Stator and motor

Abstract

To provide a stator structure in which wave windings, each wound once per phase, are disposed between slots of a stator core in a stator, and which enables securing insulation distances between the wave windings and between the wave winding and the stator core and to provide a motor employing the stator.SOLUTION: A first insulating ring 13a is disposed between one end surface 1A of a stator core 1 and first coil ends 11. Second and third insulating rings 13b, 13c are disposed between the first coil ends 11 of respective phase coils 7u, 7v, 7w. Fourth and fifth insulating rings 14a, 14b are disposed between second coil ends 12 of respective phase coils 7u, 7v, 7w. At least one sixth insulating ring 14c is disposed between a conductor 9a, which connects the other open ends 9 of the respective phase coils 7u, 7v, 7w, and the second coil ends 12.SELECTED DRAWING: Figure 13

Description

Technical Field

[0001] The present invention relates to a stator structure capable of ensuring insulation between wave windings and between a wave winding and a stator core in a stator having a wave winding wound in one turn per phase between slots of a stator core, and a motor employing the stator.

Background Art

[0002] Conventionally, a motor is known in which a conductor having a rectangular cross-sectional shape (hereinafter referred to as a rectangular wire) is wound in a slot of a stator core to form a coil. For example, a technique related to a stator in which each phase coil wound between slots of a stator core is one turn each, and a motor using the stator has been published (see Patent Document 1 below).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

[0004] The coil described in Patent Document 1 above includes a coil side extending in the axial direction of the stator core within a slot of the stator, a first coil end connecting between one ends of the coil sides on one end face side of the stator core and extending radially outward and circumferentially of the stator core, and a second coil end connecting between the other ends of the coil sides on the other end face side of the stator core and extending radially inward and circumferentially of the stator core.

[0005] Only one coil side of one-phase coil is disposed in one slot of the stator core. The coils of each phase arranged in this way are arranged in a substantially stepped manner such that a part of the first and second coil ends is located above or below a part of the first and second coil ends of other-phase coils.

Summary of the Invention

[0006] In the stator described in the above Patent Document 1, the coils of each phase are molded with insulating resin to insulate the stator core from the coils and between the coils of each phase. By filling and molding the coils, which are the main heat source of the stator, with molding resin, the cooling effect of the motor can be improved. In addition, integral molding with molding resin enables a design with low vibration, low noise, compact size, and excellent environmental resistance.

[0007] On the other hand, after molding, the stator may have thin resin burrs on its inner diameter, which may cause problems due to the thin burrs falling off. In addition, integral molding with molded resin increases the cost of the motor. Furthermore, in response to the recent demand for recycling of product materials, it is difficult to recover the internal core and coils as resources from the stator covered with hardened molded resin, which is not in line with the needs of the times.

[0008] Therefore, an object of the present invention is to provide a stator that can insulate wave winding coils, each of which is wound with one turn for each phase, between the slots of a stator core without using molding, and a motor using such a stator. [Means for solving the problem]

[0009] The invention according to claim 1 is configured such that each phase coil wound between the slots of the stator core is formed with one turn, and the coil includes a coil side extending in the axial direction of the stator core within the slot, and on one end face side of the stator core, a first coil end formed by connecting one ends of the coil sides in succession, a portion extending radially outward from the one end, and a portion extending circumferentially. On the other end face side of the stator core, a second coil end is provided, which is formed by connecting the other ends of the coil sides in succession, a portion extending radially inward from the other end, and a portion extending circumferentially. A step is provided between each phase coil by a part of the first and second coil ends being located above or below a part of the first and second coil ends of other phase coils. In the stator, an insulating ring is disposed at least at one of the positions between one end face of the stator core and the first coil end, and between the first coil ends of each phase coil and the second coil ends. The insulating ring can be appropriately disposed between one end face of the stator core and the first coil end, between the first coil ends of each phase coil, and between the second coil ends, and may be provided between all coils or at any one position. It can be appropriately used when a space distance cannot be ensured due to the mounting space of the motor, etc.

[0010] The invention according to claim 2 is characterized in that on the other end face side of the stator core according to claim 1, one open end connected to an external power source and the other open end connecting between each phase coil are drawn out, and an insulating ring is disposed between a conductor connecting between the other open ends and the second coil end.

[0011] The invention according to claim 3 is characterized in that the other side ends according to claim 2 are delta-connected or star-connected.

