insulator 50 has an insulator base 51 and insulator tooth sections 52. The insulator base 51 is cylindrical. The insulators 50 are arranged on the stator core 23, with the axes of the insulator bases 51 coinciding with the axis of the yoke 24. The insulator bases 51 are positioned at locations that overlap the yoke 24 in its axial direction. The circumferential direction of each insulator base 51 coincides with the circumferential direction of the yoke 24. The radial direction of each insulator base 51 coincides with the radial direction of the yoke 24.

[0022] One of the two insulators 50 is arranged to face the first core end face 23a of the stator core 23, while in contact with it. The other of the two insulators 50 is arranged to face the second core end face 23b, while in contact with it. In the following description, one of the two insulators 50, which is arranged to face the first core end face 23a of the stator core 23, can be referred to as a first insulator 501, and the insulator 50, which is arranged to face the second core end face 23b, can be referred to as a second insulator 502. The outer diameter of the insulator base 51 is smaller than the outer diameter of the yoke 24. The inner diameter of the insulator base 51 is equal to the inner diameter of the yoke 24.

[0023] Each insulator tooth segment 52 extends radially from an inner circumferential surface 51a of the insulator base 51. The insulator tooth segments 52 are spaced apart from each other circumferentially around the insulator base 51. Each insulator tooth segment 52 extends from the inner circumferential surface 51a of the insulator base 51 towards the axis of the insulator base 51. In the present embodiment, each insulator 50 has twelve insulator tooth segments 52. The number of insulator tooth segments 52 is the same as the number of teeth 25 of the stator core 23.

[0024] Each insulator tooth section 52 has an insulator extension 53 and an insulator flange 54. Each insulator extension 53 has the form of a post extending from the inner circumferential surface 51a of the insulator base 51. The width of each insulator extension 53 in the circumferential direction of the insulator base 51 is equal to the width of each tooth extension 53 in the circumferential direction of the yoke 24. Each insulator extension 53 is in contact with the corresponding tooth 25. The insulator flange 54 projects parallel to the insulator base 51 from the end of the insulator extension 53 on the side opposite to the end that is connected to the insulator base 51.

[0025] Several connecting wire receiving grooves 61 are formed in an outer circumferential surface 51b of the insulator base 51 of the first insulator 501. The connecting wire receiving grooves 61 are arranged side by side in the axial direction of the insulator base 51. Each connecting wire receiving groove 61 extends in the circumferential direction of the yoke 24. Each connecting wire receiving groove 61 extends over the entire circumference of the outer circumferential surface 51b of the insulator base 51. Each connecting wire receiving groove 61 does not extend through the insulator base 51 in the radial direction.

[0026] Several through-grooves 62 are formed in the insulator base 51 of the first insulator 501. Each through-groove 62 extends through the insulator base 51 in the radial direction. The number of through-grooves 62 is equal to the number of teeth 25. Each through-groove 62 extends axially along the insulator base 51 from an insulator end 51e, which is an end of the insulator base 51 located on the side opposite the stator core 23.

[0027] As in Fig. As shown in Figure 1, the stator 11 has three-phase coils 28. Each coil 28 has several wound sections 30. Each wound section is formed by a winding 31 that is wound in a concentrated manner to collectively surround one of the tooth extensions 26 and the insulator extensions 53 of the corresponding two insulators 50, which are arranged side by side in the axial direction of the stator 11. Thus, each wound section 30 is formed by a winding 31 that is wound in a concentrated manner around a tooth 25.

[0028] The winding process of the winding 31 of the coil 28 of each phase for the tooth extensions 26 and the insulator extensions 53 of the two insulators 50 is carried out automatically by, for example, a winding machine or system which includes a winding nozzle.

[0029] As in Fig. As shown in Figure 3, a section of each wound section 30 is a first coil end 281 projecting from the first core end face 23a. The first coil ends 281 are thus coil ends projecting from the first core end face 23a. The first coil ends 281 are parts of the coils 28.

[0030] As in Fig. As shown in Figure 4, a section of each wound section 30 is a second coil end 282 projecting from the second core end face 23b. The second coil ends 282 are thus coil ends projecting from the second core end face 23b. The coil ends 282 are parts of the coils 28.

[0031] As described above, each coil 28 has a first coil end 281 that projects from the first core end face 23a. Furthermore, each coil 28 has a second coil end 282 that projects from the second core end face 23b. Therefore, each coil 28 has coil ends that project from the core end faces accordingly. In this way, the coils 28 are formed by the windings 31 that are wound around the respective teeth 25.

