Armature and rotating electric machine

Abstract

A stator (14) comprises a stator core (20), an insulator (22), and a plurality of coils (26). The stator core is equipped with teeth (34) arranged at intervals along the circumference of the stator. The insulator is attached to the stator core. The coils are made of windings of conductive wires (24) around the teeth. The stator (14) also includes terminals (i.e., first terminals 28 and a second terminal 30). The terminals comprise insulator mounts (i.e., first insulator mounts 52 and a second insulator mount 74) and crimp connections (66). The insulator mounts are attached to the insulator. Each crimp connection is located between two coils that are adjacent to each other along the circumference. The ends of the coils (i.e., first ends 50A and second ends 50B) are attached to the crimp connections.

Description

CROSS-REFERENCE TO RELATED DOCUMENT

[0001] The present application claims the advantage of priority from Japanese patent application No. 2022-031101, which was filed on March 1, 2022, the disclosure of which in its entirety is incorporated herein by reference. Technical field

[0002] The present disclosure relates generally to an armature and a rotating electrical machine. BACKGROUND OF THE INVENTION

[0003] Japanese patent publication No. 2020-99174, listed below, teaches a rotating electric machine implemented by a brushless internal rotor motor. The rotating electric machine comprises a plurality of stator magnetic pole elements, in which coils are arranged, and a plurality of conductive elements. The conductive elements are electrically connected to the ends of the coils using a plurality of connecting devices. Each of the connecting devices is arranged between adjacent two stator magnetic pole elements, thereby enabling the size of the rotating electric machine to be reduced with respect to its axial dimensions. STATE OF THE TECHNICAL PATENT PRINT

[0004] FIRST PATENT PRINT: Japanese Patent Publication No. 2020-99174 SUMMARY OF THE INVENTION

[0005] In general, for rotating electrical machines that are installed in a given space in vehicles, such as motor vehicles, it is preferable to reduce the size of the rotating electrical machines in the associated axial direction in the manner described in the aforementioned publication.

[0006] It is an objective of the present disclosure to provide an armature and a rotating electrical machine that are capable of being reduced in size with respect to an associated axial direction.

[0007] According to one embodiment of the present disclosure, an armature is provided comprising: (a) a stator core comprising teeth arranged at intervals apart in a circumferential direction of the armature; (b) an insulator attached to the stator core; (c) a plurality of coils, each of which is made from a winding of a conductive wire around one of the teeth; and (d) a terminal made of an electrically conductive material comprising an insulator holder attached to the insulator and a crimp connection to which a coil end of the coils is attached and which is arranged between two of the coils that are placed adjacent to each other in the circumferential direction.

[0008] The structures described above make it possible for the armature and the rotating electrical machine to have a size that is reduced in a corresponding axial direction. BRIEF DESCRIPTION OF THE DRAWING

[0009] The above-described task, other tasks, features or advantages in this disclosure will become apparent from the detailed discussion below with reference to the drawing.

[0010] They show: Fig. 1 a schematic view illustrating a motor when viewed in an associated axial direction according to the first embodiment; Fig. 2 a perspective view illustrating a stator; Fig. 3 a top view illustrating a stator; Fig. 4 an enlarged top view illustrating a section of a stator in which a first terminal is arranged; Fig. 5 an enlarged side view illustrating a section of a stator in which a first terminal is arranged when viewed radially inside the stator; Fig. 6 a perspective view illustrating a first connection; Fig. 7. A perspective view illustrating a first connection when viewed in a direction that is different from the one shown in Fig. 6 is different; Fig. 8 a perspective view illustrating a second connection; Fig. 9 a side view illustrating a second connection when viewed radially inside an anchor; Fig. 10 a side view illustrating a second connection according to the second embodiment when viewed radially inside an anchor; Fig. 11 a top view showing a second connection and a connection coupling of a motor according to the third embodiment; Fig. 12 a side view illustrating a second connection of a motor in the third embodiment; Fig. 13 a cross-sectional side view, which is drawn along a line 13-13 in Fig. 11 is taken from which shows a connection coupling and a second connection; Fig. 14 a sectional view illustrating a terminal, an insulator and a stator core of a motor according to the fourth embodiment; Fig. 15 a sectional view showing a terminal and an insulator of a motor according to the fifth embodiment; and Fig. 16 a sectional view showing a terminal and an insulator of a motor according to the sixth embodiment. FORM OF EXECUTION OF THE INVENTION

[0011] The electric motor 10 according to the first embodiment is described below with reference to the Fig. 1 to 9 described.