[0012] The invention according to claim 4 is characterized in that a notch groove is formed on the inner circumferential side of the insulating ring according to claim 1.

[0013] The invention according to claim 5 is characterized in that it is a motor having a stator as described in any one of claims 1 to 4.

Advantages of the Invention

[0014] According to the invention described in claim 1, by disposing an insulating ring at least at one of the positions between the first coil ends and between the second coil ends, it is possible to surely insulate between the coil ends of each phase coil.

[0015] According to the invention described in claim 2, by disposing an insulating ring between the conductor connecting the other open ends of each phase and the second coil end, it is possible to surely insulate between the conductor and the second coil end.

[0016] According to the invention described in claim 3, the insulation between the coil ends of each phase coil using the insulating ring according to the present invention or between the conductors connecting the other open ends of each phase can be applied to both a stator in which each phase coil is delta-connected or a stator in which each phase coil is star-connected.

[0017] According to the invention described in claim 4, by providing a notch groove on the inner peripheral edge of the insulating ring, the coil sides of each phase coil can be fitted into the notch groove, and it is possible to prevent the insulating ring from rotating in the circumferential direction.

[0018] According to the invention described in claim 5, it is possible to realize a motor having the effects of claims 1 to 4.

Brief Description of the Drawings

[0019]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Figure 12

Figure 13

Figure 14

Figure 15

Figure 16

Best Mode for Carrying Out the Invention

[0020] The content of the present invention will be described in this specification. In this specification, the description of "axial direction" refers to the extending direction of the rotation center line of the rotor in an inner-rotating type electric motor in which the rotor, which will be described later and constitutes the motor of the present invention, is rotatably arranged on the inner diameter side of the stator.

[0021] Further, the description of "circumferential direction" refers to the circumferential direction centered on the rotation center line when viewed in a cross section perpendicular to the "axial direction" in a state where the rotor is rotatably arranged relative to the inner diameter of the stator or in a state where the coil is attached to the stator.

[0022] Furthermore, the description of "radial direction" refers to the radial direction passing through the rotation center line when viewed in a cross section perpendicular to the "axial direction" in a state where the rotor is rotatably arranged relative to the inner diameter of the stator.

[0023] Also, the description of "radially inner side" refers to the side on the rotation center line side in the radial direction, and the description of "radially outer side" refers to the side opposite to the rotation center line in the radial direction.

[0024] In addition, in this specification, the descriptions of "cylindrical", "U-shaped", "corrugated", "rectangular", and "same length" are respectively used to include "substantially cylindrical", "substantially U-shaped", "substantially corrugated", "substantially rectangular", and "substantially the same length". Furthermore, in this specification, for convenience, the illustrated "upper side" and "lower side" are respectively described as "one axial side" and "the other axial side", and the "left side" and "right side" are respectively described as "one circumferential side" and "the other circumferential side". Also, the "inner side" and "outer side" are respectively described as "radially inner side" and "radially outer side", but "one" and "the other", "inner side" and "outer side" are not limited thereto, and appropriate directions can be selected.

[0025] Hereinafter, embodiments of the present invention will be described with reference to FIGS. 1 to 16. FIG. 1 is a perspective view of a stator core 1 constituting a stator A of the present invention. The stator core 1 is composed of an annular yoke portion 2 and a plurality of teeth 3 protruding radially inward from the yoke portion 2. A plurality of slots 4 are formed in the circumferential direction between the plurality of teeth 3.

[0026] The stator core 1 is formed by laminating thin iron plates to form a laminated core, and by forming a laminated core, eddy current loss can be suppressed. However, such a laminated structure is not an essential condition for the stator core 1, and the stator core 1 may be configured as a single solid. Also, it is possible to form the stator core 1 by using a core member having a laminated structure or a core member having a divided structure in which a core member manufactured as a single solid is subdivided in the circumferential direction and joining the core members to each other in an annular shape.

[0027] A hollow portion H is formed inside the stator core 1 in the radial direction, and a cylindrical rotor (not shown) is rotatably disposed in the hollow portion H. The rotor rotates in the circumferential direction within the hollow portion H by a rotating magnetic field formed by a coil attached to the stator core 1. At this time, the rotation axis of the rotor has its extending direction coinciding with the rotation center line, and both ends of the rotation axis are pivotally supported by bearings (not shown) to rotate within the hollow portion H. That is, the longitudinal direction of the rotation axis of the rotor becomes the "axial direction".

