Stator and rotary electric machine

Abstract

To provide a stator and a rotary electric machine capable of improving manufacturing workability.SOLUTION: A stator includes: a bobbin around which coils of a plurality of phases are wound; and an insulating member that insulates the different phases of the coils wound on the bobbin from each other. The bobbin has multiple grooves that are provided along a peripheral surface of the bobbin at intervals from each other and are capable of accommodating the coils of the respective phases so that gaps are formed between the coils of the different phases that are adjacent to each other in a radial direction. The insulating member is continuously provided on an entire periphery of the gaps.SELECTED DRAWING: Figure 5

Description

[Technical field]

[0001] An embodiment of the present invention relates to a stator and a rotating electric machine. [Background technology]

[0002] It is known to form an air-core armature by winding an armature winding in a winding pattern on a generally non-magnetic former. The armature winding is configured with multiple phases in one layer, and each phase winding also includes an end turn that runs circumferentially, overlaps multiple phases, and is located outside the armature air gap. The windings or coils of each phase in the conventional configuration are located in the same radial position on the generally non-magnetic former. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Special Publication No. 2019-531046 Summary of the Invention [Problem to be solved by the invention]

[0004] In such an air-core armature having a conventional configuration, the end turns located at the ends of the coils of each phase, i.e., the coil ends, may be provided with, for example, interphase insulating paper in order to ensure insulation between the coils of different phases. However, in the conventional configuration, the rising positions of the coil ends of multiple phases overlap, making the work of providing the interphase insulating paper complicated and leaving room for improvement in manufacturing operability.

[0005] Therefore, an embodiment of the present invention provides a stator and a rotating electric machine that can improve manufacturing workability. [Means for solving the problem]

[0006] The stator of one embodiment includes a bobbin around which coils of multiple phases are wound, and an insulating member that provides insulation between the different phases of the coils wound around the bobbin, the bobbin having a plurality of grooves that are spaced apart from one another along the circumferential surface of the bobbin and capable of accommodating the coils of each phase such that gaps are formed between the coils of different phases that are adjacent to one another in the radial direction, and the insulating member is provided continuously around the entire circumference of the gap. [Brief description of the drawings]

[0007] [Figure 1] FIG. 1 is a front view showing an example of a rotating electric machine according to a first embodiment; [Diagram 2] FIG. 1 is a perspective view showing an example of a state in which a coil is wound around a bobbin in a stator according to a first embodiment; [Diagram 3] FIG. 1 is a front view showing an example of a state in which coils of each phase are housed in each groove portion of a stator according to a first embodiment; [Figure 4] FIG. 1 is an enlarged cross-sectional view showing a configuration around each groove in a stator according to a first embodiment; [Diagram 5] FIG. 1 is a front view showing an example of a state in which an insulating member is provided between coils of each phase in a stator according to a first embodiment; [Figure 6] FIG. 13 is a perspective view showing an example of a configuration of an insulating member formed in a container shape in a stator according to a second embodiment; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] Hereinafter, a number of embodiments will be described with reference to the drawings. In each drawing, for the sake of convenience, the dimensions of each component may be appropriately enlarged as necessary, and the dimensional ratios between each component may not necessarily be the same as in reality.

[0009] (First embodiment) First, the first embodiment will be described with reference to FIGS. The rotating electric machine 1 of the embodiment shown in Fig. 1 is, for example, a coreless type rotating electric machine. As shown in Fig. 1, the rotating electric machine 1 includes a frame 10, a rotor 20, and a stator 30. In the following description, a direction parallel to the central axis O of rotation of the rotor 20 is referred to as an axial direction. When the rotor 20 is rotated around the central axis O of rotation, a direction in which the outer circumferential surface of the rotor 20 rotates is referred to as a circumferential direction. A direction perpendicular to the central axis O of rotation is referred to as a radial direction.

