Electric compressor and method for manufacturing the same

Abstract

To improve workability.SOLUTION: A non-locking surface X2 of an insulator base 51 does not have respective accommodation grooves, and with which no connecting wire is engaged. Therefore, when a jig is engaged with an engaging groove 23c, interference between the connecting wire and the jig can be avoided.SELECTED DRAWING: Figure 7

Description

Technical Field

[0001] The present invention relates to an electric compressor and a method for manufacturing the electric compressor.

Background Art

[0002] For example, an electric compressor as disclosed in Patent Document 1 includes a compression part, an electric motor, and a cylindrical housing. The compression part compresses a fluid. The electric motor drives the compression part. The housing houses the electric motor.

[0003] The electric motor has a stator. The stator has an annular stator core. The stator core is fixed to the inner peripheral surface of the housing. The stator core has a cylindrical yoke and a plurality of teeth. The yoke engages with the inner peripheral surface of the housing. The plurality of teeth extend in the radial direction of the yoke at intervals in the circumferential direction of the yoke from the inner peripheral surface of the yoke. Further, the stator has U-phase, V-phase, and W-phase windings. The windings form a plurality of coils by winding around the plurality of teeth in concentrated winding.

[0004] Here, for example, in order to cope with a high voltage, the coils of each phase may be formed by series winding. In series winding, the windings of the coils of each phase are started to be wound around each tooth, and the windings of the coils of each phase are sequentially wound around the teeth arranged every other in the circumferential direction of the yoke in concentrated winding. Therefore, the coils of each phase are formed by winding the windings around each tooth in concentrated winding. Further, the stator has an insulator. The insulator has a cylindrical insulator base. The insulator base is in contact with the end face of the yoke.

[0005] The windings of each phase form a plurality of jumpers that connect adjacent coils. The jumpers are locked to the outer peripheral surface of the insulator base.

Prior Art Documents

Patent Documents

[0006] [Patent Document 1] Japanese Patent Application Laid-Open No. 2012-144997 [Summary of the Invention] [Problems to be Solved by the Invention]

[0007] By the way, for example, the stator is assembled to the housing by fitting the stator core onto the inner peripheral surface of the housing by shrink fitting. In this shrink fitting, after heating and expanding the housing to make the inner diameter of the housing larger than the outer diameter of the stator core, the stator core is inserted into the housing up to a predetermined shrink fitting position. Then, it is performed by bringing the inner peripheral surface of the housing into close contact with the outer peripheral surface of the stator core due to the shrinkage accompanying the transition of the housing to room temperature.

[0008] Therefore, when shrink fitting the stator core to the housing or the like, in order to prevent a phase shift of the stator core with respect to the housing, a jig for performing circumferential relative positioning of the stator core with respect to the housing is used. Then, with the stator core being phase-determined with respect to the housing, the stator core is inserted into the housing up to a predetermined shrink fitting position. At this time, if a jumper wire is located at the portion where the jig is to be inserted, the jumper wire and the jig will interfere with each other. As a result, the assembly workability will deteriorate. [Means for Solving the Problems]

[0009] The electric compressor that solves the above problems includes a compression part that compresses a fluid, an electric motor that drives the compression part, and a cylindrical housing that houses the electric motor. The electric motor has a stator. The stator includes a cylindrical yoke that engages with the inner peripheral surface of the housing, and an annular stator core having a plurality of teeth extending radially from the inner peripheral surface of the yoke. The stator also includes an annular insulator having a cylindrical insulator base that abuts against the end face of the yoke, and windings of U phase, V phase, and W phase that form a plurality of coils by winding the plurality of teeth in concentrated winding. Each phase winding forms a plurality of jumper wires that connect adjacent coils and are locked to the outer peripheral surface of the insulator base. The outer peripheral surface of the insulator base has a locking surface having a receiving groove for receiving the jumper wire and a non-locking surface without the receiving groove where the jumper wire is not locked. The stator core has an engaging recess that engages with a part of a jig in a region of the end face of the yoke that is radially outside the insulator base. The engaging recess is located radially outside the non-locking surface on the end face of the yoke.

[0010] According to this, the jumper wire is not locked to the non-locking surface of the insulator base. Therefore, when engaging the jig with the engaging recess, interference between the jumper wire and the jig is avoided. Thus, it becomes easy to engage the jig with the engaging recess. As a result, workability can be improved.

[0011] In the above electric compressor, the plurality of coils have a starting coil that is the start of series winding and an ending coil that is the end of winding. The plurality of jumper wires include a starting jumper wire connected to the starting coil and an ending jumper wire connected to the ending coil. When the end face of the stator core is viewed from the axial direction, the engaging recess is preferably located between the starting jumper wire and the ending jumper wire in the circumferential direction.

[0012] According to this, the non-locking surface can be preferably provided on the insulator base. In the above-described electric compressor, the stator further has an insulating cylindrical cover that is interposed between the jumper wire and the housing and surrounds the insulator base. The cover has a notch penetrating in the axial direction on the outer peripheral surface. The notch and the non-locking surface are arranged side by side in the radial direction of the stator core. When looking at the end face of the stator core in the axial direction of the stator core, at least a part of the engaging recess may be located inside the notch.

[0013] According to this, since the cover surrounds the insulator base, for example, even when the jumper wire protrudes from the accommodation groove, it is possible to avoid the jumper wire from coming into contact with the housing. As a result, the insulation between the housing and the jumper wire can be ensured, and the reliability is improved. Further, the cover has a notch penetrating in the axial direction of the cover on the outer peripheral surface. The notch and the non-locking surface are arranged side by side in the radial direction of the stator core. When looking at the end face of the stator core in the axial direction of the stator core, at least a part of the engaging recess is located inside the notch. Therefore, even in a configuration where the stator further has a cover that surrounds the insulator base, it is possible to avoid the cover from closing the engaging recess. Therefore, it becomes easy to engage the jig with the engaging recess. As a result, while improving the reliability, the workability can be improved.