[0012] In the drawing, arrows Z, R, and C indicate a first axial direction, a radially outward direction, and a first circumferential direction, respectively, of the rotor 12, which is described in detail below. In the following discussion, an axial direction, a radial direction, and a circumferential direction represent a direction in which an axis of rotation of the rotor 12 extends, a direction perpendicular to a direction in which the rotor 12 rotates, and the direction in which the rotor 12 rotates, respectively, unless otherwise specified. The motor 10, as described in this disclosure, is an example of a rotating electrical machine.

[0013] The engine 10 is, as it appears from Fig. As can be seen in Figure 1, it is a brushless internal rotor motor. The motor 10 comprises the stator 14, which acts as an armature, and the rotor 12, which is arranged radially inside the stator 14.

[0014] The rotor 12 comprises the rotor core 16, which is attached to a rotating shaft (not shown), and magnets 18, which are attached to an outer peripheral surface of the rotor core 16. The magnets 18 are, for example, made of ring magnets. The magnets 18 are arranged adjacent to each other in the circumferential direction to have N-poles and S-poles that alternately appear on radial outer surfaces of the magnets 18.

[0015] Alternatively, the magnets 18 can be attached to an outer peripheral surface of the rotor core 16 to have the N poles and the S poles appearing alternately on radial outer surfaces of the magnets 18 in the circumferential direction.

[0016] The stator 14, as it is in Fig. As shown in Figure 2, the stator 14 comprises the stator core 20, the insulator 22 attached to the stator core 20, and a plurality of coils 26, each of which is made from a winding of a conductor arranged on the stator core 20. The stator 14 is, as shown in the Fig. 2 and Fig. 3 is illustrated, equipped with three first terminals 28 and a single second terminal 30, to which the ends of the coils 26 are electrically connected.

[0017] The stator core 20 is formed by steel plates made of a soft magnetic material, stacked on top of each other in the axial direction. Each steel plate is produced by stamping a steel sheet into a desired shape. The stator core 20 comprises the annular body 32 and the teeth 34, which project radially inward from the annular body 32. The fifteen teeth 34 are, as is clear in Fig. Figure 3 illustrates that they are arranged at equal intervals apart in the circumferential direction.

[0018] The insulator 22 is made of an electrically insulating resin material or plastic material and comprises, as is clearly stated in the Fig. 2 and Fig. Figure 3 illustrates the annular cover 36, which is arranged to extend along an inner peripheral surface of the annular body 32 of the stator core 20.

[0019] The insulator 22 also includes the tooth covers 38, which project radially inwards from the annular cover 36. One tooth cover 38 is provided for each of the teeth 34 of the stator core 20. Each tooth cover 38 covers a corresponding area of ​​the teeth 34 on which the coil 26 is arranged.

[0020] The insulator 22 also includes the flanges 40, each of which projects from a radially inner end of a corresponding tooth cover 38 away from a corresponding tooth 34 and extends in the axial direction. Each of the coils 26 is arranged around a corresponding tooth cover 38 and positioned between the flange 40 and the annular cover 36. The insulator 22 in this embodiment is made of two sections that are separated from each other in the axial direction.

[0021] The insulator 22, as it is described in Fig. As illustrated in Figure 3, the first terminal supports 42 also comprise three first terminal supports 42, which hold the first terminals 28, described in detail below. The first terminal supports 42 are arranged away from one another on axially opposite end surfaces (also referred to as a first end surface) of the annular body 32 of the stator core 20, facing in the first axial direction. Each of the first terminal supports 42 has a first circumferential end and a second circumferential end, opposite to the first circumferential end, in the circumferential direction of the stator 14. The first circumferential end of each of the first terminal supports 42 is positioned at the same location as the first of two circumferentially adjacent teeth 34 in the circumferential direction of the stator 14. The first of the teeth 34 faces in the first circumferential direction of the stator 14.In other words, the first circumferential end of each of the first terminal supports 42 is positioned in accordance with the first of the teeth 34 in the radial direction of the stator 14. Similarly, the second circumferential end of each of the first terminal supports 42 is positioned in the same location as the second of two circumferentially adjacent teeth 34 in the circumferential direction of the stator 14. The second of the teeth 34 faces the second circumferential direction, which is opposite to the first circumferential direction of the stator 14. Each of the first terminal supports 42 has a circumferential center that is aligned with a center between two circumferentially adjacent teeth 34 in the radial direction of the stator 14. In this embodiment, the three first terminal supports 42 are arranged circumferentially in a region that extends circumferentially over four of the teeth 34 that are adjacent to each other.Each of the first connection brackets 42 has the first connection box 44 formed within it, which functions as a connection coupling in the form of a fitting recess. Each of the first connection boxes 44 has a concave shape with an opening that faces in the first axial direction.

