Manufacturing method of motor, coil for the motor, and the motor

Abstract

To simplify a manufacturing process of a motor.SOLUTION: A manufacturing method of a motor 1 having a plurality of stator coils 9 to be wound to two or more teeth 83, comprises: a step of preparing a stator coil 9 in which a coil element 90 having first and second parts 91 and 92 that are inserted into a gap of the teeth 83, a third part 93 that is extended to connect each end part of the first and second parts 91 and 92, and a fourth part 94 that is extended to connect an another end part of the first and second parts 91 and 92 is repeatedly arranged to a stator shaft direction; and a step of compressing the stator coil 9 inserted into the a stator core 8 to a stator shaft direction. In view along a stator radial direction, at least one of the third and fourth parts 93 and 94 is inclined to a stator peripheral direction, and an inclination angle θ1 of the third part 93 and an inclination angle θ2 of the fourth part 94 are different each other.SELECTED DRAWING: Figure 6

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing a motor, a coil for a motor, and a motor.

Background Art

[0002] For example, Patent Document 1 discloses a coil used in a rotating device such as an electric motor or a generator. Specifically, the coil disclosed in Patent Document 1 is composed of conductors that are wound in a circumferential shape and laminated. This coil has a gap with a width through which one conductor passes between adjacent conductors. By accommodating the conductors of another coil in this gap, the coils can be assembled together.

[0003] According to Patent Document 1, a stator winding is formed by assembling a plurality of coils, and by inserting this into the teeth of a stator core, a stator of a motor is obtained.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] By the way, in order to insert the stator winding as described in Patent Document 1 into the teeth, it is necessary to provide a gap between the teeth and each coil. However, the existence of such a gap is inconvenient for stabilizing the attachment of the coil. Therefore, when using the method described in Patent Document 1, it is necessary to fill the gap with varnish or the like. This is inconvenient because it complicates the manufacturing process of the motor.

[0006] Such problems are common not only in so-called axial motors but also in radial motors.

[0007] The present disclosure has been made in view of such points, and an object thereof is to simplify the manufacturing process of a motor.

Means for Solving the Problems

[0008] A first aspect of the present disclosure relates to a method for manufacturing an axial-type motor configured by a stator including a stator core having a plurality of teeth arranged in the circumferential direction of the stator, and a plurality of stator coils wound across two or more of the plurality of teeth. The manufacturing method includes preparing a plurality of coils in which coil elements having a first portion and a second portion that extend from the inside to the outside along the radial direction of the stator, are spaced apart in the circumferential direction of the stator, and are respectively inserted into gaps between the plurality of teeth, a third portion that extends to connect end portions on the inner side in the radial direction of the stator of the first and second portions, and a fourth portion that extends to connect end portions on the outer side in the radial direction of the stator of the first and second portions, are repeatedly arranged in the axial direction of the stator; inserting the plurality of stator coils into the stator core; and compressing the plurality of stator coils inserted into the stator core in the axial direction of the stator. When viewed along the radial direction of the stator, at least one of the third portion and the fourth portion is inclined with respect to the circumferential direction of the stator, and the inclination angle of the third portion with respect to the circumferential direction of the stator is made different from the inclination angle of the fourth portion with respect to the circumferential direction of the stator.

[0009] Here, the “circumferential direction of the stator” includes not only the circumferential direction of the stator in the assembled state of the stator but also the direction that will coincide with the circumferential direction of the stator when the stator is assembled. The same applies to the axial direction and the radial direction of the stator.

[0010] According to the first aspect, by inclining at least one of the third and fourth portions, the stator coil can function as a compression coil spring. For example, when a load is applied to the stator coil from above in the axial direction, the stator coil can be compressed in the axial direction.

[0011] During the compression, the fourth portion rotates downward with the first portion as a fulcrum, or the third portion rotates downward with the second portion as a fulcrum. When the third portion and the fourth portion are axially crushed, at least one of these elements will be flattened along the circumferential direction.

[0012] At this time, when the third portion and the fourth portion rotate as described above, the distance between the first portion and the second portion (particularly, the distance in the direction along the stator circumferential direction) will increase. This corresponds to the increase in the spring diameter accompanying the compression of the compression coil spring.

[0013] As a result, when inserting into the stator core, the stator coil can be inserted with a clearance. This facilitates the insertion into the stator core.

[0014] Moreover, after inserting into the stator core, by axially compressing the stator coil, as a result of expanding the spring diameter as described above, the stator coil can be in a press-fitted state. This can stabilize the attachment of the coil without using varnish or the like, contributing to the simplification of the manufacturing process.

[0015] Furthermore, by making the inclination angles of the third portion and the fourth portion different, it is possible to intentionally disrupt the balance of the amount of spring diameter expansion between the inner diameter side where the third portion is located and the outer diameter side where the fourth portion is located.

[0016] As a result, the position where the stator core and the stator coil are in close contact can be adjusted inward and outward along the stator radial direction. This can improve the robustness during coil fixing.

[0017] Also, according to a second aspect of the present disclosure, the plurality of coil elements may be configured to keep the inclination angle in at least one of the third portion and the fourth portion constant in the stator axis direction.

[0018] According to the second aspect, it can be suitable for attachment to teeth extending parallel to each other along the stator axis direction, such as an axial type motor. That is, the amount of increase in the spring diameter can be kept constant at various positions in the stator axis direction.

[0019] Also, according to a third aspect of the present disclosure, when viewed in plan along the stator axis direction, the fourth portion and the first portion may intersect perpendicularly, while the fourth portion and the second portion intersect perpendicularly.