[0032] As in Fig. As shown in Figure 3, the first insulator 501 provides insulation between the first coil ends 281 and the first core end face 23a. Accordingly, the first insulator 501 provides insulation between the coils 28 and the first core end face 23a. The inner circumferential surface 51a of the insulator base 51 of the first insulator 501 is a first circumferential surface on a first side in the radial direction of the insulator base 51, where the first coil ends 281 are located. The outer circumferential surface 51b of the insulator base 51 of the first insulator 501 is a second circumferential surface on a second side that is opposite to the first side in the radial direction of the insulator base 51.

[0033] As in Fig. As shown in Figure 4, the second insulator 502 provides insulation between the second coil ends 282 and the second core end surface 23b. Accordingly, the second insulator 502 provides insulation between the coils 28 and the second core end surface 23b. The inner circumferential surface 51a of the insulator base 51 of the second insulator 502 is a first circumferential surface on a first side in the radial direction of the insulator base 51, where the second coil ends 282 are located. The outer circumferential surface 51b of the insulator base 51 of the second insulator 502 is a second circumferential surface on a second side opposite to the first side in the radial direction of the insulator base 51. In this way, each insulator base 51 has the first circumferential surface at the first side in the radial direction of the insulator base 51, where the coil ends are located, and the second circumferential surface at the second side, which is opposite to the first side in the radial direction of the insulator base 51.

[0034] As in Fig. As shown in Figure 3, connecting wires 32, which are sections of the windings 31, are led out from the wound sections 30 of the coil 28 of each phase. The connecting wires 32 of the coil 28 of each phase are led out from the first coil ends 281. The connecting wires 32 of the coil 28 of each phase connect the wound sections 30 that form the coil 28 of that phase in series. Each connecting wire 32 is guided in the circumferential direction of the yoke 24 in a state of being received in the connecting wire receiving groove 61 via the through groove 62.

[0035] As in Fig. As shown in Figure 4, a winding start terminal wire 34, which is a section of each winding 31, is brought out from the wound section 30 of the coil 28 of each phase. The terminal wire 34 of the coil 28 of each phase is brought out from the second coil end 282. The terminal wires 34 of the coils 28 of the respective phases are electrically connected to connecting terminals (not shown) housed in a cluster block 40. Power from an external power supply is supplied to the terminal wires 34 of the coils 28 of the respective phases via connecting terminals.

[0036] Power from the external power supply is fed to the connecting wires 34 of the three-phase coils 28. In this way, when power is fed to the three-phase coils 28, the rotor 12 and the rotating shaft 14 rotate simultaneously.

[0037] A winding end connection wire 35, which is a section of each winding 31, is brought out from the wound section 30 of the coil 28 of each phase. The connection wires 35 of the coil 28 of each phase are brought out from the second coil ends 282. The connection wires 35 of the three-phase coils 28 are electrically connected to each other to form neutral points. Extraction grooves

[0038] The insulator base 51 of the second insulator 502 has several extraction grooves 70. The extraction grooves 70 open at the insulator end 51e, which is one end of the insulator base 51 on the side opposite the stator core 23. The extraction grooves 70 extend through the insulator base 51 in the radial direction of the yoke 24. Each extraction groove 70 has a first end that opens in the inner circumferential surface 51a of the insulator base 51, and a second end that opens in the outer circumferential surface 51b of the insulator base 51. The exit grooves 70 guide the connecting wires 35 from the first side to the second side in the radial direction of the insulator base 51. In this way, the exit grooves 70 guide the connecting wires 35 from the inner side to the outer side in the radial direction of the yoke 24 with reference to the insulator base 51.

[0039] As in Fig. As shown in Figure 5, each exit groove 70 has two exit groove forming surfaces 71 and a connecting surface 72. When the exit groove 70 is viewed in the radial direction of the yoke 24, the two exit groove forming surfaces 71 extend from the insulator end 51e in the axial direction of the yoke 24 and are parallel to each other. The two exit groove forming surfaces 71 are located on opposite sides of the connecting wire 35 in the circumferential direction of the yoke 24. When the exit groove 70 is viewed in the axial direction of the yoke 24, the two exit groove forming surfaces 71 extend in the radial direction of the yoke 24 from the outer circumferential surface 51b to the inner circumferential surface 51a of the insulator base 51. The connecting surface 72 connects the ends of the two leading-out groove-forming surfaces 71 on the side opposite to the insulator end 51e.When the lead-out groove 70 is viewed in the radial direction of the yoke 24, the connecting surface 72 extends in the circumferential direction of the yoke 24.

