Stator, motor, blower and method for manufacturing stator

Abstract

To provide a stator capable of preventing disconnection of an aluminum wire due to corrosion.SOLUTION: The stator 40 includes a stator core 41 having a back yoke portion 41b and a plurality of teeth portion 41b projecting radially inward from the back yoke portion 41a at intervals in a circumferential direction, aluminum wires 54 wound around the teeth portion 41a, copper wires 55 wound around the teeth portion 41a, and dissimilar connection portions D connecting the aluminum wires 54 and the copper wires 55 in series.SELECTED DRAWING: Figure 10

Description

[Technical Field]

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

[0002] In recent years, in the field of electric motors, stators have been proposed that include coils using a combination of copper wire and aluminum wire as magnet wire in order to reduce costs and weight (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 7046170 Summary of the Invention [Problem to be solved by the invention]

[0004] Aluminum is a base metal that corrodes rapidly in salt, has low yield strength, and has a strong tendency to ionize. For these reasons, aluminum is prone to galvanic corrosion. In particular, in coils in which copper wire and aluminum wire are joined in series, the magnet wires are made of different metals, and breakage due to corrosion of the aluminum wire can occur. In this regard, the stator described in Patent Document 1 also uses a coil in which copper wires and aluminum wires are joined in series, which causes a problem in that the stator described in Patent Document 1 is prone to breakage due to corrosion of the aluminum wires caused by the connection of dissimilar metals.

[0005] The present disclosure has been made to solve the above-mentioned problems, and aims to provide a stator, a motor, a blower, and a method for manufacturing a stator that can prevent aluminum wire from breaking due to corrosion. [Means for solving the problem]

[0006] The stator according to the present disclosure comprises a stator core having a back yoke portion and a plurality of teeth protruding radially inward at intervals circumferentially from the back yoke portion, an aluminum wire wound around the teeth portion, a copper wire wound around the teeth portion, and a heterogeneous connection portion that connects the aluminum wire and the copper wire in series, and the heterogeneous connection portion has an aluminum winding terminal that is an aluminum terminal joined to the aluminum wire. In addition, the method for manufacturing a stator according to the present disclosure includes the steps of inserting and winding a copper wire and an aluminum wire wound in a coil shape into a stator core, heat-crimping the ends of the aluminum wire wound in a coil shape to aluminum winding terminals formed from aluminum plates, heat-crimping the ends of the copper wire wound in a coil shape to copper winding terminals formed from copper plates, and covering the aluminum winding terminals with a protective material that protects the portions of the aluminum wire where the aluminum wire has been heat-crimped. [Effects of the Invention]

[0007] The stator, motor, blower, and stator manufacturing method according to the present disclosure have the advantage of being able to prevent breakage of aluminum wires due to corrosion. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a diagram schematically illustrating a configuration of a blower according to a first embodiment. [Figure 2] 1 is a partial cross-sectional view showing the configuration of a blower according to a first embodiment. [Figure 3] FIG. 10 is a diagram showing a state in which a coil is wound around a tooth portion. [Figure 4] FIG. 2 is a diagram showing the configuration of a coil winding. [Figure 5] 10A and 10B are diagrams showing a process of inserting a winding into a slot between teeth. [Figure 6] 10A and 10B are diagrams showing a process of inserting a winding into a slot between teeth. [Figure 7] 10A and 10B are diagrams showing a process of inserting a winding into a slot between teeth. [Figure 8] 10A and 10B are diagrams showing a process of inserting a winding into a slot between teeth. [Figure 9] FIG. 2 is a perspective view showing a stator according to the first embodiment. [Figure 10] FIG. 2 is a diagram schematically illustrating a heterogeneous connection portion. [Figure 11] FIG. 4 is a cross-sectional view showing a terminal housing portion that houses an aluminum winding terminal. [Figure 12] FIG. 1 is a diagram showing a motor circuit for operating a two-phase, four-pole AC motor. [Figure 13] FIG. 2 is a diagram illustrating a motor circuit. [Figure 14] 10 is a flowchart showing steps relating to coil winding and coil connection in the manufacturing process of the stator according to the second embodiment. [Figure 15] 10(a) to 10(c) are cross-sectional views showing steps relating to the connection of the coil. [Figure 16] 10(d) and 10(e) are cross-sectional views showing steps relating to the connection of the coil. [Figure 17] 1(a) to 1(d) are diagrams illustrating the manufacturing process of a terminal. [Figure 18] FIG. 10 is a perspective view showing another example of a terminal. DETAILED DESCRIPTION OF THE INVENTION

[0009] Hereinafter, embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. In each drawing, identical or corresponding parts are designated by the same reference numerals. Duplicate descriptions of these parts will be appropriately simplified or omitted. Furthermore, the size relationships between the components in each drawing may differ from those in reality.

[0010] Embodiment 1 FIG. 1 is a diagram schematically illustrating the configuration of a blower 1 according to a first embodiment. FIG. 2 is a partial cross-sectional view illustrating the configuration of the blower 1 according to the first embodiment. As shown in FIG. 1, the blower 1 has a motor 10 and a propeller fan 20 attached to a shaft 32 of the motor 10. As shown in FIG. 2, the motor 10 has a rotor 30 and a stator 40. The rotor 30 is a squirrel-cage rotor. The rotor 30 rotates with its outer peripheral surface facing the inner peripheral surface of the stator 40. The rotor 30 includes a rotor core 31 and a shaft 32.

[0011] The shaft 32 is fixed to the rotor 30 by press-fitting, welding, or caulking. The shaft 32 is supported on both axial sides by a pair of bearings 33a and 33b. The rotor 30 rotates around an axis C of the shaft 32. The axis C is also the axis of the rotor core 31. The stator 40 includes a stator core 41, insulating paper 42, and a coil 43. The stator core 41 includes a plurality of teeth 41a and a back yoke 41b. The teeth 41a protrude radially inward from the back yoke 41b at intervals in the circumferential direction. The insulating paper 42 is made of an insulating resin material and is attached around each tooth 41a.