[0014] A method for manufacturing an electric compressor that solves the above problems includes a compression unit that compresses a fluid, an electric motor that drives the compression unit, and a cylindrical housing that houses the electric motor. The electric motor has a stator, and the stator includes a cylindrical yoke that engages with the inner peripheral surface of the housing, and an annular stator core having a plurality of teeth extending radially from the inner peripheral surface of the yoke. The stator also includes an annular insulator having a cylindrical insulator base that abuts against the end surface of the yoke, and windings of U phase, V phase, and W phase that form a plurality of coils by winding the plurality of teeth in concentrated winding. Each phase winding forms a plurality of jumper wires that connect adjacent coils and are locked to the outer peripheral surface of the insulator base. The outer peripheral surface of the insulator base has a locking surface having a receiving groove for receiving the jumper wires and a non-locking surface without the receiving groove where the jumper wires are not locked. The stator core has an engaging recess that engages with a part of a jig in a region of the end surface of the yoke that is radially outside the insulator base. The engaging recess is radially outside the non-locking surface on the end surface of the yoke. A method for manufacturing an electric compressor, wherein the jig engages a part of a region facing the non-locking surface in the radial direction of the stator core with the engaging recess while positioning the stator in the circumferential direction.

Advantages of the Invention

[0015] According to this invention, workability can be improved.

Brief Description of the Drawings

[0016]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Mode for Carrying Out the Invention

[0017] Hereinafter, embodiments in which an electric compressor is embodied will be described with reference to FIGS. 1 to 9. <Overall Configuration of Electric Compressor 10> As shown in FIG. 1, the electric compressor 10 includes a cylindrical housing 11. The housing 11 has a discharge housing 12, a motor housing 13, and an inverter case 14. The discharge housing 12, the motor housing 13, and the inverter case 14 are made of a metal material. The discharge housing 12, the motor housing 13, and the inverter case 14 are made of, for example, aluminum.

[0018] The motor housing 13 has a plate-shaped end wall 13a and a peripheral wall 13b extending cylindrically from the outer peripheral portion of the end wall 13a. The discharge housing 12 is cylindrical. The discharge housing 12 is connected to the end of the peripheral wall 13b of the motor housing 13 on the side opposite to the end wall 13a. The inverter case 14 is cylindrical. The inverter case 14 is connected to the end wall 13a of the motor housing 13. And the accommodation space S1 is partitioned by the end wall 13a of the motor housing 13 and the inverter case 14.

[0019] At the center of the end wall 13a of the motor housing 13, a cylindrical boss portion 13c is provided. The axis of the boss portion 13c coincides with the axis of the peripheral wall 13b of the motor housing 13. Further, a through hole 13h is formed in the end wall 13a of the motor housing 13. The through hole 13h penetrates the end wall 13a of the motor housing 13 in the thickness direction. The through hole 13h is located closer to the peripheral wall 13b than the boss portion 13c.

[0020] The electric compressor 10 includes a rotating shaft 15, a compression part 16, an electric motor 20, and an inverter 17. The rotating shaft 15, the compression part 16, and the electric motor 20 are accommodated in the motor housing 13. Therefore, the housing 11 accommodates the electric motor 20. The axial direction in which the rotation axis L1 of the rotating shaft 15 extends coincides with the axial direction of the peripheral wall 13b of the motor housing 13. The inverter 17 is accommodated in the accommodation space S1.

[0021] The compression part 16 includes a fixed scroll 16a and a movable scroll 16b. The fixed scroll 16a is fixed to the motor housing 13. The movable scroll 16b is disposed opposite to the fixed scroll 16a. The compression part 16 is driven by the rotation of the rotating shaft 15. The compression part 16 compresses the refrigerant as a fluid by driving. A compression chamber S2 with a variable volume is defined between the fixed scroll 16a and the movable scroll 16b. A discharge chamber S3 is defined between the fixed scroll 16a and the discharge housing 12. The refrigerant compressed by the change in the volume of the compression chamber S2 is discharged into the discharge chamber S3. The electric motor 20 drives the compression part 16 by rotating the rotating shaft 15.

[0022] The compression part 16 and the electric motor 20 are arranged side by side in the axial direction in which the rotation axis L1 of the rotating shaft 15 extends. The electric motor 20 is disposed closer to the end wall 13a side of the motor housing 13 than the compression part 16. The compression part 16, the electric motor 20, and the inverter 17 are arranged in this order side by side in the axial direction of the rotating shaft 15.

[0023] In addition, the electric compressor 10 includes a shaft support member 18. The shaft support member 18 is disposed between the compression unit 16 and the electric motor 20. Therefore, the shaft support member 18 serves as a partition wall between the electric motor 20 and the compression unit 16. An insertion hole 18h is formed in the central portion of the shaft support member 18. The axis of the insertion hole 18h coincides with the axis of the boss portion 13c. One end portion of the rotating shaft 15 is inserted into the insertion hole 18h. A radial bearing 19b is provided between the insertion hole 18h and one end portion of the rotating shaft 15. One end portion of the rotating shaft 15 is rotatably supported by the shaft support member 18 via the radial bearing 19b. Also, the other end portion of the rotating shaft 15 is inserted inside the boss portion 13c. A radial bearing 19a is provided between the boss portion 13c and the other end portion of the rotating shaft 15. The other end portion of the rotating shaft 15 is rotatably supported by the boss portion 13c via the radial bearing 19a.

[0024] <Configuration of the electric motor 20> The electric motor 20 includes a rotor 21 and a stator 22. The rotor 21 is disposed inside the stator 22. The rotor 21 has a cylindrical rotor core 21a. The rotor core 21a is fixed to the rotating shaft 15. A plurality of permanent magnets (not shown) are embedded in the rotor core 21a.