[0020] Also, according to the third aspect of the present disclosure, by making the fourth portion intersect perpendicularly with the first or second portion in plan view, the turning of the fourth portion around the first or second portion as a fulcrum can be made smooth. Also, the amount of increase in the spring diameter accompanying the turning of the fourth portion can be made as large as possible.

[0021] Also, according to a fourth aspect of the present disclosure, before inserting the plurality of stator coils into the stator core, a coil body may be formed by combining the plurality of stator coils annularly along the stator circumferential direction, and the coil body may be inserted into the stator core.

[0022] According to the fourth aspect, by configuring the stator coils in a compression coil spring shape as in the first aspect, the intervals between the first portions in the stator axis direction and the intervals between the second portions in the same direction can be ensured to be longer. That is, since it will ultimately be compressed in the stator axis direction, at the stage before attachment to the stator core, it is allowed to ensure a longer interval between them.

[0023] Therefore, the coil body as in the fourth aspect can be easily assembled, which is advantageous in simplifying the manufacturing process.

[0024] Further, a fifth aspect of the present disclosure relates to a motor coil that constitutes a stator of an axial-type motor by being wound across two or more of a plurality of teeth arranged in the stator circumferential direction. The motor coil includes a plurality of coil elements repeatedly arranged in the stator axial direction. In a state where the plurality of coil elements are removed from the plurality of teeth, each of the coil elements extends from the outside to the inside in the stator radial direction and is spaced apart in the stator circumferential direction, and a first portion and a second portion that are respectively inserted into gaps between the plurality of teeth, a third portion that extends to connect end portions of the first and second portions on the inner side in the stator radial direction, and a fourth portion that extends to connect end portions of the first and second portions on the outer side in the stator radial direction. When viewed along the stator radial direction, at least one of the third portion and the fourth portion is inclined with respect to the stator circumferential direction, and an inclination angle of the third portion with respect to the stator circumferential direction is different from an inclination angle of the fourth portion with respect to the stator circumferential direction.

[0025] Note that the "stator circumferential direction" as used herein includes not only the "circumferential direction of the stator in the assembled state of the stator" but also the "direction that will coincide with the circumferential direction of the stator when the stator is assembled". The same applies to the stator axial direction and the stator radial direction.

[0026] According to the fifth aspect, it is possible to simplify the manufacturing process and at the same time improve the robustness during coil fixing.

[0027] Also, a sixth aspect of the present disclosure relates to a method of manufacturing a radial-type motor, which is constituted by a stator including a stator core having a plurality of teeth arranged in the circumferential direction of the stator, and a plurality of stator coils wound across two or more of the plurality of teeth. The manufacturing method includes a step of preparing a plurality of coil elements having, as the plurality of stator coils, a first portion and a second portion that extend from one end side to the other end side along the axial direction of the stator, are spaced apart in the circumferential direction of the stator, and are respectively inserted into gaps between the plurality of teeth, a third portion that extends to connect end portions on one end side in the axial direction of the stator of the first and second portions, and a fourth portion that extends to connect end portions on the other end side in the axial direction of the stator of the first and second portions, and arranging the plurality of coil elements in a plurality of coils repeatedly arranged in the radial direction of the stator; and a step of inserting the plurality of stator coils into the stator core and compressing them in the radial direction of the stator. When viewed along the axial direction of the stator, at least one of the third portion and the fourth portion is inclined with respect to the circumferential direction of the stator, and the inclination angle of the third portion with respect to the circumferential direction of the stator is made different from the inclination angle of the fourth portion with respect to the circumferential direction of the stator.

[0028] Note that the "circumferential direction of the stator" as used herein includes not only the circumferential direction of the stator in the assembled state of the stator but also the direction that will coincide with the circumferential direction of the stator when the stator is assembled. The same applies to the axial direction and the radial direction of the stator.

[0029] According to the sixth aspect, in the case of a radial-type motor, each tooth projects along the radial direction of the stator. For example, the projecting direction of the tooth arranged at the 1 o'clock or 11 o'clock position is inclined obliquely with respect to the projecting direction of the tooth arranged at the 12 o'clock position. The interval between the teeth in the circumferential direction of the stator gradually increases from the inner side to the outer side along the radial direction of the stator.

[0030] In this case, in order to wind the stator coil so as to straddle two or more of the plurality of teeth, it is conceivable to use a stator coil that expands from the inner side to the outer side in the radial direction when viewed from the center of rotation of the motor. However, such a stator coil has room for improvement because it is inconvenient for attachment to the stator core.

[0031] On the other hand, similar to the first aspect, by using a stator coil such as a compression coil spring, the stator coil can be expanded by utilizing the expansion of the coil diameter accompanying the compression of the coil. As a result, the stator coil can be smoothly inserted into the stator core and brought into a press-fitted state. Thereby, the attachment of the coil can be stabilized, contributing to the simplification of the manufacturing process.

[0032] On the other hand, when inserting into the stator core, the stator coil before the expansion of the coil diameter is used. This facilitates the insertion into the stator core for a radial type motor.

[0033] Furthermore, by making the inclination angles of the third part and the fourth part different, the position where the stator core and the stator coil are in close contact can be adjusted along the stator axis direction. Thereby, the robustness at the time of coil fixing can be improved.