[0012] The coil 43 is formed by inserting a magnet wire that has been formed into a coil shape in advance into the teeth 41a on which the insulating paper 42 is attached.

[0013] As shown in FIG. 3, the coil 43 has a copper wire 55 and an aluminum wire 54 wound in a coil shape around the teeth 41a of the stator core 41. Here, aluminum has a higher resistivity than copper and generates more heat. Therefore, by arranging the coil so that the aluminum wire 54 is on the coil end side, heat dissipation in the coil 43 can be promoted. For example, when the coil 43 is arranged in the configuration shown in Figure 3, the coil 43 of the main winding M is inserted so that the aluminum wire 54 is arranged on the outer diameter side of the teeth 41a, and the coil 43 of the sub winding S is inserted so that the aluminum wire 54 is arranged on the inner diameter side of the teeth 41a, thereby increasing the area where the aluminum wire 54 is exposed at the coil end. The main winding M is connected to an AC power supply, and the sub-winding S is connected in series with a capacitor in parallel with the main winding M. Details will be described later.

[0014] 4 shows an example of the configuration of the windings (aluminum wire and copper wire) of coil 43 in this embodiment. This example is a stator for a 16-teeth, 8-pole single-phase motor. Here, the teeth of teeth portion 41a are numbered T01 to T16 in a clockwise direction from the top end in the figure.

[0015] The first aluminum main winding M1A and the first copper main winding M1C are wound around three teeth T16, T01, and T02. The second aluminum main winding M2A and the second copper main winding M2C are wound around three teeth T04, T05, and T06. The third aluminum main winding M3A and the third copper main winding M3C are wound around three teeth T08, T09, and T10. The fourth aluminum main winding M4A and the fourth copper main winding M4C are wound around three teeth T12, T13, and T14. No main windings are wound around the four teeth T03, T07, T11, and T15.

[0016] The secondary windings are wound two teeth away from the main winding. The first aluminum secondary winding S1A and the first copper secondary winding S1C are wound around three teeth T02, T03, and T04. The second aluminum secondary winding S2A and the second copper secondary winding S2C are wound around three teeth T06, T07, and T08. The third aluminum secondary winding S3A and the third copper secondary winding S3C are wound around three teeth T10, T11, and T12. The fourth aluminum secondary winding S4A and the fourth copper secondary winding S4C are wound around three teeth T14, T15, and T16. No secondary windings are wound around the four teeth T01, T05, T09, and T13.

[0017] Looking at the slots, each slot is inserted with a pair of aluminum and copper wire for either the main winding or the secondary winding. This method of winding the winding across multiple teeth is called distributed winding. On the other hand, a method of winding the winding only around a single tooth is called concentrated winding. In this embodiment, distributed winding is used, with only the main winding or the secondary winding wound around some teeth, and both the main winding and the secondary winding wound around some teeth.

[0018] For example, tooth T01 is wound with only the main winding, tooth T02 with both the main and secondary windings, tooth T03 with only the secondary winding, and tooth T04 with both the main and secondary windings. By winding in this manner, it is possible to form eight poles with 16 teeth, half the number of teeth. Also, because the windings are arranged circumferentially in the following order: main winding only, both the main and secondary windings, secondary winding only, and both the main and secondary windings, the magnetic poles are smoothly arranged in the circumferential direction, and electromagnetic noise can be suppressed.

[0019] 5 to 8 show the details of the process of inserting the windings (aluminum wire or copper wire) into the slots between the teeth. For ease of understanding, the process will be explained using schematic diagrams in which the annular teeth are linearly developed.

[0020] Fig. 5 shows the process of forming the ring-bundle winding. In this embodiment, the winding is wound around three teeth, so a winding jig (not shown) corresponding to the three teeth is prepared, and the winding is wound around the winding jig a predetermined number of times, and then removed from the winding jig, forming the ring-bundle winding as shown in Fig. 6.

[0021] In this embodiment, a first aluminum main winding M1A, a second aluminum main winding M2A, a third aluminum main winding M3A, and a fourth aluminum main winding M4A are prepared as ring-bundled aluminum main windings, and a first copper main winding M1C, a second copper main winding M2C, a third copper main winding M3C, and a fourth copper main winding M4C are prepared as ring-bundled copper main windings. In this embodiment, the first copper sub-winding S1C, second copper sub-winding S2C, third copper sub-winding S3C, and fourth copper sub-winding S4C are prepared as the ring-bundled copper sub-windings, and the first aluminum sub-winding S1A, second aluminum sub-winding S2A, third aluminum sub-winding S3A, and fourth aluminum sub-winding S4A are prepared as the ring-bundled aluminum sub-windings.

[0022] In the following description, the first aluminum main winding M1A, the second aluminum main winding M2A, the third aluminum main winding M3A, and the fourth aluminum main winding M4A may be collectively referred to as aluminum main windings MxA. In the following description, the first copper main winding M1C, the second copper main winding M2C, the third copper main winding M3C, and the fourth copper main winding M4C may be collectively referred to as copper main windings MxC. In the following description, the first copper secondary winding S1C, the second copper secondary winding S2C, the third copper secondary winding S3C, and the fourth copper secondary winding S4C may be collectively referred to as copper secondary windings SxC. In the following description, the first aluminum secondary winding S1A, the second aluminum secondary winding S2A, the third aluminum secondary winding S3A, and the fourth aluminum secondary winding S4A may be collectively referred to as aluminum secondary winding SxA.

[0023] As shown in Fig. 7, in this embodiment, the main winding is arranged on the outer periphery side and the secondary winding is arranged on the inner periphery side. The main winding has an aluminum main winding MxA arranged on the outer periphery side and a copper main winding MxC arranged on the inner periphery side. The secondary winding has a copper secondary winding SxC arranged on the outer periphery side and an aluminum secondary winding SxA arranged on the inner periphery side. The annular windings are inserted into the slots in order from the outer periphery side.

