Electric motor manufacturing method

Abstract

To avoid an increase in manufacturing cost of an electric motor, and increase the space factor of a winding portion while improving the reliability of a conductor wound in a first layer of the winding portion.SOLUTION: An electric motor manufacturing method performs: a first operation of winding a conductor from one end side to another end side of a winding drum in a radial direction of a yoke while leaving a gap between adjacent windings in a first layer; and a second operation of after the first operation, winding the conductor in the first layer so as to be in contact with the winding located at the other end, thereby moving at least a portion of the winding wound in the first operation toward the one end to close the gap.SELECTED DRAWING: Figure 15

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing an electric motor. [Background technology]

[0002] A known electric motor includes a stator core and an insulator provided at an end of the stator core, and a winding portion having multiple layers formed by winding a conductor in a concentrated manner around the teeth of the stator core and the winding drum of the insulator. In this type of electric motor, miniaturization and high efficiency are achieved by increasing the space factor of the conductor in the winding portion. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] International Publication No. 2015 / 063877 [Patent Document 2] Japanese Patent Publication No. 2020-127255 [Patent Document 3] Japanese Patent Application Publication No. 2018-85870 Summary of the Invention [Problem to be solved by the invention]

[0004] In the electric motor described in Patent Document 1, the surface of the winding drum of the insulator is formed flat along the radial direction of the stator core. The winding portion includes a first layer formed by winding a conductor along the surface of the winding drum from one end side (outer diameter side) to the other end side (inner diameter side) in the radial direction of the stator core, and a second layer stacked on top of the first layer and formed by winding a conductor from the other end side (inner diameter side) to one end side (outer diameter side) in the radial direction of the stator core.

[0005] In such an electric motor, if the winding pitch (the amount of movement per turn of the nozzle in the winding process using a winding machine) of the first layer of windings, which are wound side by side in the radial direction of the stator core, is reduced in order to increase the space factor of the winding, a portion of a later-wound winding may ride up on an earlier-wound winding when forming the first layer of the winding. In this case, the later-wound winding may not be lined up with the other end (inner diameter side) of the earlier-wound winding, but may intrude on one end (outer diameter side) of the earlier-wound winding, and the slippery surface of the insulating film of the conductor may cause the earlier-wound winding to be pushed out to the other end (inner diameter side) of the stator core (hereinafter also referred to as "winding irregularity"). When winding irregularities occur, the conductor that makes up the winding, which is pulled so that it is pushed to the end on the inner diameter side, may break, or the cross-sectional area of ​​the pulled conductor may decrease, increasing electrical resistance and the amount of heat generated by the conductor. In other words, the reliability of the conductor wound in the first layer of the winding may decrease. Note that this phenomenon is not limited to when the first layer of the winding is wound from the outer diameter side to the inner diameter side in the radial direction of the stator core, but can also occur when the first layer of the winding is wound from the inner diameter side to the outer diameter side in the radial direction of the stator core.

[0006] Meanwhile, there is a structure in which grooves or the like are provided on the winding drum of the insulator to prevent the conductor wound in the first layer of the winding section from slipping (Patent Document 2, Patent Document 3). However, this structure requires the grooves or the like to be provided on the winding drum to match the outer diameter of the conductor, which necessitates changing the insulator depending on the outer diameter of the conductor, resulting in a problem of increased manufacturing costs for the motor. Furthermore, if a conductor with an outer diameter that does not fit the size of the grooves or the like is wound on the winding drum, a load may be applied to the conductor that has climbed onto the grooves or the like, potentially reducing the reliability of the conductor's current-carrying state. In addition, as a result, a gap may be formed between the grooves or the like and the conductor, potentially reducing the space factor.

[0007] The disclosed technology has been made in consideration of the above, and aims to provide a method for manufacturing an electric motor that can increase the space factor of the winding section while avoiding an increase in the manufacturing cost of the electric motor and improving the reliability of the wire wound in the first layer of the winding section. [Means for solving the problem]

[0008] One aspect of the method for manufacturing an electric motor disclosed in the present application is a method for manufacturing an electric motor including a stator core having an annular yoke portion and teeth extending radially from the yoke portion, an insulator having a winding drum attached to the teeth portion, and a winding portion formed with multiple layers of windings in which a conductor wire is wound around the teeth portion via the winding drum, the method comprising: a first operation in which the conductor wire is wound from one end side to the other end side of the winding drum in the radial direction while leaving a gap between adjacent windings in the first layer of the winding portion; and a second operation in which, after the first operation, the conductor wire is wound in the first layer so as to be in contact with the winding located at the other end side, thereby moving at least a portion of the winding wound in the first operation toward the one end side and closing the gap. [Effects of the Invention]

[0009] According to one aspect of the method for manufacturing an electric motor disclosed in the present application, it is possible to avoid an increase in the manufacturing cost of the electric motor, improve the reliability of the conductor wound in the first layer of the winding portion, and increase the space factor of the winding portion. [Brief explanation of the drawings]

[0010] [Figure 1] FIG. 1 is a vertical cross-sectional view showing a compressor manufactured by a method for manufacturing an electric motor according to an embodiment of the present invention. [Figure 2] FIG. 2 is a bottom view showing the stator core in the embodiment. [Figure 3] FIG. 3 is a perspective view schematically showing an insulator according to the embodiment. [Figure 4] FIG. 4 is a bottom view showing the stator in the embodiment. [Figure 5] FIG. 5 is a cross-sectional view showing a schematic view of a winding portion of the electric motor in the embodiment. [Figure 6] FIG. 6 is a cross-sectional view that schematically shows a winding portion of an electric motor in a comparative example. [Figure 7] FIG. 7 is a cross-sectional view for explaining a case where the first layer of winding is normally wound in the winding step of the comparative example. [Figure 8] FIG. 8 is a cross-sectional view illustrating a case where the winding position of the first layer of the winding is shifted in the winding process of the comparative example. [Figure 9] FIG. 9 is a side view illustrating a case where the winding position of the first layer of the winding is shifted in the winding process of the comparative example. [Figure 10] FIG. 10 is a flowchart for explaining the winding step in the manufacturing method of the electric motor of the embodiment. [Figure 11] FIG. 11 is a flowchart for explaining the winding pitch in the winding step in the manufacturing method of the electric motor of the embodiment. [Figure 12] FIG. 12 is a cross-sectional view for explaining the first and second operations performed in the winding step of the embodiment. [Figure 13] FIG. 13 is a cross-sectional view for explaining a case where the first layer of the winding is normally wound in the first operation of the winding step of the embodiment. [Figure 14] FIG. 14 is a cross-sectional view for explaining a case where the winding position of the first layer of the winding is shifted in the first operation of the winding step of the embodiment. [Figure 15] FIG. 15 is a cross-sectional view for explaining the second operation in the embodiment. [Figure 16] FIG. 16 is a cross-sectional view for explaining the first and second operations performed in the winding step of the modified example. DETAILED DESCRIPTION OF THE INVENTION

[0011] Hereinafter, examples of the method for manufacturing an electric motor disclosed in the present application will be described in detail with reference to the drawings. Note that the method for manufacturing an electric motor disclosed in the present application is not limited to the following examples. [Example]

[0012] (Compressor) FIG. 1 is a longitudinal cross-sectional view of a compressor including an electric motor manufactured by the electric motor manufacturing method of the embodiment. As shown in FIG. 1, compressor 1 is a so-called rotary compressor and includes a container 2, a shaft 3, a compression unit 5, and an electric motor 6. Container 2 is made of a metal material and defines a sealed internal space 7. Internal space 7 is generally cylindrical. When container 2 is placed upright on a horizontal surface, the central axis of internal space 7 is parallel to the vertical direction. Container 2 defines an oil sump 8 below internal space 7. The oil sump 8 stores lubricating oil for lubricating compression unit 5. Container 2 is connected to a suction pipe 11 for drawing in refrigerant and a discharge pipe 12 for discharging compressed refrigerant. Shaft 3 is provided vertically and is disposed in internal space 7 of container 2 with one end immersed in oil sump 8. Shaft 3 is supported by container 2 for rotation around the central axis of internal space 7. The shaft 3 rotates to supply the lubricating oil stored in the oil reservoir 8 to the compression section 5 .