[0010] The frame 10 constitutes an outer shell of the rotating electric machine 1. The frame 10 is formed, for example, in a cylindrical shape. The frame 10 has, for example, a plurality of fins (not shown) for heat dissipation. The plurality of fins are formed on the outer peripheral surface of the frame 10 so as to protrude in the radial direction.

[0011] The rotor 20 is disposed inside the frame 10. The rotor 20 is formed, as a whole, in, for example, a cylindrical shape centered on a central axis O. The rotor 20 is provided, for example, inside the stator 30, and is provided rotatably with respect to the stator 30 via a gap. That is, the rotating electric machine 1 is configured, for example, as an inner rotor type rotating electric machine.

[0012] The rotor 20 has a permanent magnet (not shown). A plurality of permanent magnets are arranged at intervals in the circumferential direction along the outer circumferential surface of the rotor 20. The rotor 20 is configured to be rotatable around a central rotation axis O together with the shaft 21. The central rotation axis of the shaft 21 coincides with the central rotation axis O of the rotor 20.

[0013] The stator 30 is fixed to the inside of the frame 10. The stator 30 is formed, for example, in a substantially cylindrical shape as a whole. The inner diameter dimension of the stator 30 is set to be slightly larger than the outer dimension of the rotor 20. The stator 30 has a bobbin 31, a coil 32, a back yoke 33, and an insulating member 34. The bobbin 31 is made of, for example, synthetic resin having insulating properties, and is formed in a cylindrical shape. The bobbin 31 has a plurality of phase coils 32 wound around its outer periphery. The coils 32 may be wound around the inner periphery of the bobbin 31. The coils 32 are formed, for example, by a winding formed of a round wire. The type of the winding is not limited to a round wire, and may be formed in other shapes such as a rectangular wire or a Litz wire.

[0014] 2, the coil 32 is configured, for example, by so-called wave winding in which the coil is arranged in a wave shape on the bobbin 31. The winding method of the coil 32 is not limited to wave winding, and other winding methods such as concentric winding and lap winding may be used. The coil 32 is configured, for example, by coils for each of the three phases, that is, a U-phase coil 321 as a first coil, a V-phase coil 322 as a second coil, and a W-phase coil 323 as a third coil.

[0015] The outer diameters of the coils 321, 322, 323 of each phase are set to be approximately the same. The coils 321, 322, 323 of each phase are configured with one or more windings. In this embodiment, the coils 321, 322, 323 of each phase are configured with the same number of windings, and each is configured with multiple windings, for example five windings, as one set of windings. Furthermore, the coils 321, 322, 323 of each phase are each connected to a connection terminal.

[0016] The coils 321, 322, 323 of each phase are wound, for example, in one layer around the bobbin 31. In this case, the W-phase coil 323 is first wound completely around the outer periphery of the bobbin 31, and then the V-phase coil 322 and the U-phase coil 321 are sequentially wound completely around the outer periphery of the bobbin 31 to form a cylindrical coil 32 as a whole. The winding order of the coils 321, 322, 323 of each phase around the bobbin 31 can be set arbitrarily.

[0017] The back yoke 33 is made of a magnetic material such as an electromagnetic steel plate and is formed in a cylindrical shape. The bobbin 31 around which the coil 32 is wound is, for example, fitted and fixed to the inner surface of the back yoke 33. The back yoke 33 integrated with the bobbin 31 is then fixed to the frame 10.

[0018] As shown in Figs. 3 and 4, the bobbin 31 has a main body 311 and grooves 312. The main body 311 is formed in a cylindrical shape and constitutes the main body of the bobbin 31. The grooves 312 are provided at intervals along the circumferential surface of the main body 311 (in this case, the outer circumferential surface). When the coil 32 is wound on the inner circumferential side of the bobbin 31, the grooves 312 are provided at intervals along the inner circumferential surface of the main body 311. The intervals between the grooves 312 are set to be equal, for example. The intervals between the grooves 312 may be unequal.

