Insulator, stator, rotating electric machine, and method for manufacturing stator

Abstract

This insulator has, at one end in a circumferential direction (Z) on an outer side (X1) in a radial direction (X), a first coupling portion (41) that couples to another insulator (4), and, at the other end in the circumferential direction (Z) on the outer side (X1) in the radial direction (X), a second coupling portion (42) that couples to the first coupling portion (41) of another insulator (4). The first coupling portion (41) and the second coupling portion (42) are configured with a snap-fit mechanism using elastic deformation. A pair of adjacent insulators (4) in the circumferential direction Z, which are coupled by the first coupling portion (41) and the second coupling portion (42), are formed so as be rotatable to each other around rotation center axes (T3, T4) in an axial direction Y of the first coupling portion (41) and the second coupling portion (42). The rotation center axes (T3, T4) are located on an inner side (X2) in the radial direction (X) relative to an outer circumferential surface (33) of a split core (1) on the outer side (X1) in the radial direction (X).

Description

[Technical Field]

[0001] The present application relates to an insulator, a stator, a rotating electric machine, and a method for manufacturing a stator. [Background technology]

[0002] In a conventional stator for a rotating electric machine, a configuration has been disclosed in which core pieces divided into tooth units are connected together so that they can be freely bent in a direction perpendicular to the axis (see, for example, Patent Documents 1 and 2). Adjacent teeth in the stator are close to each other on the inside in the radial direction, but with this configuration, by changing the angle of the connecting part so that the teeth are positioned on the outer diameter side, winding can be done without interfering with adjacent core pieces, improving the coil space factor. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2000-201458 [Patent Document 2] Japanese Patent Application Laid-Open No. 2006-254569 Summary of the Invention [Problem to be solved by the invention]

[0004] In the conventional technology, for example, in Patent Document 1, two types of laminated steel plates had to be prepared in order to interlock the laminated steel plates of adjacent core pieces at the connecting portion, and punching and crimping were required for the connection, which resulted in problems such as increased costs due to the increased number of components and complicated manufacturing processes.

[0005] Furthermore, for example, in Patent Document 2, a mechanism for inserting and removing in the axial direction is provided for connection and rotation, but when the teeth are facing outward, a holding mechanism or the like must be provided to prevent axial misalignment after connection, which results in complex manufacturing equipment, high costs, and further complicates the manufacturing process.

[0006] The present application discloses technology for solving the above-mentioned problems, and aims to provide an insulator, a stator, a rotating electric machine, and a method for manufacturing a stator that are low-cost and have a simple manufacturing process. [Means for solving the problem]

[0007] The insulator disclosed in the present application comprises: The insulator of a stator of a rotating electric machine includes a plurality of split coil windings arranged in an annular shape, each of the split coil windings having a split core, an insulator disposed on the split core, and a coil wound around the split core via the insulator, a first connecting portion at one end in a circumferential direction on a radially outer side, the first connecting portion being connected to another insulator adjacent in the circumferential direction; a second connecting portion at the other end in the circumferential direction on the radially outer side, the second connecting portion being connected to the first connecting portion of another insulator adjacent in the circumferential direction; the first connecting portion and the second connecting portion are configured by a snap-fit ​​mechanism that uses elastic deformation, a pair of the insulators adjacent to each other in the circumferential direction and connected by the first connecting portion and the second connecting portion are formed to be rotatable with respect to each other about a rotation center axis in the axial direction of the first connecting portion and the second connecting portion, the rotation center axis is located radially inward of the radially outer outer peripheral surface of the split core, The rotational axis of the first connecting portion and the rotational axis of the second connecting portion, one of the rotational axes is located circumferentially inward of a circumferential end surface of the split core, the other rotation center axis is located circumferentially outward of the circumferential end surface of the split core, A gap is formed between circumferentially opposing side surfaces of the pair of insulators connected by the first connecting portion and the second connecting portion so that circumferential end surfaces of the split cores connected by the pair of insulators are in contact with each other in a closed annular shape. the law of nature, The gap is formed in a space between a radially inner circumferential surface and a radially outer circumferential surface of a yoke portion extending in the circumferential direction of the split core. It is something. The stator disclosed in the present application is The stator using the insulator described above, The split core has a yoke portion extending in a circumferential direction and teeth portions protruding radially inward from an inner peripheral surface of the yoke portion on the radially inner side, One circumferential end of the yoke portion is formed in a convex shape, The other circumferential end of the yoke portion is formed into a concave shape, The convex shape and the concave shape have curved surfaces formed with the same radius of curvature. Further, the rotating electric machine disclosed in the present application is The stator described above; The rotor is disposed radially opposite the stator with a gap therebetween. Further, the method for manufacturing a stator disclosed in the present application includes: In the above-described method for manufacturing a stator, After connecting the first connecting portion and the second connecting portion of the circumferentially adjacent split cores on which the multiple insulators forming the stator are installed, a flyer arm is used to wind magnet wire continuously around the teeth portion through the insulators to form the coil. [Effects of the Invention]

[0008] According to the insulator, the stator, the rotating electric machine, and the method for manufacturing the stator disclosed in the present application, An insulator, a stator, a rotating electrical machine, and a method for manufacturing a stator can be obtained that are low cost and have a simple manufacturing process. [Brief explanation of the drawings]

