Stator, and motor

Abstract

To provide a stator provided with a coil shape in which it is significantly easy to attach a wave-winding coil to a stator core, and to provide a motor provided with the stator.SOLUTION: Coils 2u (2v, 2w) are each constituted from one winding. Each of the coils 2u (2v, 2w) comprises a first coil end 9 extending from a coil side 7 to a radial outer-peripheral side and a circumferential direction of a stator core, and a second coil end 8 extending to a radial inner-peripheral side and a circumferential direction thereof. The coil sides 7 are inserted into respective slots 35 of the stator core 1 in order by directing the coils 2u (2v, 2w) constituted in this manner from one side in an axial direction of the stator core toward the other side. At this time, the coils 2u (2v, 2w) are attached to the stator core 1 by interposing an insulation member between an upper-side end face of the stator core 1 and a lower-side end face of the first coil ends 9, or between upper-side and lower-side end faces of each phase of the second coil ends 8, or between upper-side and lower-side end faces of each phase of the first coil ends 9.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a stator having a wave winding coil and a motor having the stator. [Background technology]

[0002] Conventionally, motors have been known in which a coil is formed by wave-winding a conductor wire with a rectangular cross section (hereinafter referred to as rectangular wire) within a slot of a stator core. When installing such a wave-wound coil within a slot of the stator core, for example, a method is known in which a plurality of segment conductors for forming the coil are prepared, each of these segment conductors is placed within the slot of the stator core, and the ends of each segment conductor are connected to form the wave-wound coil of the stator.

[0003] For example, Figures 3 and 4 of Patent Document 1 below show U-shaped segment conductors and crank-shaped segment conductors that make up the plurality of segment conductors. In the case of Patent Document 1, these segment conductors are arranged in slots of a stator core, causing both end portions of the U-shaped segment conductors and crank-shaped segment conductors to protrude from both axial end face sides of the stator core, and the portions of the segment conductors that protrude from both end face sides are connected to form a wave-wound coil of the stator.

[0004] The coil in Patent Document 1 is a three-phase star-connected coil in which two coils are connected in series, but naturally, delta-connected and parallel-connected wave-wound coils are also known. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Patent Publication No. 2014-90546 Summary of the Invention [Problem to be solved by the invention]

[0006] However, the wave winding coil disclosed in Patent Document 1 requires the manufacture and preparation of segment conductors of various different shapes. The number of U-shaped segment conductors required is equal to the number of slots in the stator, and one each of the deformed segment conductors used as lead terminals for the U, V, and W phases of the three phases is required. Furthermore, three deformed segment conductors are required as transition sections for the two-phase series configuration for each phase, and one each of the deformed segment conductors used as neutral points, resulting in a very large number of segment conductors being used.

[0007] Furthermore, in order to accommodate these segment conductors in the slots of the stator core, they must be arranged in the slots from the radial inner side to the radial outer side of the stator core. This, combined with the large number of segment conductors, means that segment conductors of various different shapes must be arranged in predetermined slot positions, making the work cumbersome and complicated.

[0008] Furthermore, the open ends of the many segment conductors arranged in the slots of the stator core must be welded together using TIG welding, laser welding, or other methods, which places a heavy burden on the work and requires a considerable amount of labor.If a defect occurs in the weld, it could lead to a break in the wire on the manufacturing line or after shipment.

[0009] Therefore, an object of the present invention is to provide a wave winding coil structure that can minimize the number of components of the wave winding coil and dramatically simplify the stator assembly work, as well as technology related to a stator and a motor equipped with the same. [Means for solving the problem]