[0028] FIG. 2 is a perspective view showing a slot insulating member 5a disposed in slot 4 of stator core 1 shown in FIG. 1. The slot insulating member 5a is formed of, for example, a film made of a resin having insulating properties and is bent so that its cross-sectional shape becomes a U-shape. As the resin film, resin films formed of various known resins are used.

[0029] At both axial ends of the slot insulating member 5a, cuff portions 6a1 and 6a2 formed by bending the resin film in the axial direction are formed.

[0030] FIG. 3 shows a state in which the slot insulating member 5a shown in FIG. 2 is attached to the stator core 1 shown in FIG. 1. The slot insulating member 5a is disposed in slot 4 of the stator core 1 such that the opening side of the U-shaped slot insulating member 5a faces the opening side of slot 4.

[0031] When the slot insulating member 5a is disposed in the slot 4, the slot insulating member 5a is inserted into the slot 4 of the stator core 1 from one axial side (the upper side in FIG. 1) shown in FIG. 1 and pushed into the slot 4 toward the other axial side (the lower side in FIG. 1) of the stator core 1. As shown in FIG. 3, the slot insulating member 5a is pushed into the slot 4 until the bent lower end portion of the cuff portion 6a1 formed at one axial end contacts one end face (the upper end face in FIG. 3) 1A of the stator core 1.

[0032] When the bent lower end portion of the cuff portion 6a1 contacts one end face 1A of the stator core 1, the bent lower end portion of the cuff portion 6a1 is locked at the opening of the slot 4, and the slot insulating member 5a is not pushed in any further.

[0033] On one side, the bent upper end of the cuff portion 6a2 of the slot insulating member 5a abuts against the other end face (the lower end face in FIG. 3) 1B of the stator core 1. As a result, one end face 1A and the other end face 1B of the stator core 1 are sandwiched between the cuff portion 6a1 and the cuff portion 6a2 of the slot insulating member 5a. Thereby, the slot insulating member 5a is restricted from moving in the axial direction within the slot 4 of the stator core 1.

[0034] FIG. 4 shows the coil 7 attached to the stator core 1 of FIG. 1. The coil 7 is formed by attaching a conductor formed and manufactured in a waveform shape into the slot 4 of the stator core 1 to form a wave-wound coil, and is composed of a total of three coils 7u, 7v, and 7w for three phases of U phase, V phase, and W phase. Since the shapes and structures of the coils 7u, 7v, and 7w of each phase are the same, in FIG. 4, the U-phase coil 7u will be described.

[0035] As shown in FIG. 4, the coil 7u is formed by forming and manufacturing a single conductor in a waveform shape. Specifically, it includes one open end 8 and the other open end 9 of the coil 7u, and the portion between both open ends 8 and 9 is formed and manufactured in a waveform shape. One open end 8 is composed of a coil side 10 in the shape of a straight thin plate extending toward one side in the axial direction (the upper side in FIG. 4), and includes a first coil end 11 composed of a portion 11a extending radially outward and a portion 11b extending in one circumferential direction from the end of the coil side 10 on one side in the axial direction (the upper side in FIG. 4).

[0036] On one circumferential side of the first coil end 11, a thin plate-shaped coil side 10 extending toward the other side in the axial direction (the lower side in FIG. 4) is connected, and a second coil end 12 composed of a portion 12a extending radially inward and a portion 12b extending in one circumferential direction from the end of the coil side 10 on the other side in the axial direction (the lower side in FIG. 4) is connected.

[0037] On one circumferential side of the second coil end 12, a coil side 10 extending toward one axial side is connected. At one axial end of the coil side 10, a first coil end 11 having the same shape as described above is connected. Thereafter, similarly, the coil sides 10, the second coil end 12, and the coil sides 10 are continuous toward one circumferential side in this order. And, in front of the other open end 9, a first coil end 11 composed of a portion 11a extending radially outward from one axial end of the coil side 10 and a portion 11b extending toward one circumferential side is connected, and a coil side 10 extending toward the other axial side is continuous on one circumferential side of the first coil end 11. The other open end 9 is formed by the final coil side 10.

