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: By disposing three types of slot insulating members 5a, 5b, 5c having different axial lengths between coil sides 10 of respective phase coils 7 and slots 4 of a stator core 1, the amount of projection from at least one end surface 1A of the stator core 1 is varied. In addition, a portion 11a of at least the first coil end 11 of each phase coil 7, which extends radially outward, is disposed on one axial end of slot insulating members 5a, 5b, 5c. In addition, insulating rings 13,14 are arranged at least at one of locations between the first coil end 11 and a second coil end 12.SELECTED DRAWING: Figure 13

Description

Technical Field

[0001] The present invention relates to a stator structure capable of ensuring insulation between wave-wound coils and between a wave-wound coil and a stator core in a stator having wave-wound coils 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, 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 arranged in one slot of the stator core. The coils of each phase arranged in this way are arranged in a substantially stepped shape 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 continuously and including a portion extending radially outward from the one end and a portion extending circumferentially, and on the other end face side of the stator core, a second coil end formed by connecting the other ends of the coil sides continuously and including a portion extending radially inward from the other end and a portion extending circumferentially. In a stator in which 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, by arranging slot insulating members having different axial lengths between the coil side and the slot, the protruding amount of the slot insulating member from at least one end face of the stator core is made different, a portion extending radially outward of the first coil end is arranged on one axial end of the slot insulating member, and an insulating ring is arranged at least at one location between the first coil ends and between the second coil ends. The insulating ring can be appropriately arranged between one end face of the stator core and the first coil end, and between the first coil ends and between the second coil ends of each phase coil, and may be provided between all coils or at any one location. 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 the axial end of the slot insulating member according to claim 1 is bent to form a cuff portion, and the cuff portion is hooked on the end face of the stator core.

[0011] The invention according to claim 3 is characterized in that a notch groove is formed in the inner peripheral edge of the insulating ring according to claim 1.

[0012] The invention according to claim 4 is a motor having the stator according to any one of claims 1 to 3.

Advantages of the Invention

[0013] According to the invention described in claim 1, the slot insulating member disposed in the slot of the stator surely insulates between the stator core and the coil. Further, by the slot insulating members protruding with different lengths from one end face of the stator core, an insulation distance between the coil ends of each phase coil can be ensured. Also, by disposing an insulating ring at at least one of the first coil ends and the second coil ends, the coil ends of each phase coil can be surely insulated from each other.

[0014] According to the invention described in claim 2, since the cuff portion of the slot insulating member disposed in the slot of the stator is hooked on the end face of the stator core, it is possible to surely prevent the slot insulating member from moving axially within the slot.

[0015] According to the invention described in claim 3, 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.

[0016] According to the invention described in claim 4, it is possible to realize a motor having the effects of claims 1 to 3.

Brief Description of the Drawings

[0017]

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

Embodiments for Carrying Out the Invention

[0018] 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 disposed on the inner diameter side of the stator.

[0019] 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 disposed relative to the inner diameter of the stator or in a state where the coil is attached to the stator.

[0020] 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 disposed relative to the inner diameter of the stator.

[0021] 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.

[0022] 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". Further, in this specification, for convenience, the illustrated "upper side" and "lower side" are respectively described as "one side in the axial direction" and "the other side in the axial direction", and the "left side" and "right side" are respectively described as "one side in the circumferential direction" and "the other side in the circumferential direction". Also, the "inner side" and "outer side" are respectively described as "inner side in the radial direction" and "outer side in the radial direction", but "one side" and "the other side", "inner side" and "outer side" are not limited thereto, and appropriate directions can be selected.

[0023] 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.

[0024] The stator core 1 is formed by stacking 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. It is also 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 together in an annular shape.

[0025] 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 circumferentially 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".

[0026] FIG. 2 is a perspective view showing slot insulating members 5a, 5b, and 5c disposed in slot 4 of stator core 1 shown in FIG. 1. Slot insulating members 5a, 5b, and 5c are formed of a film made of a resin having insulating properties, for example, and are bent so as to have a U-shaped cross-sectional shape. As the resin film, a resin film formed of various known resins is used.