[0010] The invention described in claim 1 is characterized in that the coils of each phase, which are wave-wound between the slots of the stator core, are each composed of one turn, and only one coil side of the coil of one phase is arranged in one slot of the stator core for each phase, and the coil has a first coil end that connects one end of the coil side to one end face of the stator core and extends radially outward and circumferentially of the stator core, and a second coil end that connects the other end of the coil side to the other end face of the stator core and extends radially inward and circumferentially of the stator core. the circumferential thickness dimensions of the inner end face and the outer end face of the coil side are smaller than the radial width dimensions of the one circumferential end face and the other circumferential end face, the axial height dimensions between the upper end face and the lower end face of the first coil end and the second coil end are larger than the circumferential thickness dimensions of the inner end face and the outer end face of the coil side, and the axial height dimensions of the inner end face and the outer end face of the first coil end and the inner end face and the outer end face of the second coil end are substantially the same as the radial width dimensions of the upper end face and the lower end face of the first coil end and the upper end face and the lower end face of the second coil end, a curved portion is formed on the radially inner circumferential side and one axial side at the connection portion between the coil side and the first coil end, and a right-angled portion is formed on the radially outer circumferential side and the other axial side at the connection portion between the coil side and the second coil end, an inclined portion is formed on the radially inner circumferential side and one axial side at the connection portion between the coil side and the second coil end, and the first coil end and the coil side are connected by an arc portion on the radially outer circumferential side and an expanded portion on the radially inner circumferential side, and the expanded portion expands in a direction in which the width dimension increases from the coil side toward the first coil end side, and the second coil end and the coil side are connected by an arc portion on the radially inner circumferential side and a step portion on the radially outer circumferential side, The present invention relates to a stator characterized in that an insulating member is interposed between the upper end surface of the stator core and the lower end surface of the first coil end, or between each phase of the second coil end, or between each phase of the first coil end.

[0011] The invention of claim 2 relates to a stator that is attached to a stator core by inserting the coil side of the coil of claim 1 into the slot from the second coil end side for each phase.

[0012] The invention of claim 3 relates to a stator in which the stator core of either claim 1 or claim 2 and the coils of each phase are molded with insulating resin.

[0013] The invention of claim 4 relates to a motor having the stator of claim 1 or claim 2.

[0014] According to the invention of claim 1, there is no need to manufacture and prepare a large number of conductor members to form a wave-wound coil, and there is also no need to arrange a large number of conductor members in slots at predetermined positions in the stator core or to join the conductor members together. Furthermore, since the coil arrangement is simplified, the stator structure can be simplified.

[0015] According to the invention of claim 1, when attaching a coil to the stator core, it is possible to prevent the coil from interfering with the stator core or coils of other phases. Moreover, when attaching the coil to the stator core, it is possible to easily determine the position of the coil attachment relative to the stator core by interposing an insulating member between the upper end face of the stator core and the lower end face of the first coil end, or between each phase of the second coil end, or between each phase of the first coil end.

[0016] According to the invention of claim 2, the coil can be easily attached to the stator core, which reduces the workload and dramatically reduces the working time.

[0017] According to the invention as set forth in claim 3, it is possible to reliably insulate the phase coils from one another and the phase coils from the conductors such as the stator core.

[0018] According to the invention as set forth in claim 4, it is possible to provide a motor having the effects of the invention as set forth in claim 1 or claim 2 above. [Brief explanation of the drawings]

[0019] [Figure 1] FIG. 2 is a perspective view showing a stator of the present invention to which three phase coils are attached. [Figure 2] FIG. 2 is a perspective view showing one phase of a coil attached to the stator of the present invention. [Figure 3] 3 is an enlarged perspective view showing a part of a coil for one phase attached to a stator of the present invention. FIG. [Figure 4] 3 is an enlarged plan view showing a part of a coil for one phase attached to a stator of the present invention. FIG. [Figure 5] FIG. 2 is a plan view showing a stator core of the present invention. [Figure 6] 1 is an enlarged plan view showing a part of a stator according to the present invention in which one phase of coil is inserted. [Figure 7] FIG. 2 is a front view showing the stator of the present invention with one phase of coils attached. [Figure 8] FIG. 2 is a front view showing the stator of the present invention with two phase coils attached. [Figure 9] FIG. 2 is a front view showing the stator of the present invention with three phase coils attached. DETAILED DESCRIPTION OF THE INVENTION

[0020] The contents of the present invention will be explained in this specification, and in this specification, the term "axial direction" refers to the direction in which the center line of rotation of the rotor (not shown) that constitutes the motor of the present invention extends when the rotor is arranged so as to be rotatable relative to the stator.

[0021] In addition, the term "circumferential direction" refers to the circumferential direction centered on the center line of rotation when viewed in a cross section perpendicular to the "axial direction" in a state where the rotor is arranged to be rotatable relative to the stator, or in a state where the coil is attached to the stator.

[0022] Furthermore, the term "radial direction" refers to a direction passing through the center line of rotation when viewed in a cross section perpendicular to the "axial direction" in a state in which the rotor is arranged to be rotatable relative to the stator.