[0009] [Figure 1] 1 is a plan view showing a configuration of a split core according to the first embodiment. FIG. [Figure 2] 2 is a perspective view showing the configuration of an insulator to be installed in the split core shown in FIG. 1. FIG. [Figure 3]FIG. 3 is a plan view showing the configuration of the insulator shown in FIG. 2. [Figure 4] FIG. 3 is a bottom view showing the configuration of the insulator shown in FIG. 2. [Figure 5] 3 is a perspective view showing a configuration in which the insulator shown in FIG. 2 is installed on the split core shown in FIG. 1. FIG. [Figure 6] 6 is a perspective view showing a state in which the insulators of the split cores shown in FIG. 5 are connected in the circumferential direction. FIG. [Figure 7] 7 is a plan view showing a state in which a coil is formed by interposing an insulator between the split cores shown in FIG. 6. FIG. [Figure 8] 7 is a plan view showing a state in which a coil is formed by interposing an insulator between the split cores shown in FIG. 6. FIG. [Figure 9] 6 is a plan view showing a state in which a coil is formed by interposing an insulator between the split cores shown in FIG. 5. FIG. [Figure 10] 10 is a plan view showing a configuration in which the split coil winding bodies formed in FIGS. 7 to 9 are arranged in a ring shape. FIG. [Figure 11] 11 is an enlarged plan view of a portion of the divided coil winding body shown in FIG. 10 arranged in a ring shape. FIG. [Figure 12] 12 is a plan view showing a method for annularly arranging the split coil winding body shown in FIG. 11. FIG. [Figure 13] 11 is a perspective view showing the configuration of a stator in which the annularly arranged split coil winding body shown in FIG. 10 is molded. FIG. [Figure 14] 14 is a cross-sectional view showing the configuration of a rotating electric machine using the stator shown in FIG. 13. [Figure 15] 11 is a cross-sectional view showing the configuration of a rotating electric machine using the annularly arranged split coil winding body shown in FIG. [Figure 16] 15 is a flowchart illustrating a method of forming the stator shown in FIG. 13 or FIG. 14. [Figure 17] 15 is a flowchart illustrating another method of forming the stator shown in FIG. 13 or FIG. 14. [Figure 18] 15A to 15C are diagrams illustrating another method for forming the stator shown in FIG. 13 or FIG. 14. [Figure 19] FIG. 10 is a plan view showing the configuration of a split core according to a second embodiment. [Figure 20] 20 is a perspective view showing the configuration of an insulator to be installed on the split core shown in FIG. 19. FIG. [Figure 21] 21 is a perspective view showing a configuration in which the insulator shown in FIG. 20 is installed on the split core shown in FIG. 19. FIG. [Figure 22] 22 is a perspective view showing a state in which the insulators of the split cores shown in FIG. 21 are connected in the circumferential direction. FIG. [Figure 23] 22 is a plan view showing a state in which a coil is formed by interposing an insulator between the split cores shown in FIG. 21. FIG. [Figure 24] 22 is a plan view showing a state in which a coil is formed by interposing an insulator between the split cores shown in FIG. 21. FIG. [Figure 25] 22 is a plan view showing a state in which a coil is formed by interposing an insulator between the split cores shown in FIG. 21. FIG. [Figure 26] FIG. 26 is a plan view showing a configuration in which the split coil winding bodies formed in FIGS. 23 to 25 are arranged in a ring shape. [Figure 27] 27 is an enlarged plan view of a portion of the divided coil winding body shown in FIG. 26 arranged in a ring shape. FIG. [Figure 28] FIG. 11 is a perspective view showing the configuration of an insulator to be installed in a split core according to a third embodiment. [Figure 29] FIG. 11 is a perspective view showing a state in which the split coil wound bodies according to the third embodiment are connected in the circumferential direction. [Figure 30] FIG. 11 is a perspective view showing a state in which the split coil wound bodies according to the third embodiment are connected in the circumferential direction. [Figure 31] FIG. 11 is a perspective view showing the configuration of another insulator to be installed in the split core according to the third embodiment. [Figure 32] FIG. 11 is a perspective view showing a state in which other split coil wound bodies according to the third embodiment are connected in the circumferential direction. [Figure 33] FIG. 11 is a perspective view showing a state in which other split coil wound bodies according to the third embodiment are connected in the circumferential direction. [Figure 34] FIG. 10 is a plan view showing a state in which adjacent split cores of a comparative example are arranged; DETAILED DESCRIPTION OF THE INVENTION

[0010] Embodiment 1 In the following description, the directions in the rotating electric machine 100 are referred to as the axial direction Y, the circumferential direction Z, and the radial direction X. The axial direction Y is the direction parallel to the shaft 13 (output shaft) of the rotating electric machine 100, the circumferential direction Z is the rotation direction of the rotating electric machine 100, and the radial direction X is the radial direction of the rotating electric machine 100. In addition, the radial direction X will be described as the outside X1 and the inside X2 of the radial direction X. Therefore, other parts constituting the rotating electric machine 100 will also be described based on these directions. In other embodiments, the directions will also be similarly indicated and described.

[0011] Fig. 1 is a plan view showing the configuration of a split core according to embodiment 1. Fig. 2 is a perspective view showing the configuration of an insulator to be installed in the split core shown in Fig. 1. Fig. 3 is a plan view showing the configuration of the insulator shown in Fig. 2. Fig. 4 is a bottom view showing the configuration of the insulator shown in Fig. 2. Fig. 5 is a perspective view showing a configuration in which the insulator shown in Fig. 2 is installed in the split core shown in Fig. 1. Fig. 6 is a perspective view showing a state in which the insulators of the split core shown in Fig. 5 are connected in the circumferential direction.

[0012] FIG. 7 is a plan view showing a state in which a coil is formed via the insulator of the split core shown in FIG. 6. FIG. 8 is a plan view showing a state in which a coil is formed via the insulator of the split core shown in FIG. 6. FIG. 9 is a plan view showing a state in which a coil is formed via the insulator of the split core shown in FIG. 5. FIG. 10 is a plan view showing a configuration in which the split coil winding bodies formed in FIGS. 7 to 9 are arranged in an annular shape. In this application, an annular shape refers to an example in which the split coil winding bodies are formed in a circular shape. FIG. 11 is an enlarged plan view of a portion of the annularly arranged split coil winding bodies shown in FIG. 10. FIG. 12 is a plan view showing a method of annularly arranging the split coil winding bodies shown in FIG. 11.