[0040] The width H1 between the two surfaces 71 forming the exit groove is smaller than the outer diameter D1 of the original shape of the connecting wire 35. Therefore, when positioned between the two surfaces 71 forming the exit groove, the connecting wire 35 extends from the exit groove 70 to the outer side in the radial direction of the yoke 24 with respect to the insulator base 51 in a state where it is sandwiched between the two surfaces 71 forming the exit groove and squeezed between them. In this way, the exit groove 70 holds the connecting wire 35 by an interference fit. The original shape of the connecting wire 35 refers to its shape before it is sandwiched between the two surfaces 71 forming the exit groove and squeezed between them, and to its shape before it is held in the exit groove 70 by an interference fit.The width H1 is the shortest distance between the two surfaces 71 forming the lead-out groove and is a distance between the two surfaces 71 forming the lead-out groove in a direction perpendicular to the radial direction of the yoke 24 in the present embodiment. Return grooves

[0041] As in Fig. As shown in Figure 4, the insulator base 51 of the second insulator 502 has several return grooves 80. The return grooves 80 open at the insulator end 51e. The return grooves 80 extend through the insulator base 51 in the radial direction of the yoke 24. Each return groove 80 has a first end that opens in the inner circumferential surface 51a of the insulator base 51 and a second end that opens in the outer circumferential surface 51b of the insulator base 51. Each return groove 80 is located at a position adjacent to the corresponding exit groove 70 in the circumferential direction of the insulator base 51. Each return groove 80 guides the connecting wire 35, which is led out through the corresponding exit groove 70, back from the second side to the first side in the radial direction of the insulator base 51.In this way, the return groove 80 guides the connecting wire 35, which is led out through the exit groove 70, back to the inner side in the radial direction of the yoke 24 with reference to the insulator base 51.

[0042] As in Fig. As shown in Figure 5, each return groove 80 has two return groove forming surfaces 81 and a connecting surface 82. When the return groove 80 is viewed from the radial direction of the yoke 24, the two return groove forming surfaces 81 extend from the insulator end 51e in the axial direction of the yoke 24 and are parallel to each other. The two return groove forming surfaces 81 are located on opposite sides of the connecting wire 35 in the circumferential direction of the yoke 24. When the return groove 80 is viewed in the axial direction of the yoke 24, the two return groove forming surfaces 81 extend in the radial direction of the yoke 24 from the outer circumferential surface 51b to the inner circumferential surface 51a of the insulator base 51. The connecting surface 82 connects the ends of the two return groove-forming surfaces 81 on the side opposite to the insulator end 51e.When the return groove 80 is viewed in the radial direction of the yoke 24, the connecting surface 82 extends in the circumferential direction of the yoke 24.

[0043] The distance from the insulator end 51e to the connecting surface 82 along each return groove forming surface 81 is the same as the distance from the insulator end 51e to the connecting surface 72 along each output groove forming surface 71. The connecting surface 82 of each return groove 80 is adjacent to the connecting surface 72 of the corresponding output groove 70 in the circumferential direction of the yoke 24.

[0044] The width H2 between the two return groove-forming surfaces 81 is larger than the outer diameter D1 of the original shape of the connecting wire 35. Therefore, when positioned between the two return groove-forming surfaces 81, the connecting wire 35 is guided from the return groove 80 to the inner side in the radial direction of the yoke 24 with respect to the insulator base 51 into a state in which it is sandwiched between the two return groove-forming surfaces 81 without being compressed. In this way, the return groove 80 holds the connecting wire 35 by a clearance fit. The width H2 is the shortest distance between the two return groove-forming surfaces 81 and is a distance between the two return groove-forming surfaces 81 in a direction perpendicular to the radial direction of the yoke 24 in the present embodiment. Protrusions

[0045] As in Fig. As shown in Figure 4, the insulator base 51 of the second insulator 502 has several projections 90. Each projection 90 extends from a section of the outer circumferential surface 51b of the insulator base 51 between a feed-out groove 70 and a return groove 80.

[0046] As in Fig. 5 and Fig. As shown in Figure 6, the projection 90 has a hook surface 91, which is a section on the side opposite the insulator end 51e. The hook surface 91 extends in the radial direction of the yoke 24 from the outer circumferential surface 51b of the insulator base 51. The hook surface 91 is a flat surface. The hook surface 91 is located closer to the insulator end 51e than the connecting surface 72 of the outfeed groove 70 and the connecting surface 82 of the return groove 80.

[0047] The connecting wire 35, which is led out through the exit groove 70, extends towards the return groove 80, while being hooked onto the hook surface 91 of the projection 90. In this way, the connecting wire 35, which is led out through the exit groove 70, is hooked onto a section of the projection 90 on one side opposite the insulator end 51e. Operation of the first embodiment

[0048] Next, the operation of the first embodiment is described, while a procedure for winding and fixing the connecting wire 35 to the insulator 50 is described.

