Stator, rotary electric machine, and manufacturing method of stator

Abstract

To provide a stator, a rotary electric machine, and a manufacturing method of the stator, having a high insulation resistance while capable of continuously winding a separation crossover of a division iron core without cutting.SOLUTION: A stator around which a coil 30 is wound at each of teeth parts 12 via an insulator 20 so that back yoke parts 11 in a pair of division iron cores 10 are couped, comprises: an adjacent crossover wire 33 continuously connecting a coil 30 wound around the pair of division iron cores 10; and a separation crossover wire 34 that continuously connects the coil 30 wound around two pairs of division iron cores 10 arranged so as to be separated in a peripheral direction. The insulator 20 includes an outer wall 23 stood from an axial direction end surface of the back yoke part 11 in an axial direction. At both end parts in the peripheral direction in an axial end surface of the outer wall 23, separation crossover support grooves 24 supporting the separation crossover wire 34 are provided.SELECTED DRAWING: Figure 6

Description

[Technical field]

[0001] The present disclosure relates to a stator, a rotating electric machine, and a method for manufacturing a stator. [Background technology]

[0002] Conventionally, a structure that includes an iron core having multiple teeth and a conductor wound around the teeth of the iron core via an insulator is known as a stator for a rotating electric machine. By dividing this iron core into multiple pieces to form a split core, it is possible to increase the density during winding and to reduce the size of the press machine for the iron core. Also, a technique has been proposed that reduces the number of parts such as terminals and the connection work by winding continuously without cutting the jumper wire when winding around the split cores.For example, a manufacturing method has been proposed in which a pair of split cores is formed by a set of two, and the two sets of paired split cores are continuously wound via a separated jumper wire of a predetermined length to form a split stator group for one phase, in which a conductor that becomes the separated jumper wire is hung on a hook provided on a winding device (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 6242277 Summary of the Invention [Problem to be solved by the invention]

[0004] In the stator and manufacturing method thereof disclosed in Patent Document 1, when manufacturing the stator by hooking the conductor wire that serves as the separated jumper wire of the split core onto the hook of the winding device, it is proposed to provide a guide portion at the base of the hook to guide the separated jumper wire to prevent the separated jumper wire from coming into contact with the edge of the split core and damaging the coating of the separated jumper wire. However, providing the guide section makes the winding device complicated, and there is a concern that the guide section may deteriorate over time due to sliding between the guide section and the conductor. Furthermore, when a scratch occurs in the guide section, the scratch may go unnoticed and the stator may continue to be used as is, resulting in a stator with low dielectric strength.

[0005] The present disclosure has been made to solve the above-mentioned problems, and has an object to provide a stator, a rotating electric machine, and a method for manufacturing a stator that prevent damage to the spaced jumper wires of the split cores, can be wound continuously without cutting, and has high dielectric strength. [Means for solving the problem]

[0006] The stator according to the present disclosure comprises: a split core having a back yoke portion and teeth portions protruding radially inward from the back yoke portion; a stator core in which a plurality of the split cores are arranged in an annular shape, and adjacent pairs of the split cores are grouped together at the ends of the back yoke portions; coils wound in mutually opposite directions on the teeth portions of the pair of split cores via insulators; an adjacent jumper wire continuously connecting the coils wound on the pair of split cores; a spaced jumper wire that continuously connects the coils wound on the pair of split cores and the coils wound on the pair of split cores spaced apart in the circumferential direction from the pair of split cores, the adjacent crossover wire and the spaced crossover wire are disposed on the insulator, The insulator has an outer wall extending in the axial direction from the axial end face of the back yoke portion, and a spaced jumper wire support groove is provided at both circumferential ends of the axial end face of the outer wall to support the spaced jumper wire.

[0007] In addition, a method for manufacturing a stator according to the present disclosure includes the steps of: In a manufacturing method of the present disclosure, a stator is wound using a winding device having a wire path groove provided in the outer wall of the insulator and a coil hook, In the split core of the pair of split cores, the coil is wound last, and the coil is passed through the wire path groove in the outer wall of the insulator, hooked and supported in the spaced jumper wire support groove on the side adjacent to the hook among the spaced jumper wire support grooves at both ends of the outer wall, and then hooked and folded back on the hook on the axially opposite side of the spaced jumper wire support groove, Next, of the pair of split cores on which the coil is wound, the split core adjacent to the hook is hooked into the spaced jumper wire support groove on the side adjacent to the hook, of the spaced jumper wire support grooves at both ends of the outer wall of the insulator, and then the coil is wound around the split core by passing it through the wire path groove in the outer wall. Effect of the Invention

[0008] According to the present disclosure, it is possible to prevent damage to the spaced jumper wires of the split cores and to wind them continuously without cutting, thereby obtaining a stator, a rotating electric machine, and a method for manufacturing a stator having high dielectric strength. [Brief description of the drawings]