[0024] As shown in Fig. 8, within the main winding slot, the aluminum main winding MxA is arranged on the outer periphery side, and the copper main winding MxC is arranged on the inner periphery side. Within the secondary winding slot, the copper secondary winding SxC is arranged on the outer periphery side, and the aluminum secondary winding SxA is arranged on the inner periphery side. In the coil end region where the main winding and secondary winding overlap in the radial direction, the aluminum main winding MxA, copper main winding MxC, copper secondary winding SxC, and aluminum secondary winding SxA are arranged from the outer periphery side.

[0025] Assembling the coil in this manner means that the aluminum winding faces the outer and inner ends of the coil end. Because aluminum has a higher resistivity than copper, aluminum generates more heat when the same current is passed through the same wire diameter. By positioning the aluminum winding on the end side, the heat generated by the aluminum winding can be easily dissipated.

[0026] In this embodiment, the main winding M is arranged on the outer periphery side and the secondary winding S is arranged on the inner periphery side, but the secondary winding S may be arranged on the outer periphery side and the main winding M on the inner periphery side. In this case, in the region at the coil end where the main winding M and secondary winding S overlap in the radial direction, the aluminum secondary winding SxA, copper secondary winding SxC, copper main winding MxC, and aluminum main winding MxA are arranged from the outer periphery side. In any case, the coils may be assembled in the order of aluminum winding, copper winding, copper winding, and aluminum winding arranged from the outer periphery side at the coil end.

[0027] In the slot arrangement, of the main winding M and the secondary winding S, the winding placed on the outer periphery has an aluminum winding on the outer periphery and a copper winding on the inner periphery. The winding placed on the inner periphery has a copper winding on the outer periphery and an aluminum winding on the inner periphery.

[0028] Fig. 9 is a perspective view showing a stator 40 according to the first embodiment. As shown in Fig. 9, a ring-shaped terminal block 50 is installed at the coil end portion of each coil 43. The terminal block 50 has a plurality of terminal housings 51 arranged therein, each corresponding to the coil end portion of each coil 43. Each terminal housing 51 houses either an aluminum winding terminal 52, which is an aluminum terminal, or a copper winding terminal 53, which is a copper terminal. Here, the coil end portion refers to a portion of the coil 43 wound around the tooth portion 41a, which is located on the axial end surface of the tooth portion 41a.

[0029] The aluminum winding terminals 52 have a conductor mainly composed of aluminum, which is plated with tin on a nickel or copper base. The copper winding terminals 53 have a conductor mainly composed of copper, which is plated with tin on a nickel base. An end of an aluminum wire 54 wound around the tooth portion 41 a is connected to each aluminum winding terminal 52. An end of a copper wire 55 wound around the tooth portion 41 a is connected to each copper winding terminal 53. The aluminum winding terminals 52 and copper winding terminals 53 are further connected by a copper jumper wire 56. Although six terminals (aluminum winding terminals 52 and copper winding terminals 53) are shown in FIG. 9, the number of terminals may be eight, twelve, or the like.

[0030] 10 is a schematic diagram showing a dissimilar wiring connection section D for connecting an aluminum wire 54 and a copper wire 55, which are magnet wires made of dissimilar metals. As shown in FIG. 10, the dissimilar wiring connection section D has an aluminum winding terminal 52 and a copper winding terminal 53. The aluminum winding terminal 52 is bent entirely into a U-shape, and a pair of V-shaped hook portions 52b are formed on both sides of a first terminal portion 52a located below the aluminum winding terminal 52, each bent inward. Similarly, the copper winding terminal 53 is bent entirely into a U-shape, and a pair of V-shaped hook portions 53b are formed on both sides of a first terminal portion 53a located below the copper winding terminal 53, each bent inward. 9 and 10, the aluminum winding terminal 52 is covered with a protective material (not shown), which will be described later.

[0031] An end 54a of an aluminum wire 54 is sandwiched and thermally crimped (fused) inside the hook-shaped portion 52b of the aluminum winding terminal 52. An end 55a of a copper wire 55 is sandwiched and thermally crimped (fused) inside the hook-shaped portion 53b of the copper winding terminal 53. The aluminum wire 54 is a conductor having aluminum as the main conductor with an insulating coating, such as an enamel insulating coating, baked onto the outer periphery. The copper wire 55 is a conductor having copper as the main conductor with an insulating coating, such as an enamel insulating coating, baked onto the outer periphery.

[0032] In the thermal crimping process, the hook-shaped portion 52b of the aluminum winding terminal 52 is heated to destroy and remove the oxide coating on the surface of the aluminum wire 54, and the aluminum wire 54 is then joined to the tin-plated surface of the aluminum winding terminal 52 by resistance welding and crimping. The thermal crimping process melts the enamel insulating coating on the aluminum wire 54, establishing an electrical connection. Similarly, in the thermal crimping process, the hook-shaped portion 53b of the copper winding terminal 53 is heated to destroy and remove the oxide coating on the surface of the copper wire 55, and the copper wire 55 is then joined to the tin-plated surface of the copper winding terminal 53 by resistance welding and crimping. The thermal crimping process melts the enamel insulating coating on the copper wire 55, establishing an electrical connection.

[0033] Furthermore, one end 56a of a copper jumper wire 56 is joined with solder 57 to the upper surface of second terminal portion 52c located on the upper side of U-shaped aluminum winding terminal 52. Similarly, the other end 56b of jumper wire 56 is joined with solder 57 to the upper surface of second terminal portion 53c located on the upper side of copper winding terminal 53. As a result, aluminum winding terminal 52 and copper winding terminal 53 are electrically connected via jumper wire 56.

[0034] Here, two hook-shaped portions 52b are provided on both sides of aluminum winding terminal 52. Similarly, two hook-shaped portions 53b are provided on both sides of copper winding terminal 53. These two hook-shaped portions are provided so that they can be used to connect windings of the same type. For example, in the motor circuit described below, the first main winding and the second main winding are wound with the same wire without a connecting portion. However, depending on the manufacturing process, the first main winding and the second main winding may be separate windings and connected by a connecting portion. In this case, connecting the first main winding and the second main winding to two points on hook-shaped portion 52b or two points on hook-shaped portion 53b makes it possible to connect windings of the same type.