[0049] As in Fig. As shown in Figure 7, when the connecting wire 35 is wound and fixed to the insulator 50, the connecting wire 35 is first guided out from the guide groove 70 to the outer side in the radial direction of the yoke 24 with respect to the insulator base 51, such that the connecting wire 35 extends through the guide groove 70. At this time, the guide groove 70 holds the connecting wire 35 by an interference fit. Removal of the connecting wire 35 from the guide groove 70 is thus prevented.

[0050] Following this, as in Fig. As shown in Figure 8, the connecting wire 35, which is led out through the exit groove 70, is bent in the circumferential direction of the yoke 24 towards the return groove 80. At this time, the connecting wire 35 is bent in the circumferential direction of the yoke 24 so that the connecting wire 35 is hooked onto the hook surface 91 of the projection 90.

[0051] Following this, as in Fig. As shown in Figure 9, the connecting wire 35 is bent in the axial direction of the yoke towards the insulator end 51e at a point in the section that is hooked onto the projection 90. At this time, the connecting wire 35 is bent until the section of the connecting wire 35, on the side of the section hooked onto the projection 90 opposite the outfeed groove 70, partially overlaps with the return groove 80 in the radial direction of the yoke 24.

[0052] Following this, as in Fig. As shown in Figure 10, the connecting wire 35 is bent inwards in the radial direction of the yoke 24, so that the connecting wire 35 extends through the return groove 80. At this time, the return groove 80 holds the connecting wire 35 by a clearance fit. This allows the connecting wire 35 to extend easily through the return groove 80. Furthermore, when the connecting wire 35 is pulled radially from the first side, while avoiding interference with other connecting wires 35 at the second coil ends 282, in order to return the connecting wire 35 radially to the first side of the insulator base 51 through the return groove 80, interference with other connecting wires 35 is easily avoided.

[0053] Following this, as in Fig. As shown in Figure 5, the connecting wire 35, which has been guided back to the inner side of the yoke 24 in the radial direction with respect to the insulator base 51 via the return groove 80, is bent to the side opposite the exit groove 70 in the circumferential direction of the yoke 24 on the inner side of the insulator base 51. Consequently, the connecting wire 35, which has been guided back to the inner side of the yoke 24 in the radial direction with respect to the insulator base 51 via the return groove 80, extends along the inner circumferential surface 51a of the insulator base 51. This prevents any engagement between the connecting wire 35 and a component located on the outer side of the insulator base 51 in the radial direction of the yoke 24.

[0054] In this way, the connecting wire 35 is wound and fixed to the insulator 50. The connecting wire 35 is fixed to the insulator 50 in a state in which a tension is applied to the connecting wire 35 by being wound and fixed to the insulator 50.

[0055] The beginning of the winding of each wound section 30 of the coils 28 is fixed as a consequence of the winding 31 being wound around the corresponding tooth 25. This prevents the beginning of the winding of the wound section 30 from loosening. Furthermore, since the connecting wire 35 is wound to and fixed against the insulator 50, loosening of the end of the winding of the wound section 30 is prevented. Advantages of the first embodiment

[0056] The first embodiment has the following advantages. (1-1) Since the connecting wire 35 is held in the exit groove 70 by an interference fit, unstable winding and fixing of the connecting wire 35 to the insulator 50 is prevented. Furthermore, since the connecting wire 35 is held in the return groove 80 by a clearance fit, the connecting wire 35, which is guided from the exit groove 70 to the second side in the radial direction of the insulator base 51, is easily guided back to the first side in the radial direction of the insulator base 51 via the return groove 80. Therefore, if the connecting wire 35 is pulled from the first side in the radial direction of the insulator base 51, while avoiding interference with other connecting wires 35 at the second coil ends 282, in order to return the connecting wire 35 to the first side in the radial direction of the insulator base 51 through the return groove 80, interference with other connecting wires 35 is easily avoided.This facilitates the process of winding and fixing the connecting wire 35 to the insulator 50. As described above, it is possible to reliably carry out the process of winding and fixing the connecting wire 35 to the insulator 50, while preventing the winding and fixing of the connecting wire 35 to the insulator 50 from becoming unstable. (1-2) The width H2 between the two return groove-forming surfaces 81 is larger than the outer diameter D1 of the original shape of the connecting wire 35. Therefore, the return groove 80 holds the connecting wire 35 by a clearance fit. Furthermore, the two return groove-forming surfaces 81 extend in the axial direction of the yoke 24 from the insulator end 51e and are parallel to each other. This design is suitable for the return groove 80 to hold the connecting wire 35 by a clearance fit. (1-3) The width H1 between the two groove-forming surfaces 71 is smaller than the outer diameter D1 of the original shape of the connecting wire 35. Therefore, the groove 70 holds the connecting wire 35 by means of an interference fit. Furthermore, the two groove-forming surfaces 71 extend in the axial direction of the yoke 24 from the insulator end 51e and are parallel to each other. This design is suitable for the groove 70 to hold the connecting wire 35 by means of an interference fit. (1-4) The connecting wire 35, which extends from the lead-out groove 70 to the second side in the radial direction of the insulator base 51, is hooked onto a section of the projection 90 on the side opposite the insulator end 51e. This makes it possible to further stabilize the winding and fixing of the connecting wire 35 to the insulator 50. (1-5) For example, consider a case in which the insulator 50 expands thermally. In this case, even if the outfeed groove 70 holds the connecting wire 35 by an interference fit, the stress exerted on the connecting wire 35 by the insulator 50 is mitigated because the return groove 80 holds the connecting wire 35 by a clearance fit. Therefore, since the service life of the connecting wire 35 is improved, the reliability of the stator 11 of the rotating electric machine 10 is improved. Second embodiment