[0009] [Figure 1] FIG. 2 is a perspective view showing a configuration of a stator according to the first embodiment. [Diagram 2] 1 is a top view of a rotating electric machine including a stator according to a first embodiment. [Diagram 3] 2 is a schematic diagram showing an electrical configuration of a stator according to the first embodiment. FIG. [Figure 4] 1 is a perspective view showing a configuration of a pair of core segments according to a first embodiment. [Diagram 5] 2 is a top view of a pair of core segments according to the first embodiment. FIG. [Figure 6] 2 is a perspective view showing a state in which insulators are attached to a pair of split cores according to the first embodiment. FIG. [Figure 7] FIG. 2 is a perspective view showing a configuration of an insulator according to the first embodiment. [Figure 8] 5 is a schematic diagram for explaining the positional relationship of a separated crossover wire support groove according to the first embodiment. FIG. [Figure 9] 3 is a top view showing wiring of a one-phase split stator group according to the first embodiment. FIG. [Figure 10] FIG. 10 is a perspective view of FIG. [Figure 11] 1 is a front view showing a configuration of a winding device used in manufacturing a stator according to a first embodiment. [Figure 12] 12 is a top view showing the configuration of a chuck mechanism in the winding device of FIG. 11. [Figure 13] 4 is a top view showing a state in which a coil is wound around a first winding portion of a U phase according to the first embodiment. FIG. [Figure 14] 10 is a top view showing a state in which a coil is wound around a third winding portion of a U phase according to the first embodiment. FIG. [Figure 15] 12 is a perspective view showing the positional relationship between the separated crossover wire support groove, the hook, and the separated crossover wire in a state in which the separated crossover wire is hung on the hook of the chuck mechanism in the winding device of FIG. 11. FIG. [Figure 16] 11 is a perspective view showing the configuration of a winding section in which an insulator according to a second embodiment is attached to a split core. FIG. [Figure 17] 13 is a perspective view showing a state in which two wound portions of an insulator according to a second embodiment are connected by snap-fit ​​connection between the open-ring portion and the columnar portion of adjacent insulators. FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Hereinafter, the present embodiment will be described with reference to the drawings. In each drawing, the same reference numerals indicate the same or corresponding parts. Note that Figs. 1 to 17 are related to one embodiment, and the present disclosure is not limited to these drawings.

[0011] Embodiment 1 In this disclosure, unless otherwise specified, the terms "axial direction", "circumferential direction", "radial direction", "inner peripheral side", "outer peripheral side", "inner peripheral surface", and "outer peripheral surface" refer to the "axial direction", "circumferential direction", "radial direction", "inner peripheral side", "outer peripheral side", "inner peripheral surface", and "outer peripheral surface" of the stator 100, respectively. In addition, in this disclosure, unless otherwise specified, the terms "upper" and "lower" refer to a plane perpendicular to the axial direction of the stator 100 at a reference location, and the side including the center point of the stator 100 with the plane as a boundary is referred to as "lower", and the opposite side is referred to as "upper". In addition, when comparing heights, the side that is farther from the center of the stator 100 is referred to as "higher".

[0012] Fig. 1 is a perspective view showing the configuration of a stator 100. Fig. 2 is a top view of a rotating electric machine equipped with the stator 100. Fig. 3 is a schematic diagram showing the electrical configuration of the stator 100. Fig. 4 is a perspective view of a pair of core segments 10 constituting a stator core 40 of the stator 100. 1, the stator 100 includes a plurality of core segments 10, insulators 20 attached to each of the core segments 10, coils 30 wound around each of the core segments 10, and a stator core 40 in which the core segments 10 are arranged in an annular shape, and the coils 30 are insulated from the core segments 10 via the insulators 20, and form adjacent jumper wires 33 and spaced jumper wires 34 after winding. The adjacent jumper wires 33 are not shown in the figure because they are disposed on the opposite side in the axial direction. Also, spaced jumper wire support grooves 24 and wire route grooves 25, which will be described later with reference to FIGS. 6 and 7, are provided.

[0013] In FIG. 1, the stator 100 appears to have twelve ordinary core segments 10, but in reality, the stator 100 is made up of six pairs of core segments 10, with the outer circumferential ends of each pair of adjacent core segments 10 being pre-connected together. In other words, the stator core 40 has six pairs of split cores 10, each of which consists of two back yoke portions 11 (described later in FIG. 4) and teeth portions 12 protruding radially from each back yoke portion 11, which are arranged in a ring shape and connected and fixed at their circumferential abutment portions by crimping, welding, or the like.

[0014] 2, rotor 50, which faces teeth 12 of stator 100 across a gap on the inner diameter side of stator 100, is supported rotatably relative to stator 100 by bearings (not shown). Rotor 50 constitutes a field in which permanent magnets supply magnetic flux to stator 100 and windings are arranged. Stator 100 and rotor 50 are held by a frame (not shown) to form a rotating electric machine.

[0015] The electrical configuration of the stator 100 will be described with reference to Figures 2 and 3. The subscripts U, V, and W in Figures 2 and 3 correspond to the respective phases of the three-phase AC. The direction of the arrow in Figure 3 indicates the winding direction of the coil 30. The N terminal 36 is the neutral point. The U input terminal 31U of the U phase and the coil 30 wound on the tooth U1 are connected via a U winding start wire 32U, and the coil 30 wound on the tooth U1 and the coil 30 wound on the tooth U2 are connected via an adjacent crossover wire 33 and are wound in opposite directions. Here, U1 is used as the symbol for the teeth 12 to distinguish between phases, in addition to the symbols for the physical members. The same applies to the symbols V1, W1, etc. Also, the coil 30 is wound on each of the teeth 12 via the insulators 20, but the insulators 20 are omitted.