[0025] The stator 22 has an annular stator core 23. The stator core 23 is fixed to the inner peripheral surface of the peripheral wall 13b of the motor housing 13. Therefore, the stator core 23 is fixed to the inner peripheral surface of the housing 11. The stator 22 is assembled to the housing 11, for example, by fitting the stator core 23 into the inner peripheral surface of the peripheral wall 13b of the motor housing 13 by shrink fitting.

[0026] The stator core 23 has a first end face 23a and a second end face 23b. The first end face 23a is the end face located on one side in the axial direction of the stator core 23. The second end face 23b is the end face located on the other side in the axial direction of the stator core 23. The stator core 23 is disposed in the motor housing 13 such that the first end face 23a faces the end wall 13a of the motor housing 13. Therefore, the first end face 23a is located closer to the inverter 17 than the second end face 23b. The second end face 23b is located closer to the compression part 16 than the first end face 23a.

[0027] As shown in FIGS. 2 and 3, the stator core 23 has a cylindrical yoke 24 and a plurality of teeth 25 extending in the radial direction of the yoke 24 from the inner peripheral surface 24a of the yoke 24. In the present embodiment, the stator core 23 has 15 teeth 25. The yoke 24 engages with the inner peripheral surface of the housing 11.

[0028] The plurality of teeth 25 are arranged at intervals in the circumferential direction of the yoke 24. The plurality of teeth 25 are arranged at equal intervals in the circumferential direction of the yoke 24. Note that the circumferential direction of the yoke 24 is also the circumferential direction of the stator core 23. Each tooth 25 extends from the inner peripheral surface 24a of the yoke 24 toward the axis of the stator core 23. Each tooth 25 has a tooth extending portion 26 and a tooth flange portion 27. The tooth extending portion 26 extends from the inner peripheral surface 24a of the yoke 24. The tooth flange portion 27 projects from both sides in the circumferential direction of the stator core 23 from the end portion of the tooth extending portion 26 on the side opposite to the yoke 24.

[0029] As shown in FIGS. 1 and 2, the stator 22 has a plurality of coils 28U, 28V, 28W for each of the U-phase, V-phase, and W-phase. The coils 28U, 28V, 28W of each phase are formed by winding the winding 29 around each tooth 25 in a concentrated winding manner. Therefore, the stator 22 includes windings 29 of the U-phase, V-phase, and W-phase that form a plurality of coils 28U, 28V, 28W by winding a plurality of teeth 25 in a concentrated winding manner. From the first end face 23a of the stator core 23, a first coil end 28a, which is a part of the coils 28U, 28V, 28W of each phase, protrudes. From the second end face 23b of the stator core 23, a second coil end 28b, which is a part of the coils 28U, 28V, 28W of each phase, protrudes. Therefore, the coils 28U, 28V, 28W of each phase have a first coil end 28a protruding from the first end face 23a of the stator core 23 and a second coil end 28b protruding from the second end face 23b of the stator core 23.

[0030] As shown in FIG. 1, the electric compressor 10 includes motor wiring 43. The motor wiring 43 is drawn out from the electric motor 20. The motor wiring 43 is drawn out from the first coil ends 28a of the coils 28U, 28V, 28W of each phase. The motor wiring 43 is drawn out from the electric motor 20 one by one corresponding to each phase. Therefore, three motor wirings 43 are drawn out from the electric motor 20. In FIG. 1, only one motor wiring 43 is shown.

[0031] Inside the housing 11, a first region R1 where the first coil end 28a is located and a second region R2 where the second coil end 28b is located are formed. The first region R1 is a region located between the first end face 23a of the stator core 23 and the end wall 13a of the motor housing 13 inside the motor housing 13. The second region R2 is a region located between the second end face 23b of the stator core 23 and the shaft support member 18 inside the motor housing 13.

[0032] As shown in FIG. 2, a part of each phase coil 28U, 28V, 28W passes through a slot 30 which is a space formed between adjacent teeth 25 in the circumferential direction of the stator core 23. In this embodiment, the number of slots of the stator 22 is "15". Note that a part of each phase coil 28U, 28V, 28W passing through each slot 30 and the stator core 23 are insulated by a slot insulating sheet 31.

[0033] <Configuration of the insulator 50> As shown in FIGS. 1 and 3, the stator 22 includes an annular insulator 50. The insulator 50 insulates the stator core 23 and the coils 28U, 28V, 28W. Each insulator 50 is disposed on the first end face 23a and the second end face 23b of the stator core 23, respectively. Therefore, the stator 22 has two insulators 50. Each insulator 50 has a first surface 50a in contact with the stator core 23 and a second surface 50b located on the side opposite to the stator core 23. One of the two insulators 50 is disposed with respect to the stator core 23 in a state where the first surface 50a is in contact with the first end face 23a of the stator core 23. The other of the two insulators 50 is disposed with respect to the stator core 23 in a state where the first surface 50a is in contact with the second end face 23b of the stator core 23. The insulator 50 is between the shaft support member 18 and the motor housing 13.

[0034] Each insulator 50 has a cylindrical insulator base 51, an insulator extending portion 52, and an insulator flange portion 53. The insulator base 51 is disposed at a position facing the yoke 24 in the axial direction of the stator core 23. Each insulator 50 is disposed with respect to the stator core 23 in a state where the axial direction of the insulator base 51 coincides with the axial direction of the yoke 24. The insulator base 51 is in contact with the end face of the yoke 24. The outer diameter of the insulator base 51 is smaller than the outer diameter of the yoke 24. The inner diameter of the insulator base 51 is the same as the inner diameter of the yoke 24.