[0057] A stator 11 for rotating an electric machine 10 according to a second embodiment is now described with reference to Fig. 11 and Fig. 12 described. In the embodiment described below, the same reference numerals are given to those components which are the same as the corresponding components of the first embodiment which has already been described, and explanations have been omitted or simplified.

[0058] As in Fig. 11 and Fig. As shown in Figure 12, when the return groove 80 is viewed in the axial direction of the yoke 24, the two return groove-forming surfaces 81 are inclined to gradually separate from the exit groove 70, extending from the outer circumferential surface 51b to the inner circumferential surface 51a of the insulator base 51. The return groove-forming surfaces 81 extend parallel to each other. The return groove-forming surfaces 81 guide the connecting wire 35 away from the exit groove 70 when the connecting wire 35, which is led out from the exit groove 70 to the second side in the radial direction of the insulator base 51, is guided back to the first side in the radial direction of the insulator base 51 through the return groove 80.

[0059] As in Fig. As shown in Figure 12, the width H2 between the two return groove-forming surfaces 81 is smaller than the outer diameter D1 of the original shape of the connecting wire 35. Therefore, the return groove 80 holds the connecting wire 35 by an interference fit. The original shape of the connecting wire 35 refers to its shape before it is sandwiched between the two return groove-forming surfaces 81 and squeezed between them, and the shape of the connecting wire 35 before it is held in the return groove 80 by an interference fit. The width H2 is the shortest distance between the two return groove-forming surfaces 81 and is a distance between the two return groove-forming surfaces 81 that is inclined in a direction relative to the radial direction of the yoke 24 in the present embodiment.

[0060] The width H1 between the two surfaces 71 forming the exit groove is larger than the outer diameter D1 of the original shape of the connecting wire 35. Therefore, the exit groove 70 holds the connecting wire 35 by means of a clearance fit. Advantages of the second embodiment

[0061] The second embodiment has the following advantages. (2-1) The width H2 between the two return groove-forming surfaces 81 is smaller than the outer diameter D1 of the original shape of the connecting wire 35. The return groove 80 thus holds the connecting wire 35 by means of an interference fit. This prevents the winding and fixing of the connecting wire 35 to the insulator 50 from becoming unstable. Furthermore, when the return groove 80 is viewed in the axial direction of the yoke 24, the two return groove-forming surfaces 81 are inclined to gradually separate from the exit groove 70, with the return groove-forming surfaces 81 extending from the outer circumferential surface 51b to the inner circumferential surface 51a of the insulator base 51. For example, the two return groove forming surfaces 81 can extend from the outer circumferential surface 51b to the inner circumferential surface 51a of the insulator base 51, while maintaining an equal distance from the output groove 70.In comparison to this case, the connecting wire 35, which is guided from the outfeed groove 70 to the second side in the radial direction of the insulator base 51, is easily guided back to the first side in the radial direction of the insulator base 51 via the return groove 80. Therefore, when the connecting wire 35 is pulled from the first side in the radial direction of the insulator base 51, while avoiding interference with other connecting wires 35 at the second coil ends 282, in order to return the connecting wire 35 to the first side in the radial direction of the insulator base 51 through the return groove 80, interference with other connecting wires 35 is easily avoided. This facilitates the process of winding and fixing the connecting wire 35 to the insulator 50.As described above, it is possible to reliably carry out the process of winding and fixing the connecting wire 35 to the insulator 50, while preventing the winding and fixing of the connecting wire 35 to the insulator 50 from becoming unstable. (2-2) The width H1 between the two exit groove-forming surfaces 71 is larger than the outer diameter D1 of the original shape of the connecting wire 35. Consequently, the exit groove 70 holds the connecting wire 35 by a clearance fit. For example, consider a case in which the insulator 50 expands thermally. In this case, even if the return groove 80 holds the connecting wire 35 by an interference fit, the stress exerted on the connecting wire 35 by the insulator 50 is mitigated because the exit groove 70 holds the connecting wire 35 by a clearance fit. Therefore, since the service life of the connecting wire 35 is improved, the reliability of the stator 11 of the rotating electric machine 10 is improved. (2-3) When the return groove 80 is viewed in the axial direction of the yoke 24, the two return groove-forming surfaces 81 are inclined to gradually separate from the return groove 70, with the return groove-forming surfaces 81 extending from the outer circumferential surface 51b to the inner circumferential surface 51a of the insulator base 51. Therefore, if the connecting wire 35 is returned to the first side in the radial direction of the insulator base 51 via the return groove 80, the winding machine can be arranged outside the insulator base 51 in the radial direction of the yoke 24. Consequently, it is possible to avoid problems such as interference with the connecting wires 35 of the coils 28 of other phases, which could occur if the winding machine were arranged on the inner side of the insulator base 51 in the radial direction of the yoke 24. Modifications