[0016] Furthermore, the coil 30 wound on tooth U2 is connected to the coil 30 wound on tooth U3 via a spaced jumper wire 34, and the coil 30 wound on tooth U3 is connected to the coil 30 wound on tooth U4 by an adjacent jumper wire 33, and from there is connected to the neutral point N terminal 36 via a U winding end wire 35U.

[0017] The V-phase V input terminal 31V and the coil 30 wound on tooth V1 are connected via a V winding start wire 32V, and the coil 30 wound on tooth V1 and the coil 30 wound on tooth V2 are connected via an adjacent jumper wire 33 and are wound in opposite directions to each other. Furthermore, the coil 30 wound on tooth V2 is connected to the coil 30 wound on tooth V3 via a spaced jumper wire 34, and the coil 30 wound on tooth V3 is connected to the coil 30 wound on tooth V4 by an adjacent jumper wire 33, and from there is connected to the neutral terminal N 36 via a V winding end wire 35V.

[0018] The W input terminal 31W of the W phase and the coil 30 wound on the tooth W1 are connected via a W winding start wire 32W, and the coil 30 wound on the tooth W1 and the coil 30 wound on the tooth W2 are connected via an adjacent jumper wire 33 and are wound in opposite directions to each other. Furthermore, the coil 30 wound on tooth W2 is connected to the coil 30 wound on tooth W3 via a spaced jumper wire 34, and the coil 30 wound on tooth W3 is connected to the coil 30 wound on tooth W4 by an adjacent jumper wire 33, and from there is connected to the N terminal 36 for the neutral point via the W winding end wire 35W.

[0019] The adjacent crossover wire 33 and the separated crossover wire 34 are arranged on opposite sides of the stator 100 in the axial direction, sandwiching the core segment 10 therebetween via the insulator 20, and it is desirable to arrange the input terminal with the highest potential difference on the side of the adjacent crossover wire 33 where there is no risk of interference. In Fig. 1, the adjacent crossover wire 33 is arranged on the lower side, and the separated crossover wire 34 is arranged on the upper side. Note that Figs. 1 and 2 show only the U-phase separated crossover wire 34 as a representative, and the other crossover wires are omitted. In addition, in FIG. 3, the neutral point N terminal 36 is placed near the V winding end wire 35V, but as long as the U, V, and W winding end wires are electrically connected, it may be placed on any of the teeth U3, U4, V3, V4, W3, and W4 where there is no risk of interference with the other U, V, and W input terminals.

[0020] Fig. 4 shows the configuration of a pair of split cores 10, each consisting of two split cores 10. Fig. 5 is a top view showing the pair of split cores 10 before the two split cores 10 are bent between them. The pair of split cores 10 shown in Fig. 4 is obtained by bending the pair of split cores 10 from the state shown in Fig. 5 toward the outer periphery around connecting part 13. The split core 10 has a back yoke portion 11 extending in the circumferential direction, and teeth portions 12 protruding radially inward from the back yoke portion 11. P indicates the pitch distance between the two split cores 10. The pair of split cores 10 are thin-walled and connected such that the circumferential ends of the back yoke portions 11 can be bent in the axial direction with axis Q of the connecting portion 13 as the central axis.

[0021] Here, in order to make the connecting portion 13 of the back yoke portion 11 foldable, the connecting portion 13 is made thin-walled and connected. However, this is not limited to this. For example, the back yoke portion 11 may be hinged and configured to rotate freely by utilizing crimping protrusions and recesses provided in the axial direction. The back yoke portion 11 has, at its central portion on the outer periphery, a dovetail groove 14 for attaching the split core 10 to a chuck mechanism 61, which will be described later with reference to Fig. 12. The dovetail groove 14 extends in the axial direction from the upper end to the lower end of the back yoke portion 11.

[0022] Fig. 6 is a diagram showing a state in which insulators 20 are attached to the pair of split cores 10 shown in Fig. 4. In the winding process described below, for example, in the case of a U-phase, two pairs of split cores 10 are combined into one set to form a U-phase winding section group, and coils 30 are wound continuously around all of the target split cores 10 to form a U-phase split stator group 41 for one phase. As shown in Figure 2, the wound U-phase split stator group 41 is arranged so that two teeth U1, U2 and two teeth U3, U4 are positioned symmetrically around the center point O, and the remaining V-phase and W-phase split stator groups 41 are arranged in a circular ring shape, shifted 60° each on the opposite circumferential side from the U-phase split stator group 41.

[0023] A pair of split cores 10 constitute a U-phase split stator group 41, a V-phase split stator group 41, and a W-phase split stator group 41 arranged in a circular ring, and the abutting portions of the back yoke portions 11 are integrated by welding or bonding to form the stator of a 10-pole, 12-teeth three-phase DC brushless motor.

[0024] Next, the configuration of the insulator 20 will be described with reference to Fig. 6 and Fig. 7. Fig. 6 is a perspective view showing a state in which the insulator 20 is attached to a pair of core segments 10, and Fig. 7 is a perspective view showing the configuration of the insulator 20 before attachment. Insulators 20 are attached to the teeth portions 12 of the split core 10 to ensure insulation between the coils 30. The insulators 20 are often split in the axial direction with one end side and the other end side having the same shape and are attached from above and below the split core 10, but they may also be molded integrally with the split core 10. The following description will focus on one end side of the insulator 20.