[0013] The compression section 5 is disposed at the bottom of the internal space 7 and above the oil sump 8. The compressor 1 further includes an upper muffler cover 14 and a lower muffler cover 15. The upper muffler cover 14 is disposed above the compression section 5 in the internal space 7. The upper muffler cover 14 defines an upper muffler chamber 16 therein. The lower muffler cover 15 is provided below the compression section 5 in the internal space 7 and above the oil sump 8. A lower muffler chamber 17 is formed inside the lower muffler cover 15. The lower muffler chamber 17 communicates with the upper muffler chamber 16 via a communication passage (not shown) formed in the compression section 5. A discharge hole 18 for discharging the compressed refrigerant is formed between the upper muffler cover 14 and the shaft 3, and the upper muffler chamber 16 communicates with the internal space 7 via the discharge hole 18.

[0014] The compression section 5 compresses the refrigerant supplied from the suction pipe 11 as the shaft 3 driven by the electric motor 6 rotates, and supplies the compressed refrigerant to the upper muffler chamber 16 and the lower muffler chamber 17. The refrigerant is compatible with the lubricating oil.

[0015] (Electric motor) The electric motor 6 is disposed above the compression section 5 in the internal space 7. The electric motor 6 is a three-phase electric motor and includes a rotor 21 and a stator 22. The rotor 21 is fixed to the shaft 3. The stator 22 is formed in a roughly cylindrical shape and is disposed on the outer periphery of the rotor 21 so as to surround the rotor 21, and is fixed to the container 2. The stator 22 includes a stator core 23, a lower insulator 25B as a first insulator, an upper insulator 25A as a second insulator, and a plurality of windings 46.

[0016] The upper insulator 25A is attached to the upper end of the stator core 23 in the axial direction of the shaft 3. The lower insulator 25B is attached to the lower end of the stator core 23 in the axial direction of the shaft 3. The upper insulator 25A and the lower insulator 25B are an example of an insulating part that insulates the stator core 23 from the windings 46. The upper insulator 25A and the lower insulator 25B in this embodiment are formed to have the same shape, and are used as the upper insulator 25A when provided at the upper end of the stator core 23, and are used as the lower insulator 25B when provided at the lower end of the stator core 23. Hereinafter, in this embodiment, the upper insulator 25A and the lower insulator 25B will be collectively referred to as the insulator 25. Note that the upper insulator 25A and the lower insulator 25B may be formed to have different shapes.

[0017] Fig. 2 is a bottom view showing stator core 23 in the embodiment. As shown in Fig. 2, stator core 23 is formed by stacking a plurality of metal plates made of a soft magnetic material, such as electromagnetic steel plates, and includes a yoke portion 31 and a plurality of stator core teeth portions 32 (32-1 to 32-9). Yoke portion 31 is formed in a generally annular (cylindrical) shape. Of the plurality of stator core teeth portions 32-1 to 32-9, first stator core teeth portion 32-1 is formed in a generally columnar shape extending in the radial direction of stator core 23. One end of first stator core teeth portion 32-1 is formed so as to be connected to the inner circumferential surface of yoke portion 31, i.e., it extends from the inner circumferential surface of yoke portion 31 toward the inside in the radial direction of yoke portion 31. Of the multiple stator core teeth portions 32-1 to 32-9, stator core teeth portions 32-2 to 32-9 that are different from first stator core teeth portion 32-1 are also formed in a generally cylindrical shape, similar to first stator core teeth portion 32-1, and extend radially inward from the inner circumferential surface of yoke portion 31. In the case of stator 22 with nine slots, the multiple stator core teeth portions 32-1 to 32-9 are formed on the inner circumferential surface of yoke portion 31 so as to be equally spaced at 40° intervals in the circumferential direction of yoke portion 31.

[0018] FIG. 3 is a perspective view schematically illustrating an insulator 25 according to an embodiment. As shown in FIG. 3, the insulators 25 (upper insulator 25A and lower insulator 25B) are formed into an annular shape and made of an insulating material such as polybutylene terephthalate resin (PBT). As shown in FIG. 3, the insulator 25 has an outer peripheral wall portion 41, a plurality of insulator teeth 42 (42-1 to 42-9) that serve as a winding body around which a conductive wire (winding 46) is wound, and a plurality of flange portions 43 (43-1 to 43-9). The outer peripheral wall portion 41 is formed into a generally cylindrical shape. A plurality of slits 44 are formed in the outer peripheral wall portion 41 at intervals in the circumferential direction of the outer peripheral wall portion 41, the slits 44 extending along the central axis of the outer peripheral wall portion 41 from one end in a direction along the central axis of the outer peripheral wall portion 41 (the axial direction of the shaft 3). Furthermore, the other end of the outer peripheral wall portion 41 in the direction along the central axis of the outer peripheral wall portion 41 contacts the stator core 23. In other words, the multiple slits 44 are formed to extend from one end of the outer peripheral wall portion 41 opposite the stator core 23 toward the stator core 23. When a winding 46 (conductor) drawn from a winding portion 45 (described later) is passed through each slit 44, the winding 46 drawn from the inner peripheral side to the outer peripheral side of the outer peripheral wall portion 41 forms a crossover wire 49 that is laid along the outer peripheral surface of the outer peripheral wall portion 41. Note that the insulator 25 shown in FIG. 3 schematically illustrates the shape and arrangement of each slit 44 in the outer peripheral wall portion 41, and the shape and arrangement of each slit 44 will be described in detail later.

[0019] Of the multiple insulator teeth 42-1 to 42-9, the first insulator tooth 42-1 is formed in the shape of a right column with a roughly semicircular cross section. One end of the first insulator tooth 42-1 is formed to be connected to the inner circumferential surface of the outer peripheral wall 41, that is, it extends from the inner circumferential surface of the outer peripheral wall 41 to the radially inward direction of the outer peripheral wall 41. Of the multiple insulator teeth 42-1 to 42-9, the insulator teeth 42-2 to 42-9 different from the first insulator tooth 42-1 are also formed in the shape of a right column with a roughly semicircular cross section, like the first insulator tooth 42-1, and extend from the inner circumferential surface of the outer peripheral wall 41 to the radially inward direction of the outer peripheral wall 41. The multiple insulator teeth 42-1 to 42-9 are formed on the inner peripheral surface of the outer peripheral wall 41 and are arranged at equal intervals of 40 degrees in the circumferential direction of the outer peripheral wall 41. Note that the insulator teeth 42 in the embodiment are not limited to a shape of a straight column having a substantially semicircular cross section, and may be formed, for example, in a shape of a straight column having a substantially polygonal cross section.

[0020] The plurality of flange portions 43-1 to 43-9 correspond to the plurality of insulator teeth portions 42-1 to 42-9 and are each formed in a generally semicircular plate shape. Of the plurality of flange portions 43-1 to 43-9, the first flange portion 43-1 corresponding to the first insulator tooth portion 42-1 is continuous with the other end of the first insulator tooth portion 42-1 and formed integrally with the first insulator tooth portion 42-1. Similarly to the first flange portion 43-1, the other flange portion 43 of the plurality of flange portions 43-1 to 43-9 that is different from the first flange portion 43-1 is also continuous with the other end of the plurality of insulator teeth portions 42-1 to 42-9 and formed integrally with the respective insulator teeth portions 42-1 to 42-9.