[0013] FIG. 13 is a perspective view showing the configuration of a stator molded with the annularly arranged split coil winding body shown in FIG. 10. FIG. 14 is a cross-sectional view showing the configuration of a rotating electric machine using the stator shown in FIG. 13. FIG. 15 is a cross-sectional view showing the configuration of a rotating electric machine using the annularly arranged split coil winding body shown in FIG. 10. FIG. 16 is a flowchart showing a method of forming the stator shown in FIG. 13 or 14. FIG. 17 is a flowchart showing another method of forming the stator shown in FIG. 13 or 14. FIG. 18 is a diagram showing another method of forming the stator shown in FIG. 13 or 14. FIG. 34 is a plan view showing the state of adjacent split cores of a comparative example.

[0014] First, the configuration of the split core 1 will be described using Fig. 1. Fig. 1 is a plan view showing the configuration of the split core 1. In the figure, the split core 1 is formed by dividing an annular stator 12 of an inner rotor type rotating electrical machine 100 (see Fig. 14) in the circumferential direction Z by the number of slots. The split core 1 has a yoke portion 3 extending in the circumferential direction Z and teeth portions 2 protruding from the inner peripheral surface of the yoke portion 3 on the inner side X2 in the radial direction X toward the inner side X2 in the radial direction X.

[0015] A first abutment portion 31 is formed at one end in the circumferential direction Z of the yoke portion 3 of the split core 1 as a circumferential end surface that abuts against another split core 1 adjacent on one side in the circumferential direction Z. Furthermore, a second abutment portion 32 is formed at the other end in the circumferential direction Z of the yoke portion 3 of the split core 1 as a circumferential end surface that abuts against another split core 1 adjacent on the other side in the circumferential direction Z. The first abutment portion 31 and the second abutment portion 32 are formed in a surface shape that combines a curved surface and a flat surface. The first abutment portion 31 is formed in a convex shape that protrudes in the circumferential direction Z. The second contact portion 32 is formed in a concave shape recessed in the circumferential direction Z.

[0016] The curved surface portions of the first abutting portion 31 and the second abutting portion 32 are formed with a radius of curvature R. The central axis in the axial direction Y of the radius of curvature R of the first abutting portion 31 is a first central axis T1, and the central axis in the axial direction Y of the radius of curvature R of the second abutting portion 32 is a second central axis T2. The first central axis T1 is formed on a first imaginary plane A1 extending in the axial direction Y at the center in the circumferential direction Z of a pair of split cores 1 adjacent in the circumferential direction Z, and the second central axis T2 is formed on a second imaginary plane A2.

[0017] When multiple split cores 1 are combined in an annular shape, the first central axis T1 of one split core 1 adjacent to the other split core 1 in the circumferential direction Z coincides with the second central axis T2 of the other split core 1. When the annular stator 12 is assembled, the first abutment portion 31 of one split core 1 is formed in a shape that is aligned with the second abutment portion 32 of another split core 1 adjacent to the other split core 1 in the circumferential direction Z.

[0018] The first central axis T1 and the second central axis T2 are formed at a position X2 inward in the radial direction X from the outer peripheral surface 33 of the split core 1 in the radial direction X. This ensures the thickness of the molded resin portion 6 (see FIGS. 13 and 14) described below, or prevents interference with the shrink-fit frame 16 (see FIG. 15). The split cores 1 do not have means for joining or holding each other individually. As the split core 1 has such a simple shape, only one type of mold for the split core 1 is required, making manufacturing easy and low-cost.

[0019] Next, the configuration of the insulator 4 will be described with reference to Figs. 2 to 4. Fig. 2 is a perspective view showing the configuration of the insulator 4. Fig. 3 is a plan view showing the configuration of the insulator 4 of Fig. 2 as viewed from the top of the paper. Fig. 4 is a plan view showing the configuration of the insulator 4 of Fig. 2 as viewed from the back of the paper. In the figures, the insulator 4 is formed in a shape that follows the teeth portion 2 of the split core 1, so that it is fitted into and assembled to the split core 1 to insulate the split core 1 from the coil 7 (see Fig. 7) that will be wound thereon in a subsequent process. The insulator 4 also has a winding portion 45 around which the coil 7 is wound.

[0020] The insulator 4 is made of an insulating material with a low elastic modulus, such as resin. A columnar portion 41 is formed as a first connecting portion at one end in the circumferential direction Z on the outer side X1 in the radial direction X of the insulator 4. Furthermore, an opening 42 is formed as a second connecting portion at the other end in the circumferential direction Z on the outer side X1 in the radial direction X, the opening 42 connecting to the columnar portion 41 as a first connecting portion of another insulator 4 adjacent in the circumferential direction Z. The columnar portion 41 and the opening 42 are formed by a snap-fit ​​mechanism that uses elastic deformation. The columnar portion 41 and the opening 42 are formed with dimensions such that the maximum strain when engaged by the snap-fit ​​mechanism does not exceed the fracture strain.

[0021] The columnar portion 41 and the opening 42 are rotatable in an engaged state, with the columnar portion 41 having a first rotational axis T3 and the opening 42 having a second rotational axis T4, as shown in FIG. 2. The first rotational axis T3 is set to coincide with the first central axis T1 of the split core 1 shown in FIG. 1, and the second rotational axis T4 is set to coincide with the second central axis T2 of the split core 1 shown in FIG. 1. The columnar portion 41 has a claw-shaped first folded portion 43 formed on its base portion. The opening 42 has a second folded portion 44 formed on its base portion, as shown in FIG. 4. The first folded portion 43 and the second folded portion 44 hook together when the split cores 1 are assembled in an annular shape, improving the holding strength of the assembled annular shape.

[0022] Next, the assembled configuration of the insulators 4 and the split core 1 will be described. Fig. 5 is a perspective view showing the insulators 4 assembled to both ends of the split core 1 in the axial direction Y. As shown in the figure, when the insulators 4 are assembled to the split core 1, the first rotational center axis T3 of the columnar portions 41 of the insulators 4 at both ends in the axial direction Y is coaxial with the first center axis T1 of the split core 1, and the second rotational center axis T4 of the openings 42 is coaxial with the second center axis T2. Therefore, the rotational centers T3 and T4 are located on the inner side X2 in the radial direction X of the split core 1 relative to the outer peripheral surface 33 on the outer side X1 in the radial direction X.

