Motor, manufacturing method of motor, and insulator

Abstract

To easily arrange a lead wire part of a winding on an inner peripheral side of an insulator.SOLUTION: An insulator 5 attached to an annular stator core constituting a motor has a winding holding part 51 disposed on one end side in an axial direction of a stator core. A plurality of sets of first, second, and third crossover grooves 52U, 52V, and 52W which are respectively recessed from an outer peripheral side and extend in a circumferential direction and are arranged in order in an axial direction from the stator core side and a pair of slits 53-1 and 53-2 which are respectively recessed in the axial direction from a first end part of the winding holding part on both sides of a teeth 42 of the stator core in the circumferential direction and penetrate through the winding holding part in a radial direction, are formed in the winding holding part. A pair of first slits reaching the first crossover groove, a pair of second slits reaching the second crossover groove, and a pair of third slits reaching the third crossover groove which are the plurality of pairs of slits are repeatedly disposed in order in a first circumferential direction RD1.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] The present disclosure relates to a motor, a method for manufacturing a motor, and an insulator. [Background technology]

[0002] Patent Document 1 discloses a stator (armature) for a motor (electric motor) that includes a stator core, a winding, and an insulator. The stator core has multiple slots and multiple teeth formed between the slots. The winding is made of a single wire (solid wire) or a multi-filament wire formed by bundling multiple wires in a non-aligned manner. The winding has multiple coil portions wound around each of the multiple teeth, connecting portions (crossover portions) that connect the coil portions, and two lead wire portions extending from the coil portions at both ends to form the ends of the winding. The lead wire portions and crossover portions extending from each coil portion are drawn from the radially inner side to the outer side of the stator core through grooves (slits) formed in the insulator. The slits open at the ends of the insulator in the axial direction of the stator core. The crossover portions are housed in crossover grooves that extend circumferentially on the outer periphery of the insulator. A three-phase AC motor has windings for three phases. The crossover wires of the three phases (U, V, and W) are housed in three crossover grooves aligned in the axial direction of the insulator to electrically insulate the windings of different phases from each other. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] International Publication No. 2012 / 133302 Summary of the Invention [Problem to be solved by the invention]

[0004] In such a motor, when the windings of each phase are automatically attached to the stator core and insulator by a machine, first, while forming one lead-out portion, the winding is passed through a predetermined slit in the insulator and drawn into the inner periphery of the insulator, and then wound around a predetermined tooth in a concentrated winding to form a coil portion. Next, the winding is drawn out from the coil portion, passed through another slit in the insulator and drawn out to the outer periphery of the insulator, and placed in a predetermined jumper groove to form a jumper portion. After that, the winding is further passed through another slit and drawn into the inner periphery of the insulator, and then wound around another tooth in a concentrated winding to form another coil portion. Finally, the winding is drawn out from the other coil portion, passed through another slit in the insulator and drawn out to the outer periphery of the insulator to form the other lead-out portion. Therefore, the two lead-out portions of each winding are located on the outer periphery of the insulator.

[0005] In this type of motor, it is required to arrange the lead wires on the inner periphery side of the insulator to reduce the size of the motor. However, depending on the manner in which the three-phase windings are attached to the stator core and insulator, a crossover wire portion of a specific winding or a crossover wire portion of another winding may extend circumferentially around the stator core between the opening of a slit and the lead-out wire portion of the specific winding passed through the slit. In this case, the lead-out wire portion that is drawn to the outer periphery of the insulator cannot be pulled out through the opening of the slit and must be passed between the slit and the crossover wire portion, which is cumbersome. In particular, one of the two lead-out wire portions is long, which requires a long time to pass it between the slit and the crossover wire portion. This makes it difficult to manufacture motors (especially stators) efficiently.

[0006] The present disclosure has been made in consideration of such problems, and aims to provide a motor, a motor manufacturing method, and an insulator that enable the lead-out portions of a specified winding to be easily positioned on the inner side of an insulator. [Means for solving the problem]

[0007] A motor according to one aspect of the present disclosure includes a rotor, a stator including an annular stator core having a plurality of teeth and a plurality of slots arranged in a circumferential direction, an insulator attached to the stator core, and a plurality of windings wound around the plurality of teeth via the insulator, wherein when the number of poles of the rotor is P, the number of slots of the stator core is S, and n is a natural number equal to or greater than 2, the motor has the following characteristics: P:S=2n:3n or P:S=4n:3n the plurality of windings each have a plurality of coil portions wound around the teeth by concentrated winding, lead-out portions that form ends of the windings and extend from the coil portions, and crossover portions that connect adjacent ones of the coil portions, the coil portions from which the lead-out portions are drawn out from one side in the circumferential direction have the crossover portions drawn out from the other side in the circumferential direction, and the crossover portions drawn out from the other side in the circumferential direction of the coil portions extend to the other side in the circumferential direction relative to the coil portions, the plurality of windings include a first phase winding, a second phase winding, and a third phase winding, the coil portions of the first phase winding, the coil portions of the second phase winding, and the coil portions of the third phase winding are arranged repeatedly in order in a first circumferential direction in the circumferential direction, and the insulator is disposed on either one axial end side of the stator core. the winding holding portions are arranged at positions corresponding to both sides of each of the coil portions in the circumferential direction, and each of the winding holding portions has a plurality of pairs of slits that are recessed from one end side of the winding holding portion toward the other end side in the axial direction and that penetrate the stator core in a radial direction, the lead-out wire portions and the crossover wire portions extending from the coil portions can be led out to the outside of the winding holding portion in the radial direction by being inserted into the pair of slits, and of the plurality of pairs of slits, the axial depth of a pair of first-phase slits corresponding to the coil portions of the first-phase winding is equal to or greater than the axial depth of a pair of second-phase slits corresponding to the coil portions of the second-phase winding, and the axial depth of the second-phase slit is equal to or greater than the depth of a pair of third-phase slits corresponding to the coil portions of the third-phase winding.

[0008] a second step of forming a jumper wire portion by passing the first lead wire portion through the other of the pair of slits located on the first circumferential side of the first tooth and extending the first circumferential side of the first tooth while being accommodated in the jumper groove; a third step of forming a second coil portion by passing the first lead wire portion through one of the pair of slits located on the second circumferential side of a second tooth located away from the first tooth on the first circumferential side and winding the first lead wire portion on the second tooth; and a fourth step of forming a second lead wire portion by passing the first lead wire portion through the other of the pair of slits located on the first circumferential side of the second tooth. After the fourth step of the plurality of windings, the first lead-out portion of each of the plurality of windings is pulled out from the axial opening of the slit through which it passes and positioned inside the winding holding portion in the radial direction.