[0034] Moreover, a seventh aspect of the present disclosure relates to a motor coil that forms a stator of a radial-type motor by being wound across two or more of a plurality of teeth arranged in the circumferential direction of the stator. The motor coil includes a plurality of coil elements repeatedly arranged in the radial direction of the stator. In a state where the plurality of coil elements are removed from the plurality of teeth, each of the coil elements extends from one end side to the other end side in the axial direction of the stator and is spaced apart in the circumferential direction of the stator, and includes a first portion and a second portion that are respectively inserted into gaps between the plurality of teeth, a third portion that extends to connect ends of the first and second portions on one end side in the axial direction of the stator, and a fourth portion that extends to connect ends of the first and second portions on the other end side in the axial direction of the stator. When viewed along the axial direction of the stator, at least one of the third portion and the fourth portion is inclined with respect to the circumferential direction of the stator, and an inclination angle of the third portion with respect to the circumferential direction of the stator is different from an inclination angle of the fourth portion with respect to the circumferential direction of the stator.

[0035] Note that the "circumferential direction of the stator" as used herein includes not only the circumferential direction of the stator in the assembled state of the stator but also the direction that will coincide with the circumferential direction of the stator when the stator is assembled. The same applies to the axial direction and the radial direction of the stator.

[0036] According to the seventh aspect, it can be made suitable for attachment to teeth extending along the radial direction of the stator, such as in a radial-type motor. That is, by gradually increasing the inclination angle, the amount of expansion of the spring diameter can be changed in the radial direction of the stator. Thus, like in a radial-type motor Moreover, according to an eighth aspect of the present disclosure, the plurality of coil elements may be configured such that at least one of the inclination angles of the third portion and the fourth portion gradually increases as going from the inner side to the outer side in the radial direction of the stator.

[0037] According to the eighth aspect, it is possible to simplify the manufacturing process and at the same time improve the robustness during coil fixing.

[0038] Moreover, the ninth aspect of the present disclosure relates to a motor. This motor includes a stator constituted by the motor coil.

Effect of the Invention

[0039] As described above, according to the present disclosure, it is possible to simplify the manufacturing process of the motor.

Brief Description of the Drawings

[0040]

Figure 1

Figure 2A

Figure 2B

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Figure 12

Figure 13

Mode for Carrying Out the Invention

[0041] Hereinafter, embodiments of the present disclosure will be described with reference to the drawings. Note that the following description is an exemplification.

[0042] FIG. 1 is a longitudinal sectional view showing the entirety of a motor 1 according to a first embodiment (hereinafter, also simply referred to as “embodiment”) of the present disclosure. FIG. 2A is a plan view showing a main part of a stator 5. FIG. 2A exemplifies a state in which a yoke 81 of the stator 5 and the like are removed. FIG. 2B is a plan view exemplifying a part of the stator 5. FIG. 2B exemplifies a state in which the state exemplified in FIG. 2A is enlarged and only one of a plurality of stator coils 9 is attached.

[0043] (1) First Embodiment <Overall Configuration of the Motor> The motor 1 shown in FIG. 1 is a permanent magnet type synchronous motor driven by three-phase alternating current. The use of the motor 1 is not particularly limited, and for example, it is a drive motor for electric vehicles such as hybrid vehicles (HV) and electric vehicles (EV), and a motor for home appliances such as air conditioners, washing machines, and refrigerators.

[0044] As shown in FIG. 1, the motor 1 generally includes a motor case 2, a shaft 3, a rotor 4, and a stator 5.

[0045] The motor 1 is a so-called axial gap motor. The motor 1 can also be called an axial type motor 1. That is, as shown in FIG. 1, the motor 1 has a layout in which the rotor 4 and the stator 5 are arranged along the axial direction of the shaft 3.

[0046] The axial motor 1 is thinner than the conventional radial motor and is advantageous for increasing its output power. This is particularly suitable for mounting on an automobile.

[0047] Specifically, the motor case 2 is constituted by a container that forms a substantially cylindrical space. The motor case 2 houses the rotor 4 and the stator 5.

[0048] The shaft 3 is rotatably supported by bearings of the motor case 2. The shaft 3 is inserted into the rotor 4 and the stator 5. The shaft 3 rotates integrally with the rotor 4.

[0049] Hereinafter, in the assembled state of the stator 5, the direction that coincides with the stator circumferential direction is defined as the circumferential direction, the direction that coincides with the stator radial direction is defined as the radial direction, and the direction that coincides with the stator axial direction is defined as the axial direction.

[0050] In this case, as shown by the broken line Ac in FIG. 1, the axial direction coincides with the direction along the central axis of the shaft 3. As shown by the broken line Ar in FIG. 1 and the like, the radial direction coincides with the direction extending radially from the central axis of the shaft 3. As shown by the arrow Aθ in FIG. 2A, the circumferential direction coincides with the direction of orbiting around the axial direction.

[0051] Hereinafter, when explaining the structure of the stator coil 9 before assembly, the direction that will coincide with the stator circumferential direction after assembly will also be referred to as the circumferential direction. The same applies to the radial direction and the axial direction.

[0052] That is, the "stator circumferential direction (circumferential direction)" as used here includes not only the "circumferential direction of the stator 5 in the assembled state of the stator 5" but also the "direction that will coincide with the circumferential direction of the stator 5 when the stator 5 is assembled". The same applies to the stator axial direction (axial direction) and the stator radial direction (radial direction).

[0053] <Rotor> The rotor 4 has a rotor core 6 and a plurality of magnets 7 (illustrated only in FIG. 1). In this embodiment, the rotors 4 are arranged one above and one below the stator 5.