[0035] 11 is a cross-sectional view showing a terminal housing section 51 that houses an aluminum winding terminal 52. As shown in Fig. 11, the terminal housing section 51 has a wall 51a that surrounds the aluminum winding terminal 52. The height of the wall 51a is set higher than the solder joint where the jumper wire 56 is connected with the solder 57. The inside of terminal housing 51 is coated with or filled with a protective material P. Protective material P is, for example, a sealant whose main component is silicon. By coating or filling with protective material P, the portion where aluminum wire 54 is thermally crimped and the portion where jumper wire 56 is soldered are protected. As a result, moisture or salt is prevented from entering inside terminal housing 51, and breakage of aluminum wire 54 due to corrosion can be prevented. Since the copper wire 55 does not corrode, it is not necessary to apply or fill the protective material P to the terminal housing portion 51 that houses the copper winding terminal 53.

[0036] Next, a motor circuit 100 that operates a two-phase, four-pole AC motor, which is an example of motor 10, will be described with reference to Fig. 12. As shown in Fig. 12, motor circuit 100 is configured by connecting a main winding M and a secondary winding S in parallel to an AC power supply 101, and connecting a capacitor 102 in series to the secondary winding S. The main winding M and secondary winding S are shifted in phase by 90° due to capacitor 102.

[0037] The main winding M has a first main winding M1 and a second main winding M2 wound across two or more teeth 41a. The first main winding M1 and the second main winding M2 are connected in series, wound around the teeth 41a in opposite directions, and connected in opposite phases with a 180° phase difference. Similarly, the secondary winding S has a first secondary winding S1 and a second secondary winding S2 wound across two or more teeth 41a. The first secondary winding S1 and the second secondary winding S2 are connected in series, wound around the teeth 41a in opposite directions, and connected in opposite phases with a 180° phase difference. The main winding M and the secondary winding S have a phase difference of 90° due to the capacitor 102. As a result, the first main winding M1, the first secondary winding S1, the second main winding M2, and the second secondary winding S2 have a phase difference of 90° in that order, and form a rotating magnetic field by the AC current.

[0038] The first main winding M1 has a first copper main winding M1C made of copper wire 55 wound around the teeth 41a, and a first aluminum main winding M1A made of aluminum wire 54 wound around the outside of the first copper main winding M1C. The first copper main winding M1C and the first aluminum main winding M1A are connected in series. The second main winding M2 has a second copper main winding M2C made of copper wire 55 wound around the teeth 41a, and a second aluminum main winding M2A made of aluminum wire 54 wound around the outside of the second copper main winding M2C. The second copper main winding M2C and the second aluminum main winding M2A are connected in series.

[0039] Similarly, the first secondary winding S1 has a first copper secondary winding S1C made of copper wire 55 wound around the tooth portion 41a, and a first aluminum secondary winding S1A made of aluminum wire 54 wound around the outside of the first copper secondary winding S1C. The first copper secondary winding S1C and the first aluminum secondary winding S1A are connected in series. The second secondary winding S2 includes a second copper secondary winding S2C made of copper wire 55 wound around the tooth portion 41a, and a second aluminum secondary winding S2A made of aluminum wire 54 wound around the outside of the second copper secondary winding S2C. The second copper secondary winding S2C and the second aluminum secondary winding S2A are connected in series.

[0040] Two aluminum winding terminals and two copper winding terminals are provided for each phase on the terminal block 50. That is, for a two-phase, four-pole AC motor, four aluminum winding terminals TAM1, TAM2, TAS1, and TAS2 and four copper winding terminals TCM1, TCM2, TCS1, and TCS2 are provided on the terminal block 50. In Fig. 12, the aluminum winding terminals TAM1, TAM2, TAS1, and TAS2 are represented by squares, and the copper winding terminals TCM1, TCM2, TCS1, and TCS2 are represented by circles.

[0041] The aluminum winding terminals TAM1, TAM2, TAS1, and TAS2 each correspond to the above-mentioned aluminum winding terminal 52. The copper winding terminals TCM1, TCM2, TCS1, and TCS2 each correspond to the above-mentioned copper winding terminal 53. Furthermore, the first main winding M1, the second main winding M2, the first secondary winding C1, and the second secondary winding C2 each correspond to the above-mentioned coil 43. Furthermore, the first aluminum main winding M1A, the second aluminum main winding M2A, the first aluminum secondary winding S1A, and the second aluminum secondary winding S2A are sometimes collectively referred to as the "aluminum windings AW." Furthermore, the first copper main winding M1C, the second copper main winding M2C, the first copper secondary winding S1C, and the second copper secondary winding S2C are sometimes collectively referred to as the "copper windings CW."

[0042] The aluminum winding terminal TAM1 connects the aluminum wire 54 extending from the first aluminum main winding M1A to a jumper wire 561. The aluminum winding terminal TAM2 connects the aluminum wire 54 extending from the second aluminum main winding M2A to a power supply line 58 connected to the AC power supply 101. The aluminum winding terminal TAS1 connects the aluminum wire 54 extending from the first aluminum secondary winding S1A to a jumper wire 562. The aluminum winding terminal TAS2 connects the aluminum wire 54 extending from the second aluminum secondary winding S2A to a power supply line 58 connected to the AC power supply 101.

[0043] Similarly, copper winding terminal TCM1 connects copper wire 55 extending from the first copper main winding M1C to a power supply line 58 connected to the AC power supply 101. Copper winding terminal TCM2 connects copper wire 55 extending from the second copper main winding M2C to a jumper wire 561. Copper winding terminal TCS1 connects copper wire 55 extending from the first copper secondary winding S1C to a copper wire 55 connected to the capacitor 102. Copper winding terminal TCS2 connects copper wire 55 extending from the second copper secondary winding S2C to a jumper wire 562. Each of the jumper wires 561 and 562 corresponds to the jumper wire 56 described above.