[0023] Furthermore, the term "radially inner peripheral side" refers to the side of the rotation center line along the radial direction, and the term "radially outer peripheral side" refers to the side opposite the rotation center line along the radial direction.

[0024] Furthermore, in this specification, the terms "straight line," "parallel," "right angle," "annular," "cylinder," "wave-shaped," and "rectangular" are used to include "approximately straight line," "approximately parallel," "approximately right angle," "approximately annular," "approximately cylindrical," "approximately wave-shaped," and "approximately rectangular," respectively. Furthermore, for convenience, in this specification, the terms "upper side" and "lower side" are described as "one axial side" and "other axial side," respectively, the terms "left side" and "right side" are described as "one circumferential side" and "other circumferential side," respectively, and the terms "inner side" and "outer side" are described as "radially inner peripheral side" and "radially outer peripheral side," respectively. However, "one side" and "other side," "inner side" and "outer side" are not limited to these, and appropriate directions may be selected.

[0025] An embodiment of the present invention will be described below with reference to Fig. 1 to Fig. 7. Fig. 1 is a perspective view showing a stator A of the present invention. As shown in Fig. 1, the stator A of the present invention is roughly composed of a stator core 1 and a wave-wound coil 2. The stator core 1 is composed of an annular yoke portion 3 and a plurality of teeth 4 protruding radially inward from the yoke portion 2.

[0026] Stator core 1 is a laminated core made by stacking thin iron plates, and using a laminated core can suppress eddy current loss, but such a laminated structure is not an essential condition for stator core 1, and stator core 1 may be constructed as a single solid body. Also, stator core 1 can be formed by joining core members manufactured as a laminated structure or a single solid body together into a ring shape as divided core members.

[0027] Furthermore, coil 2 shown in FIG. 1 is a wave-wound coil made by fitting a conductor formed and manufactured into a wave shape into a slot in stator core 1, and is composed of a total of three coils for three phases: U phase, V phase, and W phase.

[0028] A cylindrical rotor (not shown) is rotatably disposed in hollow portion 4 on the radially inner side of stator core 1 shown in Fig. 1. The rotating magnetic field generated by coil 2 causes the rotor to rotate within hollow portion 4 around a rotation axis that passes through the center of the circular cross section of the rotor when viewed in cross section. The direction of extension of the rotation axis coincides with the rotation center line, and both ends of the rotation axis rotate within hollow portion 4 by being pivotally supported by bearings (not shown). In other words, the longitudinal direction of the rotation axis of the rotor is the "axial direction."

[0029] Next, the structure of the coil 2 will be described using Figure 2. As mentioned above, the coil 2 is composed of U-, V-, and W-phase coils 2u, 2v, and 2w, but since the coils 2u, 2v, and 2w for each phase have the same shape and structure, they will be described as the U-phase coil 2u in Figure 2.

[0030] As shown in Fig. 2, the coil 2u is made by forming a single conductor into a wave shape. Specifically, the coil 2u has one open end 5 and the other open end 6, and the portion between the open ends 5 and 6 is formed into a wave shape.

[0031] One open end 5 has a thin plate-shaped coil side 7 extending linearly from the top to the bottom, and a second coil end 8 extending from the lower end (other end) of the coil side 7 toward the radially inner side and the other circumferential side.

[0032] A thin plate-shaped coil side 7 extending radially outward and toward one axial side (upper side in FIG. 2) is connected to the other circumferential side of the second coil end 8, and a first coil end 9 extending radially outward and toward the other circumferential side is connected to an upper end (one end) of the coil side 7. The other circumferential side of the first coil end 9 is connected to the coil side 7 extending radially inward and toward the other axial side.

[0033] As described above, the second coil end 8, the coil side 7, and the first coil end 9 are connected continuously in that order in the circumferential direction to the other circumferential side of the coil side 7 that is connected to the other circumferential side of the first coil end 9. Then, just before the other open end 6, the second coil end 8 is connected from the lower end (other end) of the coil side 7 toward the radially inner circumferential side and the other circumferential side, and the coil side 7 that extends toward the radially outer circumferential side and one axial side is connected to the other circumferential side of the second coil end 8, and the other open end 6 is located on one axial side of the coil side 7.