[0054] (Rotor Core) The rotor core 6 is a disc-shaped member having a through-hole at its center. The shaft 3 is fixed to the rotor core 6. Thus, as described above, the shaft 3 and the rotor 4 rotate integrally.

[0055] (Magnet) The plurality of magnets 7 are each arranged inside the rotor core 6. The plurality of magnets 7 are arranged side by side in the circumferential direction of the rotor core 6. Each magnet 7 is composed of a permanent magnet.

[0056] <Stator> The stator 5 has a stator core 8 and a plurality of stator coils 9 arranged side by side in the circumferential direction. The stator 5 is located between the two rotors 4 in the axial direction. The stator 5 is arranged at an axial interval with respect to both of the two rotors 4.

[0057] The stator core 8 has yokes 81 and a plurality of teeth 83. In this embodiment, the yokes 81 are arranged one above and one below the plurality of teeth 83.

[0058] Each yoke 81 is a disc-shaped member having a through-hole at its center. The shaft 3 is inserted through the through-hole of each yoke 81. The two yokes 81 sandwich and support the plurality of teeth 83 from above and below.

[0059] The plurality of teeth 83 are arranged at equal intervals in the circumferential direction. The gaps between adjacent teeth 83 each form a slot 85. Each tooth 83 has two long-side portions 83a that extend radially along the radial direction when viewed along the axial direction. Each slot 85 is formed between the long-side portion 83a of one tooth 83 and the long-side portion 83a of another adjacent tooth 83.

[0060] The plurality of stator coils 9 are each wound across two or more of the plurality of teeth 83. In the present embodiment, for example, as shown in FIG. 2B, each stator coil 9 is wound across 33 teeth 83. Each stator coil 9 is wound so as to be a so-called distributed winding.

[0061] That is, assuming that n is a positive integer and the first stator coil 9 is wound across the nth tooth 83, the (n + 1)th tooth 83, and the (n + 2)th tooth 83 in the circumferential direction. In this case, the subsequent second stator coil 9 is wound across the (n + 1)th tooth 83, the (n + 2)th tooth 83, and the (n + 3)th tooth 83. Similarly, the subsequent third stator coil 9 is wound across the (n + 2)th tooth 83, the (n + 3)th tooth 83, and the (n + 4)th tooth 83.

[0062] The stator coil 9 according to the present embodiment is configured to have a characteristic shape at least before being attached to the teeth 83 or when removed from the teeth 83. Hereinafter, such characteristic portions will be described in detail.

[0063] <Details of the Stator Coil> FIG. 3 is a perspective view illustrating the structure of the stator coil 9 before attachment, and FIG. 4 is a perspective view illustrating the structure of the coil element 90 before attachment. Further, FIG. 5 is a plan view illustrating the structure of the coil element 90 before attachment, and FIG. 6 is a front view illustrating the structure of the coil element 90 before attachment. FIG. 6 corresponds to a view of the upper end portion of the stator coil 9 as seen from the outside in the radial direction toward the inside.

[0064] In addition, FIG. 7 is a diagram for explaining the compression of the stator coil 9, and FIG. 8 is a diagram for explaining the connection between the stator coils 9.

[0065] As shown in FIG. 3, the stator coil 9 has a helical shape with a central axis extending in the axial direction. Also, as shown in the same figure, in this stator coil 9, substantially ring-shaped coil elements 90 are repeatedly arranged in the axial direction. In other words, the stator coil 9 has a periodic structure with each coil element 90 as a unit. In the stator coil 8, a plurality of coil elements 90 are connected in the axial direction.

[0066] Furthermore, as shown in FIGS. 4 to 6, each coil element 90 has a first portion 91, a second portion 92, a third portion 93, and a fourth portion 94. The first portion 91, the second portion 92, the third portion 93, and the fourth portion 94 are formed of thin plate-like metal having a smaller axial thickness compared to the radial and circumferential dimensions.

[0067] Here, as shown in FIG. 5, the first portion 91 and the second portion 92 extend from the inside to the outside along the radial direction. The first portion 91 and the second portion 92 are positioned at intervals in the circumferential direction. The interval between the two gradually widens from the inside to the outside in the radial direction. As shown in FIG. 2B, the first portion 91 and the second portion 92 are respectively inserted into the gaps between the plurality of teeth 83, that is, each slot 85.

[0068] The third portion 93 extends so as to connect the inner diameter side ends of the first and second portions 91 and 92 respectively. The third portion 93 extends straight from the inner diameter side end of the first portion 91 in the radially inner (inner diameter side) direction and then extends straight in the radially outer (outer diameter side) direction toward the inner diameter side end of the second portion 92.

[0069] The fourth portion 94 extends so as to connect the outer diameter side ends of the first and second portions 91 and 92 respectively. The fourth portion 94 extends straight in the outer diameter side direction from the outer diameter side end of the first portion 91 and then extends straight in the inner diameter side direction toward the outer diameter side end of the second portion 92.

[0070] The third part 93 and the fourth part 94 are formed to be line-symmetrical in a plan view with respect to a center line (e.g., broken line Ar) extending along the radial direction. The position where the extending direction of the third part 93 changes and the part where the extending direction of the fourth part 94 changes are both located on the broken line Ar.