[0023] The first rotation axis T3 is located inside in the circumferential direction Z of the circumferential end face (first abutment portion 31) of the split core 1 (closer to the center of the teeth portion 2 in the circumferential direction Z, at a position overlapping with the split core 1 when viewed from the axial direction Y). The second rotation axis T4 is located outside in the circumferential direction Z of the circumferential end face (second abutment portion 32) of the split core 1. The circumferential end face (first abutment portion 31) of the split core 1 on the first rotation axis T3 side is formed as an arcuate surface centered on the first rotation axis T3 from the first rotation axis T3 to the outer side X1 in the radial direction X, i.e., the outer peripheral surface 33 of the split core 1. The circumferential end face (second abutment portion 32) of the split core 1 on the second rotation axis T4 side is formed as an arcuate surface recessed along the arcuate surface. As a result, when the split cores 1 are arranged in a circular ring shape, the circumferential end faces of the split cores 1 (the first abutment portion 31 and the second abutment portion 32) on the outer side X1 in the radial direction X from each rotation center axis T3, T4 can contact each other without any gaps, thereby ensuring a magnetic path and suppressing the occurrence of magnetic saturation.

[0024] If the rotational axis B is not located sufficiently inside the circumferential end face of the split core, as shown in the state of adjacent split cores in the comparative example in Figure 34, a gap C will be created when the split cores are arranged in a ring, and the split core radially outside the rotational axis B will need to be thinned, which will impair the path of the magnetic flux (magnetic circuit).

[0025] In the first embodiment, the insulator 4 at the upper side in the axial direction Y on the paper has the shape shown in Figures 2 to 4, and the insulators 4 at the upper side in the axial direction Y on the paper have shapes that are mirror-symmetrical to the insulator 4 at the upper side in the axial direction Y on the paper. Note that this is just an example, and it is also possible to form the insulators 4 at both ends in the axial direction Y in the same shape.

[0026] Next, a configuration in which two split cores 1 each having an insulator 4 assembled thereto as shown in Fig. 5 are arranged in the circumferential direction Z will be described with reference to Fig. 6. As shown in the figure, two split cores 1 each having an insulator 4 assembled thereto are arranged in the circumferential direction Z, and the columnar portion 41 of one insulator 4 is fitted into the opening 42 of the other insulator 4 using a snap-fit ​​mechanism to connect them. By inserting the columnar portion 41 into the opening 42 from the direction of arrow G, which is perpendicular to the first central axis T1, the opening 42 is elastically deformed by the snap-fit ​​mechanism, and the columnar portion 41 and the opening 42 of the insulator 4 engage with each other at positions coaxial with the first central axis of rotation T3 and the second central axis of rotation T4.

[0027] Due to this engagement, the split core 1 adjacent to the other split core 1 in the circumferential direction Z is rotatable around the first rotational axis T3 in the opening direction F1 and closing direction F2 of the teeth portion 2 (directions forming a ring as shown in FIG. 10 ) relative to the other split core 1. Furthermore, the first abutment portion 31 and the second abutment portion 32 provided at both ends of the split core 1 in the circumferential direction Z have curved surfaces with the same radius of curvature R centered on the first central axis T1 and the second central axis T2 that are coaxial with the first rotational axis T3 and the second rotational axis T4. Therefore, the split core 1 does not interfere with the rotation of the insulator 4.

[0028] Next, a method for winding magnet wire 71 around split cores 1 connected in circumferential direction Z as shown in Fig. 6 to form coil 7 will be described with reference to Fig. 7. Fig. 7 shows a state in which split core 1 is rotated around first rotation central axis T3 in opening direction F1 shown in Fig. 6. Then, outer peripheral surface 33 of split core 1 is held by chuck portion 51. Next, magnet wire 71 is supplied via nozzle 52 from flyer arm 53 located opposite teeth portion 2 of split core 1 around which magnet wire 71 is wound, and flyer arm 53 is rotated around rotation axis Q to wind magnet wire 71 around teeth portion 2 of split core 1 via insulator 4 to form coil 7, thereby forming split coil wound body 101 connected in circumferential direction Z.

[0029] At this time, the teeth 2 of the split core 1 adjacent in the circumferential direction Z that are not being wound must be retracted outside the range of the rotation trajectory of the flyer arm 53. As shown in Fig. 7, the teeth 2 of the split core 1 adjacent in the circumferential direction Z are retracted to the outside of the insulator 4 of the tooth 2 that is being wound. This allows the flyer arm 53 to swing to the left (all the way to the back) of the tooth 2 in the swing direction W, as seen in the drawing, and the coil 7 can be stored efficiently in the winding space. This allows the stator 12 to be made smaller.

[0030] For the purpose of explanation, Figure 7 shows three split cores 1: one split core 1 being wound and two split cores 1 adjacent to each other on both sides in the circumferential direction Z. However, depending on the manufacturing method, only one split core 1 or only two split cores 1 may be held by the chuck portion 51, or multiple split cores 1 may be connected in series to these three split cores 1 and supplied.

[0031] A method for forming the coil 7 that is different from the method for forming the coil 7 shown in Fig. 7 above will be described with reference to Fig. 8. Fig. 8 shows a method for forming the coil 7 by winding a magnet wire 71 around the split cores 1 connected in the circumferential direction Z as shown in Fig. 6. The split cores 1 connected in the circumferential direction Z are arranged in a straight line as shown in Fig. 8, and the outer peripheral surface 33 of the split core 1 is held by a chuck portion 51. A magnet wire 71 is supplied in a direction approximately perpendicular to the teeth portions 2 of the split core 1 from a nozzle 52 that faces the teeth portions 2 of the split core 1 and revolves around the rotation axis Q while drawing a rectangular or elliptical locus. The magnet wire 71 is supplied and wound by the nozzle 52 that swings in the swinging direction W to form the coil 7, thereby forming a split coil winding body 101 that is connected in the circumferential direction Z.

