Stator and insulator in rotary electric machine

Abstract

To provide a high-quality rotary electric machine by which a winding operation of windings is facilitated.SOLUTION: An insulator extension part 53 comprises an outer end face 55 located on an opposite side of a stator core 23. A protrusion 56 protruding from a portion close to a winding start portion 29s according to a portion closer to an insulator base part 51 than a first-turn winding 29 on the outer end face 55, while winding the first-turn winding 29 around the outer end face 55, is provided on the outer end face 55. The winding 29 that forms an outer peripheral layer 62 is arranged above the protrusion 56 after extending along a second teeth side face 262 at a second deepest part 30b.SELECTED DRAWING: Figure 10

Description

[Technical field]

[0001] The present invention relates to a stator and an insulator for a rotating electrical machine. [Background technology]

[0002] For example, as in Patent Document 1, a stator of a rotating electric machine includes a stator core, a coil, and an insulator. The stator core has a cylindrical yoke and a plurality of teeth. The plurality of teeth extend from the inner peripheral surface of the yoke toward the inside in the radial direction of the yoke. The stator core has slots between adjacent teeth in the circumferential direction of the yoke. The coil is formed by winding a winding that passes through the slot and is wound around the stator core. The insulator is disposed opposite a core end face, which is an end face of the stator core in the axial direction of the yoke. The insulator provides insulation between the coil and each core end face.

[0003] The teeth have a first teeth side surface located on one circumferential side of the yoke and a second teeth side surface located on the other circumferential side of the yoke. The insulator has a cylindrical insulator base and multiple insulator extensions. The insulator base faces the yoke in the axial direction of the yoke. The multiple insulator extensions extend from the inner peripheral surface of the insulator base toward the inside in the radial direction of the yoke and face each of the teeth in the axial direction of the yoke. The coil is formed by winding multiple layers in a concentrated manner around the teeth and insulator extensions, with the winding spiraling back and forth in the radial direction of the yoke. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2006-115565 A Summary of the Invention [Problem to be solved by the invention]

[0005] Incidentally, the first layer of the winding that forms the coil may be formed by winding from the outside to the inside in the radial direction of the yoke. In this case, the winding start portion of the winding that forms the first layer extends along the side surface of the first teeth at the first innermost portion that is, for example, on the side surface of the first teeth in the slot and on the inner peripheral surface of the yoke. In the first turn of the winding including the winding start portion, the portion that extends along the side surface of the second teeth is preferably located at the second innermost portion that is, for example, on the side surface of the second teeth in the slot and on the inner peripheral surface of the yoke.

[0006] The coil is formed by, for example, using a winding nozzle to wind the wire in a concentrated manner around the teeth and the insulator extension in a spiral manner in the radial direction of the yoke. Here, the winding operation using the winding nozzle is performed while fixing the wire so that the start of the winding forming the first layer does not loosen at the first innermost portion. Therefore, the start of the winding extends along the side surface of the first teeth at the first innermost portion.

[0007] On the other hand, in the first turn of the winding including the winding start portion, when the portion extending along the side surface of the second teeth is wound around the side surface of the second teeth, the winding nozzle may not reach the second innermost part due to the trajectory of the winding nozzle. In such a case, in the first turn of the winding including the winding start portion, the portion extending along the side surface of the second teeth is positioned farther away from the inner circumferential surface of the yoke than the second innermost part.

[0008] Therefore, a dead space is generated in the second innermost part of the slot, and the space factor of the winding in the slot is reduced. In order to make the winding extend along the side surface of the second tooth at the second innermost part, for example, in the first turn including the winding start part, the part extending along the side surface of the second tooth is forcibly pushed up to the second innermost part, but this makes the winding winding work complicated. Furthermore, if the winding is forcibly pushed up to the second innermost part, the alignment of the winding may be disturbed. The reduction in the space factor of the winding and the reduction in the alignment of the winding are factors that lead to a reduction in the quality of the rotating electric machine. Therefore, it is desired to provide a rotating electric machine in which the winding can be easily wound and which is of high quality. [Means for solving the problem]

[0009] The stator of a rotating electric machine that solves the above-mentioned problems includes a stator core having a cylindrical yoke and a plurality of teeth extending radially inward from an inner peripheral surface of the yoke, with slots formed between adjacent teeth in the circumferential direction of the yoke, a coil formed by winding a winding passing through the slots around the stator core, and an insulator that is disposed opposite a core end face that is an end face of the yoke in the axial direction of the yoke in the stator core and provides insulation between the coil and the core end face, and the teeth are disposed on one side of the circumferential direction of the yoke. and a second teeth side face located on the other circumferential side of the yoke, the insulator having a cylindrical insulator base portion facing the yoke in the axial direction, and a plurality of insulator extension portions extending radially inward from an inner circumferential surface of the insulator base portion and facing each of the teeth in the axial direction, the coil being formed by winding the winding in a plurality of layers in a concentrated winding manner around the teeth and the insulator extension portions while spirally moving back and forth in the radial direction, a first layer of a winding forming the coil is formed by winding from the outside to the inside in the radial direction, and the coil has an outer circumferential layer which is a second or subsequent layer of the winding forming the coil and is formed by winding from the inside to the outside in the radial direction, and a winding start portion of the winding forming the first layer is on the first teeth side surface side in the slot and extends along the first teeth side surface at a first innermost portion which is a portion on the inner circumferential surface side of the yoke, and in the first turn of the winding including the winding start portion, extends along the second teeth side surface a stator for a rotating electric machine, wherein the insulator extending portion is disposed within the slot on the second tooth side surface side and at a position farther from the inner circumferential surface of the yoke than a second innermost portion which is a portion on the inner circumferential surface side of the yoke, the insulator extending portion has an outer end face positioned opposite the stator core, the first turn of winding is wound around the outer end face, and a protrusion is provided on the outer end face, the protrusion protruding from a portion of the outer end face closer to the base of the insulator than the first turn of winding and closer to the winding start portion,The winding forming the outer peripheral layer extends along the side surface of the second tooth at the second innermost portion, and is then disposed on the protrusion.