[0021] Fig. 4 is a bottom view showing the stator 22 in the embodiment, as viewed from the side of the lower insulator 25B. As shown in Fig. 4, a plurality of windings 46 (U-phase windings 46-U1 to 46-U3, V-phase windings 46-V1 to 46-V3, and W-phase windings 46-W1 to 46-W3, which will be described later) are wound around each of the plurality of stator core teeth 32-1 to 32-9 of the stator core 23. As shown in Fig. 4, a winding section (coil) 45 is formed on each of the stator core teeth 32-1 to 32-9 by the windings 46 (conductor wires) of each phase. Each winding section 45 has a plurality of layers, for example, six to eight layers, of the windings 46, in which the conductor wires are wound around the stator core teeth 32 via the insulator teeth 42. The nine slot-forming winding portions 45 are numbered 1 to 9 in clockwise order in Fig. 4. The nine winding portions 45 are arranged in the circumferential direction of the stator core 23 so that the three phases repeat the same order. That is, they are arranged so that the U phase, V phase, and W phase repeat in clockwise order in Fig. 4.

[0022] The electric motor 6 in this embodiment is a 6-pole, 9-slot concentrated winding type electric motor. The plurality of windings (conductors) 46 includes a plurality of U-phase windings 46-U1 to 46-U3 that form the U-phase winding portion 45, a plurality of V-phase windings 46-V1 to 46-V3 that form the V-phase winding portion 45, and a plurality of W-phase windings 46-W1 to 46-W3 that form the W-phase winding portion 45.

[0023] Although the electric motor 6 of the embodiment is configured with nine slots, the number of slots, that is, the number of winding portions 45 (or the number of stator core teeth portions 32) is not limited thereto.

[0024] Furthermore, although stator core 23 in the embodiment has an annular yoke portion 31 that is integrally formed, the yoke portion may be formed by connecting and assembling a plurality of arc-shaped yoke components (not shown) into an annular shape. Furthermore, although stator core teeth 32 of stator core 23 in the embodiment extend from the inner peripheral surface of yoke portion 31 radially inward of yoke portion 31, they may extend from the outer peripheral surface of yoke portion 31 radially outward of yoke portion 31. Similarly, insulator teeth 42 of insulator 25 are not limited to a shape that extends from the inner peripheral surface of outer peripheral wall portion 41 radially inward of outer peripheral wall portion 41, but may extend from the outer peripheral surface of outer peripheral wall portion 41 radially outward of outer peripheral wall portion 41.

[0025] (Motor winding part) Fig. 5 is a cross-sectional view schematically showing a winding section (coil) 45 in an electric motor 6 according to an embodiment. In Fig. 5, the windings 46 (conductor wires) of the first layer 1L of the winding section 45 are indicated by the letters "F, S" to distinguish them from one another, with the windings 46 wound in a first operation (described later) being indicated by the letter "F" and the windings 46 wound in a second operation (described later) being indicated by the letter "S." Also, in Fig. 5, the numbers "2 to 8" indicated on the windings 46 of each layer of the winding section 45 indicate the second layer 2L to the eighth layer 8L.

[0026] 5, the conductor wire supplied from the nozzle N is wound around the winding section 45 in this embodiment at a predetermined winding pitch (the amount of movement of the nozzle N in the radial direction Y per turn) so as to be aligned in the radial direction Y of the yoke section 31 (which also corresponds to the radial direction Y of the outer peripheral wall section 41; hereinafter, simply referred to as the radial direction Y). The winding wire 46 wound as the first layer 1L of the winding section 45 is wound in the radial direction Y in contact with the first layer 1L of the winding section 45, i.e., the surface of the insulator teeth 42 on which the conductor wire is wound (hereinafter, referred to as the surface of the insulator teeth 42). The winding section 45 in this embodiment has an increased space factor without causing any irregular winding of the winding wire 46 of the first layer 1L, which will be described in detail later.

[0027] The winding pitch here refers to the amount of movement of the nozzle N in the radial direction Y per turn of the conductor (winding 46) wound in the radial direction Y around the insulator teeth 42 and the stator core teeth 32, and is different from the pitch dimension between adjacent windings 46 in the radial direction Y. For convenience, the winding pitch is also shown as the pitch dimension in the drawings, but in the following description, the winding pitch refers to the amount of movement of the nozzle N in the radial direction Y per turn. Note that the amount of movement of the nozzle N refers to the amount of change in the relative position between the nozzle N and the insulator teeth 42. In other words, when changing the relative position of the nozzle N with respect to the insulator teeth 42, the insulator teeth 42 side may be fixed and the nozzle N side may move, the nozzle N side may be fixed and the insulator teeth 42 side may move, or both the insulator teeth 42 side and the nozzle N side may move.

[0028] (Electric motor manufacturing method) The manufacturing method for the electric motor of this embodiment includes a winding step in which a conductor wire is wound around the stator core teeth 32 via the insulator teeth 42 to form a winding portion (coil) 45. As shown in FIG. 5 , in the winding step of this embodiment, the conductor wire is wound using a winding machine (not shown) having a nozzle N that supplies the conductor wire. Features of the manufacturing method for the electric motor of this embodiment include that in the winding step, the operation of winding the conductor wire into the first layer 1L of the winding portion 45 and the movement amount (winding pitch) of the nozzle N that supplies the conductor wire to be wound into the first layer 1L are controlled by a control unit C of the winding machine.

[0029] In the winding process, the winding wire 46 is supplied from a nozzle N that moves in the radial direction Y of the stator core 23, and the winding wire 46 is wound onto the stator core teeth portion 32 of the stator core 23 and the insulator teeth portion 42 of the insulator 25 attached overlapping the stator core teeth portion 32. The crossover wire 49 drawn out from the winding portion 45 is wound along the outer peripheral wall portion 41 of the insulator 25. In the embodiment, when forming each winding portion 45 of three phases using a winding machine, for example, when forming the winding portion 45 for each phase using three nozzles N and forming the winding portions 45 of each phase in order, the so-called three-nozzle winding method for forming the winding portions 45 of three phases is applied.

[0030] (Winding process of the comparative example) First, for comparison with the winding process in the manufacturing method of the motor of the embodiment, the winding process in the manufacturing method of the motor of the comparative example will be described. In the winding process in the comparison, in order to increase the occupation ratio of the winding portion, when the outer diameter of the conductor in the state before being wound is B and the winding pitch (the amount of movement of the nozzle N in the radial direction Y per turn) of the winding wire of the first layer 1L of the winding portion is P, the conductor is wound so as to satisfy P < B (for example, P = 0.8B). Note that the outer diameter B of the conductor tends to be slightly reduced in the outer diameter of the winding wire wound in the winding portion due to the conductor stretching in the longitudinal direction by the tension applied when the conductor is wound around the stator core teeth portion 32 through the insulator teeth portion 42.

[0031] FIG. 6 is a cross-sectional view schematically showing the winding portion 145 when the winding wire of the first layer 1L is normally wound in the motor of the comparative example. In FIG.  6, the numbers "1 to 8" attached to the winding wires 46 of each layer of the winding portion 145 indicate the first layer 1L to the eighth layer 8L. As shown in FIG. 6, in the winding portion 145 of the comparative example, for example, the winding wire 46 forms eight layers, and the conductor is wound such that the winding pitch P of all layers from the first layer 1L to the eighth layer 8L satisfies P < B. Therefore, the first layer 1L to the eighth layer 8L of the winding portion 145 are wound such that the adjacent winding wires 46 are in close contact with each other in the radial direction Y.