[0032] This figure shows magnet wire 71 being wound around three split cores 1 connected in the circumferential direction Z, but the number of split cores 1 held by the chuck portion 51 may be two or four or more, and the number of split cores 1 (= number of nozzles 52) around which magnet wire 71 is wound at the same time may be one to two, or four or more.

[0033] 7 and 8, a method for forming the coil 7 that is different from the method for forming the coil 7 shown in Fig. 5 will be described with reference to Fig. 9. Fig. 9 shows a method for forming the coil 7 by winding a magnet wire 71 around the split cores 1 before they are connected in the circumferential direction Z, as shown in Fig. 5. As shown in Fig. 9, the outer peripheral surface 33 of a single split core 1 is held by a chuck portion 51. Then, the chuck portion 51 rotates the split core 1 about the rotation axis Q, and the magnet wire 71 is supplied and wound by a nozzle 52 that swings in the swing direction W, forming the coil 7 and forming a split coil wound body 101 that is not connected in the circumferential direction Z.

[0034] Next, the configuration in which the split coil winding body 101 is assembled into a ring shape will be described using Figures 10 to 12. Figure 10 shows an example of 12 slots, but this is not limited to this and assembly can be performed in the same way with other numbers of slots, such as 9 slots. Figure 11 is an enlarged view of one location on the first rotation center axis T3 in Figure 10. Figure 12 shows the same part as Figure 11 in a state rotated in the direction in which the teeth portion 2 opens.

[0035] As described above, as shown in Figure 11, each central axis T1, T2 and each rotation central axis T3, T4 are located on each imaginary plane A1, A2 with the split core 1 adjacent to it in the circumferential direction Z, and the first abutment portion 31 and the second abutment portion 32 provided at both ends of the split core 1 in the circumferential direction Z have curved surfaces having the same radius of curvature R centered on the first central axis T1 and the second central axis T2 that are coaxial with the first rotation central axis T3 and the second rotation central axis T4.Therefore, the split coil winding body 101 on which the coil 7 is formed rotates around the first rotation central axis T3, and the split coil winding bodies 101 adjacent to each other in the circumferential direction Z come into close contact with each other at the first abutment portion 31 and the second abutment portion 32 in the circumferential direction Z. Furthermore, a convex first abutment portion 31 and a concave second abutment portion 32 that conforms to the first abutment portion 31 are formed at both ends of the yoke portion 3 of the split core 1 in the circumferential direction Z, thereby ensuring sufficient cross-sectional area for the magnetic flux path and enabling the stator 12 to be made smaller.

[0036] 11, the first bent portion 43 formed by the snap fit mechanism elastically deforms in the direction in which the teeth 2 close, allowing the second bent portion 44 to pass through, but once the teeth 2 are closed, the first bent portion 43 gets caught and prevents the teeth 2 from opening easily. In this figure, the first bent portion 43 side is configured to be easily elastically deformed, but it is also possible to configure the second bent portion 44 rather than the first bent portion 43 to be easily elastically deformed, or to configure both the first bent portion 43 and the second bent portion 44 to be easily elastically deformed.

[0037] Next, we will explain the configuration in which the stator 12 is formed by molding the split coil winding body 101 assembled into a ring shape. FIG. 13 is a diagram showing a configuration in which the split coil winding body 101 assembled into a ring shape as shown in FIG. 10 is molded with resin. In the figure, the split coil winding body 101 is held in place by the molded resin portion 6, so the connecting force of the columnar portion 41 and openings 42 of the insulator 4 is sufficient to withstand transportation to the molding process. The molding pressure of the resin aligns the split coil winding body 101 (the outer peripheral surface 33 of the split core 1) with the mold, ensuring the accuracy of the inner diameter of the stator 12. The columnar portion 41 and openings 42 (the first connecting portion and the second connecting portion) of the insulator 4 are located inward X2 in the radial direction X from the outer peripheral surface 33 of the split core 1, ensuring the thickness of the molded resin portion 6 and allowing the resin to flow easily during molding.

[0038] Next, the configuration of a rotating electric machine 100 using a molded stator 12 will be described with reference to Fig. 14. Rotating electric machine 100 is configured by installing rotor 11, in which shaft 13 is installed via bearing 15, within bracket 14, and stator 12, in which molded resin part 6 is formed on the outer periphery of rotor 11 with a gap therebetween.

[0039] 15 illustrates the configuration of a rotating electric machine 100 using a non-molded split coil winding body 101 assembled into an annular shape as shown in FIG. 10. The split coil winding body 101 assembled into an annular shape is press-fitted or shrink-fitted into a cylindrical frame 16 to form a stator 12. Since the columnar portion 41 and openings 42 (first and second connecting portions) of the insulator 4 are located inside the outer peripheral surface 33 of the split core 1 in the radial direction X2, the split coil winding body 101 can be press-fitted or shrink-fitted into the simple cylindrical frame 16, allowing for a simple assembly method. The preload created by the interference of the press-fitting or shrink-fitting allows the split coil winding bodies 101 to abut evenly against each other, ensuring the roundness of the inner diameter. The remaining configuration is formed in the same manner as in FIG. 14.

[0040] Next, a method for manufacturing the stator of the first embodiment configured as described above will be described. First, a case where the method for forming the coil 7 as shown in FIG. 7 or 8 is used will be described with reference to the flowchart in FIG. 16. First, the insulator 4 is assembled to the split core 1 as shown in FIG. 5 to perform the insulation process (step ST1 in FIG. 16). Next, the columnar portions 41 of the insulator 4 of the split core 1 are engaged with the openings 42 (first and second connecting portions) of the split core 1 adjacent to each other in the circumferential direction Z using a snap-fit ​​mechanism to perform the connecting process (step ST2 in FIG. 16).

[0041] Next, as shown in FIG. 7 or 8, a winding process is performed in which magnet wire 71 is wound around split core 1 via insulator 4 to form coil 7 and split coil winding body 101 (step ST3 in FIG. 16). Next, the split coil winding bodies 101 connected in the circumferential direction Z are assembled into an annular shape as shown in FIG. 10 (step ST4 in FIG. 16). Next, a molded resin portion 6 as shown in FIG. 13 is formed on the annular split coil winding body 101 to form stator 12 (step ST5 in FIG. 16). Alternatively, a frame 16 as shown in FIG. 15 is shrink-fitted onto the annular split coil winding body 101 as shown in FIG. 10 to form stator 12 (step ST6 in FIG. 16).

