Rotating electric machine

Abstract

To provide a rotating electric machine in which the stator core and insulator can be easily assembled. [Solution] The device comprises a winding, an annular stator core 3 in which a plurality of teeth 32 extending radially inward R1 are distributed in the circumferential direction E, and an annular insulator 4 disposed between the teeth 32 and the winding to insulate them. The insulator 4 includes an inner circumferential covering portion 41a that covers the inner circumferential surface 31a of the stator core 3, an end face covering portion 44 that covers one end face 34 of the teeth 32 in the axial direction Z of the stator core 3, and a pair of side covering portions 43 that are integrally formed with the end face covering portion 44 and cover both sides of the teeth 32 in the circumferential direction E. The pair of side covering portions 43 have a tip portion 45 that protrudes beyond the other end face 35 of the teeth 32 in the axial direction Z and is fitted onto the teeth 32.

Description

Technical Field

[0001] The present invention relates to a rotating electrical machine.

Background Art

[0002] Patent Document 1 describes an inner rotor type rotating electrical machine (referred to as an "electric motor" in the document) in which a rotor is disposed inside a stator. The stator is configured by attaching individual insulators from both axial sides of the stator to a stator core.

Prior Art Documents

Patent Documents

[0003] s

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the rotating electrical machine described in Patent Document 1, the stator is configured by assembling two insulators to a stator core. Therefore, there is room for improvement in simplifying the assembly of the stator core and the insulators.

[0005] Therefore, there has been a demand for a rotating electrical machine that can easily assemble a stator core and an insulator.

Means for Solving the Problems

[0006] The characteristic configuration of the rotating electric machine according to the present invention comprises a winding, an annular stator core in which a plurality of teeth extending radially inward are dispersed in the circumferential direction, and an annular insulator disposed between the teeth and the winding to insulate them from each other. The insulator includes an inner circumferential covering portion that covers the inner circumferential surface of the stator core, an end face covering portion that covers one end face of the teeth in the axial direction of the stator core, and a pair of side covering portions formed integrally with the end face covering portion that cover both sides of the teeth in the circumferential direction. The pair of side covering portions each have a tip portion that protrudes beyond the other end face of the teeth in the axial direction and is fitted onto the teeth.

[0007] In this configuration of a rotating electric machine, the insulator's side covering portion is pressed against the teeth portion of the stator core, sandwiching the teeth portion between them, and a pair of tip portions protrude beyond the teeth portion. Therefore, by simply pressing one insulator against the stator core from one axial side and inserting the teeth portion between the pair of tip portions and the side covering portion, the side covering portion can be fitted onto the teeth portion and the insulator can be attached to the stator core. Thus, the insulator can be easily assembled to the stator core in a rotating electric machine. Furthermore, since the stator is composed of the stator core and one insulator, the number of parts in the rotating electric machine can be reduced. [Brief explanation of the drawing]

[0008] [Figure 1] This is a side cross-sectional view of a rotating electric machine. [Figure 2] This is an exploded perspective view of a rotating electric machine. [Figure 3] This is a perspective view of a rotating electric machine. [Figure 4] This is a surface view of the stator. [Figure 5] This is a rear view of the stator. [Figure 6] This is a perspective view showing the state before the stator core and insulator are assembled. [Figure 7]This is a side cross-sectional view showing the state before the stator core and insulator are assembled. [Figure 8] This is a side cross-sectional view showing the state after the stator core and insulator have been assembled. [Modes for carrying out the invention]

[0009] The rotating electric machine according to the present invention is configured for use in, for example, a vehicle body. The rotating electric machine of this embodiment will be described below. However, the rotating electric machine is not limited to the following embodiment and can be modified in various ways without departing from the spirit of the invention.

[0010] The following describes one embodiment of the rotating electric machine 1. As shown in Figures 1 and 2, the rotating electric machine 1 comprises a stator 2, a rotor 5, and a housing 6 that accommodates the stator 2 and rotor 5.

[0011] In this embodiment, in the rotating electric machine 1 including the stator 2 and the stator core 3 described later, the "axial direction" is defined as the Z direction (Z1 direction, Z2 direction), the "circumferential direction" as the E direction (E1 direction, E2 direction), and the "radial direction" as the R direction (R1 direction, R2 direction).