[0035] One of the two insulators 50, the insulator base 51, is disposed on the first end face 23a of the stator core 23 while surrounding the first coil end 28a. The other insulator base 51 of the two insulators 50 is disposed on the second end face 23b of the stator core 23 while surrounding the second coil end 28b. Therefore, the other of the two insulators 50 has a cylindrical insulator base 51 that is disposed on the second end face 23b of the stator core 23 while surrounding the second coil end 28b.

[0036] Each insulator extending portion 52 extends radially from the inner peripheral surface 51a of the insulator base 51. The circumferential width of the insulator base 51 in each insulator extending portion 52 is the same as the circumferential width of the stator core 23 in each tooth extending portion 26. Each insulator extending portion 52 is in contact with each tooth 25. The insulator flange portion 53 projects along the insulator base 51 from the end portion of each insulator extending portion 52 on the side opposite to the insulator base 51.

[0037] As shown in FIGS. 3, 4, and 5, the other insulator base 51 of the two insulators 50 has a thick portion 55 and a thin portion 56. The thick portion 55 is a portion of the insulator base 51 closer to the second face 50b of the insulator 50. The thick portion 55 is continuous with the second face 50b of the insulator 50. The thick portion 55 is non-circular and extends in the circumferential direction of the insulator base 51 with a part excluded in the circumferential direction of the insulator base 51. A plurality of through grooves 60U, 60V, 60W are formed in the thick portion 55. Five through grooves 60U, 60V, 60W are formed in the thick portion 55. The through grooves 60U, 60V, 60W extend in the axial direction of the insulator base 51 from the second face 50b of the insulator 50 and penetrate the insulator base 51 in the radial direction.

[0038] In addition, three receiving grooves 61U, 61V, and 61W are formed on the outer peripheral surface of the thick portion 55. The three receiving grooves 61U, 61V, and 61W extend in the circumferential direction on the outer peripheral surface of the thick portion 55. The three receiving grooves 61U, 61V, and 61W are arranged side by side in the axial direction of the insulator base 51 with respect to the outer peripheral surface of the thick portion 55. The three receiving grooves 61U, 61V, and 61W do not penetrate the thick portion 55.

[0039] The thin portion 56 has no receiving grooves 61U, 61V, and 61W formed therein and is thinner than the thick portion 55. The thin portion 56 has a first thin portion 57 and a second thin portion 58. The first thin portion 57 is a portion that extends over the entire circumference in the circumferential direction of the insulator base 51 closer to the first surface 50a of the insulator 50 than the thick portion 55 in the insulator base 51. The first thin portion 57 is continuous with the first surface 50a of the insulator 50. The second thin portion 58 is located closer to the second surface 50b of the insulator 50 than the first thin portion 57 in the insulator base 51 and is a portion sandwiched between the thick portion 55 in the circumferential direction of the insulator base 51. The second thin portion 58 is continuous with the second surface 50b of the insulator 50. The second thin portion 58 is continuous with a part of the first thin portion 57. The first thin portion 57 and the second thin portion 58 have the same thickness.

[0040] <Configuration of winding 29> As shown in FIGS. 5 and 6, the coils 28U, 28V, and 28W of each phase are formed by series winding. In series winding, first, the windings 29 of the coils 28U, 28V, and 28W of each phase are wound around each tooth extending portion 26 and each insulator extending portion 52 of each insulator 50. Then, the windings 29 of the coils 28U, 28V, and 28W of each phase are sequentially wound around the tooth extending portions 26 and the insulator extending portions 52 of each insulator 50 that are arranged every other in the circumferential direction of the stator core 23 in a concentrated winding manner. Therefore, the coils 28U, 28V, and 28W of each phase are arranged every other in the circumferential direction of the stator core 23. In the present embodiment, five coils of each phase are arranged for the coils 28U, 28V, and 28W. The coils 28U, 28V, and 28W of each phase are arranged in each slot 30 such that different phases are adjacent to each other in the circumferential direction of the stator core 23.

[0041] In the U-phase, adjacent coils 28U in the circumferential direction of the stator core 23 are connected by a jumper wire 281U. The jumper wire 281U is drawn from the second coil end 28b and is part of the winding 29 located in the second region R2. The jumper wire 281U extends in the circumferential direction of the stator core 23 with respect to the second end face 23b of the stator core 23. In the V-phase, adjacent coils 28V in the circumferential direction of the stator core 23 are connected by a jumper wire 281V. The jumper wire 281V is drawn from the second coil end 28b and is part of the winding 29 located in the second region R2. The jumper wire 281V extends in the circumferential direction of the stator core 23 with respect to the second end face 23b of the stator core 23. In the W-phase, adjacent coils 28W in the circumferential direction of the stator core 23 are connected by a jumper wire 281W. The jumper wire 281W is drawn from the second coil end 28b and is part of the winding 29 located in the second region R2. The jumper wire 281W extends in the circumferential direction of the stator core 23 with respect to the second end face 23b of the stator core 23. Thus, adjacent coils 28U, 28V, 28W in the circumferential direction of the stator core 23 in each phase are connected by jumper wires 281U, 281V, 281W, respectively. The jumper wires 281U, 281V, 281W of each phase are located in the second region R2 and are accommodated in the annular space between the shaft support member 18 and the motor housing 13.

[0042] As shown in FIG. 6, in the winding 29, after the jumper wires 281U, 281V, 281W of the coils 28U, 28V, 28W of each phase are drawn from the second coil end 28b, they are wound around the teeth 25 so as to extend in the same direction in the circumferential direction of the stator core 23. Each of the jumper wires 281U, 281V, 281W extends toward the teeth 25 that are arranged with a pitch of two in the circumferential direction of the stator core 23 after being drawn from the second coil end 28b. Thus, the winding direction of the winding 29 of the coils 28U, 28V, 28W of each phase with respect to the teeth 25 is the same direction.