[0042] Next, a case where a method of forming the coil 7 as shown in Fig. 9 is used will be described with reference to the flowchart in Fig. 17. First, an insulation process is performed by assembling the insulator 4 to the split core 1 as shown in Fig. 5 (step ST11 in Fig. 17). Next, a winding process is performed in which a magnet wire 71 is wound around a single split core 1 via the insulator 4 to form the coil 7 and form the split coil winding body 101 as shown in Fig. 9 (step ST12 in Fig. 17). Next, a connection process is performed in which the columnar portion 41 of the insulator 4 of the split coil winding body 101 and the openings 42 (first connecting portion and second connecting portion) of the insulator 4 of the split coil winding body 101 adjacent to each other in the circumferential direction Z are engaged with a snap-fit ​​mechanism (step ST13 in Fig. 17).

[0043] Next, the split coil winding bodies 101 connected in the circumferential direction Z are assembled into an annular shape as shown in Fig. 10 (step ST14 in Fig. 17). Next, a molded resin portion 6 as shown in Fig. 13 is formed on the annular split coil winding body 101 to form the stator 12 (step ST15 in Fig. 17). Alternatively, a frame 16 as shown in Fig. 15 is shrink-fitted onto the annular split coil winding body 101 as shown in Fig. 10 to form the stator 12 (step ST16 in Fig. 17).

[0044] When the method of forming the coil 7 shown in Figures 7 and 8 is used, the process flow shown in Figure 16 is obtained, which increases production efficiency. In contrast, when the method of forming the coil 7 shown in Figure 9 is used, it is possible to secure space in the production line and simplify the winding device, and production can be performed using the process flow shown in Figure 17.

[0045] Next, a method for winding magnet wire 71 to form coil 7 more efficiently will be described with reference to FIG. 18. FIG. 18 shows an example of three-phase winding on stator 12 having 12 slots. First, split cores 1 for more than one stator 12 are connected by columnar portions 41 and openings 42 (first connecting portions and second connecting portions) of insulator 4, and the split cores 1 are fed into winding operation unit 58 from feeding portion 59. Then, magnet wire 71 is continuously wound by flyer arm 53. Magnet wire 71 is taken out from wire bobbin 56 in which magnet wire 71 is stored, and is supplied to nozzle 52 of flyer arm 53 after any winding kinks are removed by tensioner 57.

[0046] Flyer arms 53 are arranged in the same number as the number of phases of stator 12, three in this case, and winding operation unit 58 including flyer arms 53 only performs winding of coil 7, wiring of crossover wires between coils 7, and ON / OFF operation of chuck unit 51 of split core 1 around which magnet wire 71 is wound. Since cutting of magnet wire 71 is performed by discharge unit 55, cutting of magnet wire 71 can be performed outside the cycle time of winding operation unit 58, thereby maximizing the operating rate of the winding device. Note that the method of forming coil 7 using the winding device shown in FIG. 18 can be performed in the same way in the following embodiments, and therefore description thereof will be omitted.

[0047] According to the insulator of the first embodiment configured as described above, The insulator of a stator of a rotating electric machine includes a plurality of split coil windings arranged in an annular shape, each of the split coil windings having a split core, an insulator disposed on the split core, and a coil wound around the split core via the insulator, a first connecting portion at one end in a circumferential direction on a radially outer side, the first connecting portion being connected to another insulator adjacent in the circumferential direction; a second connecting portion at the other end in the circumferential direction on the radially outer side, the second connecting portion being connected to the first connecting portion of another insulator adjacent in the circumferential direction; the first connecting portion and the second connecting portion are configured by a snap-fit ​​mechanism that uses elastic deformation, a pair of the insulators adjacent to each other in the circumferential direction and connected by the first connecting portion and the second connecting portion are formed to be rotatable with respect to each other about a rotation center axis in the axial direction of the first connecting portion and the second connecting portion, The rotation center axis is located radially inward of the outer peripheral surface of the split core in the radial direction, Furthermore, according to the stator of the first embodiment configured as described above, The split core has a yoke portion extending in a circumferential direction and teeth portions protruding radially inward from an inner peripheral surface of the yoke portion on the radially inner side, One circumferential end of the yoke portion is formed in a convex shape, The other circumferential end of the yoke portion is formed into a concave shape, The convex shape and the concave shape have curved surfaces formed with the same radius of curvature, Furthermore, according to the rotating electric machine of the first embodiment configured as described above, The rotor is disposed radially opposite the stator with a gap therebetween, Since the coil can be formed simply by connecting the first connecting portion and the second connecting portion, the manufacturing process is simple and inexpensive.

[0048] Furthermore, according to the insulator of the first embodiment configured as described above, the first connecting portion is formed by a columnar portion having a columnar shape, The second connecting portion is formed with an opening having a columnar surface that engages with the columnar portion, which makes it easy to connect the first connecting portion and the second connecting portion.

[0049] Furthermore, according to the insulator of the first embodiment configured as described above, The rotation center axis is formed on a virtual plane extending in the axial direction at the circumferential center of the pair of split cores adjacent in the circumferential direction. This makes it easier to connect the first connecting portion and the second connecting portion.

[0050] Furthermore, according to the insulator of the first embodiment configured as described above, The first connecting portion has a first return portion that engages with the second connecting portion when the split coil winding body is arranged in a circular shape, The second connecting portion includes a second return portion that engages with the first connecting portion when the split coil winding body is arranged in a circular shape. The engagement between the first and second return portions ensures that the annular shape of the split coil winding body is maintained.

[0051] Furthermore, according to the stator of the first embodiment configured as described above, The centers of curvature of the convex shape and the concave shape in a cross section perpendicular to the axial direction of the yoke portion coincide with the central rotation axes of the first connecting portion and the second connecting portion, The divided cores and the insulators adjacent in the circumferential direction are able to rotate smoothly about the central axis of rotation.