[0010] According to this, the winding forming the outer peripheral layer is wound from the inside to the outside in the radial direction of the yoke. When the winding of the outer peripheral layer is wound around the side surface of the second teeth, the winding already wound around the side surface of the second teeth guides a part of the winding of the outer peripheral layer to the second innermost part. As a result, the winding forming the outer peripheral layer is disposed in the second innermost part. Therefore, since the winding extends along the side surface of the second teeth in the second innermost part, no dead space is generated in the second innermost part in the slot. Therefore, the space factor of the winding in the slot can be improved. Furthermore, for example, in the first turn including the winding start part, there is no need to forcibly push up the part extending along the side surface of the second teeth to the second innermost part so that the winding extends along the side surface of the second teeth in the second innermost part. Therefore, the winding can be wound while maintaining the alignment of the winding, and the quality of the winding can be improved. In addition, the first winding, including the winding start portion wound around the outer end surface, comes into contact with the protrusion, which prevents the first layer of winding from shifting radially outward of the yoke. Therefore, the first layer of winding is stable, and the winding can be wound while maintaining the alignment of the winding, resulting in good winding quality. The winding forming the outer peripheral layer extends along the side surface of the second teeth at the second innermost portion, and is then placed on the protrusion, and is guided by the protrusion to the outer side of the yoke in the circumferential direction of the yoke more than the winding forming the first layer. With this, even if the winding forming the outer peripheral layer extends along the side surface of the second teeth at the second innermost portion, the winding work thereafter can be smoothly performed. As a result, it is possible to provide a rotating electric machine that is easy to wind the winding and has high quality. In addition, by improving the space factor, it is possible to reduce the size of the rotating electric machine and improve the output of the rotating electric machine.

[0011] In the stator of the above-mentioned rotating electric machine, the protruding height of the top of the protrusion relative to the outer end face is the same as the outer diameter of the winding, and the protrusion guides the winding after it has extended along the side surface of the second teeth at the second innermost portion so that the winding is wound around the winding forming the first layer after it has extended along the side surface of the second teeth at the second innermost portion.

[0012] According to this, the protruding height of the apex of the protrusion relative to the outer end surface is the same as the outer diameter of the winding. Therefore, the winding after extending along the side surface of the second tooth at the second innermost portion can be easily aligned with the position of the winding forming the second layer. Therefore, the protrusion can easily guide the winding so that the winding is wound around the winding forming the first layer after extending along the side surface of the second tooth at the second innermost portion. As a result, the winding work can be made even easier.

[0013] In the stator of the above rotating electric machine, the winding that forms the outer peripheral layer and extends along the side surface of the second tooth at the second innermost portion may be a winding that forms the second layer.

[0014] This allows for better alignment of the windings compared to when the winding extending along the side surface of the second teeth at the second innermost portion forms a fourth layer, and therefore allows for a rotating electric machine of even higher quality to be provided.

[0015] In the stator of the above-mentioned rotating electric machine, the protrusion may have an inclined surface that is continuous with the top of the protrusion and whose protruding height relative to the outer end surface gradually increases from the portion of the outer end surface opposite the winding start portion toward the top of the protrusion.

[0016] According to this, the windings arranged on the protrusions can be extended along the inclined surface, which can prevent the windings from being locally bent and thus prevent a loss in durability of the windings, thereby providing a rotating electric machine of even higher quality.

[0017] In the stator of the above-mentioned rotating electric machine, the protrusion has a protruding end face located at the tip of the protrusion in the direction protruding from the outer end face, and the edge portion of the protruding end face located on the opposite side to the insulator base is chamfered in an arc shape.

[0018] With this, even if the windings arranged on the projections are pressed against the edge of the protruding end face located on the opposite side to the insulator base, the load applied to the windings can be reduced, and therefore the durability of the windings can be prevented from being impaired, thereby providing a rotating electric machine of even higher quality.

[0019] An insulator that solves the above problem forms part of a stator of a rotating electric machine having a stator core having a cylindrical yoke and a plurality of teeth extending radially inward from the inner surface of the yoke, with slots formed between adjacent teeth in the circumferential direction of the yoke, and is arranged opposite a core end face, which is an end face of the stator core located in the axial direction of the yoke, and has a cylindrical insulator base that faces the yoke in the axial direction, and a plurality of insulator extension portions that extend radially inward from the inner surface of the insulator base and face each of the teeth in the axial direction, and provides insulation between a coil formed by winding a winding passing through the slots around the stator core and the core end face, and the insulator extension portion has an outer end face located opposite the stator core, and a protrusion is provided on the outer end face that is the radially outer end of the outer end face and is located on one side in the circumferential direction.

[0020] This makes it possible to easily wind the windings and provide a high-quality rotating electric machine. In the above insulator, the protrusion may have an inclined surface that is continuous with the top of the protrusion and whose protruding height relative to the outer end surface gradually increases from the other circumferential side of the outer end surface toward the top of the protrusion.

[0021] In the above insulator, the protrusion may have a protruding end face located at the tip of the protrusion in the direction protruding from the outer end face, and the edge of the protruding end face located on the opposite side to the insulator base may be chamfered in an arc shape. Effect of the Invention

[0022] According to the present invention, the winding can be easily wound, and a high-quality rotating electric machine can be provided. [Brief description of the drawings]

[0023] [Figure 1] FIG. 1 is a cross-sectional view for explaining a rotating electric machine according to an embodiment. [Diagram 2] FIG. 2 is an exploded perspective view showing the stator core and a pair of insulators. [Diagram 3] FIG. 3 is a perspective view for explaining the protrusion. [Figure 4] FIG. 4 is a cross-sectional view for explaining the protrusion. [Diagram 5] FIG. 5 is a diagram for explaining the winding work of the winding wire. [Figure 6] FIG. 6 is a diagram for explaining the winding work of the winding. [Figure 7] FIG. 7 is a diagram for explaining the winding work. [Figure 8] FIG. 8 is a diagram for explaining the winding work. [Figure 9] FIG. 9 is a diagram for explaining the winding work. [Figure 10] FIG. 10 is a diagram for explaining the winding work. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0024] Hereinafter, a specific embodiment of a stator and an insulator for a rotating electrical machine will be described with reference to Figs. <Outline of rotating electric machine configuration> As shown in Fig. 1, the rotating electric machine 10 includes a rotor 21 and a stator 22. The stator 22 is cylindrical. The rotor 21 is disposed inside the stator 22. The rotor 21 includes a cylindrical rotor core 21a and a plurality of permanent magnets (not shown) embedded in the rotor core 21a. The rotor core 21a is fixed to the rotating shaft 15. The rotor core 21a is configured to be rotatable integrally with the rotating shaft 15.