[0022] The insulator 22 also includes the second terminal bracket 46, which holds the second terminal 30. The second terminal bracket 46 is located on the first end surface of the annular body 32 of the stator core 20. The second terminal bracket 46 extends over a region where four of the teeth 34 are arranged adjacent to each other in the circumferential direction. The second terminal bracket 46 is positioned on a first circumferential side of the first terminal bracket 42, which is located furthest out in the circumferential direction and faces the first circumferential direction of the stator 14. In other words, the second terminal bracket 46 is located circumferentially adjacent to the first terminal bracket 42, which is located furthest out in the circumferential direction. The second terminal bracket 46 incorporates the second terminal box 48, which functions as a terminal coupling.The second junction box 48 has a concave shape with an opening facing in the first axial direction. The structure of the second junction box 48 is also described in detail below.

[0023] Each of the coils 26 is produced by winding the copper wire 24 around a corresponding tooth 34 of the stator core 20 through the insulator 22. In this embodiment, the coils 26 comprise five U-phase coils 26, five V-phase coils 26, and five W-phase coils 26 arranged around the teeth 34. The U-phase coils 26, the V-phase coils 26, and the W-phase coils 26 are arranged circumferentially in that order. The U-phase coils 26, the V-phase coils 26, and the W-phase coils 26 are connected in series with each other.

[0024] The wire 24, which forms the five U-phase coils 26, has two ends: the first U-phase end 50A and the second U-phase end 50B.

[0025] Similarly, the wire 24, which forms the five V-phase coils 26, has two ends: the first V-phase end 50A and the second V-phase end 50B.

[0026] Similarly, the wire 24, which forms the five W-phase coils 26, has two ends: the first W-phase end 50A and the second W-phase end 50B.

[0027] The first U-phase end 50A, the first V-phase end 50A and the first W-phase end 50A are, as stated in the Fig. 3, Fig. 4 and Fig. As illustrated in Figure 5, the first terminals 28 are each connected. The second U-phase end 50B, the second V-phase end 50B, and the second W-phase end 50B are connected to the second terminal 30.

[0028] Each of the first 28 connections will, as is clear in the Fig. 6 and Fig. Figure 7 illustrates that the first terminals 28 are manufactured by pressing a copper plate into a desired shape. Each of the first terminals 28 includes the first insulator holder 52, which has a rectangular shape with a thickness in the radial direction and serves as an insulator holding device. Each of the first terminals 28 also includes the crimp strip 54, which extends radially inward from a section of the first insulator holder 52 that is positioned both at the associated circumferential center and at one of axially opposite side surfaces facing in the second axial direction of the stator 14 (i.e., the rotor 12).

[0029] The first insulator support 52 comprises the rectangular base 56, which has a length extending in the circumferential direction and a width in the axial direction. The first insulator support 52 also comprises a plurality (in this embodiment, two) interference-fit projections 58 formed at a first end of the base 56, which faces in the first circumferential direction, and which extend from a section of the first end that is located near the second side surface of the first insulator support 52, which faces in the second axial direction.The first insulator support 52 also comprises a plurality (in this embodiment, two) interference-fit sections 58 formed on a second end of the base 56, facing in the second circumferential direction, and extending from a section of the second end located near the second side surface of the first insulator support 52, facing in the second axial direction. Each of the interference-fit projections 58 has a sawtooth shape when viewed in the radial direction. The first insulator support 52 also includes clearance-filling projections 60 formed on circumferentially opposite end sections of the base 56 and located near the second side surface of the first insulator support 52. The clearance-filling projections 60 extend radially inward.

[0030] The crimp strip 54 comprises the rectangular base 62, which has a length in the radial direction and a width in the circumferential direction. The crimp strip 54 also comprises the extension 64, which extends from a radially inner end section of the base 62 in the first circumferential direction and has an end section that is separated from the base 62 and curved or bent in the second circumferential direction. The extension 64, together with the radially inner end section of the base 62, defines the crimp sleeve 66. The crimp sleeve 66 functions as a crimp connection to create an electrical connection and has an opening facing in the second circumferential direction. The first end 50A described above is, as shown in the Fig. 4 and Fig. Figure 5 illustrates that the first end 50A is firmly clamped by the crimp sleeve 66 to achieve a connection between the crimp sleeve 66 and the crimp sleeve 66.