[0032] (Winding process of the comparative example) FIG. 7 is a cross-sectional view for explaining the case where the winding of the first layer 1L is normally wound in the winding process of the comparative example. As shown in FIG. 7, in the comparative example, in the first layer 1L, the winding 46 of the second turn 2T slides down the outer peripheral surface of the winding 46 of the first turn 1T to the other end side Y2 in the radial direction Y (the inner diameter side which is the inner side of the radial direction Y). Thus, following the winding 46 of the first turn 1T, the winding 46 of the second turn 2T and the winding 46 of the third turn 3T are wound in sequence so that they are adjacent to and in contact with each other. Also, for the turns after the fourth turn 4T, by satisfying P < B for the winding pitch P, the windings 46 adjacent to each other in the radial direction Y are aligned so as to be in contact with each other and the conductor is wound. That is, when each winding 46 (conductor) forming the first layer 1L is normally wound, each winding 46 in the first layer 1L is wound densely without gaps.

[0033] FIG. 8 is a cross-sectional view for explaining the case where the winding position of the winding 46 of the first layer 1L is displaced in the winding process of the comparative example. FIG. 9 is a side view for explaining the case where the winding position of the winding 46 is displaced in the winding process of the comparative example.

[0034] As shown in FIG. 8, in the winding process of the comparative example, in the first layer 1L wound on the insulator teeth portion 42, for example, the winding 46 of the second turn 2T wound following the winding 46 of the first turn 1T slides to the other end side Y2 in the radial direction Y (the inner diameter side which is the inner side of the radial direction Y) from the position adjacent to and in contact with the winding 46 of the first turn 1T, and the winding position of the winding 46 of the second turn 2T may be greatly separated from the winding 46 of the first turn 1T.

[0035] At this time, in the comparative example, since the winding pitch (the amount of movement of the nozzle N in the radial direction Y per turn) P is P < B (P = 0.8B), the winding of the winding 46 of the third turn 3T is sent by 0.8B from the winding position where the winding 46 of the second turn 2T would normally be wound. For this reason, the winding 46 of the third turn 3T cannot cross over the winding 46 of the second turn 2T toward the other end side Y2 in the radial direction Y (the inner diameter side which is the inner side in the radial direction Y), and will be wound on the side of the winding 46 of the first turn 1T (the outer diameter side which is one end side Y1 in the radial direction Y) rather than the position of the winding 46 of the second turn 2T. As a result, the winding 46 of the third turn 3T enters between the winding 46 of the first turn 1T and the winding 46 of the second turn 2T, and a part of the winding 46 of the third turn 3T rides on and is wound on the winding 46 of the second turn 2T, causing winding disorder.

[0036] Subsequently, from the winding position of the winding 46 of the second turn 2T which is located at the winding position where the winding 46 of the third turn 3T would normally be wound, the winding 46 of the fourth turn 4T is sent by 0.8B, which is smaller than the outer diameter B of the conductor in the state before being wound. As a result, the winding 46 of the fourth turn 4T is wound adjacent to the winding 46 of the second turn 2T on the side opposite to the winding 46 of the third turn 3T (one end side Y1 in the radial direction Y) in the radial direction Y.

[0037] Also, as shown in FIG. 9, for example, when windings 46 of the third turn 3T and the fourth turn 4T are inserted between the winding 46 of the first turn 1T and the winding 46 of the second turn 2T, the winding 46 of the second turn 2T continues to be displaced in the direction away from the winding 46 of the first turn 1T in the radial direction Y (the other end side Y2 which is the direction approaching the flange portion 43), along with winding disorder. In particular, the winding 46 of the second turn 2T is pulled to the other end side Y2 (the inner diameter side which is the inner side in the radial direction Y) of the radial direction Y, the cross-sectional area decreases, the electrical resistance increases, and there arises a problem that the amount of heat generation of the winding 46 increases. Further, when winding disorder occurs in the first layer 1L, the conductor wound around the second layer 2L rides on the winding 46 causing the winding disorder, resulting in a problem that the winding portion 45 bulges greatly in the stacking direction (the winding diameter direction, for example, the axial direction of the shaft 3), and the winding portion 45 is distorted and enlarged.

[0038] As described above, in order to increase the occupation ratio of the winding portion 145, when the winding pitch P of the winding 46 (conductor) wound around the first layer 1L satisfies P < B and the conductor is wound, there is a problem that winding disorder easily occurs in the winding 46 wound around the first layer 1L. Here, as an example, a case where the winding disorder starts when the winding 46 of the second turn 2T in the first layer 1L slides on the insulator teeth portion 42 is shown. However, in the first layer 1L where the winding 46 is wound in contact with the surface of the insulator teeth portion 42, similar winding disorder may occur at any position in the radial direction Y.

[0039] (Winding process of the embodiment) In the winding process in the method of manufacturing the motor of the embodiment, when forming the first layer 1L by continuously winding a single conductor, a first operation of winding the conductor and a second operation of winding the conductor after the first operation are performed. FIG. 10 is a flowchart for explaining the winding process in the method of manufacturing the motor of the embodiment.

[0040] 10, in a first operation, the conductor is wound from the outer circumferential wall 41 side, which is one end side Y1 in the radial direction Y of the insulator teeth 42, toward the flange 43 side, which is the other end side Y2 in the radial direction Y, while leaving a gap G between adjacent windings 46 in a first layer 1L of the winding portion 45 (step S1). In a second operation, after the first operation, the next conductor is wound onto the first layer 1L so as to be in contact with the winding 46 located on the flange 43 side (the other end side Y2 in the radial direction Y) wound in the first operation, thereby moving at least a portion of the winding 46 wound in the first operation toward the outer circumferential wall 41 side (the one end side Y1 in the radial direction Y) and closing the gap G (step S2).

[0041] In the second operation, it is preferable that the conductor be wound so as to contact the winding 46 (hereinafter also referred to as the "other-end winding 46") located on the other end side Y2 (inner diameter side) in the radial direction Y of the insulator tooth portion 42, among the windings 46 wound in the first operation, because this closes the gap G from the other end side Y2 (inner diameter side) in the radial direction Y. Without being limited to this, in the second operation, the conductor may be wound so as to enter between and contact the other end winding 46 and the adjacent winding 46 on the outer peripheral wall portion 41 side of the other end winding 46, thereby pushing the adjacent winding 46 toward the outer peripheral wall portion 41 side (one end side Y1). Furthermore, it is preferable that the conductor be wound so as to contact the outer peripheral surface of the other end winding 46 on the flange portion 43 side (the other end side Y2 in the radial direction Y) of the outer peripheral surface of the other end winding 46. 15 , which will be described later, the winding 46(S) wound in the second operation comes into contact with the outer peripheral surface of the other end winding 46(F) wound in the first operation that is on the flange 43 side, so that a force f1 directed toward one end side Y1 (outer diameter side) in the radial direction Y and a force f2 directed toward the stator core 23 in the central axis direction of the outer peripheral wall 41 are applied to the other end winding 46(S) wound in the first operation. Then, the force f1 directed toward the one end side Y1 (outer diameter side) in the radial direction Y, which is received from the winding 46(S) wound in the second operation, can press the other end winding 46(F) wound in the first operation toward the outer peripheral wall 41 side (the outer diameter side that is the one end side Y1 in the radial direction Y).