[0009] According to one aspect of the present disclosure, there is provided an insulator for a stator that constitutes a motor together with a rotor, the insulator being attached to a stator core of the stator formed in an annular shape having a plurality of teeth and a plurality of slots arranged in a circumferential direction, the insulator having a winding holding portion arranged on either one end side in an axial direction of the stator core, the winding holding portions each recessed from an outer periphery and extending in the circumferential direction, having a first connecting groove, a second connecting groove, and a third connecting groove arranged in order from the stator core side in the axial direction, the winding holding portions each having a first connecting groove, a second connecting groove, and a third connecting groove arranged in order from the stator core side in the axial direction, the first connecting groove, and the third connecting groove are arranged at positions corresponding to both sides of the teeth of the stator core in the circumferential direction, and the winding holding portions each have a first connecting groove, a second connecting groove, and a third connecting groove arranged in order from the first end side of the winding holding portion where the third connecting groove is located in the axial direction. A plurality of pairs of slits are formed that are recessed toward the second end of the winding holding portion where the first transition groove is located and that penetrate the winding holding portion in the radial direction of the stator core, and the plurality of pairs of slits include a pair of first slits that extend in the axial direction from the first end of the winding holding portion to the first transition groove, a pair of second slits that extend in the axial direction from the first end of the winding holding portion to the second transition groove, and a pair of third slits that extend in the axial direction from the first end of the winding holding portion to the third transition groove, and the pair of first slits, the pair of second slits and the pair of third slits are arranged repeatedly in sequence in a first circumferential direction of the circumferential direction. [Effects of the Invention]

[0010] According to the present disclosure, it is possible to easily arrange the lead-out portions of predetermined windings on the inner peripheral side of the insulator in a motor. [Brief explanation of the drawings]

[0011] [Figure 1] 1 is a cross-sectional view schematically illustrating a motor according to an embodiment of the present disclosure. [Figure 2] FIG. 2 is a perspective view showing an example of a stator having 36 slots in the motor of FIG. 1. [Figure 3]FIG. 2 is a cross-sectional view of an example of the motor of FIG. 1, when viewed from the axial direction, in which the rotor has four poles and the stator has six slots. [Figure 4] FIG. 1 is a perspective view showing a portion of an insulator according to an embodiment of the present disclosure. [Figure 5] 1 is a circuit diagram showing an example of a three-phase AC circuit in a stator according to an embodiment of the present disclosure, in which the number of slots is six. [Figure 6] 1 is a diagram showing an example of a winding connection diagram for a stator having six slots according to an embodiment of the present disclosure, the diagram being divided into U-phase, V-phase, and W-phase. FIG. [Figure 7] 2 is a diagram schematically illustrating a winding holding portion of an insulator according to an embodiment of the present disclosure and three-phase windings attached to the winding holding portion. FIG. [Figure 8] FIG. 10 is a diagram showing another example of a winding connection diagram. DETAILED DESCRIPTION OF THE INVENTION

[0012] Hereinafter, an embodiment of the present disclosure will be described in detail with reference to FIGS. In this embodiment, the direction parallel to the axis O of the rotor 2 and stator 3 in Figures 1 to 3 is called the axial direction. The direction radial from the axis O is called the radial direction. The direction going around the axis O is called the circumferential direction. In this embodiment, one side in the axial direction is referred to as the upper side or upward direction, and the other side in the axial direction is referred to as the lower side or downward direction. In the radial direction, the direction approaching the axis O is referred to as the radially inner side, and the direction away from the axis O is referred to as the radially outer side. One side in the circumferential direction is referred to as a first circumferential direction RD1, and the other side in the circumferential direction is referred to as a second circumferential direction RD2.

[0013] <Motor> As shown in FIGS. 1 and 3, the motor 1 is a three-phase AC motor, and includes a rotor 2 and a stator 3. The rotor 2 includes a rotor shaft 21, a rotor core 22, and a plurality of magnets 23. The rotor shaft 21 is a rod-shaped member centered on an axis O. When viewed in the axial direction, the rotor shaft 21 is formed in a circular shape centered on the axis O and is provided to be rotatable about the axis O. The rotor core 22 is formed in a cylindrical shape centered on the axis O. The rotor core 22 is fixed to the outer circumferential surface of the rotor shaft 21. The rotor core 22 may be formed, for example, of a plurality of steel plates laminated in the axial direction. The magnets 23 are permanent magnets. For example, when the plurality of magnets 23 each form one magnetic pole, the plurality of magnets 23 may be arranged at equal intervals in the circumferential direction of the rotor 2 on the outer circumferential portion of the rotor 2. Alternatively, for example, one magnetic pole may be formed by the plurality of magnets 23. The plurality of magnets 23 forming one magnetic pole may be arranged at equal intervals in the circumferential direction of the rotor 2 on the outer circumferential portion of the rotor 2. The magnet 23 may be embedded inside the rotor core 22 as illustrated in FIGS. 1 and 3, or may be attached to the surface of the rotor core 22, for example.

[0014] <Stator> As shown in FIGS. 1 and 2, the stator 3 includes a stator core 4, an insulator 5, and a plurality of windings 6. <Stator core> The stator core 4 is formed in a cylindrical shape centered on the axis O. The rotor 2 described above is rotatably housed inside the stator core 4. The stator core 4 includes a cylindrical yoke 41, a plurality of teeth 42, and a plurality of slots 43.

[0015] The multiple teeth 42 protrude radially inward from the inner peripheral surface of the yoke 41 and are arranged at intervals in the circumferential direction of the stator core 4. Slots 43 are formed between the teeth 42 adjacent in the circumferential direction. As a result, the multiple teeth 42 and the multiple slots 43 are formed alternately in the circumferential direction of the stator core 4. Specifically, the teeth 42 are formed to have the same shape and size and are arranged at equal intervals in the circumferential direction. Therefore, the slots 43 are arranged at equal intervals in the circumferential direction of the stator core 4. As a result, the teeth 42 and slots 43 are alternately formed at equal intervals in the circumferential direction.