[0027] Slot insulating members 5a, 5b, and 5c have different axial lengths respectively. The first slot insulating member 5a shown in FIG. 2(a) is the shortest, and the third slot insulating member 5c shown in FIG. 2(c) is the longest. The second slot insulating member 5b shown in FIG. 2(b) has an intermediate length.

[0028] At both axial ends of the first to third slot insulating members 5a, 5b, and 5c, cuff portions 6a1, 6a2, 6b1, 6b2, 6c1, and 6c2 formed by bending the resin film in the axial direction are formed. Each of the cuff portions 6a1, 6b1, and 6c1 formed at one axial end (the upper side in FIG. 2) has a different length by changing the amount of bending of the resin film.

[0029] Note that the lengths of the fourth cuff portion 6a2 formed at the other axial end of the first slot insulating member 5a, the fifth cuff portion 6b2 formed at the other axial end of the second slot insulating member 5b, and the sixth cuff portion 6c2 formed at the other axial end of the third slot insulating member 5c are the same length. However, similar to one axial end, the lengths of the cuff portions 6a2, 6b2, and 6c2 may be made different. However, in that case, for the slot insulating member having the longest cuff portion formed at one axial end, the cuff portion at the other axial end is made the shortest, and for the slot insulating member having the shortest cuff portion formed at one axial end, the length of the cuff portion at the other axial end is made the longest.

[0030] Figure 3 shows a state in which the slot insulating members 5a, 5b, and 5c shown in FIG. 2 are attached to the stator core 1 shown in FIG. 1. The slot insulating members 5a, 5b, and 5c are arranged in a plurality of slots 4 of the stator core 1 such that the opening sides of the U-shaped slot insulating members 5a, 5b, and 5c face the opening sides of the slots 4.

[0031] The slot insulating members 5a, 5b, and 5c arranged in the slots 4 are arranged one by one in three adjacent slots 4, namely, the first slot insulating member 5a, the second slot insulating member 5b, and the third slot insulating member 5c. For example, toward one side in the circumferential direction (clockwise direction in the circumferential direction), the first slot insulating member 5a, the second slot insulating member 5b, and the third slot insulating member 5c are arranged in this order, and thereafter, they are arranged in the slots 4 toward one side in the circumferential direction in this order. In this case, the first slot insulating member 5a is arranged in the slot 4 adjacent to the third slot insulating member 5c on one side in the circumferential direction.

[0032] Alternatively, the first slot insulating member 5a, the second slot insulating member 5b, and the third slot insulating member 5c may be arranged in this order toward the other side in the circumferential direction (counterclockwise direction in the circumferential direction), and thereafter, they may be arranged in the slots 4 toward the other side in the circumferential direction in this order. In this case, the first slot insulating member 5a is arranged in the slot 4 adjacent to the third slot insulating member 5c on the other side in the circumferential direction.

[0033] Alternatively, they may be arranged in the order of the second slot insulating member 5b, the third slot insulating member 5c, and the first slot insulating member 5a, or in the order of the second slot insulating member 5b, the first slot insulating member 5a, and the third slot insulating member 5c toward one side in the circumferential direction. Alternatively, they may be arranged in the order of the second slot insulating member 5b, the third slot insulating member 5c, and the first slot insulating member 5a, or in the order of the second slot insulating member 5b, the first slot insulating member 5a, and the third slot insulating member 5c toward the other side in the circumferential direction.

[0034] When arranging the slot insulating members 5a, 5b, and 5c in the slots 4, each of the slot insulating members 5a, 5b, and 5c 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, each of the slot insulating members 5a, 5b, and 5c is pushed into the slot 4 until the bent lower ends of the respective cuff portions 6a1, 6b1, and 6c1 formed at one axial end contact the one end face (the upper end face in FIG. 3) 1A of the stator core 1.