[0071] Also, when the stator coil 9 according to this embodiment is viewed in a plan view along the axial direction, the fourth part 94 and the first part 91 intersect perpendicularly, while the fourth part 94 and the second part 92 intersect perpendicularly (angle θx = 90° in FIG. 5). Also, assuming that m is a positive integer, the fourth part 94 connects the first and second parts 91 and 92 in the m-th coil element 90. In this case, at least the third part 93 connects the first part 91 in the m-th coil element 90 and the second part 92 in the (m + 1)-th coil element 90, or connects the first part 91 in the (m + 1)-th coil element 90 and the second part 92 in the m-th coil element 90.

[0072] Alternatively, assume that the third part 93 connects the first and second parts 91 and 92 in the m-th coil element 90. In this case, at least the fourth part 94 connects the first part 91 in the m-th coil element 90 and the second part 92 in the (m + 1)-th coil element 90, or connects the first part 91 in the (m + 1)-th coil element 90 and the second part 92 in the m-th coil element 90.

[0073] For example, as shown in FIG. 6, when the stator coil 9 is viewed along the radial direction, in order from above in the axial direction, the second part 92, the fourth part 94, the first part 91, and the third part 93 belonging to the m-th coil element 90 appear, and then the second part 92, the fourth part 94, the first part 91, and the third part 93 belonging to the (m + 1)-th coil element 90 appear.

[0074] In this case, the third portion 93 belonging to the m-th coil element 90 will connect the first portion 91 in the m-th coil element 90 and the second portion 92 in the (m + 1)-th coil element 90, as exemplified above.

[0075] To realize such a connection structure, in this embodiment, as shown in FIG. 6, while the first and second portions 91 and 92 extend flat along the radial direction and the circumferential direction, the third and fourth portions 93 and 94 do not extend flat along the radial direction and the circumferential direction.

[0076] That is, at least one (both in the first embodiment) of the third and fourth portions 93 and 94 according to this embodiment is inclined with respect to the circumferential direction. And, as shown in FIG. 6, the inclination angle of the third portion 93 (first inclination angle θ1) with respect to the circumferential direction and the inclination angle of the fourth portion 94 (second inclination angle θ2) are different from each other. In the case of the example shown in FIG. 6, the first inclination angle θ1 is set to be larger than the second inclination angle θ2 (that is, θ1 > θ2).

[0077] By inclining the third and fourth portions 93 and 94 respectively, the stator coil 9 can function as a compression coil spring. For example, when a load is applied to the stator coil 9 from above in the axial direction, the stator coil 9 will be compressed in the axial direction.

[0078] During the compression, the fourth portion 94 will pivot downward with the first portion 91 as a fulcrum, and the third portion 93 will pivot downward with the second portion 92 as a fulcrum. When the third portion 93 and the fourth portion 94 are crushed in the axial direction, these elements will be stretched flat along the circumferential direction.

[0079] At that time, by the third portion 93 and the fourth portion 94 pivoting as described above respectively, the distance between the first portion 91 and the second portion 92 (particularly, the distance in the direction along the circumferential direction) will increase. This corresponds to the increase in the spring diameter accompanying the compression of the compression coil spring.

[0080] Furthermore, by making the first inclination angle θ1 different from the second inclination angle θ2, it is possible to intentionally disrupt the balance of the amount of spring diameter expansion between the inner diameter side where the third portion 93 is located and the outer diameter side where the fourth portion 94 is located.

[0081] For example, when the first inclination angle θ1 is set to be larger than the second inclination angle θ2, as shown by the double arrows in the lower diagram of FIG. 7, the amount of expansion on the inner diameter side can be intentionally made larger than the amount of expansion on the outer diameter side. By doing so, after compression, the stator coil 9 can be moved closer to the outer diameter side. This becomes a more suitable configuration when there is a margin in the space on the outer diameter side of the stator coil 9.

[0082] Also, the distance D1 between the first portion 91 belonging to the m-th coil element 90 and the first portion 91 belonging to the (m + 1)-th coil element 90 is set to be at least larger than the thickness of the plate-like metal constituting the coil element 90. This distance is larger than the thicknesses of the first portion 91 and the second portion 92.

[0083] Similarly, the distance D2 between the second portion 92 belonging to the m-th coil element 90 and the second portion 92 belonging to the (m + 1)-th coil element 90 is set to be at least larger than the thickness of the plate-like metal constituting the coil element 90. This distance is larger than the thicknesses of the first portion 91 and the second portion 92.

[0084] The same also applies to the distances between the third portion 93 and the fourth portion 94 respectively.

[0085] By configuring in this way, as illustrated in FIG. 8, it becomes easy to insert one second portion 92 of another stator coil 9 into the gap between the two first portions 91, 91 in one stator coil 9.

[0086] <Method for manufacturing a stator> Next, among the manufacturing methods of the motor 1, the manufacturing method of the stator 5 in particular will be described. FIGS. 9 and 10 are diagrams for explaining the manufacturing procedure of the stator 5. The steps shown in FIGS. 9 and 10 are all to be performed by mechanical means (assembly means) such as a robot.

[0087] First, as shown in FIG. 9(a), as the stator coil 9, a plurality of coils are prepared in which coil elements 90 composed of the first part 91, the second part 92, the third part 93, and the fourth part 94 configured as described above are arranged axially.

[0088] Subsequently, as shown in FIGS. 9(b) and 9(c), before inserting the plurality of stator coils 9 into the stator core 8 respectively, a coil body 900 is formed by combining the plurality of stator coils 9 annularly along the circumferential direction.

[0089] The formation of the coil body 900 is realized by inserting the second part 92 of another stator coil 9 between the first parts 91, 91 adjacent axially in one stator coil 9, as described with reference to FIG. 8.