[0025] <Stator core> The stator 22 includes a stator core 23. The stator core 23 includes a yoke 24 and a plurality of teeth 25. The yoke 24 is cylindrical. The axial direction of the yoke 24 is also the axial direction of the stator core 23.

[0026] The teeth 25 extend from the inner peripheral surface 24a of the yoke 24 toward the inside in the radial direction of the yoke 24. The teeth 25 are arranged at intervals in the circumferential direction of the yoke 24. The teeth 25 are arranged at equal intervals in the circumferential direction of the yoke 24. The circumferential direction of the yoke 24 is also the circumferential direction of the stator core 23. Each tooth 25 extends from the inner peripheral surface 24a of the yoke 24 toward the axis of the stator core 23. In this embodiment, the stator core 23 has 15 teeth 25. The number of teeth 25 is not particularly limited, but the number of teeth 25 is a multiple of three.

[0027] As shown in Fig. 2, both end faces of the yoke 24 located in the axial direction are flat. Both end faces of the yoke 24 located in the axial direction of each tooth 25 are flat. The axial length of the yoke 24 is the same as the axial length of the yoke 24 of each tooth 25. The end face located on one side of the axial direction of the yoke 24 is located on the same plane as the end face located on one side of the axial direction of the yoke 24 of each tooth 25. The end face located on the other side of the axial direction of the yoke 24 is located on the same plane as the end face located on the other side of the axial direction of the yoke 24 of each tooth 25.

[0028] The end face located on one side of the axial direction of the yoke 24 and the end face located on one side of the axial direction of the yoke 24 of each tooth 25 form a first core end face 23a which is an end face located on one side of the axial direction of the yoke 24 of the stator core 23. The end face located on the other side of the axial direction of the yoke 24 and the end face located on the other side of the axial direction of the yoke 24 of each tooth 25 form a second core end face 23b which is an end face located on the other side of the axial direction of the yoke 24 of the stator core 23. Therefore, the stator core 23 has a first core end face 23a and a second core end face 23b. The first core end face 23a is a core end face which is an end face located on one side of the axial direction of the yoke 24 of the stator core 23. The second core end face 23b is a core end face which is an end face located on the other side of the axial direction of the yoke 24 of the stator core 23.

[0029] As shown in FIG. 1 and FIG. 2, each tooth 25 has a tooth extension portion 26 and a tooth flange portion 27. The tooth extension portion 26 is a thin plate extending from the inner peripheral surface 24a of the yoke 24. The tooth extension portion 26 extends from the first core end surface 23a to the second core end surface 23b of the stator core 23. Each tooth extension portion 26 has a first tooth side surface 261 and a second tooth side surface 262. The first tooth side surface 261 is a side surface located on one side of the tooth extension portion 26 in the circumferential direction of the yoke 24. The second tooth side surface 262 is a side surface located on the other side of the tooth extension portion 26 in the circumferential direction of the yoke 24. Therefore, the teeth 25 have the first tooth side surface 261 located on one side of the yoke 24 in the circumferential direction and the second tooth side surface 262 located on the other side of the yoke 24 in the circumferential direction. The first teeth side surface 261 and the second teeth side surface 262 are continuous with the inner circumferential surface 24a of the yoke 24. The teeth flange portions 27 protrude in the circumferential direction of the yoke 24 from the ends of the first teeth side surface 261 and the second teeth side surface 262 opposite the yoke 24. Thus, the teeth flange portions 27 protrude on both sides in the circumferential direction of the yoke 24 from the ends of the tooth extension portions 26 opposite the yoke 24.

[0030] Slots 30 are formed in the stator core 23. The slots 30 are formed between adjacent teeth 25 in the circumferential direction of the yoke 24. The slots 30 are spaces defined by an inner peripheral surface 24a of the yoke 24, a first teeth side surface 261 and a second teeth side surface 262 adjacent in the circumferential direction of the yoke 24, and a surface of the tooth flange portion 27 located on the yoke 24 side. The stator core 23 also has slot openings 31. The slot openings 31 are gaps between adjacent tooth flange portions 27 in the circumferential direction of the yoke 24. The slot openings 31 communicate with the slots 30.

[0031] <Insulator> 2, the stator 22 includes a pair of insulators 50. Thus, the insulators 50 form a part of the stator 22. Each insulator 50 is cylindrical. Each insulator 50 is made of, for example, a resin material.

[0032] Each insulator 50 has an insulator base 51 and a plurality of insulator teeth 52. The insulator base 51 is cylindrical. Each insulator 50 is disposed relative to the stator core 23 with the axis of each insulator base 51 coinciding with the axis of the yoke 24. Each insulator base 51 faces the yoke 24 in the axial direction of the yoke 24. The axial direction of each insulator base 51 is also the axial direction of the yoke 24. In addition, the circumferential direction of each insulator base 51 is also the circumferential direction of the yoke 24. Furthermore, the radial direction of each insulator base 51 is also the radial direction of the yoke 24.

[0033] One of the pair of insulators 50 is disposed opposite the first core end face 23a of the stator core 23 while in contact with the first core end face 23a. The other of the pair of insulators 50 is disposed opposite the second core end face 23b of the stator core 23 while in contact with the second core end face 23b. Thus, the insulator 50 is disposed opposite the core end face, which is the axial end face of the yoke 24 of the stator core 23. The outer diameter of the insulator base 51 is smaller than the outer diameter of the yoke 24. The inner diameter of the insulator base 51 is the same as the inner diameter of the yoke 24.

[0034] Each insulator tooth portion 52 extends from an inner peripheral surface 51a of each insulator base 51 toward the inside in the radial direction of the insulator base 51. The multiple insulator teeth portions 52 are arranged at intervals in the circumferential direction of the insulator base 51. The multiple insulator teeth portions 52 are arranged at equal intervals in the circumferential direction of the insulator base 51. Each insulator tooth portion 52 extends from the inner peripheral surface 51a of the insulator base 51 toward the axis of the insulator base 51. In this embodiment, each insulator 50 has 15 insulator teeth portions 52. The number of insulator teeth portions 52 is the same as the number of teeth 25 of the stator core 23.