[0035] When the bent lower ends of the cuff portions 6a1, 6b1, and 6c1 contact the one end face 1A of the stator core 1, the bent lower ends of the cuff portions 6a1, 6b1, and 6c1 of the slot insulating members 5a, 5b, and 5c are locked at the openings of the slots 4 and are not pushed in any further. In this state, the protruding amount of the cuff portion from the one end face 1A of the stator core 1 toward the one axial side is the shortest for the first cuff portion 6a1 of the first slot insulating member 5a, the longest for the third cuff portion 6c1 of the third slot insulating member 5c, and the intermediate length for the second cuff portion 6b1 of the second slot insulating member 5b.

[0036] On the other hand, the bent upper ends of the fourth, fifth, and sixth cuff portions 6a2, 6b2, and 6c2 of the first, second, and third slot insulating members 5a, 5b, and 5c shown in FIG. 2 contact the other end face (the lower end face in FIG. 3) 1B of the stator core 1. As a result, the one end face 1A and the other end face 1B of the stator core 1 are sandwiched between the first, second, and third cuff portions 6a1, 6b1, and 6c1 and the fourth, fifth, and sixth cuff portions 6a2, 6b2, and 6c2 of the first, second, and third slot insulating members 5a, 5b, and 5c. Thereby, the first, second, and third slot insulating members 5a, 5b, and 5c are restricted from moving axially within the slot 4 of the stator core 1.

[0037] Figure 4 shows the coil 7 attached to the stator core 1 of FIG. 1. The coil 7 is formed into a wave winding coil by attaching a conductor formed and manufactured into a waveform into the slot 4 of the stator core 1, and is composed of three coils 7u, 7v, and 7w for the 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.

[0038] As shown in FIG. 4, the coil 7u is formed and manufactured by shaping a single conductor into a waveform. 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 into a waveform. One open end 8 consists 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 is provided with a first coil end 11 composed of a portion 11a extending radially outward from the end of the coil side 10 on one side in the axial direction (the upper side in FIG. 4) and a portion 11b extending in one direction in the circumferential direction.

[0039] On one side in the circumferential direction 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 from the end of the coil side 10 on the other side in the axial direction (the lower side in FIG. 4) and a portion 12b extending in one direction in the circumferential direction is connected.

[0040] On one circumferential side of the second coil end 12, a coil side 10 extending toward one axial side is connected. At one axial-side 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-side 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.

[0041] For the coil 7u schematically configured as described above, the detailed structures such as the width dimension, plate thickness dimension of the coil side 10 and the first and second coil ends 11, 12, and the shape and dimension of the portion where the coil side 10 is connected to the first and second coil ends 11, 12 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.

[0042] 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 having coil sides 10 in a number equal to 1 / 3 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 is omitted.

[0043] 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, for example, it is also possible to manufacture 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.

[0044] 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), and PEEK resin.

[0045] 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, i.e., the first insulating ring 13a, the second insulating ring 13b, and the third insulating ring 13c, 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, i.e., the fourth insulating ring 14a, the fifth insulating ring 14b, and the sixth insulating ring 14c, attached between the second coil ends 12 and between the second coil end 12 and the coil bar 9a.

[0046] Next, a case where the coil 7 shown in FIG. 4 is attached to the stator core 1 to which the slot insulating members 5a, 5b, and 5c shown in FIG. 3 are 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.

[0047] 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 members 5a, 5b, and 5c are located inside the insulating ring 13a in the radial direction. From above, the coil 7u is directed from one axial side of the stator core 1 toward the other axial side, and the coil side 10 is inserted into the slot 4 to which the first slot insulating member 5a of the stator core 1 is attached.

[0048] 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 located inside the coil side 10 in the radial direction 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.

[0049] 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 consists 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. Further, in this state, the portion 11a of the first coil end 11 of the coil 7u extending radially outward is disposed at the height position of the axially one end portion (the upper side in FIG. 7) of the first slot insulating member 5a.

[0050] FIG. 8 shows the state of 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 having the coil side 10 disposed in the slot 4 project 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.

[0051] 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 the axially one side of the stator core 1 to the axially other 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 of the coil side 10 located radially outside the second coil end 12 of the coil 7u, it can be surely disposed in contact with the second coil end 12 of the coil 7u and will not fall off.

[0052] 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.