[0031] The first insulator bracket 52 of each of the first terminals 28 is, as it is in Fig. As can be seen from Figure 4, the first insulator bracket 52 is inserted into the first junction box 44 of the insulator 22, thereby attaching the first insulator bracket 52 to the insulator 22 to hold the first connection 28 in the insulator 22. The first insulator bracket 52, which has been forced into the first junction box 44, has the press-fit projections 58, which are firmly fitted to the inner wall of the first junction box 44, thus ensuring stability when holding the first insulator bracket 52 in the insulator 22. When the first insulator bracket 52 is held in the insulator 22, the press-fit projections 58 on the first end of the first insulator bracket 52, which face in the first circumferential direction, are Fig. 4, Fig. 6 and Fig. As can be seen in Figure 7, the crimp strips 58 are positioned circumferentially at the same position as one of the two circumferentially adjacent teeth 34, which is located near the first end of the first insulator holder 52; in other words, they are aligned with one of the teeth 34 in the radial direction of the stator 14. Similarly, the press-fit sections 58 on the second end of the first insulator holder 52, facing in the second circumferential direction, are positioned at the same location as one of the two circumferentially adjacent teeth 34, which are located near the second ends of the first insulator holder 52; in other words, they are aligned with one of the teeth 34 in the radial direction of the stator 14. When the first insulator holder 52 is fitted into the insulator 22, the crimp strip 54, as shown in the figures, is Fig. 4 and Fig. As can be seen in section 5, the crimp strip 54 is positioned midway between two circumferentially adjacent teeth 34. The base 62 of the crimp strip 54 is, as is clearly shown in the Fig. 5 and Fig. Figure 6 illustrates that the coils are arranged between the coil ends 26A (which are also referred to as the first coil ends 26A) of two of the coils 26 that are adjacent in the circumferential direction and that look in the first axial direction Z.

[0032] Each of the first 50A ends indicates how it is in Fig. As can be seen in Figure 4, the first section 68 extends in the second circumferential direction from a radially outer end of one of the coil ends 26A, facing in the first axial direction. The first end 50A also has the second section 70, which extends radially inward (i.e., away from the annular body 2 of the stator core 20) from an end of the first section 68, facing in the second circumferential direction. The first end 50A also has the flexible section 72, which defines a boundary between the first section 68 and the second section 70. The flexible section 72 defines the first section 68 and the second section 70 in an L-shape. The second section 70 of the first end 50A is connected to the crimp sleeve 66 of the first terminal 28.The first section 68 can alternatively be configured to extend in the second circumferential direction from a radially inner end of one of the coil ends 26A, facing in the first axial direction. It is recommended that the second section 70 be configured to extend radially outward (i.e., toward the annular body 2 of the stator core 20) from an end of the first section 68, also facing in the second circumferential direction. The flexible section 72 can be shaped to be moderately curved.

[0033] The second section 70 of the first end 50A, which is connected to the crimp sleeve 66 of the first terminal 28, is, as shown in the Fig. 4 and Fig. As can be seen in Figure 5, the first section 68, the second section 70, and the flexible section 72 of the first end 50A are placed between the first coil ends 26A of two circumferentially adjacent coils 26, which also face the first axial direction Z.

[0034] The second connection 30 will be, as described in the Fig. 8 and Fig. As can be seen in Figure 9, the second terminal 30 is manufactured similarly to the first terminals 28 by pressing a conductive copper plate into a desired shape. The second terminal 30 comprises the second insulator holder 74, which has a thickness in the radial direction and a length in the circumferential direction of the stator 14.

[0035] The second insulator bracket 74 has the central fuse section 74A, which is defined by an associated circumferentially central section. The second insulator bracket 74 also has the end fuse sections 74B, which are defined by associated end sections facing the first and second circumferential directions. In the following discussion, one of the end fuse sections 74B, which faces the first circumferential direction, will also be referred to as the first end fuse section 74B, while the other, which faces the second circumferential direction, will also be referred to as the second end fuse section 74B.

[0036] The central fuse section 74A is structurally identical to the first terminals 28 of the first insulator bracket 52 (see Fig. 6) except that the central locking section 74A does not have any interference fit projections 58, but includes the connecting tags 76, both of which extend from ends of the associated length facing the first and second circumferential directions. The connecting tags 76 are positioned close to the first side surface of the central locking section 74A facing the first axial direction.

[0037] The first end-protection section 74B, which faces in the first circumferential direction, is structurally identical to the first terminals 28 of the first insulator support 52 (see Fig. 6) except that the connecting link 76 extends from a second end of the first end-locking section 74B, which faces in the second circumferential direction and is located closer to the first side surface of the first end-locking section 74B, which faces in the first axial direction. The connecting link 76 of the first end-locking section 74B leads to one of the connecting links 76 of the central locking section 74A, which faces in the first circumferential direction.