[0035] Each insulator tooth portion 52 has an insulator extension portion 53. Therefore, each insulator 50 has a plurality of insulator extension portions 53. Each insulator extension portion 53 is columnar and extends from an inner peripheral surface 51a of the insulator base portion 51 toward the inside in the radial direction of the insulator base portion 51. The circumferential width of the insulator base portion 51 at each insulator extension portion 53 is the same as the circumferential width of the yoke 24 at each tooth extension portion 26. Each insulator extension portion 53 contacts each tooth 25. Each insulator extension portion 53 is disposed at a position overlapping with each tooth extension portion 26 in the axial direction of the yoke 24. Therefore, each insulator extension portion 53 faces each tooth 25 in the axial direction of the yoke 24.

[0036] The insulator extension portion 53 has a first insulator side surface 531 and a second insulator side surface 532. The first insulator side surface 531 is a side surface located on one circumferential side of the insulator base portion 51 in the insulator extension portion 53. The first insulator side surface 531 is continuous with the first teeth side surface 261. The second insulator side surface 532 is a side surface located on the other circumferential side of the insulator base portion 51 in the insulator extension portion 53. The second insulator side surface 532 is continuous with the second teeth side surface 262.

[0037] Each insulator tooth portion 52 has an insulator inner wall 54. Therefore, each insulator 50 has an insulator inner wall 54. Each insulator inner wall 54 protrudes along the insulator base 51 from an end of each insulator extension portion 53 opposite to the insulator base 51. Each insulator inner wall 54 protrudes from each insulator extension portion 53 to both circumferential sides of the insulator base 51 and to the opposite side of the stator core 23 in the axial direction of the insulator base 51. In this manner, each insulator inner wall 54 protrudes from each insulator extension portion 53. Each insulator inner wall 54 is disposed at a position overlapping with the tooth flange portion 27 in the axial direction of the yoke 24. Therefore, each insulator inner wall 54 faces each tooth flange portion 27 in the axial direction of the yoke 24.

[0038] A surface 52a of each insulator tooth portion 52 located opposite the insulator base portion 51 is located on the same plane as a surface 25a of each tooth 25 located opposite the yoke 24. A surface of each insulator inner wall 54 located opposite the insulator base 51 forms a surface 52a of each insulator tooth portion 52 located opposite the insulator base 51. A surface of each tooth flange portion 27 located opposite the yoke 24 forms a surface 25a of each tooth 25 located opposite the yoke 24. The thickness of each insulator inner wall 54 is thicker than the thickness of each tooth flange portion 27.

[0039] The insulator extension portion 53 has an outer end surface 55 located on the opposite side to the stator core 23. The outer end surface 55 is flat. The outer end surface 55 is continuous with an inner circumferential surface 51a of the insulator base 51. The outer end surface 55 is continuous with a surface of the insulator inner wall 54 located on the insulator base 51 side. The outer end surface 55 connects the inner circumferential surface 51a of the insulator base 51 and the surface of the insulator inner wall 54 located on the insulator base 51 side.

[0040] <Coil> As shown in FIG. 1, the stator 22 includes coils 28. The stator 22 includes coils 28 corresponding to the U-phase, V-phase, and W-phase. Thus, the stator 22 includes coils 28 of multiple phases. A portion of each of the coils 28 of each phase passes through each of the slots 30. A portion of each of the coils 28 of each phase protrudes from each of the first core end faces 23a and the second core end faces 23b. One of the pair of insulators 50 insulates between the coils 28 of each phase and the first core end face 23a. The other of the pair of insulators 50 insulates between the coils 28 of each phase and the second core end face 23b. The portions of the coils 28 passing through each of the slots 30 are insulated from the stator core 23 by the slot insulating paper 36.

[0041] <Protrusion> 3 and 4, a protrusion 56 is provided on an outer end surface 55 of each insulator extension portion 53 of one of the pair of insulators 50. The protrusion 56 is provided on an end portion of the outer end surface 55 that is located radially outward of the yoke 24. The protrusion 56 has an apex 57, an inclined surface 58, and a protrusion side surface 59. The apex 57 is a flat surface. The apex 57 extends parallel to the outer end surface 55.

[0042] As shown in Fig. 4, a protruding height H1 of a top 57 of the projection 56 on the outer end surface 55 is the same as the dimension of an outer diameter D1 of the winding 29 forming the coil 28. As shown in Figs. 3 and 4, the top 57 of the projection 56 is located at an end portion located on the radial outer side of the yoke 24 on the outer end surface 55, and is located in a portion close to the first insulator side surface 531. Therefore, the outer end surface 55 is provided with a projection 56 that is located at an end portion on the radial outer side of the yoke 24 on the outer end surface 55, and is located on one side in the circumferential direction of the yoke 24.

[0043] The inclined surface 58 is flat. The inclined surface 58 extends obliquely relative to the outer end surface 55. The inclined surface 58 is continuous with the apex 57 of the protrusion 56. An end of the inclined surface 58 located opposite the apex 57 is continuous with the outer end surface 55. The protruding height of the inclined surface 58 relative to the outer end surface 55 gradually increases from a portion of the outer end surface 55 closer to the second insulator side surface 532 toward the apex 57. Therefore, the inclined surface 58 is continuous with the apex 57 of the protrusion 56, and the protruding height relative to the outer end surface 55 gradually increases from the other side of the outer end surface 55 in the circumferential direction of the yoke 24 toward the apex 57.

[0044] The protrusion side surface 59 is a side surface of the protrusion 56 located on the opposite side to the insulator base 51. The protrusion side surface 59 is flat. The protrusion side surface 59 stands up from the outer end surface 55. The protrusion side surface 59 extends in a direction perpendicular to the outer end surface 55. The protrusion side surface 59 extends in a direction perpendicular to the radial direction of the insulator base 51.