[0012] The rotating electric motor 1 is used, for example, as a drive source for actuators that drive components of a vehicle. More specifically, the rotating electric motor 1 is used as a drive source for actuators that drive sliding doors or back doors, actuators that drive window glass, actuators that drive seats, and actuators that drive sunroofs. Furthermore, the rotating electric motor 1 in this embodiment is a brushless motor.

[0013] As shown in Figures 2 and 3, the stator 2 is formed in an annular shape. The stator 2 includes a stator core 3, an insulator 4 covering the stator core 3, and a winding L (see Figure 1) wound around the stator core 3 via the insulator 4.

[0014] As shown in Figure 2, the stator core 3 is annular in shape. The stator core 3 is constructed, for example, by laminating multiple electromagnetic steel sheets. The stator core 3 has an annular portion 31 and multiple teeth 32, 33 extending radially inward. In this embodiment, the stator core 3 has six first teeth 32 (an example of a tooth portion) and six second teeth 33. In the stator core 3, the six first teeth 32 are distributed in the circumferential direction (E direction). The first teeth 32 and the second teeth 33 are arranged alternately in the circumferential direction. The winding L is wound around the first teeth 32, which are covered with an insulator 4. The first teeth 32 have a projection 36 at their radially inward (R1 direction) end that protrudes in the circumferential direction (E direction).

[0015] The insulator 4 is positioned between the first teeth 32 of the stator core 3 and the winding L to insulate them. The insulator 4 is made of an insulating resin material. The insulator 4 is formed to cover the stator core 3 from one side (Z1 direction) in the axial direction (Z direction) of the stator core 3. Here, the axial direction (Z direction) of the stator core 3 is the same as the axial direction X of the rotation axis 51, which will be described later.

[0016] As shown in Figure 2, the insulator 4 has an annular portion 41 whose size corresponds to the outer diameter of the stator core 3, and a plurality of covering portions 42 extending radially inward (R1 direction) from the annular portion 41. The annular portion 41 has an inner circumferential covering portion 41a that covers the inner circumferential surface 31a of the annular portion 31 of the stator core 3, an outer circumferential covering portion 41b that covers the outer circumferential portion 31b of the annular portion 31 of the stator core 3, and an end face covering portion 41c that covers one end face 31c in the axial direction (Z direction) of the stator core 3 (Z1 direction side). The covering portion 42 has a pair of side covering portions 43, 43 that cover both sides of the first teeth 32 of the stator core 3 in the circumferential direction (E direction), and an end face covering portion 44 that covers one end face 34 in the axial direction (Z direction) of the first teeth 32 (Z1 direction side). The pair of side covering portions 43, 43 have tip portions 45 that protrude axially (towards the other side, Z2 direction) beyond the end face 35 on the other side (towards the Z2 direction) of the first tooth 32 in the axial direction (Z direction).

[0017] As shown in FIGS. 5 to 7, the width in the circumferential direction (E direction) between the pair of tip portions 45, 45 is narrower than the width in the circumferential direction (E direction) between the pair of side covering portions 43, 43. For this reason, the first teeth 32 of the stator core 3 are held in a state of being sandwiched between the pair of side covering portions 43, 43 and the tip portions 45, 45.

[0018] The side covering portion 43 is configured such that a slit 47 is formed between it and the inner circumferential covering portion 41a on the radially outer side (R2 direction). In the present embodiment, as shown in FIG. 6, the slit 47 is formed by a notch G having a predetermined width and a predetermined depth. The shape of the slit 47 may be any shape as long as the tip portion 45 is likely to fall outward in the circumferential direction (E direction) when the stator 2 is assembled, which will be described later. Here, when the bottom portion (depth) of the slit 47 in the axial direction (Z direction) exists up to a position overlapping the stator core 3 beyond the position of the end face 35 of the stator core 3, the winding L and the stator core 3 may come into contact through the slit 47. Therefore, it is preferable that the bottom portion of the slit 47 in the axial direction (Z direction) is formed at the position of the end face 35 of the stator core 3 or on the Z2 direction side of that position.