[0062] The embodiments described above can be modified as described below. Each of the above embodiments and the following modifications can be combined, provided that the combined modifications remain technically consistent with one another.

[0063] Fig. Figure 13 shows a modification of the first embodiment. As in Fig. As shown in Figure 13, when the return groove 80 is viewed in the radial direction of the yoke 24, one of the two return groove forming surfaces 81, which is located further away from the output groove 70, has an inclined shape that gradually separates from the output groove 70 with an extension towards the insulator end 51e from the connecting surface 82, which is the bottom surface of the return groove 80.

[0064] With this design, when the connecting wire 35, which is guided from the outfeed groove 70 to the second side in the radial direction of the insulator base 51, is guided back to the first side in the radial direction of the insulator base 51 through the return groove 80, it is easily permitted for the connecting wire 35 to extend through the return groove 80. This further facilitates the process of winding and fixing the connecting wire 35 to the insulator 50. Furthermore, when the connecting wire 35 is guided back to the first side in the radial direction of the insulator base 51 via the return groove 80, the winding machine can be arranged outside the insulator base 51 in the radial direction of the yoke 24.Therefore, it is possible to avoid problems such as interference with the connecting wires 35 of the coils 28 from other phases, which could occur if the winding machine were arranged on the inner side of the insulator base 51 in the radial direction of the yoke 24.

[0065] Fig. Figure 14 shows a modification of the first embodiment. As in Fig. As shown in Figure 14, when the return groove 80 is viewed in the axial direction of the yoke 24, the two return groove-forming surfaces 81 are inclined to gradually separate from the output groove 70, with the return groove-forming surfaces 81 extending from the outer circumferential surface 51b to the inner circumferential surface 51a of the insulator base 51. The width H2 between the two return groove-forming surfaces 81 is larger than the outer diameter D1 of the original shape of the connecting wire 35.

[0066] According to this design, the return groove 80 holds the connecting wire 35 by a clearance fit. When the return groove 80 is viewed in the axial direction of the yoke 24, the two return groove-forming surfaces 81 are inclined to gradually separate from the exit groove 70, extending from the outer circumferential surface 51b to the inner circumferential surface 51a of the insulator base 51. For example, the two return groove-forming surfaces 81 can extend from the outer circumferential surface 51b to the inner circumferential surface 51a of the insulator base 51 while maintaining an equal distance from the exit groove 70. In comparison to this case, the connecting wire 35, which is guided from the outfeed groove 70 to the second side in the radial direction of the insulator base 51, is easily guided back to the first side in the radial direction of the insulator base 51 via the return groove 80.This further facilitates the process of winding and fixing the connecting wire 35 to the insulator 50.

[0067] In the second embodiment, the width H1 between the two surfaces 71 forming the exit groove can be smaller than the outer diameter D1 of the original shape of the connecting wire 35. In other words, in the second embodiment, the exit groove 70 can hold the connecting wire 35 by means of an interference fit.

[0068] In each of the embodiments described above, the insulator base 51 does not necessarily have to have the projection 90.

[0069] In each of the embodiments described above, the winding end wires 35, which extend from wound sections 30, are electrically connected to one another to form a neutral point. However, the present disclosure is not limited thereto. For example, the winding end wire 35, which extends from the wound section 30, can be electrically connected to an external power supply via a connection terminal located in the cluster block 40. In this case, winding start sections of the windings, which extend from the wound sections 30, are electrically connected to one another to form a neutral point.