[0025] The insulator 20 comprises a coil insulating portion 21 shaped to cover the teeth portion 12 of the split core 10, an inner wall 22 having a shape similar to the inner surface of the teeth portion 12 extended in the axial direction and with an upper end surface perpendicular to the axial direction, and an outer wall 23 erected axially upward from the inner edge of the axial end face, which is the surface along the axial direction of the back yoke portion 11. The outer wall 23 of the insulator 20 has, at both circumferential ends on its axial end surface, which is a surface perpendicular to the axial direction, spaced jumper wire support grooves 24 for hooking and supporting the spaced jumper wire 34. The spaced jumper wire support grooves 24 hook and support the spaced jumper wire 34 in the winding process, which will be described later, and serve to prevent the spaced jumper wire 34 from coming into contact with the edges of the core segments 10 and damaging the coating of the spaced jumper wire 34.

[0026] The separated jumper wire support groove 24 is not limited to a specific shape as long as it can hook and support the separated jumper wire 34 in the axial direction in the winding process described below. For example, the separated jumper wire support groove 24 may have grooves arranged in the radial direction, but is preferably arranged in the circumferential direction as shown in the figure, which makes it easier to hook and support the separated jumper wire 34.

[0027] 6 and 7, the outer wall 23 of the insulator 20 is provided with a slit-like wire path groove 25 that extends in the axial direction from a position that is approximately the same height as or lower than the height of the axial end of the coil insulating portion 21 and opens in the radial direction. In a winding process described later, an adjacent jumper wire 33 or a spaced jumper wire 34 is arranged in the wire path groove 25, with the adjacent jumper wire 33 at one axial end and the spaced jumper wire 34 at the other axial end.

[0028] 8 is a schematic diagram for explaining the positional relationship of the separated jumper wire support groove 24. The position at which the separated jumper wire support groove 24 is arranged is determined by the position of a hook 64 provided on a winding device 60, which will be described later. Regarding the positional relationship of the split core 10, the separated jumper wire support groove 24, and the hook 64, first, in the straight line section from the separated jumper wire support groove 24 to where the coil 30 is hooked onto the hook 64, the end point of the straight line is defined as point I on the side of the separated jumper wire support groove 24 and point F on the side of the hook 64. The coil 30 in question becomes the separated jumper wire 34. The axial length from the axial end face of the split core 10 on the axial opposite side to hook 64 to point F is distance A, the length perpendicular to the axial direction from the axial end face of the split core 10 to point F is distance B, the axial length from the axial end face of the split core 10 to point I is distance a, and the length perpendicular to the axial direction from the axial end face of the split core 10 to point I is distance b. At this time, the separated crossover wire support groove 24 is positioned so that point I is located at a position where the value obtained by dividing distance B by distance A is greater than the value obtained by dividing distance b by distance a, that is, at a position that satisfies the condition B / A>b / a.

[0029] Next, the arrangement of the separated jumper wires 34 connecting the two pairs of split cores 10 will be described with reference to Figures 1, 2, 9 and 10. Figure 9 is a top view showing the state of one-phase split stator group 41 after winding. Figure 10 is a perspective view showing the state of one-phase split stator group 41 after winding. The difference between the split stator groups 41 for the U, V and W phases after winding is the length of the separated jumper wires 34 and the winding direction of the coils 30, so Figures 9 and 10 are common drawings for each phase. As described above, after the split stator groups 41 of the U-phase, V-phase, and W-phase are integrated, the separated crossover wire 34 of the U-phase split stator group 41 is routed around the back yoke portion 11 side of the split stator group 41 of the other phase sandwiched therebetween, that is, around the outer diameter side of the outer wall 23. The same process is carried out for the V-phase and W-phase.

[0030] In the above explanation, all of the separated jumper wires 34 for the U, V and W phases are formed by hooking them into the separated jumper wire support grooves 24, and then arranged by wrapping them around the outer diameter side of the outer wall 23. However, as long as the separated jumper wires 34 do not come into contact with other coils 30, split cores 10, adjacent jumper wires 33, or other separated jumper wires 34, a groove or protrusion may be provided on the inner diameter side of the outer wall 23 so that the separated jumper wires 34 of some phases are arranged by wrapping them around the inner diameter side instead of the outer diameter side of the outer wall 23, or in a manner other than that of the embodiment.

[0031] Next, the coil winding process for winding the coil 30 around each of the winding part groups of the U-phase, V-phase, and W-phase, which become the split stator group 41 when the coil 30 is wound, will be described in conjunction with the winding device 60 of the stator 100, using the coil winding process around the winding part group of the U-phase that constitutes the U-phase as an example. The winding portion 211 of each phase is the coil insulating portion 21 of the insulator 20, and indicates the portion around which the coil 30 is wound. Fig. 11 is a front view showing the configuration of the winding device 60. Fig. 12 is a top view showing the configuration of the chuck mechanism 61 of the winding device 60. Fig. 13 is a top view showing a state in which the coil 30 is wound around the first winding portion 211 of the U-phase winding portion group. Fig. 14 is a top view showing a state in which the coil 30 is wound around the third winding portion 211 of the U-phase winding portion group. Fig. 15 is a perspective view showing the positional relationship between the separated jumper wire support groove 24, the hook 64, and the separated jumper wire 34 when the separated jumper wire 34 is hung on the hook 64 of the winding device 60.