[0019] The side covering portion 43 has an extension portion 48 that extends radially outward (R2 direction) from the inner circumferential surface A of the inner circumferential covering portion 41a. In the present embodiment, the extension portion 48 constitutes a part of the tip portion 45. In other words, the portion that extends radially outward (R2 direction) from the tip portion 45 beyond the inner circumferential surface A of the inner circumferential covering portion 41a corresponds to the extension portion 48. Also, in the present embodiment, the extension portion 48 has an extension length DS in the radially outward (R2 direction). The extension length DS is preferably, for example, not less than the radius of the winding L. When the extension length DS of the extension portion 48 is not less than the radius of the winding L, the winding L can be properly supported by the extension portion 48, making it easier to exhibit the guiding function of the winding L by the extension portion 48.

[0020] The side covering portion 43 has a protruding portion 46 that protrudes toward the other axial direction (Z2 direction) on the radially inner side (R1 direction). That is, the protruding portion 46 of each side covering portion 43 protrudes toward the other axial direction relative to each side covering portion 43 in a radial view (R-direction view). The protruding portion 46 is provided to guide the winding L wound around the first teeth 32 and prevent the winding L from falling inward in the radial direction (R1 direction). In the present embodiment, the protruding portion 46 protrudes toward the other axial direction relative to the extending portion 48. Thereby, the winding L wound around the first teeth 32 can be guided by the protruding portion 46, and in addition, the falling of the winding L inward in the radial direction (R1 direction) can be prevented by the protruding portion 46. In particular, when winding the winding L around the first teeth 32, the movement of the winding L in the radial direction (R direction) can be suppressed by the protruding portion 46.

[0021] As shown in FIGS. 2 to 4, the plurality of covering portions 42 of the insulator 4 are provided in the same number as the first teeth 32 of the stator core 3. The shape of the covering portion 42 corresponds to the shape of the first teeth 32.

[0022] The winding L includes a U-layer winding, a V-layer winding, and a W-layer winding. The U-layer winding, the V-layer winding, and the W-layer winding are wound around the first teeth 32 of the stator core 3 covered by the insulator 4. Specifically, the U-layer winding is wound around two of the six first teeth 32 of the stator core 3. The V-layer winding is wound around two of the remaining four first teeth 32. The W-layer winding is wound around the remaining two first teeth 32. Thus, the portion of the U-layer winding wound around the first teeth 32 of the stator core 3 becomes a U-layer coil, the portion of the V-layer winding wound around the first teeth 32 of the stator core 3 becomes a V-layer coil, and the portion of the W-layer winding wound around the first teeth 32 of the stator core 3 becomes a W-layer coil.

[0023] One end of each of the U-layer winding, V-layer winding, and W-layer winding is connected to three busbars, and the other ends of each of the U-layer winding, V-layer winding, and W-layer winding are connected to the neutral point terminal. In this respect, the connection method of the three-layer coil in this embodiment is a star connection. In other embodiments, the connection method of the three-layer coil may be a delta connection.

[0024] As shown in Figures 1 and 2, the rotor 5 has a cylindrical rotating shaft 51, a cylindrical holder 53, and a cylindrical permanent magnet section 54. The rotating shaft 51 has a drive gear 52 that transmits power to the object being driven. In other words, the rotating electric machine 1 transmits power to the object being driven via the drive gear 52. The holder 53 is made of, for example, a resin material. The holder 53 is fixed to the rotating shaft 51 while holding the permanent magnet section 54. In other words, in the rotor 5, the rotating shaft 51, the holder 53, and the permanent magnet section 54 rotate together as a single unit. The rotor 5 is located inside the stator 2. That is, the rotating electric machine 1 of this embodiment is an inner rotor type. Both ends of the rotating shaft 51 are supported by two bearings 71 and 72, respectively. The two bearings 71 and 72 are supported by the case (not shown) of the rotating electric machine 1. The rotor 5 rotates in response to the rotating magnetic field generated by the stator 2.