[0016] The stator core 4 is formed by, for example, laminating a plurality of electromagnetic steel sheets in the axial direction, or may be formed by, for example, powder molding.

[0017] <Insulator> The insulator 5 is attached to the stator core 4 so as to cover at least a portion of the surface of the stator core 4, with the aim of electrically insulating the winding 6 (described later) from the stator core 4. In FIGS. 1 and 2, the insulator 5 covers at least the outer peripheral surface of each tooth 42 around which a coil portion 61 of the winding 6 (described later) is wound, and the inner peripheral surface of the yoke 41 on which the teeth 42 are mounted. The insulator 5 is an insulating member. The insulating member is an electrical insulating member made of, for example, a synthetic resin. The insulator 5 may be molded by any molding method, for example, injection molding.

[0018] The insulator 5 has a main body portion that covers the outer peripheral surfaces of the multiple teeth 42 and the inner peripheral surface of the yoke 41, as well as a winding holding portion 51. The winding holding portion 51 may be disposed at either one end in the axial direction of the stator core 4. In the illustrated example, the winding holding portion 51 is disposed at the upper end side of the stator core 4, but it may also be disposed at the lower end side of the stator core 4, for example. The winding holding portion 51 is formed in an annular shape centered on the axis O.

[0019] The winding holding portion 51 has a plurality of transition grooves 52 recessed from its outer periphery and extending circumferentially. The transition grooves 52 are aligned in the axial direction. Each transition groove 52 accommodates a transition wire portion 62 of the winding 6, which will be described later. The transition grooves 52 accommodate the transition wire portions 62 of the windings 6 of different phases. In this embodiment, the number of transition grooves 52 is three. The three transition groove portions 62 accommodate the transition groove portions 62 of the windings 6 of three phases (U phase, V phase, and W phase), respectively. Specifically, the three transition grooves 52, namely, a U-phase transition groove 52U (a first-phase transition groove, a first transition groove), a V-phase transition groove 52V (a second-phase transition groove, a second transition groove), and a W-phase transition groove 52W (a third-phase transition groove, a third transition groove), are arranged in order from the stator core 4 side in the axial direction. In the illustrated example, the U-phase transition groove 52U, the V-phase transition groove 52V, and the W-phase transition groove 52W are arranged in order upward in the axial direction.

[0020] As shown in FIG. 4 , multiple pairs of slits 53-1, 53-2 are formed in the winding holding portion 51. The pairs of slits 53-1, 53-2 are arranged at positions corresponding to both sides of the teeth 42 (coil portions 61 of the winding 6, described later) of the stator core 4 in the circumferential direction. Each pair of slits 53-1, 53-2 is recessed in the axial direction from a first end 511 of the winding holding portion 51, where the W-phase jumper groove 52W is located, toward a second end 512 of the winding holding portion 51, where the U-phase jumper groove 52U is located. Therefore, each slit 53-1, 53-2 opens toward the first end 511 of the winding holding portion 51. Each pair of slits 53-1, 53-2 penetrates the winding holding portion 51 in the radial direction. The first end 511 of the winding holding portion 51 is an end of the winding holding portion 51 that corresponds to the upper end (one end) of the stator core 4 in the axial direction. The second end 512 of the winding holding portion 51 is an end of the winding holding portion 51 that corresponds to the lower end (the other end) of the stator core 4 in the axial direction.

[0021] As shown in Figures 4, 6, and 7, the multiple sets of pairs of slits 53-1, 53-2 include a pair of first slits 53U-1, 53U-2, a pair of second slits 53V-1, 53V-2, and a pair of third slits 53W-1, 53W-2. The pair of first slits 53U-1, 53U-2 extend in the axial direction from the first end 511 of the winding holding portion 51 to the U-phase transition groove 52U. The pair of first slits 53U-1, 53U-2 are U-phase slits (first phase slits) that are arranged at positions corresponding to both sides of the teeth 42 around which the coil portion 61U of the U-phase winding 6U (first phase winding) described below is wound. In the following description, the first slits 53U-1, 53U-2 are also referred to as U-phase slits 53U-1, 53U-2.

[0022] The pair of second slits 53V-1, 53V-2 extend in the axial direction from the first end 511 of the winding holding portion 51 to the V-phase transition groove 52V. Therefore, the axial length (axial depth) of the pair of second slits 53V-1, 53V-2 is shorter than the length of the pair of first slits 53U-1, 53U-2. The pair of second slits 53V-1, 53V-2 are V-phase slits (second-phase slits) that are located at positions corresponding to both sides of the teeth 42 around which a coil portion 61V of a V-phase winding 6V (second-phase winding) described later is wound. In the following description, the second slits 53V-1, 53V-2 are also referred to as V-phase slits 53V-1, 53V-2.

[0023] The pair of third slits 53W-1, 53W-2 extend in the axial direction from the first end 511 of the winding holding portion 51 to the W-phase transition groove 52W. Therefore, the axial length (axial depth) of the pair of third slits 53W-1, 53W-2 is shorter than the length of the pair of second slits 53V-1, 53V-2. The pair of third slits 53W-1, 53W-2 are W-phase slits (third-phase slits) that are located at positions corresponding to both sides of the teeth 42 around which a coil portion 61W of a W-phase winding 6W (third-phase winding) described below is wound. In the following description, the third slits 53W-1, 53W-2 are also referred to as W-phase slits 53W-1, 53W-2. The pair of U-phase slits 53U-1, 53U-2, the pair of V-phase slits 53V-1, 53V-2, and the pair of W-phase slits 53W-1, 53W-2 are repeatedly arranged in order in the first circumferential direction RD1 (see particularly FIGS. 6 and 7). The axial depth of the U-phase slits 53U-1, 53U-2 is greater than the axial depth of the V-phase slits 53V-1, 53V-2, and the axial depth of the V-phase slits 53V-1, 53V-2 is greater than the axial depth of the W-phase slits 53W-1, 53W-2.