[0032] For convenience of the following description, in Figures 11 to 15, the state is drawn upside down compared to the state in Figures 1 and 10. In other words, the separated crossover wire 34 is drawn on the lower side. Here, two pairs of split cores 10 are illustrated as an example. 11 and 12, the winding device 60 includes a chuck mechanism 61 that arranges, for example, four winding parts 211, each having two pairs of split cores 10 with insulators 20 attached thereto, in a circular shape with the inner circumferential ends of the teeth parts 12 facing outward. The drive mechanism 62 is a mechanism that rotates the chuck mechanism 61 around a rotary drive shaft C.

[0033] As shown in FIG. 13, the winding device 60 is provided with a flyer mechanism 63 which faces each winding portion 211 in order from the outer circumferential side and winds the coil 30 around each winding portion 211 by rotating around the winding portion 211 about axis R, which is the central axis of the winding portion 211, while supplying the conductor wire 301. The flyer mechanism 63 slides in the direction of the arrow in Fig. 11 in synchronization with the turning motion for the purpose of improving the alignment of the coil 30. X indicates the sliding direction. In Figure 12, the chuck mechanism 61 has a claw mechanism 613 consisting of four sets of fixed claws 611 and movable claws 612 that can be opened and closed around the rotating drive shaft C, and when the movable claws 612 are on the opposite side to the fixed claws 611, i.e., the side moving away from the fixed claws 611, and are opened in the direction separating the movable claws 612 and the fixed claws 611, the fixed claws 611 and the movable claws 612 engage with the dovetail groove 14 provided on the outer peripheral surface of the split core 10.

[0034] 12, the chuck mechanism 61 positions the four winding parts 211 so that a straight line B1 connecting the axial centers of the teeth portions 12 of one of the assembled pair of split cores 10, and a straight line B2 connecting the axial centers of the teeth portions 12 of the other of the two split cores 10, both pass through the rotating drive shaft C. This makes it possible to move each of the winding parts 211 to the same position relative to the flyer mechanism 63 simply by rotating the rotating drive shaft C, thereby shortening the adjustment time for the winding operation of the winding device 60. Furthermore, the chuck mechanism 61 includes a hook 64 used to hook the separated jumper wire 34, midway between the second winding part 211 and the third winding part 211 in the winding order of the coil 30. If the length of the separated jumper wire 34 of each phase differs depending on the routing path or the like, multiple hooks 64 may be provided. Furthermore, by providing the hook 64 with an axial adjustment function, it is possible to accommodate multiple types of stators.

[0035] Next, the winding process for winding a coil around the U-phase winding part group will be described. In Fig. 13, the winding part 211 to which the insulator 20 is attached is inserted into the chuck mechanism 61 of the winding device 60. Then, the movable claws 612 provided on the chuck mechanism 61 open to the opposite side to the fixed claws 611 to grip the dovetail groove 14 and fix the winding part to the chuck mechanism 61. Next, the first winding unit 211 on which the coil 30 is first wound is made to face the axis R of the flyer mechanism 63. The conductor wire 301 is supplied from the nozzle 631 of the flyer mechanism 63, and the terminal portion of this conductor wire 301 becomes the winding start wire (not shown in the figure). After the winding start wire of the conductor wire 301 is passed through the wire path groove 25 on the upper side of the insulator 20 of the winding unit 211 facing the flyer mechanism 63, the coil 30 is wound by the rotating operation of the flyer mechanism 63.

[0036] 14, the end of the winding of the coil 30 is passed through the upper wire path groove 25 of the insulator 20 assembled to the first winding part 211 and then through the upper wire path groove 25 of the insulator 20 assembled to the adjacent second winding part 211 by the operation of the flyer mechanism 63 and the chuck mechanism 61, thereby forming the adjacent crossover wire 33 in the pair of split cores 10. To shorten the working time, the second winding part 211 is made to face the flyer mechanism 63 during the operation of forming the adjacent crossover wire 33. Next, the flyer mechanism 63 is rotated in the opposite direction to when the coil 30 was wound around the first winding part 211, and the coil 30 is wound around the second winding part 211.

[0037] In this manner, the winding around the two winding portions 211 contained in the pair of split cores 10 is completed. Subsequently, the end wire of the coil 30 wound around the second and last winding portion 211 of the pair of split cores 10 is passed through the wire path groove 25 and the separated jumper wire support groove 24 on the lower side of the insulator 20 where the second winding portion 211 is located by the operation of the flyer mechanism 63 and the chuck mechanism 61, and as shown in Figures 8 and 15, it is hooked onto the hook 64 of the chuck mechanism 61 provided in the winding device 60 on the axially opposite side of the separated jumper wire support groove 24 of the insulator 20 where the second winding portion 211 is located, folded back, and then hooked onto the separated jumper wire support groove 24 adjacent to the hook 64 on the lower side of the insulator 20 where the third winding portion 211 is located, and passed through the wire path groove 25 on the same side, to form the separated jumper wire 34. In order to shorten the operation time, the third winding portion 211 of the other pair of core segments 10 is made to face the flyer mechanism 63 during the operation of forming the separated crossover wire 34 .

[0038] In this case, if the positional relationship of the core segments 10, the separated jumper wire support groove 24, and the hook 64 is such that B / A>b / a as shown in Fig. 8, the separated jumper wire 34 can be arranged from the separated jumper wire support groove 24 on the lower side of the insulator 20 where the second winding portion 211 is located to the hook 64, and from the hook 64 to the separated jumper wire support groove 24 on the lower side of the insulator 20 where the third winding portion 211 is located, without interfering with the core segments 10. This prevents the insulation coating of the separated jumper wire 34 from being damaged, allows continuous winding without cutting, and ensures high dielectric strength. Also, by adjusting the position of the hook 64 in the axial direction within the range where B / A>b / a, the length of the separated jumper wire 34 can be adjusted.