[0019] A plurality of grooves 312 are provided so as to accommodate coils 321, 322, and 323 of each phase. In this case, groove 312 has U-phase groove 312a as a first groove that accommodates U-phase coil 321, V-phase groove 312b as a second groove that accommodates V-phase coil 322, and W-phase groove 312c as a third groove that accommodates W-phase coil 323. In FIG. 3 and other drawings, in order to make the drawings easier to understand, only some of grooves 312a, 312b, and 312c are labeled with reference numerals, and the other grooves 312a, 312b, and 312c are not labeled with reference numerals.

[0020] Here, if the radial dimensions of the grooves that house the coils of each phase are the same, the coils of each phase rise from the grooves at the same position, and the coils of different phases are arranged overlapping each other. For this reason, when manufacturing the stator, it is necessary to perform a forming process on the so-called coil ends located at both ends in the axial direction of the coils of each phase. The forming process of the coil ends may damage the windings, for example, and the forming process is labor-intensive.

[0021] Therefore, in this embodiment, the radial dimensions of the grooves 312a, 312b, and 312c corresponding to the coils 321, 322, and 323 of each phase, that is, the dimensions from the peripheral surface of the bobbin 31 to the bottom surfaces of the grooves 312a, 312b, and 312c, are different from each other. Therefore, steps can be provided in the multiple grooves 312a, 312b, and 312c. Therefore, it is possible to suppress interference in the circumferential direction between the coils 321, 322, and 323 of each phase housed in the multiple grooves 312a, 312b, and 312c, and therefore it is possible to eliminate the need for a molding operation of the coil ends. As a result, the quality of the coil 32 can be improved and the workability can be improved.

[0022] As shown in FIG. 4, the relationship between the groove depth H1 of the groove 312a, the groove depth H2 of the groove 312b, and the groove depth H3 of the groove 312c is H3>H2>H1. The maximum dimension H3 of the groove depth of each of the grooves 312a, 312b, and 312c is set to be three times or more the outer diameter of the coil 32. In this embodiment, the dimensional difference ΔH between the groove depths H of the adjacent grooves 312a, 312b, and 312c is set to be larger than the outer diameter dimension of the coil 32. Therefore, the coils 321, 322, and 323 of each phase are accommodated in the grooves 312a, 312b, and 312c so as not to overlap in the circumferential direction of the bobbin 31. As shown in FIG. 3, a gap 324 is formed between the coils 321, 322, and 323 of each phase adjacent to each other in the radial direction of the stator 30. The gap 324 is formed over the entire circumference along the circumferential direction of the bobbin 31.

[0023] In the present embodiment, the gap 324 includes an outer gap 324a and an inner gap 324b. The outer gap 324a is located between the U-phase coil 321 and the V-phase coil 322. The inner gap 324b is located between the V-phase coil 322 and the W-phase coil 323. The outer gap 324a is located radially outward from the inner gap 324b. In other words, the inner gap 324b is located radially inward from the outer gap 324a. The radial dimensions of the outer gap 324a and the inner gap 324b are set to be substantially the same. The radial dimensions of the outer gap 324a and the inner gap 324b are not limited to being substantially the same, and may be different.

[0024] The insulating member 34 is provided between the coils 321, 322, 323 of different phases adjacent to each other in the radial direction, and insulates the coils 321, 322, 323 from each other. The insulating member 34 is made of insulating paper such as aramid paper or a resin having insulating properties. The insulating member 34 is provided in the gap 324. The insulating member 34 is formed, for example, in a ring shape. That is, the insulating member 34 is provided continuously around the entire circumference of the gap 324.

[0025] As shown in Fig. 5, the insulating member 34 includes an outer insulating member 341 and an inner insulating member 342. The outer insulating member 341 is provided in correspondence with the outer gap 324a, and the inner insulating member 342 is provided in correspondence with the inner gap 324b. The V-phase coil 322 is disposed between the outer gap 324a and the inner gap 324b. With the coils 321, 322, and 323 of each phase wound around the bobbin 31, the outer insulating member 341 is inserted into the outer gap 324a and the inner insulating member 342 is inserted into the inner gap 324b, thereby ensuring high insulation between the coils 321, 322, and 323. This makes it possible to handle a power supply voltage of, for example, 400V or more that cannot be satisfied by the coating of the winding alone.