[0024] 2 and 4 is divided into a plurality of segments in the axial and circumferential directions. The insulator 5 includes an upper-end insulator 55, a middle insulator 56, and a lower-end insulator 57, which are arranged in this order from top to bottom in the axial direction. The upper-end insulator 55 is attached to the upper end of the stator core 4 in the axial direction. The upper-end insulator 55 includes the winding holding portion 51 described above. The middle insulator 56 is attached to the middle portion of the stator core 4 in the axial direction. The lower-end insulator 57 is attached to the lower end of the stator core 4 in the axial direction. The upper-end insulator 55 is connected to the upper end of the middle insulator 56. The lower-end insulator 57 is connected to the lower end of the middle insulator 56.

[0025] FIG. 4 shows an example of a segment formed by dividing upper-end insulator 55 in the circumferential direction. In the segment shown in FIG. 4, a pair of deepest U-phase slits 53U-1, 53U-2 are located in the middle of the segment in the circumferential direction, and a pair of V-phase slits 53V-1, 53V-2 and a pair of W-phase slits 53W-1, 53W-2, each of which is shallower than U-phase slits 53U-1, 53U-2, are located at both ends of the segment in the circumferential direction. Since the pair of deepest U-phase slits 53U-1, 53U-2 are not located at both ends of the segment in the circumferential direction, the segment can be stably formed. Furthermore, the strength of the segment can be improved.

[0026] <Winding> 1 and 6, the multiple windings 6 are wound around the multiple teeth 42 via the above-mentioned insulator 5. In FIG. 6, the stator 3 is linearly developed so that the circumferential direction of the stator 3 extends in the left-right direction, and only the teeth 42 of the stator 3, the three transition grooves 52 of the insulator 5, the multiple pairs of slits 53-1, 53-2, and the three windings 6 are schematically shown, with the main body of the insulator 5 and the like being omitted. Also, an example of a wiring diagram for the windings 6 is shown divided into three phases: U phase, V phase, and W phase. As shown in Fig. 6, each of the multiple windings 6 has multiple coil portions 61, at least one crossover portion 62, and two lead-out portions 63. In the same winding 6, the multiple coil portions 61 are wound around each of the teeth 42 using concentrated winding. In Fig. 6, the coil portions 61 are depicted as surrounding the teeth 42 from below, but in reality, they are wound around the teeth 42 using concentrated winding.

[0027] The crossover portion 62 connects adjacent coil portions 61. The number of crossover portions 62 is one less than the number of coil portions 61. The two lead-out portions 63 form the ends of the same winding 6 and extend from the coil portion 61. The winding 6 in this embodiment is a multi-filament wire in which a plurality of strands are bundled together in a non-aligned manner. However, the winding 6 may also be, for example, a single strand.

[0028] In this embodiment, there are three windings 6, and each of the three windings 6 is assigned to one of three phases (U-phase, V-phase, and W-phase). That is, the three windings 6 include a U-phase winding 6U (first-phase winding), a V-phase winding 6V (second-phase winding), and a W-phase winding 6W (third-phase winding). The three phase windings 6U, 6V, and 6W have the same number of coil portions 61. In this embodiment, the number of parallel connections of the windings 6U, 6V, and 6W of each phase is one. However, the number of parallel connections of the windings 6U, 6V, and 6W of each phase may be, for example, two or more.

[0029] As shown in FIG. 5, three windings 6 form a three-phase AC circuit. This three-phase AC circuit employs a star connection, connecting the three phase windings 6 at a neutral point N1. If two or more windings 6 are connected in parallel for each phase, the same number of star connections as shown in FIG. 5 are prepared, and the input points U1, V1, and W1 of the same phase in the multiple star connections are connected to the same connection terminal. The input points U1, V1, and W1 are first ends of the windings 6 in the longitudinal direction and are terminals for inputting a drive current to the windings 6. In the following description, one of the two lead-out wires 63 of each winding 6, which forms the input point U1, V1, or W1, may be referred to as the input line 63IN for inputting a drive current.

[0030] In the motor 1 of this embodiment, the number of poles of the rotor 2 and the number of slots 43 of the stator core 4 are set so as to satisfy either the following conditional formula (1) or conditional formula (2). (Conditional expression (1)) P:S=2n:3n (Conditional expression (2)) P:S=4n:3n In conditional expressions (1) and (2), P is the number of poles of the rotor 2 (the number of magnetic poles formed by the magnets 23), S is the number of slots 43 of the stator core 4, and n is a natural number equal to or greater than 2. The number of slots S corresponds to the total number of coil portions 61. That is, the total number of coil portions 61 is set to 3n. In a motor 1 that satisfies conditional expressions (1) and (2), the coil portions 61 are all wound around the teeth 42 in the same direction. In FIG. 6, all of the coil portions 61 are wound counterclockwise around the teeth 42. In the motor 1 illustrated in FIG. 3, one magnet 23 forms one magnetic pole, so the number of magnets 23 (number of poles P) is four and the number of slots 43 (number of slots S) is six, satisfying conditional formula (1).

[0031] For example, when the natural number n is 12, the number of slots 43 (number of slots S) is 36. In the stator 3 illustrated in FIG. 2, the number of slots 43 is 36. In the stator 3 illustrated in FIG. 2, the total number of coil portions 61 is 36. Furthermore, for example, when the natural number n is 2, the number of slots 43 (number of slots S) is 6. In the stator 3 illustrated in Fig. 3, the number of slots 43 is 6. In the stator 3 illustrated in Fig. 3 and Fig. 6, the total number of coil portions 61 is 6.

[0032] As shown in FIG. 6 , in the stator 3, the coil portion 61 of the U-phase winding 6U (U-phase coil portion 61U), the coil portion 61 of the V-phase winding 6V (V-phase coil portion 61V), and the coil portion 61 of the W-phase winding 6W (W-phase coil portion 61W) are arranged in sequence in the first circumferential direction RD1. Therefore, the coil portions 61 of the winding 6 of the same phase are wound around every third tooth 42. For example, if the number of slots S is six, the two coil portions 61 of the U-phase winding 6U are wound around the first and fourth teeth 42 (42-1, 42-4). The two coil portions 61 of the V-phase winding 6V are wound around the second and fifth teeth 42 (42-2, 42-5). The two coil portions 61 of the W-phase winding 6W are wound around the third and sixth teeth 42 (42-3, 42-6). 6 shows a stator 3 that satisfies conditional formula (1), in which the U-phase coil portion 61U, the V-phase coil portion 61V, and the W-phase coil portion 61W are arranged in sequence in the rightward direction (first circumferential direction RD1). Therefore, the numbers of the teeth 42 are arranged in sequence from the left end to the rightward. In the stator 3 that satisfies conditional formula (2), the U-phase coil portion 61U, the W-phase coil portion 61W, and the V-phase coil portion 61V are repeatedly arranged in order rightward in FIG. 6 (first circumferential direction RD1).