[0039] Next, the flyer mechanism 63 is rotated in the same direction as when winding the second winding part 211, and the coil 30 is wound around the third winding part 211. The flyer mechanism 63 and the chuck mechanism 61 operate to pass the end of the winding of the coil 30 through the upper wire path groove 25 of the insulator 20 assembled to the third winding part 211 and through the upper wire path groove 25 of the insulator 20 assembled to the adjacent fourth winding part 211, forming the adjacent crossover wire 33. To shorten the operation time, the fourth winding part 211 is opposed to the flyer mechanism 63 during the operation of forming the adjacent crossover wire 33. Then, the flyer mechanism 63 is rotated in the same direction as when the first winding part 211 was wound, and the coil 30 is wound around the fourth winding part 211. The end of the winding of this coil 30 passes through the upper wire path groove 25 of the insulator 20 attached to the fourth winding part 211, and is cut off after securing a predetermined length.

[0040] In this manner, the winding process onto the U-phase winding portion group is completed to obtain the U-phase split stator group 41. The U-phase split stator group 41 which is fixed to the chuck mechanism 61 and has completed winding can be removed by closing the movable claws 612 of the chuck mechanism 61 towards the fixed claws 611. Although the winding process for winding the coil 30 around the U-phase winding part group has been described above, the same applies to winding the coil 30 around the W-phase winding part group. For the winding part 211 of the V-phase winding part group, it is only necessary to wind the coil 30 in the opposite direction to that of the U-phase as shown in Fig. 3. Also, if it is desired to change the length of the separated jumper wire 34 depending on the phase, it is only necessary to add additional hooks 64 and hook them onto the hooks 64 for each phase. According to the first embodiment, the separated jumper wire 34 can be prevented from being damaged and can be wound continuously without being cut, thereby obtaining a stator, a rotating electric machine, and a method for manufacturing a stator having high dielectric strength.

[0041] In the first embodiment, an example of the stator (armature) of a 10-pole, 12-slot three-phase DC brushless motor has been described, but the same can be applied to a 10n-pole, 12n-slot three-phase DC brushless motor (n is a natural number), such as a 20-pole, 24-slot or 30-pole, 36-slot three-phase DC brushless motor. In addition, for convenience of explanation in the first embodiment, the winding start wire of the coil 30 is described as being on the input terminal side and the winding end wire as being on the neutral point side, but the order of the winding start and end of the coil 30 may be reversed depending on the convenience of production. By using such electrical wiring, the number of connection points of the conductor 301 is reduced, and the number of points where the adjacent jumper wires 33 and the separated jumper wires 34 may come into contact can be reduced to an absolute minimum, making it possible to prevent the shape of the insulator 20 from becoming complicated and large, and ultimately to prevent the size of the stator 100 from becoming large.

[0042] Embodiment 2 Hereinafter, the second embodiment will be described with reference to Figs. 16 and 17, focusing on the parts different from the first embodiment. Fig. 16 is a perspective view showing the configuration of a wound portion 211 in which an insulator 20 according to the second embodiment is mounted on a split core 10. Fig. 17 is a perspective view showing a state in which the open-ring portions 26 and columnar portions 27 of two insulators 20 mounted on the pair of split cores 10 in Fig. 16 are connected by snap-fit ​​connection.

[0043] In FIG. 16, the insulator 20 has an open ring portion 26 formed at one axial end side, which is one circumferential end side, and the other axial end side, which rotatably connects the core segments 10 by snap-fit ​​connection. Also, a columnar portion 27 is formed at one axial end side, which is the other circumferential end side, and the other axial end side, which is one circumferential end side. Then, as shown in FIG. 17, in a pair of core segments 10, the open ring portion 26 of one insulator 20 and the columnar portion 27 of the other insulator 20, which are adjacent in the circumferential direction, are connected by snap-fit ​​connection to obtain a pair of core segments 10. Here, the open ring portion 26 and the columnar portion 27 are disposed radially on the outer diameter side of the separated crossover wire support groove 24, and disposed axially on the core segment 10 side of the separated crossover wire support groove 24. This can prevent the open portion 26 and the columnar portion 27 from interfering with the separated crossover wire 34 hooked on the hook 64 during winding.

[0044] In embodiment 2, adjacent insulators 20 of a pair of split cores 10 are snap-fitted and rotatably connected by the open ring portions 26 and the columnar portions 27, so that in the winding process after the insulators 20 are attached to the split cores 10, winding can be performed with the spacing between the teeth portions 12 of the split cores 10 widened, as in embodiment 1 shown in Figures 11 to 15. According to the second embodiment, the insulator 20 is snap-fit ​​connected in the circumferential direction and is provided with a rotatable connecting portion, thereby achieving the same effect as the first embodiment and allowing the multiple core segments 10 to rotate freely at the connecting portions of the insulator 20. Therefore, the split core 10 can be bent multiple times without reducing its mechanical strength, and rotation is facilitated, achieving improved workability during the winding process.