[0090] Thereafter, as shown in FIG. 9(d), the plurality of stator coils 9 are inserted into the stator core 8 respectively. As a result, the stator coils 9 are wound around each tooth 83 of the stator core 8. Specifically, this step is realized by inserting the coil body 900 formed by the plurality of stator coils 9 into the stator core 8.

[0091] Thereafter, as shown in FIG. 9(e), the coil body 900 inserted into each tooth 83 of the stator core 8 is compressed axially, and the yoke 81 is fixed from both the upper and lower sides in the axial direction. By fixing the yoke 81, the stator 5 is completed.

[0092] <Regarding the Simplification of the Motor Manufacturing Process> As described above, according to the first embodiment, as illustrated in FIG. 6, by inclining the third and fourth portions 93 and 94 respectively, the stator coil 9 can function as a compression coil spring. For example, when a load is applied to the stator coil 9 from above in the stator axis direction, the stator coil 9 can be compressed in the stator axis direction.

[0093] During the compression, while rotating the third portion 93 with one of the first portion 91 and the second portion 92 as a fulcrum, the fourth portion 94 is rotated with the other of the first portion 91 and the second portion 92 as a fulcrum. Due to these rotations, the distance between the first portion 91 and the second portion 92 (particularly, the distance in the direction along the stator circumferential direction) will increase. This corresponds to the increase in the spring diameter accompanying the compression of the compression coil spring.

[0094] As a result, when inserting into the stator core 8, the stator coil 9 can be inserted with a clearance. This makes it easier to insert the stator coil 9 into the stator core 8.

[0095] Moreover, as illustrated in FIGS. 7 and 10(e), after inserting into the stator core 8, by axially compressing the stator coil 9, as a result of expanding the spring diameter as described above, the stator coil 9 can be brought into a press-fitted state. This enables the attachment of the stator coil 9 to be stabilized without using varnish or the like, contributing to the simplification of the manufacturing process.

[0096] Furthermore, as illustrated in FIG. 6, by making the inclination angles of the third portion 93 and the fourth portion 94 different, the balance of the amount of spring diameter expansion can be intentionally disrupted between the inner diameter side where the third portion 93 is located and the outer diameter side where the fourth portion 94 is located.

[0097] As a result, the position where the stator core 8 and the stator coil 9 are in close contact can be adjusted inward and outward along the stator diameter direction. This can improve the robustness during coil fixation.

[0098] Also, as illustrated in FIGS. 3 and 6, the plurality of coil elements 90 according to the first embodiment are configured to keep the inclination angles θ1 and θ2 of the third portion 93 and the fourth portion 94 constant in the stator axis direction. By doing so, it can be made suitable for attachment to the teeth 83 extending in parallel along the stator axis direction, such as in the axial type motor 1. That is, the amount of increase in the spring diameter can be kept constant at various positions in the axial direction.

[0099] Also, as illustrated in FIG. 5, by making the fourth portion 94 and the first portion 91 intersect perpendicularly in a plan view, the turning of the fourth portion 94 with the first portion 91 as a fulcrum can be made smooth. Also, the amount of increase in the spring diameter accompanying the turning of the fourth portion 94 can be made as large as possible.

[0100] Also, by configuring the stator coil 9 in the form of a compression coil spring as described above, the intervals between the first portions 91 in the stator axis direction and the intervals between the second portions 92 in the same direction can be ensured to be longer. That is, since it will ultimately be compressed in the stator axis direction, at the stage before attachment to the stator core 8, it is allowed to ensure a longer interval between them.

[0101] Therefore, the connection as illustrated in FIG. 8 can be easily performed, and the coil body 900 as shown in FIG. 9(c) can be easily assembled. This is advantageous in achieving simplification of the manufacturing process.

[0102] (2) Modification of the First Embodiment In the first embodiment, the first inclination angle θ1 was set to be larger than the second inclination angle θ2, but the present disclosure is not limited to such a setting. For example, the second inclination angle θ2 may be set to be larger than the first inclination angle θ1.

[0103] For example, when the second inclination angle θ2 is set to be larger than the first inclination angle θ1, upon compression of the stator coil 9, the amount of expansion on the outer diameter side becomes larger than the amount of expansion on the inner diameter side. Due to this, after compression, the stator coil 9 can be moved closer to the inner diameter side. This becomes a more suitable configuration when there is a margin in the space on the inner diameter side of the stator coil 9.

[0104] (3) Second Embodiment <Configuration of Motor and Stator Coil> Next, a second embodiment of the present disclosure will be described. Hereinafter, descriptions overlapping with the first embodiment will be explained as appropriate. FIG. 11 is a schematic diagram illustrating a motor 1' according to the second embodiment. FIG. 12 is a schematic diagram illustrating a stator coil 9' according to the second embodiment. FIG. 13 is a diagram for explaining the manufacturing procedure of the stator 5' in the second embodiment.

[0105] The motor 1' according to the second embodiment is a radial type motor. That is, the rotor (not shown) and the stator 5' are arranged along the radial direction of the motor 1'.

[0106] In this case, each tooth 83' protrudes along the stator radial direction. For example, with respect to the protruding direction of the tooth 83' arranged at the 6 o'clock position, the protruding direction of the tooth 83' arranged at the 5 o'clock or 7 o'clock position is obliquely inclined. The interval between the teeth in the stator circumferential direction gradually expands from the inside to the outside along the stator radial direction.