[0033] Furthermore, the crossover portion 62 of the U-phase winding 6U is housed in the crossover groove 52U for the U-phase. Similarly, the crossover portion 62 of the V-phase winding 6V is housed in the crossover groove 52V for the V-phase, and the crossover portion 62 of the W-phase winding 6W is housed in the crossover groove 52W for the W-phase.

[0034] In the stator 3 illustrated in Fig. 6, the second ends of the windings 6, which are located opposite to the first ends that form the input points U1, V1, and W1, are output points Un1, Vn1, and Wn1. The three-phase output points Un1, Vn1, and Wn1 form the neutral point N1 of the star connection shown in Fig. 5. Specifically, the three-phase output points Un1, Vn1, and Wn1 are connected to each other by a neutral wire NL1 to form the neutral point N1. The three-phase output points Un1, Vn1, and Wn1 are located at positions drawn from three circumferentially adjacent coil portions 61 (61U-2, 61V-2, and 61W-2). As a result, the three-phase output points Un1, Vn1, and Wn1 are located close to each other, allowing the neutral wire NL1 connecting the three-phase output points Un1, Vn1, and Wn1 to be shortened.

[0035] In the stator 3 illustrated in Fig. 6, each winding 6 has two coil portions 61. Therefore, each winding 6 has only one crossover portion 62. As a result, in a coil portion 61 from which a lead portion 63 is drawn out from one circumferential side, a crossover portion 62 is drawn out from the other circumferential side. The crossover portion 62 drawn out from the other circumferential side of a given coil portion 61 extends from the given coil portion 61 to the other circumferential side in the crossover groove 52.

[0036] In FIG. 6 , an input wire 63IN, which is one of the lead wire portions 63, is drawn out from the left side of a first coil portion 61-1 (61U-1, 61V-1, 61W-1) located on the left side (second circumferential direction RD2 side) of the same winding 6. The input wire 63IN is the lead wire portion located on the left side of the two lead wire portions 63. A crossover portion 62 is drawn out from the right side (first circumferential direction RD1 side) of the first coil portion 61-1 and extends in the right direction (first circumferential direction RD1). Meanwhile, the other lead wire portion 63 is drawn out from the right side of a second coil portion 61-2 (61U-2, 61V-2, 61W-2) located on the right side. A crossover portion 62 is drawn out from the left side of the second coil portion 61-2 and extends in the left direction (second circumferential direction RD2).

[0037] 6 and 7, the lead-out wire portion 63 and the crossover wire portion 62 extending from each of the two coil portions 61-1 and 61-2 can be inserted into a corresponding pair of slits 53-1 and 53-2, and thereby drawn out radially to the outside of the winding holding portion 51. In Fig. 6 and Fig. 7, of the pair of slits 53-1 and 53-2, the lead-out wire portion 63 is inserted into the slit 53-1, and the crossover wire portion 62 is inserted into the slit 53-2. 6 and 7, the state in which lead-out portion 63 is inserted into slit 53-1 represents a stage during the manufacture of stator 3 and motor 1. In the manufactured stator 3 and motor 1, lead-out portion 63 is disposed radially inside winding holding portion 51, as shown in FIG.

[0038] <Motor manufacturing method> When manufacturing the motor of this embodiment, the multiple windings 6 can be formed by the following procedure, as shown in Figures 6 and 7. In Figure 7, "radially outer" and "radially inner" refer to the direction in which each winding 6 passes through the slits 53-1 and 53-2. For example, when forming the U-phase winding 6U, first, the first lead wire portion 63, which is the input wire 63IN, is passed from the radial outside through one of the slits 53U-1 (one of the pair of slits 53U-1, 53U-2) located on the second circumferential direction RD2 side of the first tooth 42-1, and then concentratedly wound around the radially inner first tooth 42-1 to form the first coil portion 61U-1 in a first step. Next, the first lead wire is passed through the other slit 53U-2 located on the first circumferential direction RD1 side of the first tooth 42-1, and then, while being housed in the radially outer jumper groove 52U, is extended toward the first circumferential direction RD1 side of the first tooth 42-1 to form the jumper wire portion 62 in a second step. Then, in a third step, the wire is passed through one of the slits 53U-2 located on the second circumferential direction RD2 side of the second tooth 42-4, which is located away from the first tooth 42-1 on the first circumferential direction RD1 side, and then wound in a concentrated manner around the second tooth 42-4 located radially inward to form the second coil portion 61U-2. Finally, in a fourth step, the wire is passed through the other slit 53U-1 located on the first circumferential direction RD1 side of the second tooth 42-4 to form the second lead-out portion 63, thereby forming the U-phase winding 6U. The V-phase winding 6V and the W-phase winding 6W are formed in the same manner as the U-phase winding 6U described above.

[0039] After the fourth process for the plurality of windings 6 (U-phase winding 6U, V-phase winding 6V, W-phase winding 6W), the first lead-out portions 63 (input wires 63IN) of each of the plurality of windings 6 are pulled out from the axial openings (openings on the first end 511 side) of the slits 53-1 through which the first lead-out portions 63 (input wires 63IN) of the plurality of windings 6 are thereby arranged radially inside the winding holding portion 51, as illustrated in FIG. Furthermore, the second lead wire portions 63 of the U-phase winding 6U and the V-phase winding 6V of the multiple windings 6 are passed between the slit 53-1 through which they pass and the crossover portions 62 of the other windings 6. Furthermore, the second lead wire portion 63 of the W-phase winding 6W of the multiple windings 6 is drawn out from the axial opening of the slit 53-1 through which it passes (the opening on the first end 511 side). This positions the second lead wire portions 63 of the multiple windings 6 inside the winding holding portion 51 in the radial direction. In each winding 6 formed through the first to fourth steps described above, the length of the second lead wire portion 63 is sufficiently shorter than the length of the first lead wire portion 63. Therefore, passing the second lead wire portions 63 of the U-phase winding 6U and the V-phase winding 6V between the slit 53-1 and the crossover portions 62 of the other windings 6 does not reduce the manufacturing efficiency of the motor 1.