[0045] Although the present disclosure describes various exemplary embodiments and examples, the various features, aspects, and functions described in one or more embodiments are not limited to application to a particular embodiment, but may be applied to the embodiments alone or in various combinations. Therefore, countless modifications not exemplified are assumed within the scope of the technology disclosed in this specification, including, for example, modifying, adding, or omitting at least one component, and further, extracting at least one component and combining it with a component of another embodiment. Various aspects of the present disclosure are summarized below as appendices.

[0046] (Appendix 1) a split core having a back yoke portion and teeth portions protruding radially inward from the back yoke portion; a stator core in which a plurality of the split cores are arranged in an annular shape, and adjacent pairs of the split cores are grouped together at the ends of the back yoke portions; coils wound in mutually opposite directions on the teeth portions of the pair of split cores via insulators; an adjacent jumper wire continuously connecting the coils wound on the pair of split cores; a spaced jumper wire that continuously connects the coils wound on the pair of split cores and the coils wound on the pair of split cores spaced apart in the circumferential direction from the pair of split cores, the adjacent crossover wire and the spaced crossover wire are disposed on the insulator, the insulator has an outer wall extending in the axial direction from the axial end face of the back yoke portion, and a spaced jumper wire support groove for supporting the spaced jumper wire is provided at both circumferential ends of the axial end face of the outer wall. (Appendix 2) The stator described in Appendix 1, wherein the outer wall is erected axially upward from an inner peripheral side edge at an axial end face of the back yoke portion, and has a wire path groove that extends axially and opens radially between the separated jumper wire support grooves at both ends, and the adjacent jumper wire or the separated jumper wire is arranged in the wire path groove. (Appendix 3) 3. The stator according to claim 1, wherein the adjacent crossover wire is arranged on one axial end side of the core segment, and the spaced crossover wire is arranged on the other axial end side of the core segment. (Appendix 4) 4. The stator according to any one of Supplementary Note 1 to Supplementary Note 3, in which a groove for supporting the separated jumper wire is formed in the separated jumper wire support groove in a circumferential direction, the separated jumper wire is arranged on the outer diameter side or the inner diameter side of the outer wall, and two pairs of the split cores are connected. (Appendix 5) 5. The stator according to any one of Supplementary Note 1 to Supplementary Note 4, wherein two pairs of the split cores are connected via the spaced jumper wire, and a winding start wire of the coil or a winding end wire of the coil is arranged in one of the respective insulators, and the spaced jumper wire is arranged in the remaining one of the respective insulators. (Appendix 6) 6. The stator according to any one of Supplementary Note 1 to Supplementary Note 5, wherein a split stator group for one phase is formed by using two pairs of the split cores connected via the spaced jumper wire as one set, and a three-phase armature is configured by arranging at least three sets of the split stator groups in the circumferential direction. (Appendix 7) 7. A stator as described in any one of Supplementary Note 1 to Supplementary Note 6, wherein the insulator has an open-ring portion at one circumferential end side on the axial end surface and a columnar portion connected to the open-ring portion at the other circumferential end side, and the pair of split cores are rotatably connected to the open-ring portion and the columnar portion of each of the adjacent insulators. (Appendix 8) 8. The stator according to claim 7, wherein the open ring portion and the columnar portion provided in the insulator are arranged radially outward of the separated jumper wire support groove and are arranged axially closer to the split core than the separated jumper wire support groove. (Appendix 9) 9. A rotating electric machine comprising: a stator according to any one of claims 1 to 8; and a rotor arranged coaxially and rotatably opposite to an inner diameter side of the stator with a gap therebetween. (Appendix 10) A method for manufacturing a stator according to any one of Supplementary Note 1 to Supplementary Note 8, comprising winding the stator using a winding device provided with a wire path groove provided in the outer wall of the insulator and a coil hook, In the split core of the pair of split cores, the coil is wound last, and the coil is passed through the wire path groove in the outer wall of the insulator, hooked and supported in the spaced jumper wire support groove on the side adjacent to the hook among the spaced jumper wire support grooves at both ends of the outer wall, and then hooked and folded back on the hook on the axially opposite side of the spaced jumper wire support groove, a second split core of the pair of split cores on which the coil is wound, the second split core being hooked into the second split core support groove adjacent to the hook, one of the second split cores at both ends of the outer wall of the insulator, and then the coil is wound around the second split core by passing the second split core through the wire path groove in the outer wall. (Appendix 11) The positional relationship between the split core, the separated crossover wire support groove, and the hook is as follows: In a section that forms a straight line from the separated crossover wire support groove to where the coil is hooked onto the hook, when the end points of the straight line are defined as point I on the side of the separated crossover wire support groove and point F on the side of the hook, Let the axial length from the axial end face of the core split on the axial opposite side to the hook to point F be distance A, the length perpendicular to the axial direction from the axial end face of the core split to point F be distance B, the axial length from the axial end face of the core split to point I be distance a, and the length perpendicular to the axial direction from the axial end face of the core split to point I be distance b, The position of the point I satisfies the condition B / A>b / a. 11. A method for manufacturing a stator according to claim 10. (Appendix 12) 12. The method for manufacturing a stator according to claim 11, wherein the position of the hook is adjusted in the axial direction of the core segments to make it possible to adjust the length of the spaced jumper wires within a range that satisfies the conditional expression. [Explanation of symbols]