[0053] When the placement of the second insulating ring 13b is completed, the coil 7v is attached to the stator core 1. The coil 7v is attached in the same manner as the coil 7u, that is, from one axial side of the stator core 1 shown in FIG. 10 toward the other axial side, by inserting the coil side 10 shown in FIG. 4 into the slot 4 to which the second slot insulating member 5b is attached.

[0054] As shown in FIG. 10, when the coil side 10 is inserted 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.

[0055] 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.

[0056] In this state, the portion 11a extending radially outside the first coil end 11 of the coil 7v is disposed at the height position of one axial end portion (the upper side in FIG. 11) of the second slot insulating member 5b. Also, 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 is located above a part of the first coil end 11 of the coil 7u.

[0057] 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.

[0058] Also, on the other axial side of the stator core 1, similar to the case where the coil 7u is attached, the one open end 8 and the other open end 9 of the coil 7v protrude downward from the other end face 1B of the stator core 1. Also, the second coil end 12 is located radially inward on the other end face 1B side of the stator core 1.

[0059] 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 axial side of the stator core 1 to the other axial side 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 abut against the second coil end 12 of the coil 7v.

[0060] 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 disposed on the first coil end 11 of the coil 7v located on the one end face 1A side of the stator core 1.

[0061] After the third insulating ring 13c is attached to the stator core 1, the coil 7w is attached to the stator core 1. The coil 7w is attached in the same manner as in the case of the coil 7u by inserting the coil side 10 shown in Fig. 4 into the slot 4 to which the slot insulating member 5c is attached from one axial side to the other axial side of the stator core 1 shown in Fig. 12.

[0062] As shown in FIG. 12, when inserting the coil side 10 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.

[0063] Then, when the coil 7w is deeply inserted into the slot 4 of the stator core 1, as shown in FIG. 13, since 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, 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. Further, the portion 11a extending radially outside the first coil end 11 of the coil 7w is disposed at the height position on the axial one side (the upper side in FIG. 13) of the third slot insulating member 5c.

[0064] 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 radially inside the stator core 1 on the other end face 1B side of the stator core 1.

[0065] 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.

[0066] On the other hand, the second coil end 12 of the coil 7w that has passed through the hollow portion H of the stator core 1 abuts against a 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.

[0067] As shown in FIG. 13, in a state where 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 within the slot 4 toward 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 within the slot 4 toward the other end face 1B side of the stator core 1.

[0068] One open end 8 of each phase coil 7u, 7v, 7w is electrically connected to an external power source (not shown), and by applying three-phase power to each phase coil 7u, 7v, 7w from the external power source, a rotating magnetic field is generated by each phase coil 7u, 7v, 7w to rotate a rotor (described later) disposed in the hollow portion H of the stator core 1.

[0069] Note that if the shape of the 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, by simply attaching the one open end 8 to the connector, complicated terminal processing can be avoided.

[0070] Figure 14 shows the other end face 1B of the stator core 1 shown in Figure 13. On the side of the other end face 1B, the other open end 9 functions as a neutral point when the phase coils 7u, 7v, and 7w are star-connected. For example, as shown in Figure 13, the three other open ends 9 protruding from the side of the other end face 1B of the stator core 1 are bent in the circumferential direction as shown in Figure 14 to form coil bars 9a. The coil bars 9a are crimped by crimping terminals 17 with the coils 7u and 7v, and the coils 7v and 7w overlapped respectively to connect the neutral points. In addition to forming the neutral points at two locations in this way, the coils 7u, 7v, and 7w can also be crimped with a crimping terminal as a single neutral point. Alternatively, the neutral points can be connected by welding the three other open ends 9 protruding from the side of the other end face 1B of the stator core 1 to a coil bar of another member. Or, the three other open ends 9 can be connected to a terminal by husing or soldered to form the neutral points.

[0071] Also, when the phase coils 7u, 7v, and 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 is applicable regardless of star connection or delta connection.

[0072] As shown in Figure 14, a sixth insulating ring 14c is placed in contact with the second coil end 12 of the coil 7u protruding from the lead side of the stator core 1. The sixth insulating ring 14c is installed by sliding it in laterally into the gap between the coil bar 9a and the second coil end 12 of the coil 7u shown in Figure 14. This makes it possible to reliably insulate between the coil 7u and the coil bar 9a.