[0040] <Effects> As described above, in the stator 3 of this embodiment, the lead-out wire portion 63 is led out from one circumferential side of a given coil portion 61. Furthermore, in a given coil portion 61, the crossover wire portion 62 is led out from the other circumferential side and extends to the other circumferential side relative to the coil portion 61. Therefore, between the lead-out wire portion 63 passed through the slit 53-1 and the opening of the slit 53-1 at the first end 511 of the winding holding portion 51, the crossover wire portion 62, which constitutes the same winding 6 together with the lead-out wire portion 63, does not extend in the circumferential direction of the stator core 4.

[0041] In addition, the pair of U-phase slits 53U-1, 53U-2, which are the longest and reach the jumper groove 52U for the U-phase, the pair of V-phase slits 53V-1, 53V-2, which reach the jumper groove 52V for the V-phase and are therefore shorter than the U-phase slits 53U-1, 53U-2, and the pair of W-phase slits 53W-1, 53W-2, which reach the jumper groove 52W for the W-phase, are arranged in order in the first circumferential direction RD1 in which the coil portion 61U of the U-phase winding 6U, the coil portion 61V of the V-phase winding 6V, and the coil portion 61W of the W-phase winding 6W are aligned. For this reason, between the first lead-out portion 63 (one of the lead-out portions) of the U-phase winding 6U passed through the U-phase slit 53U-1 and the opening of the U-phase slit 53U-1, the crossover portion 62 constituting the winding 6 (V-phase winding 6V, W-phase winding 6W) other than the lead-out portion 63 does not extend in the circumferential direction of the stator core 4. Similarly, between the first lead-out portion 63 of the V-phase winding 6V passed through the V-phase slit 53V-1 and the opening of the V-phase slit 53V-1, the crossover portion 62 constituting the winding 6 (W-phase winding 6W) other than the lead-out portion 63 does not extend in the circumferential direction of the stator core 4. From the above, the first lead wire portions 63 of the U-phase winding 6U, the V-phase winding 6V, and the W-phase winding 6W can be easily drawn out from the openings of the respective slits 53U-1, 53V-1, and 53W-1 and arranged on the inner circumferential side of the insulator 5.

[0042] In the stator 3 of this embodiment, the lead wire portion 63 is drawn out from one circumferential side of a given coil portion 61. In addition, in a given coil portion 61, the crossover wire portion 62 is drawn out from the other circumferential side and extends to the other circumferential side of the coil portion 61. Therefore, the crossover wire portions 62 extending from the coil portion 61 do not extend across the coil portion 61 from one side to the other in the circumferential direction in the crossover groove 52. Furthermore, the draw-out wire portions 63 extending from the coil portion 61 do not extend across the coil portion 61 from one side to the other in the circumferential direction. This prevents the crossover wire portions 62 and the draw-out wire portions 63 that constitute the same winding 6 from crossing each other. In other words, it is possible to prevent the same winding 6 from crossing each other in the crossover groove 52 and in the vicinity of the crossover groove 52.

[0043] The same winding 6 does not cross over in the jumper grooves 52 and in the vicinity of the jumper grooves 52, thereby preventing the winding 6 from collapsing. Even if a multi-strand wire, which is prone to collapsing, is used as the winding 6, the winding 6 can be prevented from collapsing. This ensures a sufficient creepage distance between the jumper wire portions 62 housed in different jumper grooves 52. Furthermore, since the occurrence of defective products in which the creepage distance cannot be ensured can be prevented, a decrease in yield can also be prevented.

[0044] Furthermore, in the stator 3 of this embodiment, the same windings 6 do not cross over each other in the crossing grooves 52 or in the vicinity of the crossing grooves 52, so the overall length of the windings 6 can be kept shorter than in the case where there is such crossing. Furthermore, by shortening the overall length of the winding 6, it is possible to reduce the resistance value of the winding 6. This makes it possible to improve the efficiency of the motor including the stator 3. Furthermore, because the same windings 6 do not cross over each other at or near the transition grooves 52, it is possible to prevent pinholes from being formed in the insulating coating of the windings 6 due to friction between the windings 6 at these crossings, thereby ensuring insulation of the windings 6.

[0045] <Other embodiments> Although the embodiments of the present disclosure have been described above, the present disclosure is not limited to these and can be modified as appropriate within the scope of the technical idea of ​​the invention.

[0046] In the present disclosure, as illustrated in Fig. 8, the same winding 6 may have three or more coil portions 61. In Fig. 8 as well, the coil portions 61 are depicted as surrounding the teeth 42 from below, but in reality, they are wound around the teeth 42 using concentrated winding. When the same winding 6 has three or more coil portions 61, the multiple coil portions 61 include two end coil portions 61-4 located at both ends in the arrangement direction of the multiple coil portions 61 (the left-right direction in Fig. 8), and a middle coil portion 61-5 located between the two end coil portions 61-4.

[0047] The end coil portion 61-4 has a lead wire portion 63 drawn from one circumferential side thereof and a crossover wire portion 62 drawn from the other circumferential side thereof. The crossover wire portion 62 drawn from the other circumferential side of the end coil portion 61-4 extends toward the other circumferential side of the end coil portion 61-4. For example, in FIG. 8 , the lead wire portion 63 is drawn from the left side of the end coil portion 61-4 located at the left end. The crossover wire portion 62 is drawn from the right side of the end coil portion 61-4 located at the left end, and extends to the right. Meanwhile, the lead wire portion 63 is drawn from the right side of the end coil portion 61-4 located at the right end. The crossover wire portion 62 is drawn from the left side of the end coil portion 61-4 located at the right end, and extends to the left. This makes it possible to prevent the crossover wire portion 62 and the lead wire portion 63 that constitute the same winding 6 from crossing each other in the crossover groove 52 and in the vicinity of the crossover groove 52 . As in the above-described embodiment, the pull-out wire portion 63 and the jumper wire portion 62 extending from the end coil portion 61-4 can be pulled out radially to the outside of the winding holding portion 51 by being inserted into a pair of slits 53-1, 53-2 of the winding holding portion 51 corresponding to the end coil portion 61-4.