[0038] The second end-protection section 74B, which faces in the second circumferential direction, is structurally identical to the first terminals 28 of the first insulator support 52 (see Fig. 6) except that the connecting link 76 extends from a first end of the second end-locking section 74B, which faces in the first circumferential direction and is located closer to the first side surface of the first end-locking section 74B, which faces in the first axial direction. The connecting link 76 of the second end-locking section 74B leads to one of the connecting links 76 of the central locking section 74A, which faces in the second circumferential direction.

[0039] Parts of the central fuse section 74A and the end fuse sections 74B, which are identical to those of the first insulator bracket 52 of each of the first terminals 28, are designated by the same reference drawings as those in the first insulator bracket 52.

[0040] The second terminal 30 also comprises three crimp strips 54 extending radially inward from the second side surfaces of the central locking section 74A, the first end locking section 74B, and the second end locking section 74B, facing in the second axial direction. The crimp strips 54 are arranged at equal intervals around the circumference. Each of the crimp strips 54 of the second terminal 30 is structurally identical to those of the first terminal 28. The corresponding parts of the crimp strips of the second terminal 30 as those of the first terminals 28 are designated by the same reference numerals. The second ends 50B described above are, as shown in Fig. Figure 3 illustrates how the crimp sleeves 66 hold the crimp strips 54 in order to electrically connect the second ends 50B to the crimp sleeves 66 of the crimp strips 54.

[0041] The second insulator bracket 74 of the second terminal 30 is, as shown in the Fig. 3 and Fig. As illustrated in Figure 9, the second junction box 48 of the insulator 22 is fitted into the second junction box 48. The second junction box 48, as shown in Figure 9, has a... Fig. As can be seen in Figure 9, the central fitting recess 48A is formed in a circumferentially central section of the base of the second junction box 48, into which a second side section of the central fuse section 47A, facing in the second axial direction, is fitted. The second junction box 48 also has a side fitting recess 48B (also referred to as the first side fitting recess 48B), which is formed in a first circumferential side section of the base of the second junction box 48, facing in the first circumferential direction, and into which a second side section of the first terminal fuse section 74B, facing in the second axial direction, is fitted.The second junction box 48 also has the side-fitting recess 48B (also referred to as the second side-fitting recess 48B), which is formed in a second circumferential side section of the base of the second junction box 48, facing in the second circumferential direction, and into which a second side section of the second terminal fuse section 74B, facing in the second axial direction, is fitted. When the second insulator holder 74 of the second terminal 30 is fitted into the second junction box 48 of the insulator 22, the second side section of the central fuse section 74A, facing in the second axial direction, is fitted into the central fitting recess 48A. Simultaneously, the second side sections of the first and second terminal fuse sections 74B, facing in the second axial direction, are likewise fitted into the side-fitting recesses 48B.This secures the second insulator bracket 74 to the insulator 22, so that the second terminal 30 is held by the insulator 22. When the second side sections of the first and second end locking sections 74B are fitted into the side-fitting recesses 48B, the press-fit projections 58 on the inner walls of the side-fitting recesses 48B are press-fitted, thus ensuring stability when the second insulator bracket 74 is held by the insulator 22. The press-fit projections 58 of the second terminal 30 are positioned, like those of the first terminals 28, in the same positions as the selected teeth 34 in the circumferential direction. Each of the three crimp strips 54 of the second terminal 30 is, as shown in . Fig. 3 can be seen, placed at the midpoint between two circumferentially adjacent teeth 34.

[0042] As can be seen from the preceding discussion, the second terminal 30 has the multitude of press-fit projections 58 that are only formed at the first and second end locking sections 74B; in other words, it does not have any press-fit projections 58 at the central locking section 74A, although the central locking section 74 of the second terminal 30 can alternatively be designed, as in the second embodiment shown in Fig. Figure 10 illustrates the interference fit projections 58 that are formed on it. In this structure, the first and second end securing sections 74B cannot have interference fit projections 58.

[0043] The second ends 50B are, as it appears from Fig. As can be seen in Figure 3, the structure is identical to that of the first ends 50A. The same parts of the second ends 50B as those of the first ends 50A are designated by the same reference numerals. The second section 70 of each of the second ends 50B of the U-phase, the V-phase, and the W-phase is connected to a corresponding crimp sleeve 66 of the second terminal 30. OPERATION ACCORDING TO THIS EXAMPLE AND THE ADVANTAGES SUCCEEDED THEREFORE

[0044] The operation according to this implementation example and the advantages offered by it are described below.