[0070] In each of the embodiments described above, the rotor 12 is arranged inside the stator 11, but the stator 11 can also be arranged inside the tubular rotor 12. In this case, the teeth 25 extend outwards in the radial direction of the yoke 24 from the outer circumferential surface, which is a circumferential surface of the yoke 24. It is sufficient that the teeth 25 extend in the radial direction of the yoke 24 from a circumferential surface of the yoke 24. When the stator 11 is arranged inside the rotor 12, the outer circumferential surface 51b of the insulator base 51 is a first circumferential surface at the first side in the radial direction of the yoke 24 (insulator base 51) where a coil end is located, and the inner circumferential surface 51a of the insulator base 51 is a second circumferential surface at the second side, opposite to the first side in the radial direction of the yoke 24 (insulator base 51).

[0071] In each of the embodiments described above, the winding process for the tooth extension 26 and the insulator extensions 53 of the two insulators 50 in the winding 31 of the coil 28 can be carried out manually by each phase.

[0072] Various modifications regarding form and details can be made to the foregoing examples without deviating from the core and scope of the claims and their equivalents. The examples serve only for descriptive purposes and not for limitation. Descriptions of features in each example are to be considered applicable to identical or similar features or aspects in other examples. Suitable results can be achieved if sequences are carried out in a different order, and / or if components in a described system, architecture, device, or circuit are combined differently and / or replaced or supplemented by other components or their equivalents. The scope of disclosure is not defined by the detailed description but by the claims and their equivalents.All variations within the scope of the claims and their equivalents are included in the disclosure.

[0073] A stator for a rotating electric machine has a stator core with a tubular yoke and teeth, coils formed by windings wound around the teeth, and insulators. Each insulator has a tubular base. The base has a first circumferential surface on one side radially aligned with the yoke, a second circumferential surface on the other side radially opposite the first, exit slots, each of which guides a connecting wire of a coil from the first side to the second side radially, and return slots, each of which guides the connecting wire, exiting through an exit slot, back from the second side to the first side radially. Each exit slot holds the connecting wire by an interference fit. Each return slot holds the connecting wire by a clearance fit. QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] JP 2010-259318

[0002]