[0048] The crossover wire portion 62 drawn out from the intermediate coil portion 61-5 to one circumferential side extends to one circumferential side of the intermediate coil portion 61-5. Similarly, the crossover wire portion 62 drawn out from the intermediate coil portion 61-5 to the other circumferential side extends to the other circumferential side of the intermediate coil portion 61-5. For example, the crossover wire portion 62 drawn out to the right side from the intermediate coil portion 61-5 shown in FIG. 8 extends rightward from the intermediate coil portion 61-5. Similarly, the crossover wire portion 62 drawn out to the left side from the intermediate coil portion 61-5 extends leftward from the intermediate coil. This prevents the crossover wire portions 62 constituting the same winding 6 from crossing each other at the crossover groove 52. The two crossover wire portions 62 extending from the intermediate coil portion 61-5 are inserted into a pair of slits 53-2, 53-2 of the winding holding portion 51 corresponding to the intermediate coil portion 61-5, and are thereby drawn out to the outside of the winding holding portion 51 in the radial direction.

[0049] The above-described arrangement of the crossover wire portions 62 and the lead-out wire portions 63 drawn from the end coil portion 61-4 and the intermediate coil portion 61-5 provides the same effect as in the above-described embodiment, i.e., it is possible to prevent the same winding 6 from crossing over in the crossover groove 52 and in the vicinity of the crossover groove 52.

[0050] 8, only the U-phase winding 6U is shown, but the V-phase and W-phase windings 6 are configured in the same manner. The stator illustrated in FIG. 8 has three coil portions 61 in each phase winding 6, making the total number of windings 6 for the three phases nine. In other words, the stator illustrated in FIG. 8 is applicable to a motor that satisfies conditional expressions (1) and (2).

[0051] As shown in FIG. 8, when the same winding 6 has three or more coil portions 61, in the manufacturing method of the motor, for example, each of the windings 6 can be formed by the following procedure. 8, for example, when forming the U-phase winding 6U, a first step is performed in which the first lead wire portion 63 is formed and passed through one slit 53U-1 located on the second circumferential direction RD2 side of the first tooth 42, and then the first end coil portion 61-4 is formed by concentrated winding around the first tooth 42. Next, a second step is performed in which the first lead wire portion 63 is passed through the other slit 53U-2 located on the first circumferential direction RD1 side of the first tooth 42, and then extended toward the first circumferential direction RD1 side of the first tooth 42 while being housed in the jumper groove 52U, thereby forming the jumper wire portion 62. Thereafter, a fifth step is performed in which the wire is passed through a slit 53U-2 located on the second circumferential direction RD2 side of a third tooth 42 that is located away from the first tooth 42 on the first circumferential direction RD1 side, and then wound concentratedly around the third tooth 42 to form an intermediate coil portion 61-5. Furthermore, after the fifth step, a sixth step is performed in which the wire is passed through a slit 53U-2 located on the first circumferential direction RD1 side of the third tooth 42, and then extended to the first circumferential direction RD1 side of the third tooth 42 while being housed in the jumper groove 52U, to form another jumper wire portion 62.

[0052] Then, after the sixth step, a third step is performed in which the wire is passed through one of the slits 53U-2 located on the second circumferential direction RD2 side of the second tooth 42 that is located away from the third tooth 42 on the first circumferential direction RD1 side, and then concentratedly wound around the second tooth 42 to form a second end coil portion 61-4. Finally, a fourth step is performed in which the wire is passed through the other slit 53U-1 located on the second tooth 42 on the first circumferential direction RD1 side to form a second lead-out portion 63, thereby forming the U-phase winding 6U illustrated in FIG. If the same winding 6 has a plurality of intermediate coil portions 61-5, the fifth and sixth steps may be repeated a plurality of times. The V-phase winding 6V and the W-phase winding 6W, each having the intermediate coil portion 61-5, can be formed in the same manner as the method for forming the U-phase winding 6U described above.

[0053] Then, after the fourth step for the U-phase winding 6U, the V-phase winding 6V, and the W-phase winding 6W, similarly to the above embodiment, the first lead wire portion 63 (input wire 63IN) of each of the plurality of windings 6 is pulled out from the axial opening (the opening on the first end 511 side) of the slit 53-1 through which it passes. This allows the first lead wire portion 63 to be positioned radially inside the winding holding portion 51. Also, as in the above embodiment, the second lead wire portions 63 of the U-phase winding 6U and the V-phase winding 6V among the multiple windings 6 are disposed radially inside the winding holding portion 51 by passing them between the slit 53-1 through which they pass and the crossover portions 62 of the other windings 6. In each winding 6 formed in the order of the first, second, fifth, sixth, third, and fourth steps, the length of the second lead wire portion 63 is sufficiently shorter than the length of the first lead wire portion 63. Therefore, passing the second lead wire portion 63 between the slit 53-1 and the crossover portions 62 of the other windings 6 does not reduce the manufacturing efficiency of the motor.

[0054] In the present disclosure, it is sufficient that the axial depth of at least U-phase slits (first slits, first phase slits) 53U-1 and 53U-2 is equal to or greater than the axial depth of V-phase slits (second slits, second phase slits) 53V-1 and 53V-2, and that the axial depth of V-phase slits 53V-1 and 53V-2 is equal to or greater than the axial depth of W-phase slits (third slits, third phase slits) 53W-1 and 53W-2. In other words, the axial depths of U-phase slits 53U-1 and 53U-2, V-phase slits 53V-1 and 53V-2, and W-phase slits 53W-1 and 53W-2 may be, for example, equal. [Explanation of symbols]

[0055] 1...motor, 2...rotor, 3...stator, 4...stator core, 5...insulator, 6...winding, 6U...U-phase winding (first phase winding), 6V...V-phase winding (second phase winding), 6W-phase winding (third phase winding), 42...teeth, 43...slot, 51...winding holder, 511...first end of winding holder 51, 512...second end of winding holder 51, 52...crossover groove, 53U-1, 53U-2...U-phase slit (first phase slit, first slit), 53V-1, 53V-2...V-phase slit (second phase slit, second slit), 53W-1, 53W-2...W-phase slit (third phase slit, third slit), 61...coil portion, 62...crossover portion, 63...lead-out portion, 63IN...input line, P...number of poles, S...number of slots, RD1...first circumferential direction, RD2...second circumferential direction