[0034] The detailed structure of the coil 2u roughly configured in this manner, such as the width and thickness dimensions of the coil side 7 and the first and second coil ends 8 and 9, and the shape and dimensions of the portion connecting the coil side 7 to the first and second coil ends 8 and 9, are determined taking into consideration the size of the motor in which the coil 2u is incorporated and the various devices in which the motor is incorporated, the cross-sectional area required to pass current through the coil 2u, or the spatial distance (insulation distance) between the coils of each phase 2u, 2v, and 2w.

[0035] Figure 3 is an enlarged perspective view of a portion of the coil 2u shown in Figure 2. In the case of Figure 3, the coil side 7 has small thicknesses at its inner end face 10, outer end face 11, and upper end faces 12 and 13, and large widths at its one circumferential end face 14 and other circumferential end face 15. Furthermore, the widths of the upper end face 16 and lower end face 17 of the first coil end 9 and the upper end face 18 and lower end face 19 of the second coil end 8 are larger than the thicknesses of the inner end face 10 and outer end face 11 of the coil side 7.

[0036] Furthermore, the height dimensions of the inner end face 19 and outer end face 20 of the first coil end 9 and the inner end face 21 and outer end face 22 of the second coil end 8 are formed to be approximately the same as or slightly larger than the width dimensions of the upper end face 16 and lower end face 17 of the first coil end 9 and the upper end face 18 and lower end face 19 of the second coil end 8.

[0037] Furthermore, the connecting portion of the first coil end 9 of the coil side 7 (one end of the coil side 7) has a curved portion 23 formed on the radially inner circumferential side and one axial side, and a right-angled portion 24 formed on the radially outer circumferential side and the other axial side. The connecting portion of the coil side 7 and the second coil end 8 (the other end of the coil side 7) has an inclined portion 25 formed on the radially inner circumferential side and one axial side, and a curved portion 26 formed on the radially outer circumferential side and the other axial side.

[0038] Fig. 4 is an enlarged plan view of a portion of the coil 2u. As shown in Fig. 4, the first coil end 9 and the coil side 7 are connected by arc portions 27, 28 on the radially outer side and flared portions 29, 30 on the radially inner side. The flared portions 29, 30 flare in a direction that increases in width from the coil side 7 toward the first coil end 9.

[0039] The second coil end 8 and the coil side 7 are connected by arc portions 31, 32 on the radially inner side and stepped portions 33, 34 on the radially outer side.

[0040] The structure of the coil 2u described above is determined taking into consideration the size of the motor and the various devices into which it is incorporated, the cross-sectional area required for current flow, and the insulation distance between other phases. However, when the various devices are different, the structure will naturally be different, and the structure of the coil 2u can be appropriately determined by comprehensively assessing the above-mentioned factors. Therefore, the coil 2u of the present invention is not limited to the structure shown in Figures 2 to 4.

[0041] Furthermore, the number of waveforms between one open end 5 and the other open end of the coil 2u is not limited to the number shown in Figure 2, and the waveforms formed are 1 / 3 of the number of slots in the stator core 1.

[0042] The coils 2u, 2v, 2w of each phase all have the same structure as that shown in FIGS. 2 to 4, and therefore a description of 2v and 2w will be omitted.

[0043] The coils 2u, 2v, and 2w described above can be manufactured by, for example, casting or forging, or by manufacturing them from strip or plate-shaped materials. By adopting any of these methods, it is no longer necessary to join multiple members by welding or the like, as in the past, thereby reducing the burden and labor costs associated with the coil molding and manufacturing work. However, if such benefits are not required, the coil shown in FIG. 2 may be manufactured by joining multiple members by welding or the like.

[0044] Fig. 5 is a plan view of the stator core 1 shown in Fig. 1, as seen from the axial direction of the rotation shaft (not shown) of the rotor. As shown in Fig. 5, the stator core 1 of the present invention is composed of an annular yoke portion 3 and a plurality of teeth 4 protruding radially inward from the yoke portion 3.

[0045] The teeth 3 form a plurality of slots 35 between the teeth. The shape of the slots 35 is substantially the same as the cross-sectional shape of the coil 2u in Fig. 2. Specifically, as shown in Fig. 2, when the cross-sectional shape of the coil 2u is rectangular, the shape of the slots 35 is also rectangular, and the dimensions of the slots 35 are formed to be slightly larger than the dimensions of the coil 2u.