[0045] The motor 10 according to this embodiment example is, as shown in the Fig. As can be seen from 1 to 3, it is operated by switching a voltage between the first terminals 28 to change the flow of an electric current between the U-phase, V-phase and W-phase coils 26, thereby generating a rotating magnetic field around the stator 14 to rotate the rotor 12.

[0046] The motor 10 according to this embodiment is, as shown in the Fig. As can be seen from Figures 2 to 5, the crimp sleeves 66 of the first terminals 28 and the crimp sleeve 66 of the second terminal 30 are designed to have each crimp sleeve 66 positioned between circumferentially adjacent two teeth 34 (i.e., the coils 26). This design of the crimp sleeves 66 allows the stator 14 to be reduced in size in the axial direction compared to when the crimp sleeves 66 of the first terminals 28 and the crimp sleeve 66 of the second terminal 30 are placed on one of the axially opposite ends of the stator core 20.

[0047] When the first insulator brackets 52 of the first terminals 28 are fitted into the first terminal boxes 44 of the insulator 22, the press-fit projections 58 of the first insulator brackets 52, as shown in the Fig. 3, Fig. 4, Fig. 6, Fig. 7, Fig. 8 and Fig. As can be seen in Figure 9, the inner walls of the first terminal boxes 44 are press-fitted, thereby minimizing misalignment of the first terminals 28 on the insulator 22, which typically arises from mechanical vibration of the motor 10. This improves or ensures the reliability of the motor 10's operation in the face of mechanical vibration. In particular, the multitude of press-fit projections 58, arranged on circumferentially opposite sides of each of the crimp strips 54, serves to reduce mechanical vibration of the crimp strips 54.

[0048] When the second insulator holder 74 of the second terminal 30 is fitted into the second terminal box 48 of the insulator 22, the press-fit projections 58 are press-fitted to the inner wall of the side fitting recess 48B, thereby minimizing misalignment of the second terminal 30 on the insulator 22, which typically arises from mechanical vibration of the motor 10. This ensures or improves the reliability of the motor 10's operation despite mechanical vibration.The second terminal 30 has the plurality of press-fit projections 58 that are formed only on the first and second end locking sections 74B; in other words, it has no press-fit projections 58 on the central locking section 74A, which minimizes mechanical vibration of the circumferentially opposite ends of the second terminal 30 more than in the central section of the second terminal 30. The second terminal 30 of the motor in the second embodiment, which is shown in . Fig. As illustrated in Figure 10, the second terminal 30 has press-fit projections 58 formed on the central locking section 74A and no press-fit projections 58 formed on the first and second end locking sections 74B. This design of the press-fit projections 58 serves to minimize the mechanical vibration of the circumferentially central section of the second terminal 30. The determination of which of the structures of the second terminal 30 of the motor 10 should be used in the first embodiment or in the second embodiment depends on the frequency of a vibration of the motor 10 and the natural frequency of a vibration of the second terminal 30. Alternatively, the second terminal 30 can be designed to have the press-fit projections 58 on the central locking section 74A in addition to the press-fit projections 58 formed on the first and second end locking sections 74B.

[0049] Each of the press-fit projections 58 of the first terminals 28 and the second terminal 30 is aligned with a corresponding tooth 34 of the stator core 20 in the radial direction of the stator 14. In other words, each of the press-fit projections 58 of the first terminals 28 and the second terminal 30 is located near a highly rigid section of the stator core 20, thus preventing an undesirable increase in the amplitude of a vibration transmitted from the stator core 20 to the press-fit projections 58.

[0050] The coils 26 in this embodiment have first ends 50A and second ends 50B, each of which, as shown in the Fig. 3, Fig. 4 and Fig. As illustrated in Figure 5, the system comprises the first section 68, the second section 70, and the flexible section 72. The flexible section 72 operates to minimize any stress that may appear at either the first end 50A or the second end 50B, thereby reducing any stress that may occur in a connection between one of the coils 26 and either the first terminal 28 or the second terminal 30, thus minimizing the risk of an open circuit or disconnection at either the first end 50A or the second end 50B of the coils 26.

[0051] Each of the first ends 50A and the second ends 50B is designed to have the second section 70, which, as described in the Fig. As illustrated in Figures 3 to 5, the second section 70 is arranged to extend on a surface of the base 62 of the crimp strip 54 facing in the first axial direction, thereby causing the base 62 of the crimp strip 54 to minimize a displacement of the second section 70 in the second axial direction, which arises from a mechanical vibration of the motor 10 in the axial direction. This reduces a torsional deformation of the first section 68, which arises from a displacement of the second section 70 in the axial direction of the motor 10.