[0043] The start-end coils 282U, 282V, 282W that are the start of winding for each tooth 25 in the windings 29 of the coils 28U, 28V, 28W of each phase are adjacent to each other in the circumferential direction of the stator core 23. Also, the end-end coils 283U, 283V, 283W that are the end of winding for each tooth 25 in the windings 29 of the coils 28U, 28V, 28W of each phase are adjacent to each other in the circumferential direction of the stator core 23. Therefore, the coils 28U, 28V, 28W of each phase have the start-end coils 282U, 282V, 282W that are the start of series winding and the end-end coils 283U, 283V, 283W that are the end of winding. In this embodiment, the start-end coil 282W of the W-phase coil 28W and the end-end coil 283U of the U-phase coil 28U are the closest and adjacent to each other in the circumferential direction of the stator core 23 among the start-end coils 282U, 282V, 282W and the end-end coils 283U, 283V, 283W of the coils 28U, 28V, 28W of each phase. And, in the circumferential direction of the stator core 23, there are no jumper wires 281U, 281V, 281W between the start-end coil 282W of the W-phase coil 28W and the end-end coil 283U of the U-phase coil 28U.

[0044] As shown in FIGS. 5 and 6, each of the jumper wires 281U, 281V, 281W is drawn from the second coil end 28b and passes through each of the through grooves 60U, 60V, 60W. And each of the jumper wires 281U, 281V, 281W is respectively housed in each of the housing grooves 61U, 61V, 61W and locked to the outer peripheral surface of the thick portion 55. Thereby, contact between the jumper wires 281U, 281V, 281W of the coils 28U, 28V, 28W of each phase is avoided. Therefore, on the outer peripheral surface 51b of the insulator base 51, the outer peripheral surface of the thick portion 55 is a locking surface X1 having the housing grooves 61U, 61V, 61W in which the jumper wires 281U, 281V, 281W are housed.

[0045] Therefore, the U-phase winding 29 forms a plurality of coils 28U and a plurality of connecting wires 281U that connect adjacent coils 28U to each other and are locked to the outer peripheral surface 51b of the insulator base 51. The V-phase winding 29 forms a plurality of coils 28V and a plurality of connecting wires 281V that connect adjacent coils 28V to each other and are locked to the outer peripheral surface 51b of the insulator base 51. The W-phase winding 29 forms a plurality of coils 28W and a plurality of connecting wires 281W that connect adjacent coils 28W to each other and are locked to the outer peripheral surface 51b of the insulator base 51.

[0046] The connecting wire 281U has a starting connecting wire 284U connected to the starting coil 282U and an ending connecting wire 285U connected to the ending coil 283U. The connecting wire 281V has a starting connecting wire 284V connected to the starting coil 282V and an ending connecting wire 285V connected to the ending coil 283V. The connecting wire 281W has a starting connecting wire 284W connected to the starting coil 282W and an ending connecting wire 285W connected to the ending coil 283W.

[0047] Each of the connecting wires 281U, 281V, and 281W extends in the circumferential direction of the stator core 23 with respect to the second end face 23b of the stator core 23 while being respectively housed in the respective housing grooves 61U, 61V, and 61W. The outer peripheral surface of the second thin portion 58 is a non-locking surface X2 that does not have the respective housing grooves 61U, 61V, and 61W and to which none of the connecting wires 281U, 281V, and 281W are locked. The non-locking surface X2 is located between the starting connecting wire 284W of the connecting wire 281W that is connected to the starting coil 282W and the starting connecting wire 284U of the connecting wire 281U that is connected to the starting coil 282U in the circumferential direction of the insulator base 51.

[0048] <Regarding the engagement groove 23c> As shown in FIGS. 7 and 8, the stator core 23 has an engagement groove 23c as an engagement recess. The engagement groove 23c is formed on the outer peripheral surface of the stator core 23. The engagement groove 23c extends in the axial direction of the stator core 23. One end of the engagement groove 23c opens to the first end face 23a of the stator core 23. The other end of the engagement groove 23c opens to the second end face 23b of the stator core 23. The engagement groove 23c is disposed within a phase range A1 where the non-locking surface X2 exists when the stator 22 is viewed from the second end face 23b side in the axial direction of the stator core 23. Therefore, when the stator 22 is viewed from the second end face 23b side in the axial direction of the stator core 23, a part of the thin portion 56 and the engagement groove 23c are disposed within the phase range A1. Accordingly, when the second end face 23b of the stator core 23 is viewed from the axial direction, the engagement groove 23c is positioned between the start-end connecting line 284W and the end-end connecting line 285U in the circumferential direction. And when the stator 22 is viewed from the second end face 23b side in the axial direction of the stator core 23, the engagement groove 23c is positioned radially outside the stator core 23 with respect to the non-locking surface X2.

[0049] <Configuration of Cover 70> The stator 22 further has an insulating cylindrical cover 70. The cover 70 has an end wall 70a and a peripheral wall 70b extending cylindrically from the outer peripheral portion of the end wall 70a. The cover 70 is disposed with respect to the insulator 50 in a state where the peripheral wall 70b of the cover 70 surrounds the insulator base 51. The peripheral wall 70b of the cover 70 is interposed between the connecting lines 281U, 281V, 281W and the peripheral wall 13b of the motor housing 13. Therefore, the cover 70 is interposed between the connecting lines 281U, 281V, 281W and the housing 11 and surrounds the insulator base 51.

[0050] Further, the cover 70 has a notch portion 71. The notch portion 71 is formed on the outer peripheral surface 70c of the cover 70. The notch portion 71 penetrates the cover 70 in the axial direction of the cover 70. Therefore, the cover 70 has the notch portion 71 penetrating therethrough on the outer peripheral surface 70c. The cover 70 is arranged such that the notch portion 71 overlaps the phase range A1 in the axial direction of the stator core 23. Thus, the notch portion 71 and a part of the thin portion 56 are arranged side by side in the radial direction of the stator core 23. When the stator 22 is viewed from the second end face 23b side in the axial direction of the stator core 23, the engaging groove 23c is located inside the notch portion 71. Therefore, when the second end face 23b of the stator core 23 is viewed in the axial direction of the stator core 23, at least a part of the engaging groove 23c is located inside the notch portion 71.