[0046] 5 illustrates a case in which the stator core 1 is formed by joining a plurality of core members each having a split structure formed as a single solid into an annular shape. Therefore, the stator core 1 includes first teeth 36 that are wide in the circumferential direction, and second and third teeth 37, 38 that are narrow in the circumferential direction. The first teeth 36 are arranged in the center of the split core member, the second teeth 37 are arranged on one circumferential side of the split core member, and the third teeth 38 are arranged on the other circumferential side of the split core member.

[0047] By joining the second teeth 37 and the third teeth 38 of the core member having such a structure at the joining surface 39, the sum of the width dimensions of the second and third teeth 37, 38 is formed to be the same width dimension as the first teeth 36.

[0048] As mentioned above, the stator core 1 according to the present invention does not need to adopt such a divided structure, and may be configured as a single solid body.

[0049] In the case of Fig. 5, the stator core 1 has 48 slots 35, but is not limited to this number. Since the coil 2 shown in Fig. 2 has three phases, it is sufficient to form slots in a number that is a multiple of 3. As mentioned above, the number of coil sides 7 of the coil 2u shown in Fig. 2 changes depending on the number of slots selected.

[0050] Next, a description will be given of the case where the coil 2u shown in Fig. 2 is attached to the stator core 1 shown in Fig. 5. When manufacturing the stator core 1 of the present invention, one each of the coils 2u, 2v, and 2w shown in Fig. 2 is prepared, that is, three coils in total.

[0051] The coils 2u, 2v, and 2w of each phase are attached in order to the stator core 1. In this embodiment, the coils are attached to the stator core 1 in the order of V-phase coil 2v, U-phase coil 2u, and W-phase coil 2w, but the order is not limited to this. Any of six possible arrangements in which the coils are attached in a different order may be selected.

[0052] When first attaching the V-phase coil 2v to the stator core 1, the coil 2v is inserted from one axial side (the front side of the paper) of the stator core 1 shown in Figure 5 to the other axial side (the back side of the paper) so that the coil side 7 is aligned within the slot 12 of the stator core 1.

[0053] 2 are inserted into every third slot 12. FIG. 6 is an enlarged plan view of a main portion showing a state in which coil 2v is attached to stator core 1. As shown in FIG.

[0054] As shown in Figure 6, when inserting the coil side 7 into the slot 35 of the stator core 1, the second coil end 8 of the coil 2v extends circumferentially at a position on the radially inner side of the stator core 1, so that the second coil end 8 does not interfere with (contact with) the stator core 1 during the process of inserting the coil side 7 into the slot 35 of the stator core 1.

[0055] Furthermore, since the first coil end 9 extends circumferentially on one end face of the stator core 1 on the radially outer side of the stator core 1, if the coil side 7 is inserted deeply into the slot 35 of the stator core 1, the first coil end 9 will interfere with (contact) one end face of the stator core 1 above a certain depth position, and therefore cannot be inserted any deeper.

[0056] Fig. 7 is a front view showing the state in which coil 2v is attached to stator core 1. Coil 2v is in a state in which coil sides 7 are inserted to a certain depth into slots 35 (see Fig. 5) of stator core 1 from the upper side (one axial side) to the lower side (the other axial side) shown in Fig. 7, and in this state, second coil end 8 is located on the lower side (the other axial side) of stator core 1, and first coil end 9 is located on the upper side (one axial side) of stator core 1.

[0057] The insertion amount of the first coil end 9 into the slot 35 of the coil side 7 is adjusted so as to form a gap that ensures an insulating distance between the first coil end 9 and one end face (upper side face in FIG. 5 ) of the stator core 1. Note that if an insulating coating is applied to the stator core 5, the first coil end 9 may be brought into contact with the one end face of the stator core 1.

[0058] The insertion amount of the coil side 7 into the slot 35 may be adjusted, for example, by interposing an insulating member such as a spacer (not shown) between the upper surface of the stator core 1 and the lower end surface 17 of the first coil end 9. In this way, the insertion amount of the coil 2v into the slot 35 of the stator core 1 can be easily and reliably adjusted.

[0059] After the coil 2v has been attached to the stator core 1, the coil 2u is then attached to the stator core 1. The method of attaching the coil 2u is the same as that of the coil 2v, in that the coil side 7 shown in Fig. 2 is inserted into the slot 35 shown in Fig. 5 from one axial side of the stator core 1 shown in Fig. 5 (the upper side in Fig. 7) to the other axial side (the lower side in Fig. 7).