[0042] In the second operation, if the conductor is wound so as to contact the outer peripheral surface of the other-end winding 46(F) on the outer peripheral wall 41 side (one end side Y1 in the radial direction Y), the winding 46(S) wound in the second operation will enter between the other-end winding 46(F) wound in the first operation and the adjacent winding 46(F) on the outer peripheral wall 41 side (one end side Y1 in the radial direction Y) of the other-end winding 46, and will push the adjacent winding 46(F) toward the outer peripheral wall 41 side (one end side Y1 in the radial direction Y). In this case, a part of the winding 46(S) wound in the second operation will ride up on the other-end winding 46(F) wound in the first operation, causing slight winding irregularities on the other end side Y2 in the radial direction Y of the first layer 1L. However, such winding irregularities only occur on the other end side Y2 in the radial direction Y of the first layer 1L after the winding of the winding 46 in the first layer 1L is almost complete, and are tolerable because they have little effect on the winding state of the winding portion 45 or the reliability of the conductor.

[0043] Furthermore, in the second operation, the conductor wire is not limited to being wound one turn (one circumference), but may be wound multiple times, for example, two to four turns, depending on the size of the gap G between the windings 46 (F) wound in the first operation. Increasing the number of turns in this way enhances the effect of reducing the gap G, and also increases the number of windings 46 (F, S) wound in the first layer 1L, thereby improving the space factor.

[0044] In the winding process of the embodiment, the first operation is an operation to prevent irregular winding that is likely to occur in the winding 46 of the first layer 1L. The second operation is an operation to close the gaps G between the windings 46(F) wound in one operation. The second operation may be an operation to reduce (narrow) at least one gap G among the gaps G at multiple locations. The second operation increases the number of turns of the winding 46 in the first layer 1L, thereby improving the alignment of the windings 46 of the second layer 2L and subsequent layers that are layered on the first layer 1L where the gaps G between the windings 46 have been reduced.

[0045] (winding pitch) FIG. 11 is a flowchart for explaining the winding pitch in the winding process of the motor manufacturing method of the embodiment. FIG. 12 is a cross-sectional view for explaining the first operation and the second operation performed in the winding process of the embodiment. Hereinafter, description will be made with reference to FIGS. 11, 12, and FIG. 5. In FIG. 12, similar to FIG. 5, in the first layer 1L of the winding portion 45, “F” is attached to the winding 46 wound in the first operation, and “S” is attached to the winding 46 wound in the second operation for illustration.

[0046] In contrast to the winding pitch P (the amount of movement of the nozzle N in the radial direction Y per turn) of the above-described comparative example being P < B (P = 0.8B), in the first operation of the winding process of the embodiment, as shown in FIGS. 5 and 11, when the first pitch, which is the winding pitch for winding the conductor in the first operation, is P1 and the outer diameter of the conductor in the state before being wound is B, the conductor is wound on the first layer 1L of the winding portion 45 such that the first pitch P1 satisfies P1 > B (step S3). Thereby, the winding 46 (F) can be wound so that winding disorder does not occur in the first layer 1L (see FIG. 14). When winding the conductor on the first layer 1L in the first operation, the nozzle N moves along the radial direction Y from the outer peripheral wall portion 41 side as one end side Y1 in the radial direction Y of the insulator teeth portion 42 toward the flange portion 43 side as the other end side Y2 in the radial direction Y. The first pitch P1, which is the amount of movement of the nozzle N, is controlled by the control unit C of the winding machine.

[0047] When the second pitch, which is the winding pitch for winding the conductor in the second operation after the first operation, is P2, in the second operation, the conductor is wound on the first layer 1L of the winding portion 45 such that the second pitch P2 satisfies P2 < P1 (step S4). Thereby, the gap G between the windings 46 (F) wound in the first operation can be filled by the winding 46 (S) wound in the second operation (see FIG. 15). Also in the second operation, the second pitch P2, which is the amount of movement of the nozzle N, is controlled by the control unit C of the winding machine.

[0048] When the third pitch, which is the winding pitch of the conducting wire wound after the second layer 2L of the winding section 45, is defined as P3, after the second operation in which the winding of the winding wire 46 in the first layer 1L is completed, the conducting wire is wound in the subsequent layers starting from the second layer 2L such that the third pitch P3 satisfies P3 < P1 (step S5). As a result, the number of turns in each layer after the second layer 2L can be increased, so that the occupancy ratio of the winding section 45 can be increased. The third pitch P3, which is the movement amount of the nozzle N, is also controlled by the control unit C of the winding machine. In the embodiment, the third pitch P3 is set to a value that satisfies P2 < P3 < P1.

[0049] As described above, the nozzle N winds the conducting wire while reciprocating in the radial direction Y. That is, the nozzle N winds the conducting wire on the first layer 1L by the first operation and the second operation in the forward path of the reciprocating movement, winds the conducting wire on the second layer 2L in the return path of the reciprocating movement, and winds the conducting wire while repeating the reciprocating movement a predetermined number of times after the third layer 3L. Further, in the winding process of the embodiment, the stator core 23 and the insulator 25 are rotated around the radial direction Y in accordance with the movement of the nozzle N, and the conducting wire is wound around the stator core tooth portion 32 via the insulator tooth portion 42. Note that the direction in which the winding wire 46 (conducting wire) is wound with respect to the radial direction Y in the first layer 1L, that is, the moving direction of the nozzle N in the first layer 1L, is not limited to the direction from the outer peripheral wall portion 41 side toward the flange portion 43 side (the direction from one end side Y1 (outer side) to the other end side Y2 (inner side) of the radial direction Y), and may be the direction from the flange portion 43 side toward the outer peripheral wall portion 41 side (the direction from the other end side Y2 (inner side) to the one end side Y1 (outer side) of the radial direction Y).

[0050] In the first operation, it is preferable to wind the conducting wire such that the first pitch P1 satisfies P1 < 2B. When the first pitch P1 becomes 2B or more, the gap G between adjacent winding wires 46 becomes large, and there is a possibility that the gap G cannot be properly filled by the second operation. Further, when the first pitch P1 becomes 2B or more, the number of turns in the first layer 1L decreases, and the winding wire 46 in the second layer 2L easily enters the gap G between the winding wires 46 in the first layer 1L, and there is a possibility that the alignment of the winding section 45 deteriorates. These problems can be avoided by the first pitch P1 satisfying P1 < 2B.

[0051] In the second operation, multiple turns of the conductor are wound. In the embodiment, as an example, a two-turn winding 46 (conductor) is wound in the second operation, but the number of turns of the winding 46 in the second operation is not limited. The number of turns of the winding 46 in the second operation is set to, for example, approximately 1 to 4 turns. In the second operation, the second turn of the winding 46(S) is wound by advancing the second pitch P2 relative to the first turn of the winding 46(S), but the second pitch P2 may be different for each turn. In the second operation, the conductor may be wound so that the second pitch P2 gradually decreases, for example, from the first turn to the last turn.

[0052] In the second operation, the conductor wire is wound so that the second pitch P2 satisfies 0≦P2<(B / 2). This allows the gap G between the windings 46 wound in the first operation to be appropriately reduced.

[0053] When the second pitch P2 satisfies P2 = 0, the conductor wire is wound at the same position on the insulator tooth portion 42 in the radial direction Y. In other words, when the second pitch P2 satisfies P2 = 0, the conductor wire wound in the second operation is wound around the winding 46(F) located at the other end (on the flange 43 side) wound in the first operation while contacting either the flange 43 side (the other end side Y2 in the radial direction Y) or the outer circumferential wall portion 41 side (one end side Y1 in the radial direction Y) of the outer circumferential surface of the other end winding 46.