[0051] <Configuration of the Hermetic Terminal 40> As shown in FIG. 1, the electric compressor 10 includes a hermetic terminal 40. The hermetic terminal 40 is housed in the housing 11. The hermetic terminal 40 has three conductive members 41 corresponding to the coils 28U, 28V, and 28W of each phase. In FIG. 1, only one conductive member 41 is shown. Each conductive member 41 is a columnar metal terminal extending linearly. One end of each conductive member 41 is electrically connected to the inverter 17 in the accommodation space S1. The other end of each conductive member 41 protrudes from the accommodation space S1 into the motor housing 13 through the through hole 13h. Further, the hermetic terminal 40 has a support plate 42. The support plate 42 supports the three conductive members 41 in a mutually insulated state. The support plate 42 is fixed around the through hole 13h on the outer surface of the end wall 13a in the accommodation space S1.

[0052] <Configuration of the Connector 44> Inside the motor housing 13, a connector 44 is accommodated. The connector 44 is located in the first region R1. The connector 44 includes three connection terminals 45 corresponding to the coils 28U, 28V, 28W of each phase, and an insulating cluster block 46 that houses the three connection terminals 45. Therefore, the cluster block 46 is located in the first region R1.

[0053] The cluster block 46 has three conductive member insertion holes 47 and three motor wiring insertion holes 48. In FIG. 1, only one conductive member insertion hole 47 is shown, and only one motor wiring insertion hole 48 is shown. Each conductive member 41 is inserted into each conductive member insertion hole 47. Each motor wiring 43 is inserted into each motor wiring insertion hole 48. And each connection terminal 45 electrically connects each conductive member 41 and each motor wiring 43. The cluster block 46 is arranged in the motor housing 13 such that the conductive member insertion holes 47 extend in the axial direction of the rotation shaft 15.

[0054] The power from the inverter 17 is supplied to the electric motor 20 via each conductive member 41, each connection terminal 45, and each motor wiring 43. Thereby, the electric motor 20 is driven. Therefore, the inverter 17 drives the electric motor 20. And by the driving of the electric motor 20, the compression part 16 is driven and the compression part 16 compresses the refrigerant.

[0055] <Relationship between the engagement groove 23c and the engagement convex part 83 of the jig 80> As shown in Fig. 9, when the stator core 23 is shrink-fitted into the motor housing 13, a jig 80 is used to perform circumferential relative positioning of the stator core 23 with respect to the motor housing 13. The jig 80 has a cylindrical main body portion 81, a plate-shaped mounting portion 82, and an elongated plate-shaped engaging convex portion 83. The mounting portion 82 protrudes from a part of the outer peripheral edge of one end surface of the main body portion 81. The engaging convex portion 83 protrudes from the tip of the mounting portion 82. The engaging convex portion 83 can be engaged with the engaging groove 23c of the stator core 23. Therefore, the stator core 23 has an engaging groove 23c that engages with the engaging convex portion 83 of the jig 80 for inserting the stator 22 into the housing 11 in a region radially outside the insulator base 51 in the end face of the yoke 24.

[0056] The jig 80 is attached to the stator 22 with the axis of the main body portion 81 aligned with the axial direction of the stator core 23. At this time, the mounting portion 82 is attached along the notch portion 71 of the cover 70. The length of the engaging convex portion 83 is set to a length such that the engaging convex portion 83 can be engaged with the engaging groove 23c of the stator core 23 when the mounting portion 82 is attached to the notch portion 71.

[0057] <Function> Next, the function of this embodiment will be described while explaining the manufacturing method of the electric compressor 10 of this embodiment. Here, as the manufacturing method of the electric compressor 10, the method of assembling the stator 22 to the motor housing 13 will be described.

[0058] By the way, the stator 22 is assembled to the housing 11, for example, by shrink-fitting the stator core 23 into the inner peripheral surface of the motor housing 13. This shrink-fitting is performed by heating and expanding the motor housing 13 to make the inner diameter of the motor housing 13 larger than the outer diameter of the stator core 23, and then inserting the stator core 23 into the motor housing 13 to a predetermined shrink-fitting position. Then, it is performed by bringing the inner peripheral surface of the motor housing 13 into close contact with the outer peripheral surface of the stator core 23 due to the shrinkage accompanying the transition of the motor housing 13 to room temperature.

[0059] Therefore, when press-fitting the stator core 23 into the motor housing 13, a jig 80 for performing relative positioning in the circumferential direction is used to prevent a phase shift of the stator core 23 relative to the motor housing 13. The jig 80 engages a part of the portion facing the non-locking surface X2 in the radial direction of the stator core 23 with the engaging groove 23c and pushes the stator 22 into the housing 11, thereby relatively positioning the stator 22 in the circumferential direction with respect to the housing 11.

[0060] Here, when the stator 22 is viewed from the second end face 23b side of the stator core 23 in the axial direction of the stator core 23, the engaging groove 23c is arranged within the phase range A1 where the non-locking surface X2 exists. And the engaging groove 23c is located radially outside the stator core 23 with respect to the non-locking surface X2. Thereby, it is avoided that the jumper wires 281U, 281V, 281W interfere with the engaging convex portion 83 of the jig 80.

[0061] Also, the cover 70 surrounds the insulator base 51. Therefore, for example, even when the jumper wires 281U, 281V, 281W protrude from the accommodating grooves 61U, 61V, 61W, it is avoided that the jumper wires 281U, 281V, 281W come into contact with the housing 11. As a result, the insulation between the housing 11 and the jumper wires 281U, 281V, 281W is ensured.