[0052] Each of the first ends 50A and the second ends 50B has the first section 68, the second section 70, and the flexible section 72, which are arranged between the first coil ends 26A of circumferentially adjacent two coils 26. The first coil ends 26A face in the first axial direction. The design of the first section 68, the second section 70, and the flexible section 72 described above allows the first ends 50A or the second ends 50B to have a reduced length. ENGINE STRUCTURES IN OTHER DESIGNS

[0053] The Fig. Figures 11 to 16 illustrate other embodiments of electric motors. 10. In the Fig. Reference numerals 11 to 16 denote the same parts as those used in the first embodiment, without any detailed explanation thereof. ENGINE IN THE THIRD EXECUTION EXAMPLE

[0054] Fig. Figure 11 illustrates the second terminal 30 and the second terminal box 48 of the motor 10 in the third embodiment. The second insulator holder 74 of the second terminal 30, as shown in the Fig. 11 and Fig. As illustrated in Figure 12, the base 82 comprises a base and a pair of fastening ends 86. The base 82 is made from a plate with a thickness in the axial direction and extends in the circumferential direction. The fastening ends 86 are bent from circumferentially opposite ends of the base 82 and extend in the first axial direction. Each of the fastening ends 86 has a plurality of press-fit projections 58 formed on associated radial outer and inner side surfaces.

[0055] The insulator 22, as it is described in the Fig. 11 and Fig. As illustrated in Figure 13, the assembly also comprises a pair of second junction boxes 48 into which circumferentially opposite ends of the second insulator bracket 74 of the second terminal 30 (i.e., the mounting ends 86 and associated peripheral sections) are fitted. The fitting of the ends of the second insulator bracket 74 of the second terminal 30 into the second junction box 48 provides a retention capability for the second terminal 30 within the insulator 22.

[0056] The structure of the third embodiment described above makes it possible to reduce the size of a main part of the second insulator holder 74 in the axial direction compared with the second terminal 30 of the motor 10 in the first embodiment. ENGINE IN THE FOURTH EXAMPLE

[0057] Fig. Figure 14 shows a sectional view illustrating the second terminal 30, the insulator 22, and the stator core 20 of the motor 10 in the fourth embodiment. The second insulator support 74 of the second terminal 30 comprises the base 82 and the barbed fit 88. The base 82 is made from a plate having a thickness in the axial direction and extending in the circumferential direction. Each of the barbed fits 88 is bent from a radially outer end of the base 82 and extends in the second axial direction. Each of the barbed fits 88 and a corresponding crimp strip 54 are positioned at the same location in the circumferential direction. Each of the barbed fits 88 has a plurality of press-fit projections 58 formed on associated circumferentially opposite ends.

[0058] The annular body 32 of the stator 14 has the fitting holes 90 formed therein, each of which has an opening facing in the first axial direction. The insulator 22 also includes the second terminal boxes 48, each of which is arranged on an inner peripheral surface corresponding to the fitting holes 90 of the stator core 20. The barbed fits 88 of the second insulator holder 74 of the second terminal 30 are fitted into the second terminal boxes 48, thereby holding the second terminal 30 firmly in the insulator 22.

[0059] As can be seen from the preceding discussion, the barb fits 88, as described in Fig. The barbed fits 88, which can be seen in the second terminal boxes 48, are inserted to force the barbed fits 88 into the fitting holes 90 of the stator core 20. This structure allows the stator 14 to be reduced in size in the axial direction compared to when the barbed fits 88 are designed to protrude outwards from the stator core 20 in the first axial direction. ENGINE IN THE FIFTH EXAMPLE

[0060] Fig. Figure 15 shows a sectional view illustrating the second terminal 30 and the insulator 22 of the motor 10 according to the fifth embodiment. The second insulator support 74 of the second terminal 30 comprises the base 82 and the snap-lock fasteners 92. The base 82 is made from a plate having a thickness in the radial direction and extending in the circumferential direction. The snap-lock fasteners 92 project radially outward from the base 82. Each snap-lock fastener 92 is produced by cutting and bending a section of the base 82 in a radially outward direction of the stator 14.

[0061] The insulator 22 in this embodiment has the second terminal boxes 48 formed therein, each of which has an opening facing in the second axial direction. The insulator 22 has the fits 94, each of which projects radially inward from a radially outer section of a corresponding second terminal box 48. Insertion of the second insulator holder 74 of the second terminal 30 into the second terminal boxes 48 of the insulator 22 causes the snap-lock fastening devices 92 to contact the fits 94, so that the snap-lock fastening devices 92 are elastically deformed toward the base 82.After the second insulator holder 74 has been inserted into the second junction box 48, the snap-lock fasteners 92 are returned to their initial position, so that the snap-lock fasteners 92 are positioned to face the fits 94 in the axial direction of the stator 14. This ensures the stability of the connection between the second insulator holder 74 and the second junction box 48.