[0038] The coil 7u schematically configured in this way has details of the structural dimensions such as the width dimension, the plate thickness dimension of the coil sides 10 and the first and second coil ends 11, 12, and the shape and dimensions of the portions where the coil sides 10 and the first and second coil ends 11, 12 are connected, which are determined in consideration of the motor incorporating the coil 7u, the size of various devices incorporating the motor, the cross-sectional area required to pass current through the coil 7u, or the space distance (insulation distance) between the phase coils 7u, 7v, 7w.

[0039] Note that the number of waveforms between one open end 8 and the other open end 9 of the coil 7u is not limited to the number shown in FIG. 4, and has a waveform with the number of coil sides 10 being one-third of the number of slots of the stator core 1. Since the coils 7v, 7w both have the same structure as the coil 7u shown in FIG. 4, the description of the structures of the V-phase coil 7v and the W-phase coil 7w will be omitted.

[0040] As a manufacturing method of the coils 7u, 7v, 7w, in addition to the method of forming and manufacturing the above-described single conductor into a waveform, it is also possible to manufacture, for example, from a strip material or a plate-like material. Further, the coils 7u, 7v, 7w shown in FIG. 4 may be manufactured by joining a large number of members by welding or the like.

[0041] FIG. 5 shows the insulating rings 13 attached to the stator core 1 shown in FIG. 1. FIG. 5(a) shows the insulating ring 13 attached to one end face 1A side of the stator core 1, and FIG. 5(b) shows the insulating ring 14 attached to the other end face 1B side of the stator core 1. The insulating rings 13 and 14 are made of, for example, PC (polycarbonate), POM (polyacetal), PET (polyethylene terephthalate), PPS (polyphenylene sulfide), PBT (polybutylene terephthalate), LCP (liquid crystal polymer), SPS (syndiotactic polystyrene), PA66 (nylon 66), or PEEK resin.

[0042] The outer diameter and inner diameter of the insulating ring 14 are smaller than those of the insulating ring 13. The outer diameter of the insulating ring 13 is slightly smaller than the outer diameter of the stator core 1 shown in FIG. 1, and the inner diameter is substantially the same as the outer diameter of the radial bottom 4a of the slot 4 of the stator core 1. The outer diameter of the insulating ring 14 is substantially the same as the inner diameter of the coil side 10 located radially outside the portion 12a extending radially inward of the second coil end 12 of the coil 7u (7v, 7w) shown in FIG. 4, and is smaller than the diameter of the hollow portion H of the stator core 1 shown in FIG. 1. Also, the inner diameter of the insulating ring 14 is larger than the shaft diameter for rotationally driving the rotor. The insulating ring 13 shown in FIG. 5(a) has three sheets, namely, the first insulating ring 13a, the second insulating ring 13b, and the third insulating ring 13c, which are attached between one end face 1A of the stator core 1 and the first coil end 11, and between the first coil ends 11. Also, the second insulating ring 14 shown in FIG. 5(b) has three sheets, namely, the fourth insulating ring 14a, the fifth insulating ring 14b, and the sixth insulating ring 14c, which are attached between the second coil ends 12 and between the second coil end 12 and the coil bar 9a.

[0043] Next, the case of attaching the coil 7 shown in FIG. 4 to the stator core 1 to which the slot insulating member 5a shown in FIG. 3 is attached will be described. When manufacturing the stator A according to the present invention, a total of three coils 7u, 7v, and 7w shown in FIG. 4 are prepared, one for each phase. To the stator core 1, the coils 7u, 7v, and 7w of each phase are attached in order. In this embodiment, the order of attachment to the stator core 1 will be described for the case of attaching the U-phase coil 7u, the V-phase coil 7v, and the W-phase coil 7w in this order, but it is not limited to this order. Any of the six ways of mutually swapping the order may be selected.

[0044] First, the U-phase coil 7u is attached to the stator core 1. First, as shown in FIG. 6, the first insulating ring 13a shown in FIG. 5(a) is disposed on the yoke portion 2 of one end face 1A of the stator core 1. At this time, the slot insulating member 5a is positioned radially inside the insulating ring 13a. From above, the coil 7u is inserted into the slot 4 of the stator core 1 where the slot insulating member 5a is attached from one axial side of the stator core 1 toward the other axial side, with the coil side 10 being inserted.