[0054] In this case, from the viewpoint of moving the other-end winding 46 toward the outer peripheral wall 41 by the conductor wound in the second operation to close the gap G, it is desirable for the conductor wound in the second operation to contact the flange 43 side of the outer peripheral surface of the other-end winding 46, but it may also contact the outer peripheral wall 41 side of the outer peripheral surface of the other-end winding 46. When the conductor wound in the second operation is wound in contact with the outer peripheral wall 41 side of the outer peripheral surface of the other-end winding 46, it enters between the other-end winding 46 and the adjacent winding 46, pushing the adjacent winding 46 toward the outer peripheral wall 41 side (one end side Y1 in the radial direction Y), thereby closing the gap G. At this time, a portion of the winding 46 wound in the second operation rides up on the other-end winding 46, causing slight winding irregularities at the other end side Y2 in the radial direction Y of the first layer 1L. However, such irregular winding only occurs on the other end Y2 in the radial direction Y of the first layer 1L after the winding of the winding 46 in the first layer 1L is almost complete, and is tolerable because it has little effect on the winding state of the winding portion 45 or the reliability of the conductor. If the second pitch P2 is (B / 2) or greater, the conductor wound in the second operation will be wound away from the winding 46 at the other end (on the flange 43 side) wound in the first operation without coming into contact with it, and there is a risk that the gap G will not be closed.

[0055] (Details of the first operation) 13 is a cross-sectional view illustrating a case where the winding 46 of the first layer 1L is normally wound in the first operation of the winding process of the embodiment. As shown in FIG. 13, in the first operation of the winding process of the embodiment, in the first layer 1L, the conductor is wound in order from the first turn 1T of the winding 46 to the second turn 2T of the winding 46 and the third turn 3T of the winding 46 so that a gap G is left between them. From the fourth turn 4T onwards, the conductor is wound so that the first pitch P1 satisfies P1 > B, so that the windings 46 are aligned in the radial direction Y with a gap G between them.

[0056] 14 is a cross-sectional view illustrating a case where the winding position of the first layer 1L winding 46 is shifted in the first operation of the winding process of the embodiment. As shown in Fig. 14, in the first operation of the winding process of the embodiment, as in the winding process of the comparative example described above (see Fig. 8), for example, in the first layer 1L, the second turn 2T winding 46 wound following the first turn 1T winding 46 may slip in the radial direction Y on the insulator teeth 42 from the winding position where the second turn 2T winding 46 would normally be wound, and the winding position of the second turn 2T winding 46 may become separated from the first turn 1T winding 46.

[0057] Even in such a case, in the first operation of the winding process of this embodiment, the conductor wire is wound so that the first pitch P1 of the first layer 1L satisfies P1>B, thereby ensuring an appropriate amount of movement of the nozzle N. This allows the next third-turn 3T winding 46 to smoothly pass over the misaligned second-turn 2T winding 46. The third-turn 3T winding 46 is wound around the surface of the insulator teeth 42 while contacting the flange 43 side of the outer circumferential surface of the second-turn 2T winding 46, for example. Therefore, the third-turn 3T winding 46 does not get caught between the first-turn 1T winding 46 and the second-turn 2T winding 46 as in the comparative example, but is appropriately wound on the opposite side of the second-turn 2T winding 46 from the first-turn 1T winding 46.

[0058] In other words, the first pitch P1 (movement amount of the nozzle N) of the first layer 1L in the first operation is preferably set to a value obtained by adding a predetermined value corresponding to the maximum amount of misalignment of the winding position of the winding 46 expected in the first layer 1L, i.e., the maximum amount of slippage of the winding 46, to the outer diameter B of the conductor (the upper limit of the dimensional tolerance). Note that the first pitch P1 of the first layer 1L in the first operation may be set to a value equal to or greater than a value that allows the next winding 46 to be wound so as to come into contact with the outer peripheral surface (the other end side Y2 of the outer peripheral surface that is closer to the flange 43) of the misaligned winding 46. This allows the next winding 46 to pass over the misaligned winding 46 in the first operation of the winding process of this embodiment. Therefore, in the first operation of the winding process of the embodiment, the order of each turn of the winding 46 wound on the first layer 1L is not disturbed, and the order of each turn of the winding 46 is correctly wound, thereby preventing winding disturbances on the first layer 1L.

[0059] As described above, even if the winding position of the previously wound winding 46 is shifted in the windings 46 from the fourth turn 4T onwards in the first operation, the next winding 46 is wound while smoothly passing over the previously wound winding 46, thereby preventing winding irregularities from occurring in the first layer 1L.

[0060] (Details of the second operation) Fig. 15 is a cross-sectional view illustrating the second operation in the embodiment. In Fig. 15, in the first layer 1L of the winding section 45, the windings 46 wound in the first operation are marked with an "F" and the windings 46 wound in the second operation are marked with an "S."

[0061] As shown in Fig. 15, in the second operation, the conductor is wound such that the second pitch P2 satisfies P2 < P1, so that the conductor (S) is wound so as to contact the winding 46(F) located at the other end in the radial direction Y among the windings 46(F) wound in the first operation. When the conductor (S) is wound in the second operation, the conductor (S) is wound around the surface of the insulator tooth portion 42 while contacting the outer peripheral surface of the winding 46(F) at the other end in the radial direction Y on the side of the flange portion 43 (the other end side Y2 in the radial direction Y). Thus, a force f1 directed toward the one end side Y1 (outer diameter side) in the radial direction Y is applied to the winding 46(F) at the other end from the winding 46(S) wound in the second operation. By this force f1 directed toward the one end side Y1 (outer diameter side) in the radial direction Y, the winding 46(F) at the other end is pushed toward the one end side Y1 (outer diameter side) in the radial direction Y and moved toward the outer peripheral wall portion 41 side (the one end side Y1 in the radial direction Y). As a result, the gap G between the winding 46(F) at the other end and the winding 46(F) adjacent to the winding 46(F) at the other end is filled, and the two windings 46(F) contact each other.

[0062] Subsequently, in the second operation, the conductor (S) to be wound next is wound such that the second pitch P2 satisfies P2 < P1, so that the conductor (S) contacts the outer peripheral surface of the winding 46(S) wound earlier in the second operation on the side of the flange portion 43 (the other end side Y1 in the radial direction Y) and is wound around the surface of the insulator tooth portion 42. Thus, the winding 46(S) wound earlier in the second operation is pushed and moved toward the outer peripheral wall portion 41 side (the one end side Y1 in the radial direction Y). As a result, the gap G between the windings 46(F) located closer to the outer peripheral wall portion 41 than the winding 46(S) wound earlier in the second operation is filled. Thereafter, the same applies when the conductor is further wound in the second operation, and the gap G between the windings 46(F) wound on the outer peripheral wall portion 41 side is further filled.

[0063] In addition, when viewed in cross section along the radial direction Y, the surface of the insulator tooth 42 around which the conductor wire is wound has a flat surface 42a extending along the radial direction Y and an arc-shaped curved surface 42b that is inclined relative to the flat surface 42a. The flat surface 42a extends from the inner circumferential surface of the outer peripheral wall 41. The curved surface 42b extends from a side surface of the flange 43 that faces the outer peripheral wall 41, and is formed smoothly and continuously on the flange 43 side of the flat surface 42a (the other end side Y2 in the radial direction Y).

[0064] In the second operation, the winding 46 wound on the curved surface 42b of the insulator tooth 42 may slide along the curved surface 42b toward the flat surface 42a, thereby moving the winding 46 wound on the flange 43 side of the insulator tooth 42 in the radial direction Y (the other end side Y2 in the radial direction Y) toward the outer circumferential wall 41 side (the one end side Y1 in the radial direction Y). By utilizing the sliding force of the winding 46 wound on the curved surface 42b in this way, the gap G between the windings 46(F) wound in the first operation can be smoothly closed.

[0065] The inclined surfaces formed on insulator teeth 42 are not limited to curved surfaces (R-surfaces) 42b formed with a single curvature, but may be, for example, C-surfaces, surfaces formed by a series of C-surfaces with different inclination angles, or surfaces formed by a series of R-surfaces with different curvatures. To facilitate sliding of winding 46 wound on the inclined surfaces, insulator teeth 42 may be subjected to a surface treatment such as a coating that reduces the static friction coefficient on the flange 43 side.