[0107] In this case, in order to wind the stator coil 9' so as to straddle two or more of the plurality of teeth 83', it is conceivable to use a stator coil 9' that widens from the inner side to the outer side in the radial direction when viewed from the rotation center of the motor 1'. However, such a stator coil 9' has a problem in attaching it to the stator core 8', and thus there is room for improvement. In fact, when using a stator coil that widens before compression, it cannot be inserted into the tip of the tooth 83' to be wound in the first place. When using a stator coil that does not widen regardless of compression, it cannot be inserted to the back of the tooth 83' to be wound.

[0108] On the other hand, the stator coil 9' according to the second embodiment is devised in the same way as the first embodiment. Thereby, even when used in a radial type motor 1', the same operational effects as those of the first embodiment can be utilized to solve the above-described problems.

[0109] Here, in the assembled state of the stator 5', the direction that coincides with the stator circumferential direction is defined as the circumferential direction (see double-headed arrow A1), the direction that coincides with the stator axial direction is defined as the axial direction (see circle A2), and the direction that coincides with the stator radial direction is defined as the radial direction (see chain line A3).

[0110] Similar to the first embodiment, the "stator circumferential direction (circumferential direction)" as used herein includes not only the circumferential direction of the stator 5' in the assembled state of the stator 5', but also the direction that will coincide with the circumferential direction of the stator 5' when the stator 5' is assembled. The same applies to the stator axial direction (axial direction) and the stator radial direction (radial direction).

[0111] In this case, as the plurality (only one is shown in the figure) of stator coils 9', a coil in which coil elements 90' having a first portion 91', a second portion 92', a third portion 93' and a fourth portion 94' are repeatedly arranged in the radial direction is used.

[0112] The first part 91' and the second part 92' extend axially from one end side to the other end side (one side and the other side in the direction perpendicular to the paper surface) and are circumferentially spaced apart, and are respectively inserted into the gaps between the plurality of teeth 83'.

[0113] The third part 93' extends so as to connect the end portions on the axially one end side (the back side of the paper surface) of the first part 91' and the second part 92' respectively.

[0114] The fourth part 94' extends so as to connect the end portions on the axially other end side (the front side of the paper surface) of the first part 91' and the second part 92' respectively.

[0115] Assuming that l is a positive integer, particularly in the illustrated example, the fourth part 94' connects the first and second parts 91', 92' in the l-th coil element 90', and the third part 93' connects the first part 91' in the l-th coil element 90' and the second part 92' in the (l + 1)-th coil element 90'. The connection structure is not limited to such a structure as in the first embodiment.

[0116] And, as suggested in FIG. 12, at least one of the third part 93' and the fourth part 94' (only the third part 93' in the second embodiment) is configured to be inclined with respect to the circumferential direction (particularly, the tangent in the circumferential direction perpendicular to the radial direction) when viewed axially.

[0117] Also, in this second embodiment, the fourth part 94' is not inclined with respect to the circumferential direction. Therefore, similar to the first embodiment, the inclination angle of the third part 93' with respect to the circumferential direction and the inclination angle of the fourth part 94' are made different from each other.

[0118] Also, in this second embodiment, the third part 93' is configured such that its inclination angle θ3 gradually increases as it goes from the inner side to the outer side in the radial direction (from the upper side to the lower side of the paper surface).

[0119] <Method for manufacturing a stator coil> Hereinafter, among the manufacturing methods of the motor 1', the manufacturing method of the stator 5' in particular will be described. FIG. 13 is a diagram for explaining the manufacturing procedure of the stator 5'. All the steps shown in FIG. 13 are configured to be performed by mechanical means (assembly means) such as a robot.

[0120] First, as shown in FIG. 13(a), as the stator coil 9', a plurality of coils are prepared in which coil elements 90' composed of the aforementioned first part 91', second part 92', third part 93', and fourth part 94' are arranged in the axial direction. In FIG. 13, only one coil is shown for simplicity.

[0121] Subsequently, as shown in FIG. 13(b), each stator coil 9' is inserted into the stator core 8', and at the same time as the insertion, each stator coil 9' is compressed in the radial direction. As a result, the spring diameter of each stator coil 9' expands. By utilizing the expansion of the spring diameter, the attachment of the stator coil 9' can be stabilized.

[0122] Also, in a portion where the inclination angle is set large, the spring diameter expands more greatly than in a portion where it is set small. As a result, even if the teeth 83' extend obliquely along the stator radial direction, it becomes possible to mount the stator coil 9' so as to straddle a plurality of teeth 83'.

[0123] Then, as shown in FIG. 13(c), by pressing the ring-shaped support member 10' from the inner diameter side, the stator coil 9' is held in a compressed state.

[0124] <Regarding Simplification of the Motor Manufacturing Process> As described above, similar to the first embodiment, by using the stator coil 9' such as a compression coil spring, the spring diameter expands as the coil is compressed, and the stator coil 9' can be widened. As a result, the stator coil 9' can be in a press-fitted state with respect to the stator core 8'. This can stabilize the attachment of the coil and contribute to the simplification of the manufacturing process.

[0125] On the other hand, when inserting into the stator core 8', the stator coil 9' before the spring diameter expands is used. This facilitates the insertion into the stator core 8' for the radial type motor 1'.

[0126] Furthermore, by making the inclination angles of the third part 93' and the fourth part 94' different, the position where the stator core 8' and the stator coil 9' are in close contact can be adjusted along the stator axis direction. By doing so, the robustness during coil fixation can be improved.