Claims

1. A rotor, a stator including an annular stator core having a plurality of teeth and a plurality of slots arranged in a circumferential direction, an insulator attached to the stator core, and a plurality of windings wound around the plurality of teeth via the insulator, When the number of poles of the rotor is P, the number of slots of the stator core is S, and n is a natural number equal to or greater than 2, P:S=2n:3n or P:S=4n:3n Meet the conditions of Each of the plurality of windings comprises: a plurality of coil portions wound around the teeth by concentrated winding; a lead portion that forms an end of the winding and extends from the coil portion; a crossover portion connecting adjacent coil portions, The coil portion from which the lead wire portion is drawn out from one side in the circumferential direction has the crossover wire portion drawn out from the other side in the circumferential direction, the crossover wire portion drawn out from the other circumferential side of the coil portion extends toward the other circumferential side with respect to the coil portion, the plurality of windings include a first phase winding, a second phase winding, and a third phase winding; the coil portion of the first phase winding, the coil portion of the second phase winding, and the coil portion of the third phase winding are repeatedly arranged in order on a first circumferential direction side in the circumferential direction, The insulator is a winding holding portion disposed on either one end side of the stator core in the axial direction, the winding holding portions are arranged at positions corresponding to both sides of each of the coil portions in the circumferential direction, and each of the winding holding portions has a plurality of pairs of slits recessed from an end on the one end side of the winding holding portion toward the other end side in the axial direction and penetrating the stator core in a radial direction, the lead-out wire portion and the crossover wire portion extending from the coil portion are inserted through the pair of slits, and can be led out to the outside of the winding holding portion in the radial direction, A motor in which, among the multiple sets of pairs of slits, the axial depth of a pair of first phase slits corresponding to the coil portion of the first phase winding is equal to or greater than the axial depth of a pair of second phase slits corresponding to the coil portion of the second phase winding, and the axial depth of the second phase slits is equal to or greater than the depth of a pair of third phase slits corresponding to the coil portion of the third phase winding.

2. the winding holding portion further includes a plurality of connecting grooves recessed from an outer circumferential side, extending in the circumferential direction, and aligned in the axial direction; the plurality of transition grooves include a first-phase transition groove in which the transition wire portion of the first-phase winding is accommodated, a second-phase transition groove in which the transition wire portion of the second-phase winding is accommodated, and a third-phase transition groove in which the transition wire portion of the third-phase winding is accommodated; the first-phase transition groove, the second-phase transition groove, and the third-phase transition groove are arranged in this order from the stator core side in the axial direction, 2. The motor according to claim 1, wherein the first-phase slit extends in the axial direction from an end of the winding holding portion on the one side to reach the first-phase jumper groove, the second-phase slit extends in the axial direction from the end of the winding holding portion on the one side to reach the second-phase jumper groove, and the third-phase slit extends in the axial direction from the end of the winding holding portion on the one side to reach the third-phase jumper groove.

3. 3. The motor according to claim 1, wherein the lead wire portion located on a second circumferential direction side opposite the first circumferential direction in the circumferential direction is an input wire for inputting a drive current.

4. 3. The motor according to claim 1, wherein the winding is a multi-filament winding in which a plurality of strands are bundled together in a non-aligned manner.

5. the insulator is divided into a plurality of divisions in the circumferential direction, 3. The motor according to claim 1, wherein the first phase slit, which has the greatest depth, is arranged in a middle portion of the divided body in the circumferential direction, and at least one of the second phase slit and the third phase slit, which has a depth smaller than that of the first phase slit, is arranged at both end portions of the divided body in the circumferential direction.

6. 3. The motor according to claim 1, wherein the lead-out portion is disposed inside the winding holding portion in the radial direction.

7. A method for manufacturing the motor according to claim 1 or 2, comprising the steps of: Each of the plurality of windings comprises: a first step of passing a first lead wire portion through one of the pair of slits located on a second circumferential direction side opposite to the first circumferential direction with respect to the first tooth, and then winding the first lead wire portion around the first tooth in a concentrated manner to form a first coil portion; a second step of forming a crossover wire portion by passing the wire through the other of the pair of slits located on the first circumferential side of the first tooth, and then extending the wire in the first circumferential side of the first tooth while being housed in the crossover groove; a third step of forming a second coil portion by passing the wire through one of the pair of slits located on the second circumferential side of a second tooth located away from the first tooth in the first circumferential direction, and then winding the wire around the second tooth in a concentrated manner; and a fourth step of forming a second lead wire portion by passing the second lead wire through the other of the pair of slits located on the first circumferential direction side of the second tooth after the third step, a first lead-out portion of each of the plurality of windings being pulled out from an axial opening of the slit through which the first lead-out portion passes, and disposed inside the winding holding portion in the radial direction, after the fourth step of the plurality of windings;

8. An insulator provided in a stator that constitutes a motor together with a rotor, the insulator being attached to a stator core of the stator formed in an annular shape having a plurality of teeth and a plurality of slots arranged in a circumferential direction, a winding holding portion disposed on either one end side of the stator core in the axial direction, the winding holding portions each include a first connecting groove, a second connecting groove, and a third connecting groove that are recessed from an outer circumferential side, extend in the circumferential direction, and are arranged in this order from the stator core side in the axial direction, the winding holding portion is formed with a plurality of pairs of slits, each of which is disposed at positions corresponding to both sides of the teeth of the stator core in the circumferential direction, recessed in the axial direction from a first end of the winding holding portion where the third transition groove is located toward a second end of the winding holding portion where the first transition groove is located, and penetrating the winding holding portion in a radial direction of the stator core; The multiple sets of pairs of slits include a pair of first slits extending in the axial direction from a first end of the winding holding portion to the first connecting groove, a pair of second slits extending in the axial direction from the first end of the winding holding portion to the second connecting groove, and a pair of third slits extending in the axial direction from the first end of the winding holding portion to the third connecting groove, and the pair of first slits, the pair of second slits and the pair of third slits are arranged repeatedly in sequence in a first circumferential direction of the insulator.

9. divided into a plurality of segments in the circumferential direction, An insulator as described in claim 8, wherein the first slit, which has the greatest depth, is arranged in the middle portion of the division body in the circumferential direction, and at least one of the second slit and the third slit, which has a depth smaller than that of the first slit, is arranged at both end portions of the division body in the circumferential direction.

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