[0060] In this case, the coil side 7 of the coil 2u may be inserted in the slot 35 one slot away from the slot 35 into which the coil side 7 of the coil 2v is inserted, or may be inserted in the slot 35 two slots away from it, in the clockwise direction in Figure 5.

[0061] In this way, when coil 2u is attached to stator core 1, a portion of second coil end 8 of coil 2u is located above second coil end 8 of coil 2v, and a portion of first coil end 9 is located above first coil end 7b of coil 2v.

[0062] Fig. 8 is a front view showing the state in which coil 2v and coil 2u are attached to stator core 1. As shown in Fig. 8, first coil end 9 of coil 2u is attached so as to form a gap that can ensure an insulation distance between it and first coil end 9 of coil 2v. Also, second coil end 8d of coil 2u is attached so as to form a gap that can ensure an insulation distance between it and second coil end 8 of coil 2v.

[0063] As in the case of coil 2v described above, the insertion amount of coil 2u into slot 35 of coil side 7 can be adjusted by interposing an insulating member such as a spacer (not shown) between the upper end face 18 of second coil end 8 or the upper end face 16 of first coil end 9 of coil 2v and the lower end face 19 of second coil end 8 or the lower end face 17 of first coil end 9 of coil 2u, since a portion of second coil end 8 of coil 2u is located above the second coil end 8 of coil 2v and a portion of first coil end 9 is located above the first coil end 9 of coil 2v.

[0064] After the coil 2u has been attached to the stator core 1, the coil 2w is then attached to the stator core 1. The method of attaching the coil 2w is the same as that of the coils 2v and 2u, in that the coil side 7 shown in Fig. 2 is inserted into the slot 35 shown in Fig. 5 from one axial side (upper side in Fig. 8) of the stator core 1 shown in Fig. 8 to the other axial side (lower side in Fig. 8).

[0065] In this case, if the coil side 7 of coil 2u is inserted into the slot 35 that is one slot adjacent in the clockwise direction as shown in Figure 4 from the slot 35 in which the coil side 7 of coil 2v is inserted, the coil side 7 of coil 2w is inserted into the slot 35 that is two slots adjacent in the clockwise direction from the slot 35 in which the coil side 7 of coil 2v is inserted, and if the coil side 7 of coil 2u is inserted into the slot 35 that is two slots adjacent in the clockwise direction as shown in Figure 4 from the slot 5 in which the coil side 7 of coil 2v is inserted, the coil side 7 of coil 2w is inserted into the slot 35 that is one slot adjacent in the clockwise direction from the slot 35 in which the coil side 7 of coil 2u is inserted.

[0066] In this way, when coil 2w is attached to stator core 1, a portion of second coil end 8 of coil 2w is located above second coil end 8 of coil 2u, and a portion of first coil end 9 is located above first coil end 9 of coil 2u.

[0067] Fig. 9 is a front view showing the state in which coils 2v, 2u, and 2w are attached to stator core 1. As shown in Fig. 9, first coil end 9 of coil 2w is attached with a gap that can ensure an insulation distance between it and first coil end 9 of coil 2u. Also, second coil end 8d of coil 2w is attached with a gap that can ensure an insulation distance between it and second coil end 8 of coil 2u.

[0068] As mentioned above, since a portion of the second coil end 8 of coil 2w is located above the second coil end 8 of coil 2u and a portion of the first coil end 9 is located above the first coil end 9 of coil 2u, the insertion amount of coil 2w into the slot 35 can also be adjusted by interposing an insulating member such as a spacer (not shown) between the upper end face 18 of the second coil end 8 of coil 2u or the upper end face 16 of the first coil end 9 and the lower end face 19 of the second coil end 8 of coil 2u or the lower end face 17 of the first coil end 9.

[0069] As with coil 2v, as shown in Figure 6, when the coil side 7 of coils 2u and 2w is inserted into slot 35 of stator core 1, the second coil ends 8 of coils 2u and 2w extend circumferentially at a position on the radially inner side of stator core 1, so that the second coil ends 8 do not interfere with (contact) the stator core 1 during the process of inserting the coil side 7 into slot 35 of stator core 1.