[0047] 100: stator, 10: split core, 11: back yoke portion, 12: teeth portion, 13: connecting portion, 14: dovetail groove, 20: insulator, 21: coil insulation portion, 211: winding portion, 22: inner wall, 23: outer wall, 24: spaced jumper wire support groove, 25: wire routing groove, 26: open loop portion, 27: columnar portion, 30: coil, 301: conductor, 31U: U input terminal, 31V: V input terminal, 31W: W input terminal, 32U: U winding start wire, 32V: V winding start wire, 32W: W winding start wire, 33: adjacent jumper wire, 34: spaced jumper wire, 35U: U winding end wire, 35V: V winding end wire, 35W: W winding end wire, 36: N terminal, 40: stator core, 41: divided stator group, 50: rotor, 60: winding device, 61: chuck mechanism, 611: fixed claw, 612: movable claw, 613: claw mechanism, 62: drive mechanism, 63: flyer mechanism, 631: nozzle, 64: hook, O: center point, Q, R: axis, I, F: points, A, a, B, b: distance, C: rotating drive shaft, B1, B2: straight line

Claims

1. a split core having a back yoke portion and teeth portions protruding radially inward from the back yoke portion; a stator core in which a plurality of the split cores are arranged in an annular shape, and ends of the back yoke portions of adjacent pairs of the split cores are connected to each other as a set; coils wound in mutually opposite directions on the teeth portions of the pair of split cores via insulators; an adjacent jumper wire continuously connecting the coils wound on the pair of split cores; a spaced jumper wire that continuously connects the coils wound on the pair of split cores and the coils wound on the pair of split cores spaced apart in the circumferential direction from the pair of split cores, the adjacent crossover wire and the spaced crossover wire are disposed on the insulator, the insulator has an outer wall extending in the axial direction from the axial end face of the back yoke portion, and a spaced jumper wire support groove for supporting the spaced jumper wire is provided at both circumferential ends of the axial end face of the outer wall.

2. 2. The stator according to claim 1, wherein the outer wall is erected axially upward from an inner peripheral side edge at an axial end face of the back yoke portion, and has a wire path groove that extends axially and opens radially between the spaced jumper wire support grooves at both ends, and the adjacent jumper wire or the spaced jumper wire is arranged in the wire path groove.

3. 2. The stator according to claim 1, wherein the adjacent crossover wire is arranged on one axial end side of the core segment, and the spaced crossover wire is arranged on the other axial end side of the core segment.

4. 2. The stator according to claim 1, wherein a groove for supporting the spaced jumper wires is formed in the spaced jumper wire support groove in a circumferential direction, and the spaced jumper wires are arranged on the outer diameter side or the inner diameter side of the outer wall, and two pairs of the split cores are connected.

5. 2. The stator according to claim 1, wherein the two pairs of split cores are connected via the spaced jumper wire, and the winding start wire of the coil or the winding end wire of the coil is arranged in one of the insulators, and the spaced jumper wire is arranged in the remaining one of the insulators.

6. 2. The stator according to claim 1, wherein a split stator group for one phase is formed by forming two pairs of the split cores connected via the spaced jumper wires as one set, and a three-phase armature is configured by arranging at least three sets of the split stator groups in the circumferential direction.

7. 2. The stator according to claim 1, wherein the insulator has an open ring portion on one circumferential end side at an axial end face and a columnar portion connecting to the open ring portion on the other circumferential end side, and the pair of split cores are rotatably connected to the open ring portion and the columnar portion of each of the adjacent insulators.

8. 8. The stator according to claim 7, wherein the open ring portion and the columnar portion provided in the insulator are arranged radially outwardly of the spaced jumper wire support groove and are arranged axially closer to the split core than the spaced jumper wire support groove.

9. 9. A rotating electric machine comprising: the stator according to claim 1; and a rotor disposed coaxially and rotatably on an inner diameter side of the stator so as to face the stator with a gap therebetween.

10. A method for manufacturing a stator according to any one of claims 1 to 8, comprising winding the stator using a winding device provided with a wire path groove provided in the outer wall of the insulator and a hook for a coil, In the split core of the pair of split cores, the coil is wound last, and the coil is passed through the wire path groove in the outer wall of the insulator, hooked and supported in the spaced jumper wire support groove on the side adjacent to the hook among the spaced jumper wire support grooves at both ends of the outer wall, and then hooked and folded back on the hook on the axially opposite side of the spaced jumper wire support groove, a second split core of the pair of split cores on which the coil is wound, the second split core being hooked into the second split core support groove adjacent to the hook, one of the second split cores at both ends of the outer wall of the insulator, and then the coil is wound around the second split core by passing the second split core through the wire path groove in the outer wall.

11. The positional relationship between the split core, the separated crossover wire support groove, and the hook is as follows: In a section of the line from the separated crossover wire support groove to where the coil is hooked onto the hook, when the end points of the line are defined as point I on the side of the separated crossover wire support groove and point F on the side of the hook, Let A be the axial length from the axial end face of the core segment on the axial opposite side to the hook to point F, B be the length perpendicular to the axial direction from the axial end face of the core segment to point F, a be the axial length from the axial end face of the core segment to point I, and b be the length perpendicular to the axial direction from the axial end face of the core segment to point I, The position of the point I satisfies the condition B / A>b / a. The method for manufacturing a stator according to claim 10 .

12. The method for manufacturing a stator according to claim 11, wherein the length of the separated jumper wires is adjustable by adjusting the position of the hook in the axial direction of the core segments within a range that satisfies the conditional expression.

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