Claims

[1] Stator (1) for a rotating electric machine (10), wherein the stator (11) has the following: a stator core (23) having a tubular yoke (24) and several teeth (25) extending in a radial direction of the yoke (24) from a circumferential surface (24a) of the yoke (24); several coils (28) formed by windings (31) wound around the teeth (25), the coils (28) having coil ends (282) projecting from a core end face (23b), the core end face (23b) being an end face of the stator core (23) in an axial direction of the yoke (24); and an insulator (50) arranged to face the core end face (23b), wherein the insulator (50) insulates the coil ends (282) and the core end face (23b) from each other, wherein Each coil (28) has the following: a wound section (30) formed by the winding (31) which is wound in a concentrated manner around one of the teeth (25); and a winding end terminal wire (35), which is a section of the winding (31) that is brought out from the wound section (30), the insulator (50) has a tubular insulator base (51) which is arranged in a position that overlaps the yoke (24) in the axial direction, the insulator base (51) has the following: a first circumferential surface (51a) at a first side in the radial direction where the coil ends (282) are located; a second circumferential surface (51b) at a second side which is opposite to the first side in the radial direction; an insulator end (51e) which is an end of the insulator base (51) on one side opposite the stator core (23); a lead-out groove (70) which opens at the insulator end (51e), wherein the lead-out groove (70) has a first end which opens in the first circumferential surface (51a) and a second end which opens in the second circumferential surface (51b), wherein the lead-out groove (70) guides the connecting wire (35) from the first side to the second side in the radial direction; and a return groove (80) which opens at the insulator end (51e), wherein the return groove (80) has a first end which opens in the first circumferential surface (51a) and a second end which opens in the second circumferential surface (51b), wherein the return groove (80) is arranged at a position which is adjacent to the exit groove (70) in a circumferential direction of the insulator base (51), and returns the connecting wire (35) which is brought out through the exit groove (70) from the second side to the first side in the radial direction, the lead-out groove (70) holds the connecting wire (35) by means of an interference fit, and The return groove (80) holds the connecting wire (35) by means of a clearance fit. [2] Stator (11) for the rotating electric machine (10) according to claim 1, wherein the return groove (80) has two return groove-forming surfaces (81) which are located on opposite sides of the connecting wire (35) in the circumferential direction, the two return groove-forming surfaces (81) extend in the axial direction from the insulator end (51e) and extend parallel to each other, and a width between the two return groove forming surfaces (81) is greater than an outer diameter of an original shape of the connecting wire (35). [3] Stator (11) for the rotating electric machine (10) according to claim 1, wherein the return groove (80) has two return groove forming surfaces (81) which are located on opposite sides of the connecting wire (35) in the circumferential direction, and one of the two return groove forming surfaces (81), which is located further away from the output groove (70) at a position, is inclined to gradually separate from the output groove (80) with the extension of one of the return groove forming surfaces (81) towards the insulator end (51e). [4] Stator (11) for the rotating electric machine (10) according to claim 1, wherein the return groove (80) has two return groove-forming surfaces (81) which are located on opposite sides of the connecting wire (35) in the circumferential direction, When the return groove (80) is viewed in the axial direction, the two return groove forming surfaces (81) are inclined to gradually separate from the output groove (70) with the return groove forming surfaces (81) extending from the second circumferential surface (51b) to the first circumferential surface (51a), and a width between the two return groove forming surfaces (81) is greater than an outer diameter of an original shape of the connecting wire (35). [5] Stator (11) for the rotating electric machine (10) according to one of claims 1 to 4, wherein the exit groove (70) has two exit groove forming surfaces (71) which are located on opposite sides of the connecting wire (35) in the circumferential direction, the two surfaces forming the lead-out groove (71) extend in the axial direction from the insulator end (51e) and extend parallel to each other, and a width between the two surfaces forming the lead-out groove (71) is smaller than an outer diameter of an original shape of the connecting wire (35). [6] Stator (11) for a rotating electric machine (10), wherein the stator (11) has the following: a stator core (23) having a tubular yoke (24) and several teeth (25) extending in a radial direction of the yoke (24) from a circumferential surface (24a) of the yoke (24); several coils (28) formed by windings (31) wound around the teeth (25), the coils (28) having coil ends (282) projecting from a core end face (23b), the core end face (23b) being an end face of the stator core (23) in an axial direction of the yoke (24); and an insulator (50) arranged to face the core end face (23b), wherein the insulator (50) insulates the coil ends (282) and the core end face (23b) from each other, wherein Each coil (28) has the following: a wound section (30) formed by the winding (31) which is wound in a concentrated manner around one of the teeth (25); and a winding end terminal wire (35), which is a section of the winding (31) that is brought out from the wound section (30), the insulator (50) has a tubular insulator base (51) which is arranged in a position that overlaps the yoke (24) in the axial direction, the insulator base (51) has the following: a first circumferential surface (51a) at a first side in the radial direction where the coil ends (282) are located; a second circumferential surface (51b) on one side opposite to the first side in the radial direction; an insulator end (51b) which is an end of the insulator base (51) on one side opposite the stator core (23); a lead-out groove (70) which opens at the insulator end (51e), wherein the lead-out groove (70) has a first end which opens in the first circumferential surface (51a) and a second end which opens in the second circumferential surface (51b), wherein the lead-out groove (70) guides the connecting wire (35) from the first side to the second side in the radial direction; and a return groove (80) which opens at the insulator end (51e), wherein the return groove (80) has a first end which opens in the first circumferential surface (51a) and a second end which opens in the second circumferential surface (51b), wherein the return groove (80) is arranged at a position which is adjacent to the exit groove (70) in a circumferential direction of the insulator base (51), and returns the connecting wire (35) which is brought out through the exit groove (70) from the second side to the first side in the radial direction, the return groove (80) has two return groove-forming surfaces (81) which are located on opposite sides of the connecting wire (35) in the circumferential direction, When the return groove (80) is viewed in the axial direction, the two return groove forming surfaces (81) are inclined to gradually separate from the output groove (70) with the return groove forming surfaces (81) extending from the second circumferential surface (51b) to the first circumferential surface (51a), and a width between the two return groove forming surfaces (81) is smaller than an outer diameter of an original shape of the connecting wire (35). [7] Stator (11) for the rotating electric machine (10) according to claim 6, wherein the exit groove (70) has two exit groove forming surfaces (71) which are located on opposite sides of the connecting wire (35) in the circumferential direction, and a width between the two surfaces forming the lead-out groove (71) is greater than an outer diameter of an original shape of the connecting wire (35). [8] Stator (11) for the rotating electric machine (10) according to one of claims 1 to 7, wherein the insulator base (51) has a projection (90) that extends from a section of the second circumferential surface (51b) between the outfeed groove (70) and the return groove (80), and the connecting wire (35), which is led out through the exit groove (70), is hooked onto a section of the projection (90) on one side opposite to the insulator end (51e).

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