[0070] Furthermore, the first coil ends 9 of coils 2u, 2w extend circumferentially at a position on one end face of the stator core 1 on the radially outer side of the stator core 1, so that when the coil side 7 is inserted into the slot 35 of the stator core 1 and reaches a certain depth position, the first coil end 9 is positioned above the upper end face 16 of the first coil end 9 of coil 2v (or above the upper end face 16 of the first coil end 9 of coil 2u).

[0071] 1 is a perspective view showing the state in which the three-phase coils 2u, 2v, 2w of the U, V, and W phases are attached to the stator core 1. As shown in FIG. 1, the coils 2u, 2v, 2w of each phase are wave-wound in slots 35 of the stator core 1, and the first and second coil ends 9, 8 of the coils 2u, 2v, 2w of each phase are arranged in a generally stepped pattern.

[0072] In FIG. 1, the first and second coil ends 9, 8 of the coils 2u, 2v, 2w of each phase are arranged in a generally stepped manner in the order of v phase, u phase, and w phase, starting from the other axial side (the lower side in FIG. 1). However, the stator of the present invention is not limited to this configuration, and the first and second coil ends 9, 8 of the coils 2u, 2v, 2w of each phase may be arranged in a state where the order is reversed as appropriate.

[0073] As shown in Figure 1, when each phase coil 2u, 2v, 2w is attached to the stator core 1, one open end 5 of the coils 2u, 2v, 2w is inserted into a slot 35 located two slots 35 away in the clockwise direction from the slot 35 into which the coil side 7 of the coils 2u, 2v, 2w is inserted, and protrudes upward from one end face of the stator core 1 (the upper end face in Figure 1).

[0074] In addition, the other open end 6 of each phase coil 2u, 2v, 2w is inserted into a slot 35 located two slots 35 away in the clockwise direction from the slot 35 into which the one open end 5 of the coil 2u, 2v, 2w is inserted, and protrudes upward from one end face of the stator core 1 (the upper end face in Figure 1).

[0075] One open end 5 of each of the phase coils 2u, 2v, 2w is electrically connected to an external power supply (not shown). By supplying three-phase AC power from the external power supply to each of the phase coils 2u, 2v, 2w, a rotating magnetic field is generated by each of the phase coils 2u, 2v, 2w, which rotates a rotor (not shown) located in a hollow portion 4 on the radially inner side of the stator core 1.

[0076] In this case, if the shape of the one-side open end 5 is such that it can be fitted into a power supply connector (not shown) of an external power source, it is possible to avoid complicated terminal processing by simply attaching the one-side open end 5 to the connector.

[0077] The other-side open end 6 shown in Fig. 1 functions as a neutral point when the phase coils 2u, 2v, and 2w are star-connected, and the three other-side open end portions 6 can be connected by the neutral coil 40 shown in Fig. 1. Furthermore, when the phase coils 2u, 2v, and 2w are delta-connected, the neutral coil 40 shown in Fig. 1 is not used, and the three other-side open end portions 6 can be connected so that the phase coils 2u, 2v, and 2w are delta-connected. In other words, the motor according to the present invention can be applied regardless of whether the connection is star or delta.

[0078] Furthermore, the stator core 1 to which the phase coils 2u, 2v, 2w are attached as shown in Figure 1 can be reliably insulated between the stator core 1 and the coils 2u, 2v, 2w, and between the phase coils 2u, 2v, 2w, by molding the periphery of the stator core 1 and the phase coils 2u, 2v, 2w with insulating resin.

[0079] In the above embodiment, the coil sides 7 of the coils 2u, 2v, 2w of each phase are formed of conductor wires having a rectangular cross section, but the coils 2u, 2v, 2w according to the present invention may have a cross section that is circular, elliptical, square, or any other polygonal shape other than a rectangle. In this case, the slots 35 of the stator core 1 shown in Fig. 5 may have substantially the same shape as the cross section of the coils 2u, 2v, 2w, and may be slightly larger than the coil sides 7 to accommodate the coils 2u, 2v, 2w, thereby increasing the space factor of the coils 2u, 2v, 2w in the slots 35.

[0080] As described above, the wave-wound coil used in the stator of the present invention is configured with one winding for each phase, so there is no need to prepare a large number of coil members to form the coil, and welding work, etc. is not required when forming the wave-wound coil.