Explanation of reference numerals

[0127] 1, 1' motor 4 rotor 5, 5' stator 8, 8' stator core 83, 83' teeth 9, 9' stator coil 90, 90' coil element 91, 91' first part 92, 92' second part 93, 93' third part 94, 94' fourth part 900 coil body

Claims

1. A method for manufacturing an axial-type motor, comprising a stator composed of a stator core having a plurality of teeth arranged in the circumferential direction of the stator, and a plurality of stator coils wound across two or more of the plurality of teeth, wherein: As the plurality of stator coils, A first portion and a second portion that extend from the inside to the outside along the radial direction of the stator, are spaced apart in the circumferential direction of the stator, and are respectively inserted into gaps between the plurality of teeth; A third portion that extends to connect the inner ends of the first and second portions in the radial direction of the stator; A fourth portion that extends to connect the outer ends of the first and second portions in the radial direction of the stator, and preparing a plurality of coils in which coil elements having the fourth portion are repeatedly arranged in the axial direction of the stator; Inserting the plurality of stator coils into the stator core; Compressing the plurality of stator coils inserted into the stator core in the axial direction of the stator, and When viewed along the radial direction of the stator, At least one of the third portion and the fourth portion is inclined with respect to the circumferential direction of the stator, and The inclination angle of the third portion with respect to the circumferential direction of the stator is made different from the inclination angle of the fourth portion with respect to the circumferential direction of the stator. A method for manufacturing a motor, characterized by the above.

2. In the method for manufacturing a motor according to Claim 1, The plurality of coil elements are configured to keep the inclination angle in at least one of the third portion and the fourth portion constant in the axial direction of the stator. A coil for a motor, characterized by the above.

3. In the method for manufacturing a motor according to Claim 1, When viewed in a plan view along the axial direction of the stator, the fourth portion and the first portion intersect perpendicularly, while the fourth portion and the second portion intersect perpendicularly. A coil for a motor, characterized by the above.

4. In the method for manufacturing a motor according to Claim 1, Before inserting the plurality of stator coils into the stator core, a coil body is formed by combining the plurality of stator coils annularly along the circumferential direction of the stator, and the coil body is inserted into the stator core. A method for manufacturing a motor, characterized by the above.

5. A coil for a motor that constitutes a stator of an axial-type motor by being wound across two or more of a plurality of teeth arranged in the circumferential direction of the stator. comprising a plurality of coil elements repeatedly arranged in the stator axial direction; when the plurality of coil elements are removed from the plurality of teeth, each of them extends from the outside to the inside in the stator radial direction and is spaced apart in the stator circumferential direction, and has a first portion and a second portion respectively inserted into the gaps between the plurality of teeth, a third portion extending to connect the inner ends in the stator radial direction of the first and second portions respectively; a fourth portion extending to connect the outer ends in the stator radial direction of the first and second portions respectively, and having when viewed along the stator radial direction, at least one of the third portion and the fourth portion is inclined with respect to the stator circumferential direction, the inclination angle of the third portion with respect to the stator circumferential direction and the inclination angle of the fourth portion with respect to the stator circumferential direction are different from each other A coil for a motor, characterized in that.

6. A method for manufacturing a radial-type motor, comprising a stator core having a plurality of teeth arranged in the stator circumferential direction and a plurality of stator coils wound across two or more of the plurality of teeth, as the plurality of stator coils, a first portion and a second portion extending from one end side to the other end side along the stator axial direction and spaced apart in the stator circumferential direction, and respectively inserted into the gaps between the plurality of teeth, a third portion extending to connect the ends on one end side in the stator axial direction of the first and second portions respectively; a step of preparing a plurality of coils in which coil elements having a fourth portion extending to connect the ends on the other end side in the stator axial direction of the first and second portions respectively are repeatedly arranged in the stator radial direction, inserting the plurality of stator coils into the stator core respectively and compressing them in the stator radial direction, when viewed along the stator axial direction, inclining at least one of the third portion and the fourth portion with respect to the stator circumferential direction, and making the inclination angle of the third portion with respect to the stator circumferential direction and the inclination angle of the fourth portion with respect to the stator circumferential direction different from each other A method for manufacturing a motor, characterized in that.

7. A motor coil that constitutes a stator of a radial-type motor by being wound across two or more of a plurality of teeth arranged in the stator circumferential direction, comprising a plurality of coil elements repeatedly arranged in the radial direction of the stator; when the plurality of coil elements are removed from the plurality of teeth, each of them extends from one end side to the other end side in the stator axial direction and is spaced apart in the stator circumferential direction, and has a first portion and a second portion respectively inserted into the gaps between the plurality of teeth; a third portion extending so as to connect the ends of the first and second portions on one end side in the stator axial direction; a fourth portion extending so as to connect the ends of the first and second portions on the other end side in the stator axial direction, and has when viewed along the stator axial direction, at least one of the third portion and the fourth portion is inclined with respect to the stator circumferential direction, the inclination angle of the third portion with respect to the stator circumferential direction and the inclination angle of the fourth portion with respect to the stator circumferential direction are different from each other A coil for a motor, characterized in that.

8. In the coil for a motor according to claim 5, the plurality of coil elements are configured such that at least one of the inclination angles of the third portion and the fourth portion gradually increases as going from the inner side to the outer side in the radial direction of the stator A coil for a motor, characterized in that.

9. A motor comprising a stator constituted by the coil for a motor according to claim 4 or 6 A motor, characterized in that.

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