[0066] The relational expression for the outer diameter B of the conductor used in the winding process of the embodiment preferably holds even when this outer diameter B is set to the upper limit of the dimensional tolerance of the outer diameter of the conductor (maximum finished outer diameter). This allows the winding pitch (first pitch P1, second pitch P2, etc.) to be optimally set, thereby most appropriately preventing irregular winding of the winding 46 wound in the first layer 1L by the first operation and reducing the gap G between the windings 46 by the second operation. As shown in FIG. 5, the conductor (winding 46) here has a conductor 46a and an insulating film 46b covering the conductor 46a, and the outer diameter B of the conductor is a dimension that includes the thickness of the insulating film 46b. For example, the outer diameter of the conductor 46a of the conductor in the embodiment is set to 0.8 mm, and the upper limit of the dimensional tolerance of the outer diameter B of the conductor covered with the insulating film 46b is set to 0.88 mm.

[0067] Unlike winding 46, crossover wire 49 drawn out from winding portion 45 is less likely to stretch due to tension, and therefore has a larger outer diameter than the portion of the conductor forming winding 46 and is closer to outer diameter B of the conductor before being wound. Therefore, outer diameter B of the conductor before being wound can be approximated to the outer diameter of the conductor as crossover wire 49 extending from winding portion 45 to outer peripheral wall 41. In this embodiment, the outer diameter of the conductor in crossover wire 49 extending from winding portion 45 to outer peripheral wall 41 is treated as outer diameter B of the conductor before being wound.

[0068] The insulating film 46b contains, for example, polyamideimide, and has a static friction coefficient of 0.12 or less. In the embodiment, the insulating film 46b has high lubricity, with a static friction coefficient of approximately 0.05. Therefore, the winding 46 wound in the second operation easily slides the winding 46 wound in the first operation in the radial direction Y on the surface of the insulator teeth 42, thereby smoothly closing the gaps G between the windings 46. Additionally, as described above, a conductor (winding 46) with a small static friction coefficient on the surface of the insulating film 46b can prevent the conductor from getting caught during the winding process, but it also easily slides on the first layer 1L that contacts the surface of the insulator teeth 42, making it more likely for the winding position of the winding 46 to shift. Therefore, when using a conductor with a small static friction coefficient for the insulating film 46b as described above, satisfying the first pitch P1 of the first layer 1L in the first operation, P1 > B, as in the embodiment, is highly effective in preventing irregular winding of the first layer 1L.

[0069] In addition, the insulator 25 in the embodiment contains 15% to 45% by weight of glass fiber, which increases the dynamic friction coefficient on the surface of the insulator teeth 42. Adding less than 15% by weight increases the molding shrinkage of the resin material containing the glass fiber, reducing the moldability of the insulator 25, which is undesirable. Adding more than 45% by weight is undesirable because it does not significantly increase the dynamic friction coefficient and simply increases manufacturing costs. The addition of glass fiber in the insulator 25 prevents the winding 46 wound on the surface of the insulator teeth 42 from slipping, which prevents irregular winding of the first layer 1L wound in the first operation and improves the reliability of the conductor wound in the first layer 1L.

[0070] In addition, in the winding process of the embodiment, the conductor is wound using a winding machine having a nozzle N, and the control unit C of the winding machine controls the movement amount of the nozzle N (first pitch P1 and second pitch P2), so that in the first operation, a winding section 45 without winding irregularities can be easily formed at the desired first pitch P1, and in the second operation, the gap G between the windings 46 can be appropriately narrowed at the desired second pitch P2.

[0071] (Modified Example) In the winding process of the modified example, the number of turns of winding the winding 46 in the second operation is 4 turns, which is different from the winding process of the embodiment in which the number of turns of the winding 46 in the second operation is 2 turns. FIG. 16 is a cross-sectional view for explaining the first operation and the second operation performed in the winding process of the modified example. In FIG. 16, in the first layer 1L of the winding portion 45, “F” is attached to the winding 46 wound in the first operation, and “S” is attached to the winding 46 wound in the second operation.

[0072] As shown in FIG. 16, in the first operation in the winding process of the modified example, similar to the embodiment, the first pitch P1 is wound on the first layer 1L of the winding portion 55 so that P1 > B, and the conductor is wound so that the winding 46 is wound without winding disorder. In the second operation in the winding process of the modified example, the conductor is wound so that the second pitch P2 satisfies P2 < P1, whereby the gap G on the flange portion 43 side (the other end side Y2 in the radial direction Y) between the windings 46 wound in the first operation is filled.

[0073] Then, in the second operation of the modified example, by repeatedly winding the conductor up to 4 turns at the second pitch P2, the gaps G at a plurality of locations between the windings 46 wound in the first operation are filled in order from the flange portion 43 side, and when all the gaps G are filled, the windings 56 in the first layer 1L are brought into close contact with each other. In the winding process of the modified example, similar to the embodiment, the winding portion 55 is formed by winding the conductor so that the third pitch P3 satisfies P3 < P1 after the second layer 2L.

[0074] (Effect of the Embodiment) As described above, the manufacturing method of the electric motor of the embodiment includes a first operation of winding the conductor from the outer peripheral wall portion 41 side (one end side Y1 in the radial direction Y) of the insulator tooth portion 42 toward the flange portion 43 side (the other end side Y2 in the radial direction Y) in the radial direction Y while leaving a gap G between adjacent windings 46 in the first layer 1L of the winding portion 45, and a second operation of winding the conductor in the first operation after the first operation so as to contact the winding 46 located on the flange portion 43 side (the other end side Y2 in the radial direction Y), thereby moving at least a portion of the winding 46 wound in the first operation toward the outer peripheral wall portion 41 side (one end side Y1 in the radial direction Y) and closing the gap G. By winding the conductor wire on the first layer 1L in the first operation while leaving gaps G between the windings 46 in this way, even if the winding 46 wound on the first layer 1L slips on the surface of the insulator teeth 42, the next winding 46 can smoothly move over the misaligned winding 46 and be wound appropriately, preventing winding irregularities in the first layer 1L. Furthermore, by winding the conductor wire on the first layer 1L in the second operation so as to reduce the gaps G between the windings 46, the number of turns of the winding 46 in the first layer 1L can be increased, improving the alignment of the windings 46 of the second layer 2L and subsequent layers that are layered on the first layer 1L with reduced gaps G between the windings 46 in the first layer 1L. Therefore, according to the embodiment, for example, there is no need to change the insulator having grooves to prevent winding slippage depending on the outer diameter of the conductor wire, and an increase in the manufacturing cost of the motor 6 can be avoided. Furthermore, according to the embodiment, the winding 46 of the first layer 1L of the winding section 45 can be prevented from stretching due to winding irregularities, thereby suppressing increases in the resistance value and heat generation of the winding 46 and improving the reliability of the conductor wound in the first layer 1L.

[0075] Furthermore, in the manufacturing method of the electric motor of the embodiment, in the first operation, the conductor wire is wound so that the first pitch P1 satisfies P1>B. As a result, even if the winding 46 wound in the first layer 1L slips on the surface of the insulator teeth 42, the next winding 46 can smoothly overcome the misaligned winding 46 and be wound appropriately. Therefore, the winding 46 can be wound without causing any irregularities in the winding in the first layer 1L.