[0025] The housing 6 is made of resin material. The housing 6 has a disc-shaped bottom wall 61 and a cylindrical wall 62. A circular hole is provided in the center of the bottom wall 61. The cylindrical wall 62 extends axially (Z direction) from the outer edge of the bottom wall 61. In other words, one end of the cylindrical wall 62 is open in the axial direction (Z direction), and the other end in the axial direction (Z direction) is closed by the bottom wall 61. The tip surface of the cylindrical wall 62 is a plane perpendicular to the axial direction (Z direction). The housing 6 houses the stator 2 and the rotor 5. At this time, the stator 2 is fixed to the housing 6. A cover 63 is placed on the opening side of the housing 6, and the cover 63 is made of resin material.

[0026] <How to assemble Stator 2> The stator 2 is constructed by assembling a stator core 3 and an insulator 4. Specifically, the stator core 3 is moved from above to below relative to the insulator 4, which is positioned so that a pair of tip portions 45, 45 face in the Z2 direction (see Figures 6 and 7). At this time, while properly aligning the first teeth 32 with the pair of side covering portions 43, 43, for example, a jig (not shown) is placed below the first teeth 32, and the jig causes the tip portions 45, 45 to be tilted outward in the circumferential direction (E direction), thereby widening the opening between them. In this state, the jig and the first teeth 32 are inserted between the pair of side covering portions 43, 43. After that, the jig is removed from between the pair of side covering portions 43, 43, and the entire first teeth 32 is inserted between the pair of side covering portions 43, 43. In this embodiment, because the slit 47 is formed, the tip portions 45, 45 tend to tilt outward in the circumferential direction (E direction), making it easier to insert the first teeth 32 between the pair of side covering portions 43, 43.

[0027] When the first teeth 32 of the stator core 3 are fully inserted into the pair of side covering portions 43, 43 of the insulator 4, the tip portion 45 of the stator core 3 in the axial direction (Z direction) protrudes more than the first teeth 32. In this way, as shown in Figure 8, the first teeth 32 of the stator core 3 are sandwiched between the pair of side covering portions 43, 43 and the tip portion 45 of the insulator 4, and the assembly of the stator core 3 and the insulator 4 is completed.

[0028] [Other Embodiments] (1) In the above embodiment, an example was shown in which the insulator 4 has a slit 47 between a pair of side covering portions 43, 43 and an inner circumferential covering portion 41a, but the insulator 4 may be configured without having a slit 47.

[0029] (2) In the above embodiment, the pair of side covering portions 43, 43 were shown to have extension portions 48 that extend radially outward (in the R2 direction) from the inner surface A of the inner covering portion 41a, but the pair of side covering portions 43, 43 may be configured without extension portions 48.

[0030] (3) In the above embodiment, the pair of side covering portions 43 are shown to have a projection 46 that protrudes radially inward (R1 direction) and on the other axial side (Z2 direction). However, the pair of side covering portions 43 may be configured without having a projection 46.

[0031] (4) In the above embodiment, an example was shown in which the insulator 4 covers the entire end face 34 of one of the first teeth 32. However, the insulator 4 may also cover a part of the end face 34 of one of the first teeth 32. In this case, both end faces 34 and 35 of the first teeth 32 that are perpendicular to the axial direction (Z direction) are exposed.

[0032] [Summary of the above embodiment] In the embodiments described above, the following configuration can be envisioned. <1> One embodiment of the rotating electric machine (1) comprises a winding (L), an annular stator core (3) having a plurality of teeth (32) extending radially inward (R1 direction) and distributed in the circumferential direction (E direction), and an annular insulator (4) disposed between the teeth (32) and the winding (L) to insulate them, wherein the insulator (4) has an inner circumferential covering portion (41a) that covers the inner circumferential surface (31a) of the stator core (3), and the teeth (32) The core (3) includes an end face covering portion (44) that covers one end face (34) in the axial direction (Z direction), and a pair of side covering portions (43, 43) that are integrally formed with the end face covering portion (44) and cover both sides of the teeth portion (32) in the circumferential direction (E direction). The pair of side covering portions (43, 43) have a tip portion (45) that protrudes beyond the other end face (35) in the axial direction (Z direction) of the teeth portion (32), and are fitted onto the teeth portion (32).