[0045] As shown in FIG. 6, when the coil side 10 is inserted into the slot 4 of the stator core 1, since the second coil end 12 (see FIG. 4) of the coil 7u is composed of a portion 12a extending radially inward from the second coil end 12 positioned radially inside the coil side 10 and a portion 12b extending in the circumferential direction, in the process of inserting the coil side 10 into the slot 4 of the stator core 1, the second coil end 12 does not interfere (contact) with the stator core 1 and passes through the hollow portion H.

[0046] And when the coil 7u is deeply inserted into the slot 4 of the stator core 1, as shown in FIG. 7, the first coil end 11 of the coil 7u is composed of a portion 11a extending radially outward of the coil end 10 and a portion 11b extending circumferentially on the yoke portion 2 of one end face 1A of the stator core 1. Therefore, the portion 11b of the first coil end 11 of the coil 7u extending circumferentially abuts against the first insulating ring 13a disposed on the yoke portion 2 of the one end face 1A, and no further deep insertion occurs.

[0047] FIG. 8 shows the state on the other axial side of the coil 7u attached to the stator core 1. As shown in FIG. 8, one open end 8 and the other open end 9 of the coil 7u with the coil side 10 disposed in the slot 4 protrude downward from the other end face 1B. Further, a portion 12a extending radially inward and a portion 12b extending circumferentially of the second coil end 12 are disposed radially inward on the other end face 1B side of the stator core 1. FIG. 9 is a perspective view showing that state from the other end face 1B side of the stator core 1.

[0048] After completing the attachment of the coil 7u to the stator core 1, next, the fourth insulating ring 14a shown in FIG. 5(b) is passed through the hollow portion H of the stator core 1 from one axial side of the stator core 1 to the other axial side and disposed on the second coil end 12 of the coil 7u. Since the outer diameter of the insulating ring 14a is substantially the same as the inner diameter in the radial direction of the coil side 10 located radially outside the second coil end 12 of the coil 7u, it can be reliably disposed in contact with the second coil end 12 of the coil 7u and will not fall off.

[0049] After attaching the fourth insulating ring 14a, next, the V-phase coil 7v is attached to the stator core 1. When attaching the coil 7v, the second insulating ring 13b shown in FIG. 5(a) is disposed on the first coil end 11 of the coil 7u located on the one end face 1A side of the stator core 1.

[0050] Once the placement of the second insulating ring 13b is completed, attach the coil 7v to the stator core 1. The coil 7v is attached in the same manner as the coil 7u, by inserting the coil side 10 shown in FIG. 4 into the slot 4 to which the slot insulating member 5a is attached, from one axial side of the stator core 1 shown in FIG. 10 toward the other axial side.

[0051] As shown in FIG. 10, when inserting the coil side 10 into the slot 4, since the second coil end 12 (see FIG. 4) of the coil 7v is located radially inside the coil side 10, in the process of inserting the coil side 10 into the slot 4 of the stator core 1, the second coil end 12 does not interfere (contact) with the stator core 1 and passes through the hollow portion H.

[0052] When the coil 7v is deeply inserted into the slot 4 of the stator core 1, as shown in FIG. 11, since the first coil end 11 of the coil 7v is located on the yoke portion 2 of one end face 1A of the stator core 1, the first coil end 11 of the coil 7v abuts against the second insulating ring 13b disposed on the first coil end 11 of the coil 7u and is not inserted deeper.

[0053] In this state, since the portion 11b extending in the circumferential direction of the first coil end 11 of the coil 7v extends in the circumferential direction of the yoke portion 2 of the stator core 1, when the coil side 10 is inserted into the slot 4 of the stator core 1 and reaches a certain depth position, a part of the first coil end 11 of the coil 7v will be located above a part of the first coil end 11 of the coil 7u.

[0054] On the other hand, the second coil end 12 of the coil 7v that has passed through the hollow portion H of the stator core 1 abuts against the fourth insulating ring 14a disposed on the second coil end 12 of the coil 7u on the other end face 1B side of the stator core 1 and sandwiches the fourth insulating ring 14a together with the second coil end 12 of the coil 7u.

[0055] On the other side in the axial direction of the stator core 1, similar to the case where the coil 7u is attached, one open end 8 and the other open end 9 of the coil 7v project downward from the other end face 1B of the stator core 1. Also, the second coil end 12 is located radially inward on the side of the other end face 1B of the stator core 1.