[0073] 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, and thus the motor B of the present invention is configured. 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. Thereby, the demerit of cost increase due to molding can be eliminated, and it can contribute to the demand for recycling of product materials. If cost increase and recycling are not considered, it is also possible to enhance the insulation characteristics by molding the periphery of the stator core 1 and each phase coil 7u, 7v, 7w with an insulating resin.

[0074] 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 U phase, V phase, and W phase in this order 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.

[0075] 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 only necessary 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 to be selected.

[0076] 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 wire 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 slot insulating members 5a, 5b, 5c arranged in the slots 4 is also made to be a shape that can accommodate the cross-sectional shape of the coils 7u, 7v, 7w. Also, by designing the gaps between the slots 4 and the slot insulating members 5a, 5b, 5c and the coils 7u, 7v, 7w to be as narrow as possible, the occupation ratio of the coils 7u, 7v, 7w in the slots 4 can be increased.

[0077] 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.

[0078] 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 the same number of notch grooves 16 formed in its inner peripheral edge as the total number of coil sides 10 of each phase coil 7. When the insulating ring 15 (15a, 15b, 15c) is arranged 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 fix it firmly.

[0079] 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 (nylon 66), PEEK resin, etc., similar to the insulating rings 13 and 14.

[0080] As described above, the stator of the present invention is configured such that the protruding amount of the slot insulating member attached to the stator core from the end face (at least one end face) of the stator core 1 is made different, and the first coil end is arranged on one side in the axial direction and the second coil end is arranged on the other side in the axial direction. Therefore, the insulation distance between the first and second coil ends of each phase coil can be surely ensured by the slot insulating member.

[0081] In addition, 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.

[0082] Furthermore, by arranging an insulating ring at least at one location between the first coil ends and between the second coil ends of each phase, the first and second coil ends can be surely insulated by the insulating ring.

[0083] 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 it is possible to restrict the insulating ring from rotating in the circumferential direction.

[0084] Note that the technical scope of the present invention naturally extends to configurations variously modified within the scope not 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

[0085] It can be used for the stators constituting various motors.

Explanation of Signs

[0086] 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 5 Slot insulating member 5a First slot insulating member 5b Second slot insulating member 5c Third slot insulating member 6a1 First cuff part 6a2 Second cuff part 6b1 Third cuff part 6b2 Fourth cuff part 6c1 Fifth cuff part 6c2 Sixth 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 sides 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 12a portion extending radially inward from the second coil end 12b portion extending circumferentially from the second coil end 13, 14, 15 insulating rings 13a first insulating ring 13b second insulating ring 13c third insulating ring 14a fourth insulating ring 14b fifth insulating ring 14c sixth insulating ring 15a seventh insulating ring 15b eighth insulating ring 15c ninth insulating ring 16 notch groove 17 crimp terminal 18 rotor A stator B motor H hollow portion

Claims

1. Each phase coil wound between slots of a stator core is configured with one turn each, 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 continuously and including a portion extending radially outward from the one end and a portion extending in the circumferential direction, and on the other end face side of the stator core, a second coil end formed by connecting the other ends of the coil sides continuously and including a portion extending radially inward from the other end and a portion extending in the circumferential direction. In a stator having a step 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 another phase coil, by arranging slot insulation members having different axial lengths between the coil side and the slot, the protruding amounts of the slot insulation members from at least one end face of the stator core are made different, a portion extending radially outward of the first coil end is arranged on one axial end of the slot insulation member, and an insulation ring is arranged at least at one location between the first coil ends and between the second coil ends. A stator characterized by this.

2. The stator according to claim 1, characterized in that the slot insulation member forms a cuff portion by bending an axial end portion and hooks the cuff portion on the end face of the stator core.

3. The stator according to claim 1, characterized in that a notch groove is formed on the inner circumferential side of the insulation ring.

4. A motor characterized by having the stator according to claims 1 to 3.

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