[0076] Also, in the method for manufacturing the electric motor of the embodiment, in the first operation, the conductor is wound such that the first pitch P1 satisfies P1 < 2B. In other words, for the winding 46 wound around the first layer 1L of the winding portion 45, the outer diameter B and the winding pitch P satisfy 2B > P. When the first pitch P1 becomes 2B or more, the gap G between adjacent windings 46 becomes large, and there is a risk that the gap G cannot be appropriately filled in the second operation. Also, when the first pitch P1 becomes 2B or more, the number of turns in the first layer 1L decreases, and it becomes easier for the winding 46 of the second layer 2L to enter the gap G between the windings 46 in the first layer 1L, and there is a risk that the alignment of the winding portion 45 deteriorates. These problems are avoided by the first pitch P1 satisfying P1 < 2B.

[0077] Also, in the method for manufacturing the electric motor of the embodiment, in the second operation, the conductor is wound such that the second pitch P2 satisfies P2 < P1. Thereby, the gap G between the windings 46 wound in the first operation can be filled by the winding 46 wound in the second operation.

[0078] Also, in the method for manufacturing the electric motor of the embodiment, in the second operation, the conductor is wound such that the second pitch P2 and the outer diameter B of the conductor satisfy 0 ≦ P2 < (B / 2). Thereby, the gap G between the windings 46 wound in the first operation can be appropriately filled.

[0079] Also, in the method for manufacturing the electric motor of the embodiment, in the second operation, a plurality of turns of the conductor are repeatedly wound. By increasing the number of turns in this way, the effect of reducing the gap G is enhanced, and the number of windings 46 wound around the first layer 1L can be increased.

[0080] Also, in the method for manufacturing the electric motor of the embodiment, the conductor is wound such that the third pitch P3 of the winding 46 wound after the second layer 2L of the winding portion 45 satisfies P3 < P1. Thereby, the number of turns of each layer after the second layer 2L can be increased, and the occupation ratio of the winding portion 45 can be increased.

[0081] Furthermore, the outer diameter B of the conductor used in the manufacturing method of the electric motor of this embodiment is the upper limit of the dimensional tolerance. This allows the winding pitch (first pitch P1, second pitch P2, etc.) to be set optimally, thereby most appropriately preventing irregular winding of the winding 46 wound in the first layer 1L in the first operation and most appropriately reducing the gap G between the windings 46 in the second operation.

[0082] Furthermore, when viewed in cross section along the radial direction Y, the insulator teeth 42 of the insulator 25 used in the manufacturing method of the electric motor of the embodiment have a flat surface 42a extending along the radial direction Y and a curved surface 42b formed continuously with the flat surface 42a on the flange 43 side (the other end side Y2 in the radial direction Y) and inclined with respect to the radial direction Y. Then, in the second operation, the winding 46 wound on the curved surface 42b slides along the curved surface 42b toward the flat surface 42a, thereby moving the winding 46 wound on the flange 43 side toward the outer circumferential wall 41 (the one end side Y1 in the radial direction Y). By utilizing the sliding force of the winding 46 wound on the curved surface 42b in this way, the gap G between the windings 46 wound in the first operation can be smoothly closed.

[0083] Furthermore, the insulating film 46b of the conductor wire (winding 46) used in the manufacturing method of the electric motor of the embodiment contains polyamideimide. This provides the insulating film 46b with high lubricity, which allows the winding 46 wound in the second operation to easily slide in the radial direction Y on the surface of the insulator teeth 42, thereby smoothly closing the gaps G between the windings 46. Additionally, while the insulating film 46b's high lubricity prevents the conductor wire from getting caught during the winding process, it also makes the first layer 1L, which contacts the surface of the insulator teeth 42, more likely to slip, resulting in misalignment of the winding position of the winding 46. Therefore, by making the first pitch P1 of the first layer 1L in the first operation satisfy P1>B, as in the embodiment, it is highly effective in preventing irregular winding of the first layer 1L.

[0084] Furthermore, the insulators 25 used in the manufacturing method of the electric motor of the embodiment contain glass fiber in an amount of 15% by weight or more and 45% by weight or less, which increases the coefficient of dynamic friction on the surfaces of the insulator teeth 42 and prevents the winding 46 wound on the surfaces of the insulator teeth 42 from slipping, thereby preventing irregular winding of the first layer 1L wound in the first operation and improving the reliability of the conductor wound in the first layer 1L.

[0085] In addition, in the method for manufacturing an electric motor according to the embodiment, the conductor wire is wound using a winding machine having a nozzle N that supplies the conductor wire. As a result, a control unit C of the winding machine controls the movement amount (first pitch P1, second pitch P2) of the nozzle N, so that a winding portion 45 without irregular winding can be easily formed at the desired first pitch P1 in the first operation, and gaps G between the windings 46 can be appropriately narrowed at the desired second pitch P2 in the second operation. [Explanation of symbols]

[0086] 6 Electric motor 23 stator core 25(25A, 25B) insulator 31 York 32 (32-1 to 32-9) Stator core teeth (teeth) 41 Outer wall 42 (42-1 to 42-9) Insulator teeth (winding drum) 42a flat surface 45, 55 winding section 46 windings 46a Conductor 46b insulating film 49 Crossover B Conductor outer diameter G Gap P1 First pitch (winding pitch in the first operation) P2 Second pitch (winding pitch in the second operation) P3 Winding pitch from the second layer onwards 1L 1st layer 2L~8L 2nd to 8th layers M length N nozzle Y radial direction

Claims

1. a stator core having an annular yoke portion and teeth portions extending radially from the yoke portion; an insulator having a winding drum attached to the tooth portion; a winding portion in which a plurality of layers are formed by windings in which a conductor is wound around the teeth portion via the winding drum portion, a first operation of winding the conductor from one end side to the other end side of the winding drum in the radial direction while leaving a gap between adjacent windings in a first layer of the winding portion; and a second operation, after the first operation, of winding the conductor in the first layer so as to contact the winding located on the other end side, thereby moving at least a portion of the winding wound in the first operation toward the one end side and closing the gap.

2. In the first operation, when a first pitch, which is a winding pitch in the first operation, is P1 and an outer diameter of the conductor wire is B, The conductor is wound so that P1>B is satisfied. A method for manufacturing the electric motor according to claim 1.

3. In the first operation, The conductor is wound so as to satisfy P1<2B. A method for manufacturing an electric motor according to claim 2.

4. In the second operation, when a second pitch, which is a winding pitch in the second operation, is P2, The conductor is wound so that P2<P1 is satisfied. A method for manufacturing an electric motor according to claim 2.

5. In the second operation, The conductor is wound so as to satisfy 0≦P2<(B / 2). The method for manufacturing the electric motor according to claim 4.

6. In the second operation, the conductive wire is wound repeatedly a plurality of turns. A method for manufacturing the electric motor according to claim 1.

7. When a third pitch, which is the winding pitch of the conductor wound in the second layer and thereafter of the winding portion, is P3, The conductor is wound so that P3<P1 is satisfied. A method for manufacturing the electric motor according to claim 1.

8. The outer diameter B of the conductor is the upper limit of the dimensional tolerance of the outer diameter. A method for manufacturing an electric motor according to any one of claims 2 to 5.

9. When viewed in a cross section of the winding drum portion along the radial direction, the winding drum portion of the insulator has a flat surface extending along the radial direction and an inclined surface formed continuously with the other end side of the flat surface and inclined with respect to the radial direction, In the second operation, the winding wound on the inclined surface slides along the inclined surface toward the flat surface, thereby moving the winding wound on the other end toward the one end. A method for manufacturing the electric motor according to claim 1.

10. the conducting wire has a conductor and an insulating film covering the conductor, the insulating film contains polyamideimide; A method for manufacturing the electric motor according to claim 1.

11. The insulator contains glass fibers in an amount of 15% by weight or more and 45% by weight or less. A method for manufacturing the electric motor according to claim 1.

12. winding the conductor wire using a winding machine having a nozzle for supplying the conductor wire; A method for manufacturing the electric motor according to claim 1.

Images