[0062] As can be seen from the preceding discussion, the structure of this embodiment minimizes the risk that the second insulator holder 74 will be removed from the second junction boxes 48 in an undesirable manner without the need to use the press-fit projections 58 (see Fig. 13). ENGINE IN THE SIXTH EXECUTION EXAMPLE

[0063] Fig. Figure 16 shows a sectional view illustrating the second terminal 30 and the insulator 22 of the motor 10 according to the sixth embodiment. The second insulator support 74 of the second terminal 30 comprises the base 82, which is made from a plate having a thickness in the radial direction and extending in the circumferential direction.

[0064] The insulator 22 in this embodiment comprises the pile element 96, which is made of an iron-based material and is molded or cast into it. The base 82 of the second insulator support 74 of the second connection 30 is positioned along the pile element 96. The pile element 96 is then partially deformed to create the deformed section 96A, which is pressed against the base 82 of the second insulator support 74, thereby securing the second insulator support 74.

[0065] As can be seen from the preceding discussion, the structure of the sixth embodiment achieves a firm connection of the second insulator holder 74 of the second terminal 30 with the insulator 22 without the use of the press-fit projections 58 (see Fig. 13).

[0066] The disclosure is not limited to the orientation examples and modifications described above, but can be implemented through various embodiments without deviating from the purpose of the disclosure. For example, the structure of motor 10 can be used for an electric generator. The structure of motor 10 can be used in a brushless external rotor motor in which the rotor 12 is arranged radially outside the stator 14. The structure in this disclosure can also be used in a rotor equipped with an armature that is structurally identical to the stator 14.

[0067] This disclosure refers to the embodiments described above, but it can be implemented by various embodiments and equivalents without departing from the purpose of the disclosure. This disclosure includes all possible combinations of the features of the embodiments and modifications described above, or of features similar to the parts of the embodiments and modifications described above. 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 2022-031101

[0001]

Claims

[1] Anchor (14) comprising: a stator core (20) comprising teeth (34) arranged at intervals apart from each other in a circumferential direction of the armature; an insulator (22) attached to the stator core; a plurality of coils (26), each made from a winding of a conductive wire (24) around a respective one of the teeth; and a terminal (28, 30) made of an electrically conductive material and comprising an insulator holder (52, 74) attached to the insulator, and a crimp connection (66) to which a coil end (50A, 50B) of the coils is attached and which is arranged between two of the coils placed adjacent to each other in the circumferential direction. [2] An armature according to claim 1, wherein the insulator has formed therein a terminal coupling (44, 48) to which the insulator support is coupled, and the insulator support has portions formed as press-fit portions (58) that are press-fitted into the terminal coupling. [3] An armature according to claim 2, wherein each of the press-fitting portions is placed in alignment with one of the teeth in a radial direction of the armature. [4] An armature according to claim 2 or 3, wherein the insulator support has a crimp strip (54) extending therefrom, the crimp strip comprising the crimp connection, and the press-fit portions are placed at portions of the insulator support located at circumferentially opposite ends of the crimp strip. [5] An armature according to claim 2 or 3, wherein the insulator holder has extending therefrom a plurality of crimp strips comprising crimp connections, the crimp strips being arranged at an interval apart from each other in the circumferential direction, and the press-fitting portions comprising first press-fitting portions and second press-fitting portions, the first press-fitting portions being placed at portions of the insulator holder located at circumferentially opposite sides of an outermost one of the crimp strips facing a first circumferential direction of the armature, the second press-fitting portions being placed at portions of the insulator holder located at circumferentially opposite sides of an outermost one of the crimp strips facing a second circumferential direction of the armature that is opposite to the first circumferential direction. [6] An anchor according to claim 2 and 3, wherein the insulator holder has extending therefrom a plurality of crimp strips comprising crimp connections, the crimp strips being arranged at an interval apart from each other in the circumferential direction, and the press-fitting portions are placed at portions of the insulator holder arranged on circumferentially opposite sides of a circumferentially central crimp strip of the crimp strips. [7] Rotating electrical machine (10) with: a first of a stator (14) and a rotor (12) comprising the armature specified in any one of claims 1 to 6; and a second of the stator and the rotor, which comprises a magnet (18) radially opposite the armature.

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