[0052] Furthermore, according to the stator of the first embodiment configured as described above, The molded resin portion covering the split coil winding body is provided, The roundness of the stator can be improved.

[0053] Furthermore, according to the stator of the first embodiment configured as described above, The frame applies a preload radially inward to the outer peripheral surface of the annularly arranged split coil winding body. The roundness of the stator can be improved.

[0054] Furthermore, according to the rotating electric machine of the first embodiment configured as described above, After connecting the first connecting portions and the second connecting portions of the divided cores adjacent in the circumferential direction on which the plurality of insulators forming the stator are installed, the coil is formed by winding a magnet wire continuously around the teeth via the insulators using a flyer arm. Magnet wire can be efficiently wound around multiple split cores via insulators.

[0055] Furthermore, according to the rotating electric machine of the first embodiment configured as described above, The rotational axis of the first connecting portion and the rotational axis of the second connecting portion, one of the rotational axes is located circumferentially inward of a circumferential end surface of the split core, The other rotational center axis is located circumferentially outward of the circumferential end surface of the split core, The circumferential end faces of the divided cores radially outward from the central rotation axis can be in contact with each other without any gaps, ensuring a magnetic path and suppressing the occurrence of magnetic saturation.

[0056] Embodiment 2 FIG. 19 is a plan view showing the configuration of a split core according to embodiment 2. FIG. 20 is a perspective view showing the configuration of an insulator installed in the split core shown in FIG. 19. FIG. 21 is a perspective view showing a configuration in which the insulator shown in FIG. 20 is installed in the split core shown in FIG. 19. FIG. 22 is a plan view showing the configuration of a split coil winding body connected in the circumferential direction according to embodiment 2. FIGS. 23 to 25 are diagrams showing a method for manufacturing the split coil winding body shown in FIG. 22. FIG. 26 is a diagram showing a configuration in which the split coil winding body shown in FIGS. 23 to 25 is formed into an annular shape. FIG. 27 is an enlarged view showing a portion of the split coil winding body formed into an annular shape shown in FIG. 26.

[0057] In the figures, the same parts as those in the first embodiment are denoted by the same reference numerals, and the description thereof will be omitted. The difference between the second embodiment and the first embodiment is the positions of the first central axis T1, the second central axis T2, the first rotation central axis T3, and the second rotation central axis T4. As the other parts are the same as those in the first embodiment, the following description will mainly focus on the parts that differ from the first embodiment.

[0058] 19 , the first and second contact portions 31 and 32 provided at both ends of the split core 1 in the circumferential direction Z have curved surfaces that are formed away in the circumferential direction Z from the respective imaginary surfaces A1 and A2 of the split core 1 adjacent in the circumferential direction Z, and have the same radius of curvature R1 centered on the first and second central axes T11 and T21 that are coaxial with the first and second rotation central axes T31 and T41. By shifting the first central axis T11 in the circumferential direction Z from the first central axis T1 of the first embodiment, the sharp corners on the outer periphery of the concave-convex shape of the first and second contact portions 31 and 32 are softened, thereby reducing wear on the mold used to manufacture the split core 1.

[0059] Furthermore, the width H2 of the yoke portion 3 of the split core 1 in the circumferential direction Z can be made smaller than the width H1 (see FIG. 1) in the first embodiment. Therefore, when manufacturing the split core 1 by punching and laminating steel plates, less material is used, resulting in lower costs. Furthermore, when punching, the overall circumferential length of the split core 1 can be made shorter than in the first embodiment, reducing the punching load and resulting in lower costs.

[0060] As shown in Fig. 20, the insulator 4 of the second embodiment is formed so that the first rotation center axis T31 of the columnar portion 41 and the second rotation center axis T41 of the opening 42 are coaxial with the first center axis T11 or the second center axis T21, and is therefore formed to be shifted from the imaginary planes A1 and A2 compared to Fig. 2 of the first embodiment. Note that although shapes corresponding to the first folded portion 43 and the second folded portion 44 of the first embodiment are omitted, similar shapes can be added.

[0061] Then, as shown in Fig. 21, the insulator 4 is attached to the split core 1. Then, as shown in Fig. 22, the columnar portion 41 and the opening 42 of the insulator 4 of the split core 1 are connected and rotated around the first central axis T11 in the direction in which the teeth 2 open. In this way, by appropriately designing the shapes of the first abutment portion 31 and the second abutment portion 32 at both ends in the circumferential direction Z of the yoke portion 3 of the split core 1, the split core 1 can be retracted to a position where it does not interfere with the flyer arm 53 and the nozzle 52, as shown in Fig. 23.

[0062] As shown in FIG. 24, by holding the split core 1 with a chuck portion 511 having a seating surface with a step in the radial direction X, it is possible to wind the magnet wire 71 similar to that shown in FIG. 8 of the first embodiment. As shown in FIG. 25, it is also possible to form the coil 7 by winding the magnet wire 71 before connecting the columnar portions 41 and the openings 42 of the insulators 4 of the split core 1.

[0063] The split coil wound body 101 configured in this manner can be assembled into a ring shape in the same manner as in the first embodiment, as shown in FIGS.

[0064] According to the insulator, stator, rotating electric machine, and method of manufacturing a stator of the second embodiment configured as described above, the same effects as those of the first embodiment can be achieved, and in addition, The rotation center axis is formed so as to be spaced apart in the circumferential direction from an imaginary plane extending in the axial direction at the circumferential center of the pair of divided cores adjacent in the circumferential direction. The size of the split core can be reduced, further reducing costs.

[0065] Embodiment 3 In each of the above-described embodiments, the shape of the columnar portion 41 is cylindrical and the shape of the opening 42 is a shape having a cylindrical surface, but this is not limited to this. In the third embodiment, the columnar portion 411 or 412 of the insulator 4 is formed in a polygonal columnar shape or a cylindrical shape with irregularities. Therefore, the inner surface of the opening 421 or 422 that fits the columnar portion 411 or 412 is formed in a polygonal columnar surface or a cylindrical surface with irregularities. The other configurations are the same as those in the above-described embodiments, and therefore description thereof will be omitted as appropriate.