[0033] According to this embodiment, the insulator (4) has side covering portions (43, 43) that are pressed against the teeth portion (32) of the stator core (3) while sandwiching the teeth portion (32), and a pair of tip portions (45, 45) that protrude beyond the teeth portion (32). Therefore, by simply pressing one insulator (4) against the stator core (3) from one side in the axial direction (Z direction) of the stator core (3) and inserting the teeth portion (32) between the pair of tip portions (43, 43) and the side covering portions (43, 43), the side covering portions (43, 43) can be fitted onto the teeth portion (32) and the insulator (4) can be attached to the stator core (3). Thus, the insulator (4) can be easily assembled to the stator core (3) in the rotating electric machine (1). Furthermore, since the stator (2) is composed of a stator core (3) and one insulator (4), the number of parts in the rotating electric machine (1) can be reduced.

[0034] <2> <1> In the rotating electric machine (1), it is preferable that a slit (47) is formed between the side covering portion (43, 43) and the inner circumferential covering portion (41a).

[0035] According to this embodiment, the presence of a slit (47) between the pair of side covering portions (43,43) and the inner circumferential covering portion (41a) makes it easier for the tip portions (45) of the pair of side covering portions (43,43) to be pushed by the teeth portion (32) when assembling the stator core (3) and the insulator (4), causing the side covering portions (43,43) to tilt outward in the circumferential direction (E direction). In other words, the pair of side covering portions (43,43) can easily widen their opening when inserting the teeth portion (32) of the stator core (3) due to the slit (47). This improves the ease of assembly between the stator core (3) and the insulator (4). Furthermore, the rotating electric machine (1), having the slit (47), allows for strength settings to be adjusted according to each part for the pair of side covering portions (43,43) positioned on the teeth portion (32) and the inner circumferential covering portion (41a) positioned on the radially outward side (R2 direction side).

[0036] <3> <1> or <2> In the rotating electric machine (1), it is preferable that the side covering portion (43) has an extension portion (48) that extends radially outward (in the R2 direction) from the inner surface (A) of the inner covering portion (41a).

[0037] According to this embodiment, the extension portion (48) provided on the radially outward side of the side covering portion (43) of the insulator (4) can prevent the winding (L) from tilting radially outward (in the R2 direction).

[0038] <4> <3> In the rotating electric machine (1), the side covering portion (43) has a projection portion (46) that protrudes radially inward (R1 direction) toward the other axial direction (Z2 direction), and it is preferable that the projection portion (46) protrudes more toward the other axial direction (Z2 direction) than the extension portion (48).

[0039] According to this embodiment, the protrusion (46) can guide the winding (L) wound around the first tooth 32, and in addition, the protrusion (46) can prevent the winding (L) from tilting radially inward (in the R1 direction). In particular, when winding the winding (L) around the first tooth (32), the protrusion (46) can suppress the radial movement (R direction) of the winding (L). [Explanation of Symbols]

[0040] 1: Rotating electric machine, 3: Stator core, 4: Insulator, 31a: Inner circumferential surface, 32: First tooth (tooth portion), 34: End face on one side, 35: End face on the other side, 41a: Inner circumferential covering portion, 43: Side covering portion, 44: End face covering portion, 45: Tip portion, 46: Protruding portion, 47: Slit, 48: Extension portion, A: Inner circumferential surface, E: Circumferential direction, L: Winding, R: Radial direction, Z: Axial direction

Claims

1. Winding and, An annular stator core having multiple teeth extending radially inward and distributed circumferentially, The system includes an annular insulator positioned between the teeth portion and the winding to insulate them from each other. The aforementioned insulator is The inner circumferential covering portion covers the inner circumferential surface of the stator core, The tooth portion includes an end face covering portion that covers one end face of the stator core in the axial direction, and a pair of side covering portions that are integrally formed with the end face covering portion and cover both sides of the tooth portion in the circumferential direction. The pair of side covering portions have tip portions that protrude beyond the other end face of the teeth portion in the axial direction, and are fitted onto the teeth portion of the rotating electric machine.

2. The rotating electric machine according to claim 1, wherein a slit is formed between the side covering portion and the inner covering portion.

3. The rotating electric machine according to claim 1 or 2, wherein the side covering portion has an extension portion that extends radially outward from the inner surface of the inner covering portion.

4. The aforementioned side covering portion has a projection that protrudes radially inward toward the other axial direction, The rotating electric machine according to claim 3, wherein the protruding portion protrudes further in the other axial direction than the extended portion.

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