[0026] According to the embodiment described above, the stator 30 includes a bobbin 31 and an insulating member 34. The coils 321, 322, and 323 of multiple phases are wound around the bobbin 31. The insulating member 34 insulates the different phases of the coils 321, 322, and 323 wound around the bobbin 31. The bobbin 31 has multiple grooves 312a, 312b, and 312c. The multiple grooves 312a, 312b, and 312c are provided at intervals along the circumferential surface of the bobbin 31, and can accommodate the coils 312a, 312b, and 312c of each phase such that a gap 324 is formed between the coils 312a, 312b, and 312c of different phases adjacent to each other in the radial direction. The insulating member 34 is provided continuously around the entire circumference of the gap 324.

[0027] According to this, by utilizing the gaps 324 between the coils 321, 322, and 323 of different phases adjacent to each other in the radial direction, it is possible to easily insert the insulating member 34. This improves the manufacturability of the stator 30. In addition, by making it a simple task of inserting the insulating member 34 into the gaps 324, it becomes easier to automate coil production.

[0028] Second embodiment Next, a second embodiment will be described with reference to FIG. 6. In the second embodiment, the shape of the insulating member 34 is different from that of the first embodiment. Specifically, in the first embodiment, the insulating member 34 is formed in an annular shape, whereas in the second embodiment, the insulating member 34 is formed in a container shape. In this case, the insulating member 34 is formed such that the end on the side inserted into the gap 324 is open and the end on the opposite side to the side inserted into the gap 324 is closed. By forming the insulating member 34 in a container shape, it is possible to easily manage the insertion position of the insulating member 34 relative to the gap 324 in the axial direction, etc. This can improve the manufacturability of the stator 30 while improving reliability.

[0029] 6, the insulating member 34 has a lid 343. The lid 343 is formed, for example, in a circular shape, and is attached to the ends of the outer insulating member 341 and the inner insulating member 342 opposite to the ends inserted into the gaps 324a, 324b. In other words, the outer insulating member 341 and the inner insulating member 342 are integrally configured via the lid 343 at the ends opposite to the ends inserted into the gaps 324a, 324b.

[0030] This eliminates the need to insert outer insulating member 341 and inner insulating member 342 into gaps 324a, 324b, respectively, and thus the workability in manufacturing stator 30 can be further improved.

[0031] Although several embodiments of the present invention have been described above, these embodiments are presented as examples and are not intended to limit the scope of the invention. These novel embodiments can be implemented in various other forms, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention. These embodiments and their modifications are included in the scope and spirit of the invention, and are included in the scope of the invention and its equivalents described in the claims. [Explanation of symbols]

[0032] In the drawings, 1 indicates a rotating electric machine, 20 indicates a rotor, 30 indicates a stator, 31 indicates a bobbin, 321, 322, 323 indicate coils, 312a, 312b, 312c indicate grooves, 324a indicates an outer gap (gap), 24b indicates an inner gap (gap), 341 indicates an outer insulating member (insulating member), and 342 indicates an inner insulating member (insulating member).

Claims

1. A bobbin around which coils of multiple phases are wound; an insulating member for insulating between different phases of the coil wound around the bobbin, the bobbin has a plurality of grooves that are spaced apart from one another along a circumferential surface of the bobbin and that can accommodate the coils of each phase such that a gap is formed between the coils of different phases that are adjacent to one another in the radial direction; The insulating member is provided continuously around the entire periphery of the gap. stator.

2. The insulating member is formed in a container shape having an open end on a side to be inserted into the gap and a closed end on an opposite side to the side to be inserted into the gap. The stator according to claim 1 .

3. A stator according to claim 1 or 2; A rotor provided inside the stator. Rotating electric motor.

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