[0056] When the attachment of the coil 7v to the stator core 1 is completed, the fifth insulating ring 14b shown in Fig. 5(b) is passed through the hollow portion H of the stator core 1 from one side in the axial direction of the stator core 1 to the other side in the axial direction and is placed in contact with the second coil end 12 of the coil 7v. Since the outer diameter of the insulating ring 14b is substantially the same as the inner diameter in the radial direction of the coil side 10 located radially outside the second coil end 12 of the coil 7v, the insulating ring 14b can surely come into contact with the second coil end 12 of the coil 7v.

[0057] Next, the W-phase coil 7w is attached to the stator core 1. When attaching the coil 7w, the third insulating ring 13c shown in Fig. 5(a) is placed on the first coil end 11 of the coil 7v located on the side of one end face 1A of the stator core 1.

[0058] After the third insulating ring 13c is attached to the stator core 1, the coil 7w is attached to the stator core 1. The method of attaching the coil 7w is the same as in the case of the coil 7u. From one side in the axial direction to the other side in the axial direction of the stator core 1 shown in Fig. 12, the coil side 10 shown in Fig. 4 is inserted into the slot 4 to which the slot insulating member 5a is attached.

[0059] As shown in Fig. 12, when the coil side 10 is inserted into the slot 4, since the second coil end 12 (see Fig. 4) of the coil 7w is located radially inside the coil side 10, in the process of inserting the coil side 10 into the slot 4 of the stator core 1, the second coil end 12 does not interfere (contact) with the stator core 1 and passes through the hollow portion H.

[0060] When the coil 7w is deeply inserted into the slot 4 of the stator core 1, as shown in Fig. 13, the portion 11b extending in the circumferential direction of the first coil end 11 of the coil 7w extends in the circumferential direction on the yoke portion 2 of one end face 1A of the stator core 1. Therefore, the first coil end 11 of the coil 7w abuts against the third insulating ring 13c disposed on the first coil end 11 of the coil 7v and is not inserted deeper.

[0061] In this state, on the other axial side of the stator core 1, similar to the case where the coils 7u and 7v are attached, one open end 8 and the other open end 9 of the coil 7w protrude downward from the other end face 1B. Also, the second coil end 12 is located on the inner side in the radial direction of the stator core 1 on the other end face 1B side of the stator core 1.

[0062] And since the portion 11b extending in the circumferential direction of the first coil end 11 of the coil 7w extends in the circumferential direction at the position on the yoke portion 2 of the stator core 1, when the coil side 10 is inserted into the slot 4 of the stator core 1 and reaches a certain depth position, a part of the first coil end 11 of the coil 7w will be located above a part of the first coil end 11 of the coil 7v.

[0063] On the other hand, the second coil end 12 of the coil 7w passing through the hollow portion H of the stator core 1 abuts against the fifth insulating ring 14b disposed on the second coil end 12 of the coil 7v on the other end face 1B side of the stator core 1, and the fifth insulating ring 14b is clamped by the second coil ends 12 of the coils 7v and 7w.

[0064] As shown in Fig. 13, when each phase coil 7u, 7v, 7w is attached to the stator core 1, one open end 8 of each phase coil 7u, 7v, 7w protrudes from the slot 4 to the other end face 1B side of the stator core 1. Also, the other open end 9 of each phase coil 7u, 7v, 7w protrudes from the slot 4 to the other end face 1B side of the stator core 1.

[0065] One open end 8 of each phase coil 7u, 7v, 7w is electrically connected to an external power source (not shown), and a three-phase power supply is applied to each phase coil 7u, 7v, 7w from the external power source, thereby generating a rotating magnetic field by each phase coil 7u, 7v, 7w and rotating a rotor (described later) disposed in the hollow portion H of the stator core 1.

[0066] In addition, if the shape of one open end 8 is made to be a shape that can be fitted to a power supply connection connector (not shown) of the external power source, complicated terminal processing can be avoided only by attaching one open end 8 to the connector.