[0045] The projection 56 has a protruding end surface 60 located at the tip in the protruding direction from the outer end surface 55. The protruding end surface 60 is composed of a top 57 and an inclined surface 58. An edge portion located on the opposite side of the top 57 from the insulator base 51 is continuous with an edge portion located on the opposite side of the insulator base 51 from the insulator base 51 from the insulator base 58. The edge portion located on the opposite side of the top 57 from the insulator base 51 and the edge portion located on the opposite side of the insulator base 51 from the insulator base 58 from the insulator base 51 are an edge portion 61 located on the opposite side of the protruding end surface 60 from the insulator base 51. The edge portion located on the opposite side of the top 57 from the insulator base 51 is chamfered in an arc shape. The edge portion located on the opposite side of the insulator base 51 from the insulator base 51 from the insulator base 58 is chamfered in an arc shape. Therefore, the edge portion 61 located on the opposite side of the protruding end surface 60 from the insulator base 51 is chamfered in an arc shape.

[0046] <Winding> Next, the configuration of the coil 28 will be described together with an explanation of the winding operation of the winding 29. 5, the coil 28 is formed by winding the winding 29, which passes through the slots 30, around the stator core 23. The coil 28 is formed by winding the winding 29 in a concentrated manner in multiple layers around the teeth 25 and the insulator extending portion 53 while spirally moving back and forth in the radial direction of the yoke 24. The winding operation of the winding 29 is performed, for example, by using a winding nozzle (not shown).

[0047] As shown in FIGS. 5, 6, 7, 8, 9, and 10, the first layer of the winding 29 forming the coil 28 is formed by winding from the outside to the inside in the radial direction of the yoke 24. The second layer of the winding 29 forming the coil 28 is formed by winding from the inside to the outside in the radial direction of the yoke 24. The third layer of the winding 29 forming the coil 28 is formed by winding from the outside to the inside in the radial direction of the yoke 24. The fourth layer of the winding 29 forming the coil 28 is formed by winding from the inside to the outside in the radial direction of the yoke 24. In this way, the second and fourth layers of the winding 29 forming the coil 28 are layers subsequent to the second layer of the winding 29 forming the coil 28, and are outer peripheral layers 62 formed by winding from the inside to the outside in the radial direction of the yoke 24. Therefore, coil 28 has an outer peripheral layer 62 which is the second or subsequent layer of winding 29 forming coil 28 and which is formed by winding from the inside to the outside in the radial direction of yoke 24. Note that the third and fourth layers which form coil 28 are not shown in Figures 5, 6, 7, 8, 9, and 10.

[0048] As shown in FIG. 5, the winding 29 has a lead portion 63. The lead portion 63 passes over an end face of one of the insulator base portions 51 of the pair of insulators 50 and is drawn outward in the radial direction of the yoke 24. A winding start portion 29s of the winding 29 forming the first layer of the coil 28 is continuous with the lead portion 63. The winding start portion 29s is inserted into the slot 30 from one side of the pair of insulators 50. The winding start portion 29s of the winding 29 forming the first layer of the coil 28 is on the first teeth side surface 261 side in the slot 30 and extends along the first teeth side surface 261 at the first innermost portion 30a, which is the portion on the inner circumferential surface 24a side of the yoke 24. The winding operation of the winding 29 using the winding nozzle is performed while fixing the winding 29 so that the winding start portion 29s of the winding 29 forming the first layer does not loosen at the first innermost portion 30a.

[0049] 6, the portion of the first turn of the winding 29 including the winding start portion 29s that is wound around the outer end surface 55 of the other insulator extension portion 53 of the pair of insulators 50 is indicated by a dashed line. As shown in FIG. 6, the portion that is wound around the outer end surface 55 of the other insulator extension portion 53 of the pair of insulators 50 extends so as to approach the radial inside of the yoke 24 as it moves from the first insulator side surface 531 toward the second insulator side surface 532. In the first turn of the winding 29 including the winding start portion 29s, the portion that extends along the second teeth side surface 262 is located on the second teeth side surface 262 side in the slot 30 and is located farther away from the inner circumferential surface 24a of the yoke 24 than the second innermost portion 30b, which is the portion on the inner circumferential surface 24a side of the yoke 24.

[0050] In the first turn of winding 29 including winding start portion 29s, when the portion extending along second teeth side surface 262 is wound around second teeth side surface 262, the winding nozzle does not reach second innermost portion 30b along its trajectory. Therefore, in the first turn of winding 29 including winding start portion 29s, the portion extending along second teeth side surface 262 is positioned farther away from inner circumferential surface 24a of yoke 24 than second innermost portion 30b.

[0051] 7, a portion of the winding 29 forming the first layer immediately before the second turn is wound around an outer end surface 55 of one of the insulator extending portions 53 of the pair of insulators 50. At this time, the portion of the winding 29 wound around the outer end surface 55 of one of the insulator extending portions 53 of the pair of insulators 50 extends in a direction perpendicular to the radial direction of the yoke 24. The portion of the winding 29 wound around the outer end surface 55 of one of the insulator extending portions 53 of the pair of insulators 50 extends along the protrusion side surface 59 of the protrusion 56 at a position overlapping with the protrusion 56 on the radial inner side of the yoke 24. Then, the second turn of the winding 29 forming the first layer extends along the first teeth side surface 261 in a state where it is aligned with the winding start portion 29s on the radial inner side of the yoke 24.

[0052] 8, the second and subsequent turns of the winding 29 are wound spirally from the outside to the inside in the radial direction of the yoke 24, similar to the first turn, thus forming the first layer of the winding 29 that forms the coil 28.

[0053] 9, the winding 29 forming the second layer is wound around the winding 29 forming the first layer. The second layer of the winding 29 forming the coil 28 is formed by winding the winding 29 spirally from the inside to the outside in the radial direction of the yoke 24 around the winding 29 forming the first layer.

[0054] As shown in FIG. 10, the winding 29 forming the second layer is wound from the inside to the outside in the radial direction of the yoke 24. When the second layer winding 29 is wound around the second tooth side surface 262, the first layer winding 29 already wound around the second tooth side surface 262 guides a part of the second layer winding 29 shown by the two-dot chain line in FIG. 10 to the second innermost portion 30b as shown by the arrow A1. As a result, the winding 29 forming the second layer is disposed in the second innermost portion 30b. The winding 29 forming the second layer extends along the second tooth side surface 262 at the second innermost portion 30b, and is then disposed on the protrusion 56 and is guided by the protrusion 56 to the outside in the circumferential direction of the yoke 24 more than the winding 29 forming the first layer. The winding 29 disposed on the protrusion 56 extends along the inclined surface 58. Therefore, the inclined surface 58 of the protrusion 56 is continuous with the top 57 of the protrusion 56, and the protruding height from the outer end surface 55 gradually increases from the portion of the outer end surface 55 opposite the start portion 29s of the winding toward the top 57.