[0062] The cover 70 has a notch 71. The notch 71 and the non-locking surface X2 are arranged side by side in the radial direction of the stator core 23. When the stator 22 is viewed from the second end face 23b side of the stator core 23 in the axial direction of the stator core 23, the engaging groove 23c is located inside the notch 71. Therefore, even when the stator 22 further has a cover 70 surrounding the insulator base 51, the cover 70 is prevented from blocking the engaging groove 23c. Accordingly, it is easy to engage the engaging convex portion 83 of the jig 80 with the engaging groove 23c while viewing the stator 22 from the second end face 23b side of the stator core 23 in the axial direction of the stator core 23.

[0063] The following effects can be obtained in the above embodiment. (1) The non-locking surface X2 of the insulator base 51 does not have the respective receiving grooves 61U, 61V, 61W, and the jumper wires 281U, 281V, 281W are not locked. For this reason, when the jig 80 is engaged with the engaging groove 23c, interference between the jumper wires 281U, 281V, 281W and the jig 80 is avoided. Accordingly, it is easy to engage the engaging convex portion 83 of the jig 80 with the engaging groove 23c while viewing the stator 22 from the second end face 23b side of the stator core 23 in the axial direction of the stator core 23. As a result, workability can be improved.

[0064] (2) When the second end face 23b of the stator core 23 is viewed from the axial direction, in the circumferential direction, the engaging groove 23c is located between the start-end jumper wire 284W and the end-end jumper wire 285U. According to this, there is no need to provide the non-locking surface X2 other than between the start-end jumper wire 284W and the end-end jumper wire 285U. Therefore, the non-locking surface X2 can be preferably provided on the insulator base 51.

[0065] (3) The cover 70 surrounds the insulator base 51. Therefore, for example, even if the jumper wires 281U, 281V, and 281W protrude from the accommodation grooves 61U, 61V, and 61W, it is possible to avoid the jumper wires 281U, 281V, and 281W from coming into contact with the housing 11. As a result, the insulation between the housing 11 and the jumper wires 281U, 281V, and 281W can be ensured, improving the reliability.

[0066] Further, the cover 70 has a notch 71. The notch 71 and a part of the non-locking surface X2 are arranged side by side in the radial direction of the stator core 23. Further, when the stator 22 is viewed from the second end face 23b side of the stator core 23 in the axial direction of the stator core 23, the engagement groove 23c is located inside the notch 71. Thus, even if the stator 22 further has a cover 70 surrounding the insulator base 51, the cover 70 is prevented from blocking the engagement groove 23c. Therefore, it becomes easy to engage the engagement convex portion 83 of the jig 80 with the engagement groove 23c. As a result, while improving the reliability, the workability can be improved.

[0067] (4) According to the present embodiment, even if the depth of each of the accommodation grooves 61U, 61V, and 61W is increased, the thickness of the portion provided with the non-locking surface X2 does not increase, and the insulator base 51 does not block the engagement groove 23c. Therefore, it is easy to ensure the depth of each of the accommodation grooves 61U, 61V, and 61W so that each of the jumper wires 281U, 281V, and 281W does not protrude from each of the accommodation grooves 61U, 61V, and 61W. Thus, it becomes easy to ensure the reliability of the electric compressor 10.

[0068] (5) According to this embodiment, when the stator core 23 is shrink-fitted into the motor housing 13, it is possible to suppress the occurrence of a phase shift of the stator core 23 with respect to the motor housing 13. Therefore, for example, when connecting each conductive member 41 and each connection terminal 45 in the cluster block 46, it is possible to avoid the situation where each motor wiring 43 is overly taut or each motor wiring 43 is overly bent. As a result, it is possible to suppress an excessive load from being applied to each motor wiring 43.

[0069] (6) For example, even when the jumpers 281U, 281V, 281W protrude from the accommodation grooves 61U, 61V, 61W, the cover 70 can avoid the jumpers 281U, 281V, 281W from coming into contact with the housing 11. Therefore, by setting the depth of the accommodation grooves 61U, 61V, 61W to a depth that can minimally accommodate the jumpers 281U, 281V, 281W, the thickness of the thick portion 55 can be made as thin as possible.

[0070] (7) An annular space is formed between the shaft support member 18 having a taper and the motor housing 13. For miniaturization of the electric compressor 10, the insulator 50 to which the jumpers 281U, 281V, 281W are locked is disposed in this annular space. On the other hand, since the motor housing 13 before joining the shaft support member 18 has an opening, it is easy to insert the jig 80. Due to the above circumstances, the engaging convex portion 83 of the jig 80 and the jumpers 281U, 281V, 281W are likely to interfere. By providing a non-locking surface X2 on the insulator base 51, this interference is avoided.

[0071] <Modification example> Note that the above embodiment can be implemented with the following modifications. The above embodiment and the following modification examples can be implemented in combination with each other within a technically non-conflicting range.

[0072] ○ As shown in FIG. 10, the stator 22 may not have the cover 70. In short, when the stator 22 is viewed from the second end face 23b side in the axial direction of the stator core 23, the engagement groove 23c may be located radially outside the stator core 23 than the non-locking surface X2. Note that when the stator 22 does not have the cover 70 in this way, it is necessary to set the depths of the accommodation grooves 61U, 61V, and 61W so that the connecting wires 281U, 281V, and 281W can be reliably accommodated in the accommodation grooves 61U, 61V, and 61W.

[0073] ○ In the embodiment, the insulator base 51 had the thick portion 55 and the thin portion 56, but it is not limited thereto. For example, the insulator base 51 may have a constant thickness. In short, the outer peripheral surface 51b of the insulator base 51 may have the locking surface X1 and the non-locking surface X2.