[0044] Fig. 13 is a diagram schematically showing the motor circuit 100 of Fig. 12. As shown in Fig. 13, the phase on the main winding M side is connected in the following order: AC power supply 101 → copper winding terminal TCM1 → first copper main winding M1C → second copper main winding M2C → copper winding terminal TCM2 → jumper wire 561 → aluminum winding terminal TAM1 → first aluminum main winding M1A → second aluminum main winding M2A → aluminum winding terminal TAM2 → AC power supply 101.

[0045] In addition, the phase on the secondary winding S side is connected in the following order: AC power supply 101 → capacitor 102 → copper winding terminal TCS1 → first copper secondary winding S1C → second copper secondary winding S2C → copper winding terminal TCS2 → jumper wire 562 → aluminum winding terminal TAS1 → first aluminum secondary winding S1A → second aluminum secondary winding S2A → aluminum winding terminal TAS2 → AC power supply 101.

[0046] That is, two copper winding terminals and two aluminum winding terminals are provided for each phase. Because motor circuit 100 is a two-phase motor circuit, four copper winding terminals and four aluminum winding terminals are provided. By using this connection method, even if the number of poles increases, the copper windings and aluminum windings of the same phase can be wired without connection terminals, so the number of connections does not increase. In other words, whether the circuit is for operating a two-phase, four-pole AC motor or a two-phase, eight-pole AC motor, it is sufficient to provide four copper winding terminals and four aluminum winding terminals.

[0047] In this way, in the motor circuit 100, the copper windings CW of each pole of the same phase, the heterogeneous connection parts D1, D2, and the aluminum windings AW of each pole of the same phase are connected to take out output lines, so that the stator 40 of the motor 10 can be wired using aluminum wires 54 and copper wires 55 with a small number of terminals.

[0048] In the motor circuit 100, aluminum wires and copper wires are connected using heterogeneous wiring sections D1 and D2. In the heterogeneous wiring section D1, an aluminum wire 54 extending from the first aluminum main winding M1A is connected to the aluminum winding terminal TAM1 by thermal crimping. A copper wire 55 extending from the second copper main winding M2C is also connected to the copper winding terminal TCM2 by thermal crimping. Furthermore, the aluminum winding terminal TAM1 is connected to one end of a jumper wire 561 by soldering. Furthermore, the copper winding terminal TCM2 is connected to the other end of the jumper wire 561 by soldering. As a result, in the heterogeneous wiring section D1, the connections are made in the following order: aluminum wire 54 → aluminum winding terminal TAM1 → jumper wire 561 → copper winding terminal TCM2 → copper wire 55.

[0049] In the heterogeneous connection section D2, the aluminum wire 54 extending from the first aluminum secondary winding S1A is connected to the aluminum winding terminal TAS1 by thermal crimping. In addition, the copper wire 55 extending from the second copper secondary winding S2C is connected to the copper winding terminal TCS2 by thermal crimping. Furthermore, the aluminum winding terminal TAS1 is connected to one end of the jumper wire 562 by soldering. In addition, the copper winding terminal TCS2 is connected to the other end of the jumper wire 562 by soldering. As a result, in the heterogeneous connection section D2, the connections are made in the following order: aluminum wire 54 → aluminum winding terminal TAS1 → jumper wire 562 → copper winding terminal TCS2 → copper wire 55. Each of the heterogeneous connection portions D1 and D2 corresponds to the heterogeneous connection portion D described above.

[0050] At the dissimilar connection sections D1 and D2, the aluminum wire 54 is connected by thermal caulking to the aluminum winding terminals TAM1 and TAS1, both made of aluminum. Aluminum corrodes rapidly in salt, has low yield strength, and is a base metal with a high tendency to ionize, making it susceptible to galvanic corrosion. Therefore, directly joining copper and aluminum poses the problem of aluminum corrosion. However, because the connection between the aluminum wire 54 and the aluminum winding terminals TAM1 and TAS1 is aluminum-to-aluminum, the aluminum wire 54 will not corrode due to the dissimilar connection. In addition, in the dissimilar wiring portions D1 and D2, the copper wire 55 is connected to the copper winding terminals TCM2 and TCS2 made of the same copper by thermal caulking (fusing). Since this connection is between copper wires, corrosion due to dissimilar wiring does not occur.

[0051] The copper wire 55 is coated with a strong coating that can withstand friction when wound around the tooth portion 41a. Therefore, when connecting the copper wire 55 to the copper winding terminals TCM2 and TCS2, the coating does not melt with solder, and therefore there is no electrical continuity between the copper wire 55 and the copper winding terminals TCM2 and TCS2. In contrast, thermal crimping (fusing) can break the coating and establish electrical continuity between the copper wire 55 and the copper winding terminals TCM2 and TCS2. Therefore, thermal crimping (fusing) is used to connect the copper wire 55 to the copper winding terminals TCM2 and TCS2 in the dissimilar connection sections D1 and D2.

[0052] Furthermore, in dissimilar connection sections D1 and D2, aluminum winding terminals TAM1 and TAS1 are connected by soldering to one end of jumper wires 561 and 562. Because jumper wires 561 and 562 are vinyl-coated copper wires, the copper and aluminum are directly connected. However, even if the aluminum winding terminals TAM1 and TAS1 connected to jumper wires 561 and 562 corrode, the area of ​​the aluminum winding terminals TAM1 and TAS1 is large, so the wire will not break. In the dissimilar connection sections D1 and D2, the copper winding terminals TCM2 and TCS2 are connected by soldering to the other ends of the jumper wires 561 and 562. Because this connection is between copper wires, corrosion due to dissimilar connections does not occur.