[0055] In this manner, the first winding 29 is wound around the outer end surface 55 of one of the insulator extension parts 53 of the pair of insulators 50. The outer end surface 55 of one of the insulator extension parts 53 of the pair of insulators 50 is provided with a protrusion 56 that protrudes from a portion of the outer end surface 55 closer to the insulator base 51 than the first winding 29 and closer to the winding start portion 29s. The winding 29 forming the second layer extends along the second teeth side surface 262 at the second innermost portion 30b and is then disposed on the protrusion 56. Therefore, the winding 29 forming the outer peripheral layer 62 extends along the second teeth side surface 262 at the second innermost portion 30b and is then disposed on the protrusion 56. In this embodiment, the winding 29 forming the outer peripheral layer 62, and the winding 29 extending along the second teeth side surface 262 at the second innermost portion 30b, is the winding 29 forming the second layer.

[0056] The protrusion 56 guides the winding 29 after it extends along the second teeth side surface 262 at the second innermost portion 30b so that the protrusion 56 is wound around the winding 29 forming the first layer after it extends along the second teeth side surface 262 at the second innermost portion 30b. Thereafter, the third and fourth layers are also formed by winding the winding 29 around the teeth 25 and the insulator extending portion 53 in a concentrated winding manner while spirally moving back and forth in the radial direction of the yoke 24, as in the first and second layers. In this manner, the winding 29 is wound around the teeth 25 and the insulator extending portion 53 in a concentrated winding manner in multiple layers while spirally moving back and forth in the radial direction of the yoke 24, thereby forming the coil 28. The winding operation of the winding 29 is performed as described above to form the coil 28.

[0057] [Operation of the embodiment] Next, the operation of this embodiment will be described. The first winding 29, including the winding start portion 29s of the winding 29 wound around the outer end surface 55, comes into contact with the protrusion 56, thereby preventing the first layer of the winding 29 from shifting radially outward of the yoke 24. Therefore, the first layer of the winding 29 is stabilized, and the winding 29 is well aligned. The second layer of the winding 29 extends along the second teeth side surface 262 at the second innermost portion 30b, and is then placed on the protrusion 56, and is guided by the protrusion 56 to the outer side in the circumferential direction of the yoke 24 more than the first layer of the winding 29. Therefore, even if the second layer of the winding 29 extends along the second teeth side surface 262 at the second innermost portion 30b, the subsequent winding of the winding 29 can be smoothly performed.

[0058] [Effects of the embodiment] The above embodiment can provide the following effects. (1) The winding 29 forming the second layer is wound from the inside to the outside in the radial direction of the yoke 24. When the second layer of winding 29 is wound around the second tooth side surface 262, the winding 29 already wound around the second tooth side surface 262 guides a part of the second layer of winding 29 to the second innermost portion 30b. As a result, the winding 29 forming the second layer is disposed in the second innermost portion 30b. Therefore, since the winding 29 extends along the second tooth side surface 262 in the second innermost portion 30b, no dead space is generated in the second innermost portion 30b in the slot 30. This improves the space factor of the winding 29 in the slot 30. Furthermore, in order for the winding 29 to extend along the second tooth side surface 262 at the second innermost portion 30b, for example, in the first turn including the winding start portion 29s of the winding 29, it is not necessary to forcibly push up the portion extending along the second tooth side surface 262 to the second innermost portion 30b. Therefore, the winding 29 can be wound while maintaining the alignment, and the quality of the winding 29 can be improved. In addition, the first turn of the winding 29 including the winding start portion 29s of the winding 29 wound around the outer end surface 55 comes into contact with the protrusion 56, which prevents the first layer of the winding 29 from shifting radially outward of the yoke 24. Therefore, the first layer of the winding 29 is stable, and the winding 29 can be wound while maintaining the alignment, and the quality of the winding 29 can be improved. The second layer of winding 29 extends along the second tooth side surface 262 at the second innermost portion 30b, and is then placed on the protrusion 56, and is guided by the protrusion 56 to the outside in the circumferential direction of the yoke 24 more than the first layer of winding 29. This allows the winding 29 to be wound smoothly even if the second layer of winding 29 extends along the second tooth side surface 262 at the second innermost portion 30b. As a result, the winding 29 can be wound easily, and a high-quality rotating electric machine 10 can be provided. Furthermore, by improving the space factor, the rotating electric machine 10 can be made smaller and its output can be improved.

[0059] (2) The protruding height H1 of the apex 57 of the protrusion 56 relative to the outer end surface 55 is the same as the outer diameter D1 of the winding 29. This makes it easier to align the winding 29 after it extends along the second teeth side surface 262 at the second innermost portion 30b with the position of the winding 29 forming the second layer. This makes it easier to guide the winding 29 by the protrusion 56 so that the winding 29 is wound around the winding 29 forming the first layer after it extends along the second teeth side surface 262 at the second innermost portion 30b. As a result, the winding operation of the winding 29 can be made even easier.

[0060] (3) The windings 29 that form the outer peripheral layer 62 and extend along the second teeth side surface 262 at the second innermost portion 30b are the windings 29 that form the second layer. This allows for better alignment of the windings 29 compared to the case where the windings 29 that extend along the second teeth side surface 262 at the second innermost portion 30b are the windings 29 that form the fourth layer. Therefore, it is possible to provide a rotating electric machine 10 of even higher quality.

[0061] (4) The projection 56 has an inclined surface 58 that is continuous with the apex 57 of the projection 56 and that gradually increases in height from the portion of the outer end surface 55 opposite the winding start portion 29s toward the apex 57. This allows the winding 29 arranged on the projection 56 to extend along the inclined surface 58. This prevents the winding 29 from bending locally, thereby preventing the durability of the winding 29 from being impaired. This makes it possible to provide a rotating electric machine 10 of even higher quality.