[0074] ○ In the embodiment, the number of slots of the stator core 23 may be changed as appropriate. ○ In the embodiment, instead of the engagement groove 23c, the stator core 23 may have, for example, a recess recessed in the second end face 23b of the stator core 23 as an engagement recess.

[0075] ○ In the embodiment, the shape of the cover 70 may be changed as appropriate. For example, the cover 70 may be composed of only the peripheral wall 70b. In short, the cover 70 may ensure the insulation between the housing 11 and the connecting wires 281U, 281V, and 281W by surrounding the insulator base 51.

[0076] ○ In the embodiment, the first region R1 may be located on the compression portion 16 side and the second region R2 may be located on the inverter 17 side. ○ In the embodiment, the thin portion 56 may not have the first thin portion 57, and the second thin portion 58 may extend from the first surface 50a to the second surface 50b of the insulator 50. That is, in the insulator base 51, when viewed from the second end face 23b side of the stator 22 in the axial direction of the stator core 23, only the portion arranged within the phase range A1 may be the thin portion 56.

[0077] ○ In the embodiment, when press-fitting the stator core 23 into the motor housing 13, in order to prevent the phase shift of the stator core 23 with respect to the motor housing 13, the jig 80 was engaged with the engagement groove 23c, but it is not limited to this. For example, on the assembly line of the stator 22, when winding the winding 29 around the stator core 23, the jig 80 may be engaged with the engagement groove 23c to position the stator 22 in the circumferential direction. The key point is that when manufacturing the electric compressor 10 or the electric motor 20, the jig 80 engages a part of the portion facing the non-locking surface X2 in the radial direction of the stator core 23 with the engagement groove 23c, and the stator 22 may be positioned in the circumferential direction, and the use of the jig 80 is not particularly limited.

Description of Reference Numerals

[0078] 10... Electric compressor, 11... Housing, 16... Compression part, 17... Inverter, 20... Electric motor, 22... Stator, 23... Stator core, 23c... Engagement groove as an engagement recess, 24... Yoke, 25... Teeth, 28U, 28V, 28W... Coils, 29... Winding, 50... Insulator, 51... Insulator base, 61U, 61V, 61W... Accommodation grooves, 70... Cover, 71... Notch, 80... Jig, 83... Engagement protrusion, 281U, 281V, 281W... Jumper wires, 282U, 282V, 282W... Starting coils, 283U, 283V, 283W... End coils, 284U, 284V, 284W... Starting jumper wires, 285U, 285V, 285W... End jumper wires, X1... Locking surface, X2... Non-locking surface.

Claims

1. A compression unit that compresses a fluid, an electric motor that drives the compression unit, and a cylindrical housing that houses the electric motor, wherein the electric motor has a stator, the stator includes a cylindrical yoke that engages with the inner peripheral surface of the housing, and an annular stator core having a plurality of teeth extending radially from the inner peripheral surface of the yoke, an annular insulator having a cylindrical insulator base that abuts one end surface of the yoke in the axial direction, and windings of U-phase, V-phase, and W-phase that form a plurality of coils by winding the plurality of teeth in concentrated winding, wherein each phase winding is an electric compressor that forms a plurality of jumper wires that connect adjacent coils and are locked to the outer peripheral surface of the insulator base, the outer peripheral surface of the insulator base has a locking surface having a receiving groove for receiving the jumper wire, and a non-locking surface that does not have the receiving groove and to which the jumper wire is not locked, the stator core has an engaging recess that engages with a part of a jig, the engaging recess is formed on the outer peripheral surface of the stator core, and is located radially outside the non-locking surface when viewed from one end surface side of the yoke in the axial direction. An electric compressor characterized by this.

2. The plurality of coils have a starting coil that is the start of series winding, and an end coil that is the end of winding, the plurality of jumper wires have a starting jumper wire connected to the starting coil, and an end jumper wire connected to the end coil, When the end face of the stator core is viewed from the axial direction, in the circumferential direction, the engaging recess is located between the starting jumper wire and the end jumper wire. The electric compressor according to claim 1, characterized by this.

3. The stator further has an insulating cylindrical cover that is interposed between the jumper wire and the housing and surrounds the insulator base, the cover has a notch portion penetrating in the axial direction on the outer peripheral surface, the notch portion and the non-locking surface are arranged side by side in the radial direction of the stator core, When the end face of the stator core is viewed in the axial direction of the stator core, at least a part of the engaging recess is located inside the notch portion. The electric compressor according to claim 1 or claim 2, characterized by this.

4. A compression unit that compresses a fluid, an electric motor that drives the compression unit, and a cylindrical housing that houses the electric motor, wherein the electric motor has a stator, The stator includes: a cylindrical yoke that engages with the inner peripheral surface of the housing, and an annular stator core having a plurality of teeth extending radially from the inner peripheral surface of the yoke; an annular insulator having a cylindrical insulator base that abuts against one end surface of the yoke in the axial direction; windings of U-phase, V-phase, and W-phase that form a plurality of coils by winding the plurality of teeth in concentrated winding; and the windings of each phase form a plurality of jumper wires that connect adjacent coils and are locked to the outer peripheral surface of the insulator base; The outer peripheral surface of the insulator base has: a locking surface having a receiving groove for receiving the jumper wire; and a non-locking surface that does not have the receiving groove and to which the jumper wire is not locked; The stator core has an engaging recess that engages with a part of a jig; The engaging recess is formed on the outer peripheral surface of the stator core and is on the radially outer side of the non-locking surface when viewed from one end surface side of the yoke in the axial direction. A method for manufacturing an electric compressor, characterized in that: while the jig engages a part of a portion facing the non-locking surface in the radial direction of the stator core with the engaging recess, positioning in the circumferential direction of the stator is performed. A method for manufacturing an electric compressor.

Images