[0053] Copper wire 55 is a copper wire with an insulating coating such as enamel, while power wire 58 and jumper wires 561, 562 are vinyl-coated copper wires. Because the materials are different even though they are the same metal, copper wire 55 and power wire 58 are connected via copper winding terminals TCM1, TCS1. Similarly, copper wire 55 and jumper wires 561, 562 are connected via copper winding terminals TCM2, TCS2. Furthermore, thermal caulking (fusing) of the aluminum winding terminals TAM1 and TAS1 to copper wires cannot be used because the fusing discharge conditions are not met. For this reason, connections are made by soldering using jumper wires 561 and 562.

[0054] As described above, the stator 40, motor 10, and blower 1 according to embodiment 1 include the aluminum winding AW wound around the teeth 41 a, the copper winding CW wound around the teeth 41 a, and dissimilar connection portions D1 and D2 that connect the aluminum winding AW and the copper winding CW. The dissimilar connection portions D1 and D2 have aluminum winding terminals TAM1 and TAS1 that are aluminum terminals joined to the aluminum winding AW.

[0055] Therefore, in the stator 40, motor 10, and blower 1 according to embodiment 1, the aluminum wires 54 extending from the aluminum winding AW are connected to the aluminum winding terminals TAM1 and TAS1 to join the aluminum winding AW to the aluminum winding terminals TAM1 and TAS1, so that the aluminum is joined to the aluminum, and dissimilar connections do not corrode the aluminum wires 54. Therefore, with the stator 40, motor 10, and blower 1 according to embodiment 1, breakage of the aluminum wires 54 due to corrosion can be prevented.

[0056] The heterogeneous connection portions D1 and D2 also have copper winding terminals TCM2 and TCS2, which are copper terminals joined to the copper winding CW. Therefore, in the stator 40, motor 10, and blower 1 according to the first embodiment, copper wires 55 extending from the copper winding CW are connected to the copper winding terminals TCM2 and TCS2 to join the copper winding CW to the copper winding terminals TCM2 and TCS2, resulting in a copper-to-copper connection, and corrosion due to dissimilar connections does not occur. Therefore, with the stator 40, motor 10, and blower 1 according to the first embodiment, breaks due to corrosion can be prevented.

[0057] Furthermore, the different type connection sections D1 and D2 have copper jumper wires 561 and 562 that electrically connect the aluminum winding terminals TAM1 and TAS1 to the copper winding terminals TCM2 and TCS2. For this reason, in the stator 40, motor 10, and blower 1 according to embodiment 1, copper and aluminum are directly bonded to each other at the joints between the aluminum winding terminals TAM1, TAS1 and the jumper wires 561, 562. However, even if the joints between the aluminum winding terminals TAM1, TAS1 corrode, the area on the aluminum winding terminals TAM1, TAS1 side is large, so the wire will not break. Therefore, with the stator 40, motor 10, and blower 1 according to embodiment 1, wire breaks due to corrosion can be prevented.

[0058] Embodiment 2 In the second embodiment, a method for manufacturing the stator 40 according to the first embodiment will be described. Fig. 14 is a flowchart showing steps relating to coil winding and coil connection in the manufacturing process of the stator according to embodiment 2. Also, Figs. 15(a) to 15(c), 16(d) and 16(e) are cross-sectional views showing steps relating to coil connection in the manufacturing process of the stator according to embodiment 2. Note that parts that are the same as or equivalent to parts in embodiment 1 are given the same reference numerals, and description of these parts will be omitted.

[0059] 14, first, copper wire 55, which has an insulating coating applied to the outer periphery of a conductor whose main conductor is copper, is wound around a bobbin as a magnet wire to form a coil, and then inserted into stator core 41 (step S10). Similarly, aluminum wire 54, which has an insulating coating applied to the outer periphery of a conductor whose main conductor is aluminum, is wound around a bobbin as a magnet wire to form a coil, and then inserted into stator core 41 (step S11). Note that the inserting steps S10 and S11 may be performed simultaneously. 15(a), an end 54a of the coiled aluminum wire 54 is sandwiched inside the hook-shaped portion 52b of the aluminum winding terminal 52 formed from an aluminum plate and thermally crimped (fused) (step S12). Similarly, an end 55a of the coiled copper wire 55 is sandwiched inside the hook-shaped portion 53b of the copper winding terminal 53 formed from a copper plate and thermally crimped (fused) (step S13).

[0060] 15(b), the first terminal portion 52a of the aluminum winding terminal 52 is bent toward the second terminal portion 52c (step S14). Similarly, the first terminal portion 53a of the copper winding terminal 53 is bent toward the second terminal portion 53c (step S15). 15(c), the second terminal portion 52c of the aluminum winding terminal 52 is bent so as to overlap the first terminal portion 52a with a gap therebetween (step S16). Similarly, the second terminal portion 53c of the copper winding terminal 53 is bent so as to overlap the first terminal portion 53a with a gap therebetween (step S17).

[0061] 16(d), one end 56a of the copper jumper wire 56 is joined to the upper surface of the second terminal portion 52c of the aluminum winding terminal 52 with solder 57 (step S18). Similarly, the other end 56b of the copper jumper wire 56 is joined to the upper surface of the second terminal portion 53c of the copper winding terminal 53 with solder 57 (step S19). 16(e), the aluminum winding terminal 52 is covered with the protective material P by applying or filling the area around the aluminum winding terminal 52 (step S20). The protective material P protects the area where the end 54a of the aluminum wire 54 is thermally crimped and the area where one end 56a of the jumper wire 56 is soldered to the upper surface of the second terminal portion 52c. Furthermore, because the copper wire 55 does not corrode, it is not necessary to apply or fill the protective material P around the copper winding terminal 53.

[0062] Although not shown in the manufacturing process shown in FIG. 14, in reality, a process of storing the aluminum winding terminal 52 and the copper winding terminal 53 in the terminal storage portion 51 is performed after the process of step S17, for example. Furthermore, the order of steps S12 and S13, steps S14 and S15, steps S16 and S17, and steps S18 and S19 may be any order.