[0062] (5) The edge 61 of the protruding end surface 60 located on the opposite side to the insulator base 51 is chamfered in an arc shape. With this, even if the winding 29 arranged on the projection 56 is pressed against the edge 61 of the protruding end surface 60 located on the opposite side to the insulator base 51, the load applied to the winding 29 can be reduced, and therefore the durability of the winding 29 can be prevented from being impaired. Therefore, a rotating electric machine 10 of even higher quality can be provided.

[0063] (6) Protrusion 56 is provided on outer end surface 55 at an end portion on the outer side in the radial direction of yoke 24 and on one side in the circumferential direction of yoke 24. This facilitates the winding of winding 29 and provides a high-quality rotating electric machine 10.

[0064] [Example of change] The above embodiment can be modified as follows: The above embodiment and the following modifications can be combined with each other to the extent that no technical contradiction occurs.

[0065] In the above embodiment, the protruding height H1 of the top 57 of the projection 56 relative to the outer end surface 55 may be greater than the outer diameter D1 of the winding 29. In the above embodiment, the protruding height H1 of the top 57 of the projection 56 relative to the outer end surface 55 may be smaller than the outer diameter D1 of the winding 29.

[0066] In the embodiment, the winding 29 extending along the second tooth side surface 262 at the second innermost portion 30b may be, for example, the winding 29 forming the fourth layer. In short, it is only necessary that the winding 29 extending along the second tooth side surface 262 at the second innermost portion 30b is the winding 29 forming the outer peripheral layer 62.

[0067] In the embodiment, the winding 29 extending along the second tooth side surface 262 at the second innermost portion 30b may be, for example, the winding 29 forming a fourth layer. Then, the winding 29 may be guided by the protrusion 56 so that after the winding 29 extends along the second tooth side surface 262 at the second innermost portion 30b, it is wound around the winding 29 forming, for example, a third layer. In such a case, the protruding height H1 of the top portion 57 of the protrusion 56 relative to the outer end surface 55 may be three times the outer diameter D1 of the winding 29.

[0068] In the embodiment, the protrusion 56 does not have to have the inclined surface 58. It is sufficient that the protrusion 56 is provided so as to protrude from a portion of the outer end surface 55 that is closer to the insulator base 51 than the first turn of the first layer winding 29 and closer to the winding start portion 29s. It is sufficient that the protrusion 56 is provided at an end portion of the outer end surface 55 that is located radially outward from the yoke 24 and is located circumferentially outward from the yoke 24.

[0069] In the above embodiment, the edge 61 of the protrusion 56 on the protruding end surface 60 opposite the insulator base portion 51 may not be chamfered into an arc shape. In the above embodiment, the number of layers of the winding 29 forming the coil 28 is not particularly limited.

[0070] [Note] The technical ideas that can be understood from the above-described embodiment and modified examples will be described below. <Appendix 1> a stator core having a cylindrical yoke and a plurality of teeth extending radially inward from an inner peripheral surface of the yoke, with slots formed between adjacent teeth in a circumferential direction of the yoke; a coil formed by winding a winding passing through the slots around the stator core; an insulator disposed opposite a core end face, which is an axial end face of the yoke of the stator core, and providing insulation between the coil and the core end face, the teeth have a first teeth side surface located on one circumferential side of the yoke and a second teeth side surface located on the other circumferential side of the yoke, The insulator comprises: a cylindrical insulator base portion facing the yoke in the axial direction; a plurality of insulator extension portions extending radially inward from an inner circumferential surface of the insulator base and facing each of the teeth in the axial direction, the coil is formed by winding the winding in a plurality of layers in a concentrated winding manner around the teeth and the insulator extension while spirally moving back and forth in the radial direction, A first layer of a winding that forms the coil is formed by winding from the outside to the inside in the radial direction, The coil has an outer circumferential layer which is a second or subsequent layer of a winding that forms the coil and is formed by winding from the inside to the outside in the radial direction, a stator for a rotating electric machine, wherein a winding start portion of a winding forming the first layer extends along the first teeth side surface at a first innermost portion which is a portion on the first teeth side surface side and on the inner circumferential surface side of the yoke within the slot, and a portion of the first turn of the winding including the winding start portion which extends along the second teeth side surface is located at a position farther from the inner circumferential surface of the yoke than a second innermost portion which is a portion on the second teeth side surface side and on the inner circumferential surface side of the yoke within the slot, the insulator extension portion has an outer end surface located on the opposite side to the stator core, The first winding is wound around the outer end surface, a protrusion is provided on the outer end surface, the protrusion protruding from a portion of the outer end surface that is closer to the base of the insulator than the first turn of the winding and closer to the winding start portion, A stator for a rotating electric machine, characterized in that the winding forming the outer peripheral layer extends along the side surface of the second tooth at the second innermost portion and is then placed on the protrusion.

[0071] <Appendix 2> a protruding height of the top of each of the projections relative to the outer end surface is equal to an outer diameter of the winding; The stator of a rotating electric machine described in <Appendix 1>, characterized in that the protrusion guides the winding after it extends along the side surface of the second tooth at the second innermost portion so that the winding is wound around the winding that forms the first layer after it extends along the side surface of the second tooth at the second innermost portion.

[0072] <Appendix 3> The stator of a rotating electric machine described in <Appendix 1> or <Appendix 2>, characterized in that the winding that forms the outer peripheral layer and extends along the side surface of the second tooth at the second innermost portion is a winding that forms the second layer.

[0073] <Appendix 4> The stator of a rotating electric machine described in any one of <Appendix 1> to <Appendix 3>, characterized in that the protrusion has an inclined surface that is continuous with the top of the protrusion and whose protruding height from the outer end surface gradually increases from a portion of the outer end surface opposite the winding start portion toward the top of the protrusion.

[0074] <Appendix 5> The projection has a protruding end surface located at a tip end in a protruding direction from the outer end surface, A stator for a rotating electric machine as described in any one of <Appendix 1> to <Appendix 4>, characterized in that an edge portion of the protruding end face located on the opposite side to the insulator base portion is chamfered in an arc shape.