[0081] Furthermore, since the cross-sectional shape of the coil side of the wave-wound coil is substantially the same as the shape of the slot in the stator core, the space factor of the coil relative to the slot can be increased.

[0082] Furthermore, since the coils, each formed with one turn for each phase, are configured with a second coil end extending radially inward from the coil side and a first coil end extending radially outward, the coils can be attached to the stator core simply by inserting the coil side of each coil into the slot of the stator core from one end face of the stator core to the other end face, which dramatically simplifies the stator manufacturing process.

[0083] Furthermore, since a portion of the coil end of each phase coil is positioned above and below a portion of the coil end of the other phase, when attaching each phase coil to the stator core, the attachment position of each phase coil to the stator core can be easily set by interposing an insulating member between the portions.

[0084] Furthermore, each phase coil can be formed and manufactured simply and reliably by casting, forging, or manufacturing from strip material or plate material.

[0085] It goes without saying that the technical scope of the present invention also encompasses various modifications within the scope of the invention described above. For example, an in-slot insulating film may be provided within the slots of the stator core, or each phase coil may be molded and manufactured and then coated with an insulating resin such as enamel, polyurethane, or polyester. [Industrial Applicability]

[0086] It can be used for the stators that make up various motors. [Explanation of symbols]

[0087] 1 stator core 2 coils 2u U-phase coil 2v V phase coil 2w W-phase coil 3. Yoke 4 Teeth 5 One side open end 6 Other open end 7 Coilside 8 Second coil end 9 First coil end 10,21 Inner end face 11,20,22 Outer end face 12,13,16,18 Upper end surface 14 End face on one side in the circumferential direction 15 End surface on the other side in the circumferential direction 17,19 Lower end face 20 Radial outer end face 23,26 Curve section 24 Right angle 25 Slope 27, 28, 31, 32 Arc section 29,30 Expansion section 33,34 Step 35 slots 36 First Teeth 37 Second Teeth 38 Third Teeth 39 Joint surface 40 Neutral coil A Stator H Hollow part

Claims

1. The coils of each phase are wave-wound between the slots of the stator core and each consist of one turn, and only one coil side of the coil of one phase is arranged in one slot of the stator core for each phase, and the coil includes a first coil end that connects one end of the coil side to the coil side and extends toward the radially outer periphery and circumferential direction of the stator core on one end face side of the stator core, and a second coil end that connects the other end of the coil side to the radially inner periphery and circumferential direction of the stator core on the other end face side of the stator core, and the coil side is formed such that the circumferential thickness dimensions of the inner end face and the outer end face are smaller than the radial width dimensions of the one circumferential end face and the other circumferential end face, the axial height dimensions between the upper end face and the lower end face of the first coil end and the second coil end are larger than the circumferential thickness dimensions of the inner end face and the outer end face of the coil side, and the axial height dimensions of the inner end face and the outer end face of the first coil end and the inner end face and the outer end face of the second coil end are formed to be approximately the same as the radial width dimensions of the upper end face and the lower end face of the first coil end and the upper end face and the lower end face of the second coil end, a curved portion on the radially inner circumferential side and one axial side and a right-angled portion on the radially outer circumferential side and the other axial side are formed at the connection portion between the coil side and the first coil end, an inclined portion on the radially inner circumferential side and one axial side and a curved portion on the radially outer circumferential side and the other axial side are formed at the connection portion between the coil side and the second coil end, the first coil end and the coil side are connected by an arc portion on the radially outer circumferential side and an expanded portion on the radially inner circumferential side, the expanded portion expanding in a direction such that the width dimension increases from the coil side toward the first coil end side, and the second coil end and the coil side are connected by an arc portion on the radially inner circumferential side and a step portion on the radially outer circumferential side, A stator characterized in that an insulating member is interposed between the upper end surface of the stator core and the lower end surface of the first coil end, or between each phase of the second coil end, or between each phase of the first coil end.

2. 2. The stator according to claim 1, wherein the coils are attached to the stator core by inserting the coil side into the slot from the second coil end side for each phase, from one end face side to the other end face side of the stator core.

3. 3. The stator according to claim 1, wherein the stator core and the coils of each phase are molded with insulating resin to insulate the stator core from the coils and the coils of each phase from each other.

4. A motor comprising the stator according to claim 1 or 2.

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