[0067] FIG. 14 shows the other end face 1B of the stator core 1 shown in FIG. 13. On the other end face 1B side, when the phase coils 7u, 7v, 7w are star-connected, the other open end 9 functions as a neutral point. For example, as shown in FIG. 13, three other open ends 9 protruding to the other end face 1B side of the stator core 1 are bent in the circumferential direction as shown in FIG. 14, and the coil bars 9a are overlapped with the coils 7u and 7v, and the coils 7v and 7w, respectively, and are crimped by the crimp terminals 17 to connect the neutral points. In addition to forming the neutral points at two locations in this way, the coils 7u, 7v, 7w can also be crimped with a crimp terminal as a single neutral point. Alternatively, the neutral points can be connected by welding the three other open ends 9 protruding to the other end face 1B side of the stator core 1 to a coil bar of another member. Or, the neutral points may be formed by connecting the three other open ends 9 to a terminal by hugging or soldering.

[0068] In addition, when the phase coils 7u, 7v, 7w are delta-connected, the one open end 8 and the other open end 9 of each phase are connected and wired according to various motor specifications. That is, the motor according to the present invention can be applied regardless of star connection or delta connection.

[0069] To the second coil end 12 of the coil 7u protruding on the lead side of the stator core 1, a sixth insulating ring 14c is placed in contact as shown in FIG. 14. The sixth insulating ring 14c is attached by sliding it laterally into the gap between the coil bar 9a and the second coil end 12 of the coil 7u shown in FIG. 14. This makes it possible to reliably insulate between the coil 7u and the coil bar 9a.

[0070] The stator A of the present invention is configured as described above. Further, as shown in FIG. 15, the rotor 18 is rotatably assembled to the stator A of the present invention, etc., to configure the motor B of the present invention. That is, the stator A and the motor B of the present invention can insulate between the stator core 1 and each phase coil 7u, 7v, 7w, and between each phase coil 7u, 7v, 7w without using a mold. This eliminates the demerit of cost increase due to molding and can also contribute to the demand for recycling of product materials. If cost increase and recycling are not considered, it is also possible to improve the insulation characteristics by molding the periphery of the stator core 1 and each phase coil 7u, 7v, 7w with an insulating resin.

[0071] In the above embodiment, the first coil ends 11 and the second coil ends 12 of each phase coil 7u, 7v, 7w are arranged with steps in the order of the U phase, V phase, and W phase in sequence from the other side in the axial direction (the lower side in FIG. 1). However, the stator of the present invention is not limited to this configuration, and the first coil ends 11 and the second coil ends 12 of each phase coil 7u, 7v, 7w may be arranged in a state where the order is appropriately changed.

[0072] Also, in FIG. 1, the case where 30 slots 4 are formed in the stator core 1 is described, but the number of slots 4 is not limited to this. Since the coil 7 shown in FIG. 4 is three-phase, it is sufficient to form a number of slots that is a multiple of 3. Naturally, the number of coil sides 10 of the coil 7u shown in FIG. 4 also changes accordingly depending on the number of slots selected.

[0073] Furthermore, in the above embodiments, the case where the cross-sectional shape of the coil sides 10 of each phase coil 7u, 7v, 7w is formed by a rectangular conductor has been described. However, the coils 7u, 7v, 7w according to the present invention may have a cross-sectional shape that is circular, elliptical, square, or other polygons other than quadrilaterals. In that case, the shape of the slots 4 of the stator core 1 shown in FIG. 1 and the shape of the slot insulating member 5a disposed in the slots 4 are also shaped to accommodate the cross-sectional shape of the coils 7u, 7v, 7w. And, by designing the gaps between the slots 4 and the slot insulating member 5a and the coils 7u, 7v, 7w to be as narrow as possible, the occupancy ratio of the coils 7u, 7v, 7w in the slots 4 can be increased.

[0074] FIG. 16 shows another embodiment of the insulating ring according to the present invention. The insulating ring 15 in FIG. 16 is used in place of the insulating ring 13 shown in FIG. 5(a). Similar to the insulating ring 13, three sheets of the seventh insulating ring 15a, the eighth insulating ring 15b, and the ninth insulating ring 15c can be used.

[0075] The seventh insulating ring 15a is used in place of the first insulating ring 13a, the eighth insulating ring 15b is used in place of the second insulating ring 13b, and the ninth insulating ring 15c is used in place of the third insulating ring 13c. The insulating ring 15 (15a, 15b, 15c) has formed therein the same number of notch grooves 16 as the total number of coil sides 10 of each phase coil 7 on its inner peripheral edge. When the insulating ring 15 (15a, 15b, 15c) is disposed above the yoke portion 2 of one end face 1A of the stator core 1, the coil sides 10 of each phase coil 7 are fitted into the notch grooves 16. As a result, it is possible to prevent the insulating ring 15 from rotating along the circumferential direction of the yoke portion 2 and to firmly fix it.