[0075] <Appendix 6> an insulator constituting part of a stator of a rotating electric machine including a stator core having a cylindrical yoke and a plurality of teeth extending radially inward from an inner peripheral surface of the yoke, with slots formed between adjacent teeth in the circumferential direction of the yoke, the insulator having a cylindrical insulator base arranged facing a core end face, which is an end face of the stator core located in the axial direction of the yoke, and facing the yoke in the axial direction, and a plurality of insulator extension portions extending radially inward from the inner peripheral surface of the insulator base and facing each of the teeth in the axial direction, and providing insulation between a coil formed by winding a winding passing through the slots around the stator core and the core end face, the insulator extension portion has an outer end surface located on the opposite side to the stator core, An insulator comprising: an insulator member having an outer end surface, the outer end surface being provided with a protrusion located at an outer end portion in the radial direction and on one side in the circumferential direction.

[0076] <Appendix 7> The insulator described in <Appendix 6>, characterized in that the protrusion has an inclined surface that is continuous with the top of the protrusion and whose protruding height from the outer end surface gradually increases from the other circumferential side of the outer end surface toward the top.

[0077] <Appendix 8> The projection has a protruding end surface located at a tip end in a protruding direction from the outer end surface, The insulator described in <Appendix 6> or <Appendix 7>, wherein an edge portion of the protruding end surface located on the opposite side to the insulator base portion is chamfered in an arc shape. [Explanation of symbols]

[0078] 10...rotating electric machine, 22...stator, 23...stator core, 23a...first core end face which is core end face, 23b...second core end face which is core end face, 24...yoke, 24a...inner circumferential surface, 25...teeth, 28...coil, 29...winding, 29s...winding start portion, 30...slot, 30a...first innermost portion, 30b...second innermost portion, 50...insulator, 51...insulator base, 51a...inner circumferential surface, 53...insulator extension portion, 55...outer end surface, 56...protrusion, 57...top portion, 58...inclined surface, 60...protruding end surface, 61...edge, 62...outer layer, 261...first teeth side surface, 262...second teeth side surface, D1...outer diameter, H1...protrusion height.

Claims

1. a stator core having a cylindrical yoke and a plurality of teeth extending radially inward from an inner peripheral surface of the yoke, with slots formed between adjacent teeth in a circumferential direction of the yoke; a coil formed by winding a winding passing through the slots around the stator core; an insulator disposed opposite a core end face, which is an axial end face of the yoke of the stator core, and providing insulation between the coil and the core end face, the teeth have a first teeth side surface located on one circumferential side of the yoke and a second teeth side surface located on the other circumferential side of the yoke, The insulator comprises: a cylindrical insulator base portion facing the yoke in the axial direction; a plurality of insulator extension portions extending radially inward from an inner circumferential surface of the insulator base and facing each of the teeth in the axial direction, the coil is formed by winding the winding in a plurality of layers in a concentrated winding manner around the teeth and the insulator extension while spirally moving back and forth in the radial direction, A first layer of a winding that forms the coil is formed by winding from the outside to the inside in the radial direction, The coil has an outer circumferential layer which is a second or subsequent layer of a winding that forms the coil and is formed by winding from the inside to the outside in the radial direction, a stator for a rotating electric machine, wherein a winding start portion of a winding forming the first layer extends along the first teeth side surface at a first innermost portion which is a portion on the first teeth side surface side and on the inner circumferential surface side of the yoke within the slot, and a portion of the first turn of the winding including the winding start portion which extends along the second teeth side surface is located at a position farther from the inner circumferential surface of the yoke than a second innermost portion which is a portion on the second teeth side surface side and on the inner circumferential surface side of the yoke within the slot, the insulator extension portion has an outer end surface located on the opposite side to the stator core, The first winding is wound around the outer end surface, a protrusion is provided on the outer end surface, the protrusion protruding from a portion of the outer end surface that is closer to the insulator base portion than the first turn of the winding and closer to the winding start portion, A stator for a rotating electric machine, characterized in that the winding forming the outer peripheral layer extends along the side surface of the second tooth at the second innermost portion and is then placed on the protrusion.

2. a protruding height of the top of each of the projections relative to the outer end surface is equal to an outer diameter of the winding; 2. The stator of a rotating electric machine as described in claim 1, characterized in that the protrusion guides the winding after it extends along the side surface of the second tooth at the second innermost portion so that the winding is wound around the winding that forms the first layer after it extends along the side surface of the second tooth at the second innermost portion.

3. 3. The stator of a rotating electric machine according to claim 1 or claim 2, characterized in that the winding that forms the outer peripheral layer and that extends along the side surface of the second tooth at the second innermost portion is the winding that forms the second layer.

4. 2. The stator of a rotating electric machine as described in claim 1, characterized in that the protrusion has an inclined surface that is continuous with the top of the protrusion and whose protruding height from the outer end surface gradually increases from a portion of the outer end surface opposite the winding start portion toward the top of the protrusion.

5. The projection has a protruding end surface located at a tip end in a protruding direction from the outer end surface, 2. The stator for a rotating electric machine according to claim 1, wherein an edge of the protruding end surface located on a side opposite to the insulator base portion is chamfered in an arc shape.

6. an insulator constituting part of a stator of a rotating electric machine including a stator core having a cylindrical yoke and a plurality of teeth extending radially inward from an inner peripheral surface of the yoke, with slots formed between adjacent teeth in the circumferential direction of the yoke, the insulator having: a cylindrical insulator base portion arranged facing a core end face which is an end face of the stator core located in the axial direction of the yoke and facing the yoke in the axial direction; and a plurality of insulator extension portions extending radially inward from the inner peripheral surface of the insulator base portion and facing each of the teeth in the axial direction, the insulator providing insulation between a coil formed by winding a winding passing through the slots around the stator core and the core end face, the insulator extension portion has an outer end surface located on the opposite side to the stator core, An insulator comprising: an insulator member having an outer end surface, the outer end surface being provided with a protrusion located at an outer end portion in the radial direction and on one side in the circumferential direction.

7. The insulator according to claim 6, characterized in that the protrusion has an inclined surface that is continuous with the top of the protrusion and whose protruding height relative to the outer end surface gradually increases from the other circumferential side of the outer end surface toward the top of the protrusion.

8. The projection has a protruding end surface located at a tip end in a protruding direction from the outer end surface, 8. The insulator according to claim 6, wherein an edge of the protruding end surface located on the opposite side to the insulator base portion is chamfered in an arc shape.

Images