[0063] Next, a manufacturing process for the terminal 60 used as the aluminum winding terminal 52 and the copper winding terminal 53 will be described with reference to FIGS. 17(a) to 17(d). 17(a), terminal 60 is made of a rectangular parallelepiped flat plate 61 made of aluminum or copper. Flat plate 61 is divided into three parts along its length, with a first terminal portion 61a at one end, a second terminal portion 61b at the other end, and a bottom surface portion 61c between first terminal portion 61a and second terminal portion 61b. A notch has been made in advance in the portion of first terminal portion 61a where hook-shaped portion 61d will be formed.

[0064] 17(b), the first terminal 61a is bent inward toward the second terminal 61b so that the angle between the first terminal 61a and the bottom surface 61c is 90 degrees. The second terminal 61b is bent inward toward the first terminal 61a so that the angle between the second terminal 61b and the bottom surface 61c is 90 degrees. Furthermore, the lower ends of both sides of the first terminal 61a are bent in a rolled-up manner to form a pair of V-shaped hook portions 61d. A winding wire (aluminum wire or copper wire) (not shown) is sandwiched between the hook portions 61d and joined by thermal caulking.

[0065] Next, as shown in Fig. 17(c), the first terminal 61a is bent inward toward the second terminal 61b so that the first terminal 61a and the bottom surface 61c are parallel to each other. Then, as shown in Fig. 17(d), the second terminal 61b is bent inward so that the second terminal 61b and the bottom surface 61c are parallel to each other. A jumper wire (not shown) is joined to the top surface of the second terminal 61b with solder.

[0066] The hook portion of the terminal 60 is not limited to a V-shape, and may be, for example, a U-shaped hook portion 61e as shown in Fig. 18. In this case, too, thermal crimping can be performed by sandwiching a winding wire (aluminum wire or copper wire) (not shown) between the hook portion 61e.

[0067] As described above, the manufacturing method of stator 40 according to embodiment 2 includes the steps of thermally crimping end 54a of coiled aluminum wire 54 to aluminum winding terminal 52 formed from an aluminum plate, and thermally crimping end 55a of coiled copper wire 55 to copper winding terminal 53 formed from a copper plate. In stator 40 manufactured through these steps, aluminum wire 54 is connected to aluminum winding terminal 52 by thermal crimping, and copper wire 55 is connected to copper winding terminal 53 by thermal crimping. Therefore, aluminum wire 54 and copper wire 55 are not directly joined, and dissimilar wiring does not cause corrosion of aluminum wire 54. Therefore, the manufacturing method of stator 40 according to embodiment 2 can prevent breakage of aluminum wire 54 due to corrosion.

[0068] Furthermore, the method for manufacturing stator 40 according to embodiment 2 includes a step of covering aluminum winding terminals 52 with protective material P that protects the thermally crimped portions of aluminum wires 54. In stator 40 manufactured by this step, aluminum winding terminals 52 are covered with protective material P, so the thermally crimped portions of aluminum wires 54 are protected. As a result, breakage of aluminum wires 54 due to corrosion can be prevented.

[0069] Furthermore, the manufacturing method of stator 40 according to embodiment 2 includes a step of joining one end 56a of copper jumper wire 56 to aluminum winding terminal 52 by soldering, and joining the other end 56b of jumper wire 56 to copper winding terminal 53 by soldering. In stator 40 manufactured by this step, copper and aluminum are directly joined at the joint between aluminum winding terminal 52 and jumper wire 56. However, even if the joints of the aluminum winding terminals 52 corrode, the aluminum wires 54 will not break because of the large area on the aluminum winding terminal 52 side. Therefore, the method for manufacturing the stator 40 according to the second embodiment can prevent breaks in the aluminum wires 54 due to corrosion.

[0070] In addition, in the manufacturing method of the stator 40 according to the second embodiment, the first terminal portion 52a and the second terminal portion 52c are folded sequentially, and processed so that the second terminal portion 52c overlaps the first terminal portion 52a with a gap therebetween. Here, the aluminum wire 54 is joined to the hook-shaped portion 52b of the first terminal portion 52a by thermal crimping, but when the second terminal portion 52c overlaps the first terminal portion 52a, the second terminal portion 52c gets in the way, making the thermal crimping process difficult. In the manufacturing method of the stator 40 according to the second embodiment, the aluminum wire 54 is thermally crimped to the hook-shaped portion 52b in step S12, which is a stage before the first terminal portion 52a is bent, thereby facilitating the thermal crimping work and improving work efficiency. The same is true for the thermal crimping of the copper wire 55; since the copper wire 55 is thermally crimped to the hook-shaped portion 53b in step S13, which is a stage before the first terminal portion 53a is bent, the thermal crimping work is facilitated and work efficiency is improved.

[0071] Furthermore, in the manufacturing method of the stator 40 according to the second embodiment, after bending the second terminal portion 52c of the aluminum winding terminal 52 in the process of step S16, the jumper wire 56 is soldered to the upper surface of the second terminal portion 52c. By bending the second terminal portion 52c, the worker can solder the jumper wire 56 to the upper surface of the second terminal portion 52c from above, which makes the soldering work easier and improves work efficiency. The same is true for soldering the jumper wire 56 to the copper winding terminal 53; after bending the second terminal portion 53c in step S17, the jumper wire 56 is soldered from above to the upper surface of the second terminal portion 53c, which makes the soldering work easier and improves work efficiency.

[0072] The terminal 60 is manufactured using a rectangular parallelepiped flat plate 61, and the terminal 60 is manufactured simply by bending the first terminal portion 61a and the second terminal portion 61b of the flat plate 61 inward so that they overlap each other. The hook-shaped portion 61d is also manufactured simply by bending the lower ends of both sides of the first terminal portion 61a along pre-made notches. In this way, the manufacturing of the terminal 60 does not require sheet metal cutting or welding, thereby improving work efficiency.

[0073] The configurations described in the above embodiments are merely examples, and may be combined with other known technologies. Furthermore, parts of the configurations may be omitted or modified without departing from the spirit of the invention.

[0074] Various aspects of the present disclosure are summarized below as appendices.