[0076] Note that the insulating ring 15 can also be made of PC (polycarbonate ≡), POM (polyacetal), PET (polyethylene terephthalate), PPS (polyphenylene sulfide), PBT (polybutylene terephthalate), LCP (liquid crystal polymer), SPS (syndiotactic polystyrene), PA66 (66 nylon), PEEK resin, etc., which is the same as the insulating rings 13 and 14.

[0077] As described above, in the stator of the present invention, by arranging insulating rings between one end face of the stator core and the first coil end, and between the first coil ends and the second coil ends of each phase, insulation can be surely provided by the insulating ring at least at one of the locations between the stator core and the first coil end, and between the first and second coil ends.

[0078] Also, by arranging an insulating ring between the conductor connecting the other open ends of each phase and the second coil end, insulation between the conductor and the second coil end can be surely provided.

[0079] Furthermore, since the slot insulating member forms a cuff portion by bending the axial end portion, the cuff portion can be hooked on the end face of the stator core, and it is possible to surely prevent the slot insulating member from moving axially within the slot.

[0080] Moreover, by providing a notch groove on the inner peripheral edge of the insulating ring, the coil sides of each phase coil can be fitted into the notch groove, and rotation of the insulating ring in the circumferential direction can be restricted.

[0081] It should be noted that the technical scope of the present invention naturally extends to various modified configurations without departing from the gist of the invention described above. For example, after forming and manufacturing each phase coil, it is also possible to cover it with an insulating resin such as enamel, polyurethane, PC (polycarbonate), POM (polyacetal), PET (polyethylene terephthalate), PPS (polyphenylene sulfide), PBT (polybutylene terephthalate), LCP (liquid crystal polymer), SPS (syndiotactic polystyrene), PA66 (66 nylon), PEEK resin, etc.

Industrial Applicability

[0082] It can be used for the stator constituting various motors.

Explanation of Signs

[0083] 1 Stator core 1A One end face 1B The other end face 2 Yoke part 7u U-phase coil 7v V-phase coil 7w W-phase coil 3 Teeth 4 Slots 4a Radial bottom of the slot 5a Slot insulating member 6a1 First cuff part 6a2 Second cuff part 7 Coil 7u U-phase coil 7v V-phase coil 7w W-phase coil 8 One open end 9 The other open end 9a Coil bar 10 Coil side 11 First coil end 11a Portion extending radially outward from the first coil end 11b Portion extending circumferentially from the first coil end 12 Second coil end The part of the second coil end extending radially inward The part of the second coil end extending circumferentially 13, 14, 15 Insulating rings 13a The first insulating ring 13b The second insulating ring 13c The third insulating ring 14a The fourth insulating ring 14b The fifth insulating ring 14c The sixth insulating ring 15a The seventh insulating ring 15b The eighth insulating ring 15c The ninth insulating ring 16 Notch groove 17 Crimp terminal 18 Rotor A Stator B Motor H Hollow part

Claims

1. Each phase coil wound between slots of the stator core is configured with one turn each, and the coil has a coil side extending in the axial direction of the stator core within the slot, and on one end face side of the stator core, a first coil end formed by connecting one ends of the coil sides in one continuous piece, a portion extending radially outward from the one end, and a portion extending circumferentially. On the other end face side of the stator core, a second coil end formed by connecting the other ends of the coil sides in one continuous piece, a portion extending radially inward from the other end, and a portion extending circumferentially. A step is provided between each phase coil by a part of the first and second coil ends being located above or below a part of the first and second coil ends of other phase coils. In the stator, an insulating ring is disposed at least at one location between one end face of the stator core and the first coil end, and between the first coil ends of each phase coil and the second coil ends. A stator characterized by this.

2. On the other end face side of the stator core, one open end connected to an external power source and the other open end connecting between each phase coil are drawn out, and an insulating ring is disposed between a conductor connecting between the other open ends of each phase and the second coil end. The stator according to claim 1, characterized by this.

3. The stator according to claim 2, characterized in that the other side ends of each phase are delta-connected or star-connected.

4. The stator according to claim 1, characterized in that a notch groove is formed on the inner peripheral side of the insulating ring.

5. A motor characterized by having the stator according to claims 1 to 4.

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