[0075] (Appendix 1) a stator core having a back yoke portion and a plurality of teeth protruding radially inward from the back yoke portion at intervals in the circumferential direction; an aluminum wire wound around the teeth; a copper wire wound around the teeth; a heterogeneous wiring section that connects the aluminum wire and the copper wire in series, The dissimilar wiring portion is a stator having an aluminum winding terminal, which is an aluminum terminal joined to the aluminum wire. (Appendix 2) 2. The stator according to claim 1, wherein the dissimilar wiring portion has a copper winding terminal that is a copper terminal joined to the copper wire. (Appendix 3) 3. The stator according to claim 2, wherein the aluminum winding terminals and the copper winding terminals are connected by copper jumper wires. (Appendix 4) The aluminum winding terminal may further include a terminal housing portion for housing the aluminum winding terminal, 4. The stator according to claim 1, wherein the aluminum winding terminals are covered with a protective material while housed in the terminal housing portions. (Appendix 5) the windings wound around the teeth include a main winding connected to an AC power supply and a secondary winding connected in series with a capacitor in parallel with the main winding, 5. The stator according to any one of Supplementary note 1 to Supplementary note 4, wherein, of the main winding and the auxiliary winding, in the winding arranged on the outer periphery of the coil end portion, the aluminum wire is arranged on the outer periphery of the slot portion and the copper wire is arranged on the inner periphery of the slot portion, and in the winding arranged on the inner periphery of the coil end portion, the copper wire is arranged on the outer periphery of the slot portion and the aluminum wire is arranged on the inner periphery of the slot portion. (Appendix 6) A stator according to any one of Supplementary Note 1 to Supplementary Note 5; a rotor rotatably supported with its outer peripheral surface facing the inner peripheral surface of the stator. (Appendix 7) a motor according to Appendix 6; a propeller fan attached to the rotor shaft. (Appendix 8) a step of inserting and winding a coiled copper wire and aluminum wire into a stator core; a step of thermally crimping an end of the coiled aluminum wire to an aluminum winding terminal formed of an aluminum plate; a step of thermally crimping an end of the coiled copper wire to a copper winding terminal formed of a copper plate; and covering the aluminum winding terminals with a protective material that protects the portions of the aluminum wires that have been thermally crimped. (Appendix 9) 9. The method for manufacturing a stator according to claim 8, further comprising the steps of joining one end of a copper jumper wire to the aluminum winding terminal with solder and joining the other end of the jumper wire to the copper winding terminal with solder. (Appendix 10) The method for manufacturing a stator according to Supplementary Note 8 or 9, further comprising the step of: using a rectangular parallelepiped flat plate, bending inward a first terminal portion on one end side of the flat plate and a second terminal portion on the other end side of the flat plate so that they overlap each other, thereby producing at least one of the aluminum winding terminal and the copper winding terminal. [Explanation of symbols]

[0076] 1 blower, 10 motor, 20 propeller fan, 30 rotor, 32 shaft, 40 stator, 41 stator core, 41a teeth portion, 41b back yoke portion, 51 terminal storage portion, 52 aluminum winding terminal, 52a first terminal portion, 52b hook portion, 52c second terminal portion, 53 copper winding terminal, 53a first terminal portion, 53b hook portion, 53c second terminal portion, 54 aluminum wire, 55 copper wire, 56 jumper wire, 60 terminal, 61 plane plate, 61a first terminal portion, 61b second terminal portion, D, D1, D2 dissimilar wiring portion, P protective material.

Claims

1. a stator core having a back yoke portion and a plurality of teeth protruding radially inward from the back yoke portion at intervals in the circumferential direction; an aluminum wire wound around the teeth; a copper wire wound around the teeth; a heterogeneous wiring section that connects the aluminum wire and the copper wire in series, The dissimilar wiring portion is a stator having an aluminum winding terminal, which is an aluminum terminal joined to the aluminum wire.

2. The stator according to claim 1 , wherein the dissimilar wire connection portion has a copper winding terminal that is a copper terminal joined to the copper wire.

3. 3. The stator according to claim 2, wherein the aluminum winding terminals and the copper winding terminals are connected by copper jumper wires.

4. The terminal housing further includes a terminal housing portion for housing the aluminum winding terminal, 4. The stator according to claim 1, wherein the aluminum winding terminals are covered with a protective material while housed in the terminal housing portions.

5. the windings wound around the teeth include a main winding connected to an AC power supply and a secondary winding connected in series with a capacitor in parallel with the main winding, 4. The stator according to claim 1, wherein, of the main winding and the auxiliary winding, in the winding arranged on the outer periphery of the coil end portion, the aluminum wire is arranged on the outer periphery of the slot portion and the copper wire is arranged on the inner periphery of the slot portion, and in the winding arranged on the inner periphery of the coil end portion, the copper wire is arranged on the outer periphery of the slot portion and the aluminum wire is arranged on the inner periphery of the slot portion.

6. The stator according to any one of claims 1 to 3; a rotor rotatably supported with its outer peripheral surface facing the inner peripheral surface of the stator.

7. A motor according to claim 6; a propeller fan attached to the rotor shaft.

8. a step of inserting and winding a coiled copper wire and aluminum wire into a stator core; a step of thermally crimping an end of the coiled aluminum wire to an aluminum winding terminal formed of an aluminum plate; a step of thermally crimping an end of the coiled copper wire to a copper winding terminal formed of a copper plate; and covering the aluminum winding terminals with a protective material that protects the portions of the aluminum wires that have been thermally crimped.

9. 9. The method for manufacturing a stator according to claim 8, further comprising the step of joining one end of a copper jumper wire to the aluminum winding terminal by soldering, and joining the other end of the jumper wire to the copper winding terminal by soldering.

10. 10. The method for manufacturing a stator according to claim 8 or 9, further comprising the step of: using a flat plate having a rectangular parallelepiped shape, bending a first terminal portion on one end side of the flat plate and a second terminal portion on the other end side of the flat plate inward so that they overlap each other, thereby fabricating at least one of the aluminum winding terminal and the copper winding terminal.

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