[0066] 28 to 30 are views showing a case where the columnar portion 411 of the insulator 4 is formed in a polygonal columnar shape, here a hexagonal columnar shape, and the inner surface of the opening 422 along the columnar portion 411 is formed in a polygonal columnar surface, here a hexagonal columnar surface. FIG. 28 is a perspective view showing the configuration of the insulator 4. FIGS. 29 and 30 are perspective views showing the configuration of the split coil winding body 101 in which the columnar portion 411 and the opening 421 of the insulator 4 are connected. FIG. 29 is a view showing the state when the coil 7 of the split coil winding body 101 is formed, and FIG. 30 is a view showing the state when the coil 7 of the split coil winding body 101 is formed and then formed into a ring shape. Note that the hexagonal shape is just an example, and other polygonal columnar shapes can be similarly configured and performed in the same manner.

[0067] 31 to 33 are diagrams illustrating a case in which the columnar portion 412 of the insulator 4 is formed in a cylindrical shape with two protrusions, and the inner surface of the opening 422 along the columnar portion 412 is formed as a cylindrical surface with two recesses. FIG. 31 is a perspective view showing the configuration of the insulator 4. FIGS. 32 and 33 are perspective views showing the configuration of the split coil winding body 101 in which the columnar portion 412 and the opening 422 of the insulator 4 are connected. FIG. 32 is a diagram showing the state when the coil 7 of the split coil winding body 101 is formed, and FIG. 33 is a diagram showing the state when the coil 7 of the split coil winding body 101 is formed and then formed into a ring shape. Note that two protrusions and recesses are just an example, and other numbers of protrusions and recesses can be configured in the same way and can be similarly performed.

[0068] This shape generates resistance due to the polygonal columns or unevenness when the insulator 4 and split core 1 are rotated around the first rotational center axis T3 (second rotational center axis T4). The dimensions are designed so that when rotated with a force exceeding the resistance, the maximum strain generated in the columnar portions 411, 412 and openings 421, 422 does not exceed the fracture strain of the material of the insulator 4. This allows rotation around the first central axis T1 by elastically deforming the insulator 4 with a force greater than the rotational resistance, and the rotation is intermittently stopped by the polygonal columns or unevenness. Because the rotation can be stopped intermittently, the posture of the split coil winding body 101 is stable during transportation between processes and when assembled into a ring.

[0069] According to the insulator, stator, rotating electric machine, and method of manufacturing a stator of the third embodiment configured as described above, the same effects as those of the above embodiments can be achieved, and The columnar portion of the connecting portion is formed in a polygonal columnar shape or a columnar shape with concaves and convexes added thereto. Since the connection between the columnar portion of the insulator and the opening can intermittently prevent rotation, the position of the split coil winding body is stable during transportation and when assembled into a ring, simplifying the manufacturing process.

[0070] Although the present application describes various exemplary embodiments and examples, the various features, aspects, and functions described in one or more embodiments are not limited to application to a particular embodiment, but may be applied to the embodiments alone or in various combinations. Therefore, countless variations not illustrated are conceivable within the scope of the technology disclosed in this application, including, for example, cases where at least one component is modified, added, or omitted, and cases where at least one component is extracted and combined with a component of another embodiment.

[0071] Various aspects of the present disclosure are summarized below as appendices.

[0072] (Appendix 1) The insulator of a stator of a rotating electric machine includes a plurality of split coil windings arranged in an annular shape, each of the split coil windings having a split core, an insulator disposed on the split core, and a coil wound around the split core via the insulator, a first connecting portion at one end in a circumferential direction on a radially outer side, the first connecting portion being connected to another insulator adjacent in the circumferential direction; a second connecting portion at the other end in the circumferential direction on the radially outer side, the second connecting portion being connected to the first connecting portion of another insulator adjacent in the circumferential direction; the first connecting portion and the second connecting portion are configured by a snap-fit ​​mechanism that uses elastic deformation, a pair of the insulators adjacent to each other in the circumferential direction and connected by the first connecting portion and the second connecting portion are formed to be rotatable with respect to each other about a rotation center axis in the axial direction of the first connecting portion and the second connecting portion, The insulator has a rotational center axis located radially inward of the radially outer outer peripheral surface of the split core. (Appendix 2) the first connecting portion is formed by a columnar portion having a columnar shape, 2. The insulator according to claim 1, wherein the second connecting portion is formed as an opening having a columnar surface that engages with the columnar portion. (Appendix 3) 3. The insulator according to claim 2, wherein the columnar portion of the first connecting portion is formed in a polygonal columnar shape or a cylindrical shape with concaves and convexes added. (Appendix 4) 4. The insulator according to claim 1, wherein the central axis of rotation is formed on an imaginary plane extending in the axial direction at the circumferential center of a pair of the split cores adjacent in the circumferential direction. (Appendix 5) An insulator described in any one of Appendix 1 to Appendix 3, wherein the rotation center axis is formed circumferentially away from an imaginary plane extending in the axial direction at the circumferential center of a pair of circumferentially adjacent split cores. (Appendix 6) The first connecting portion has a first return portion that engages with the second connecting portion when the split coil winding body is arranged in a circular shape, An insulator according to any one of claims 1 to 4, wherein the second connecting portion has a second return portion that engages with the first connecting portion when the split coil winding body is arranged in a circular shape. (Appendix 7) The stator using the insulator according to any one of Supplementary Note 1 to Supplementary Note 6, The split core has a yoke portion extending in a circumferential direction and teeth portions protruding radially inward from an inner peripheral surface of the yoke portion on the radially inner side, One circumferential end of the yoke portion is formed in a convex shape, The other circumferential end of the yoke portion is formed into a concave shape, The stator has curved surfaces formed with the same radius of curvature in the convex and concave shapes. (Appendix 8) 8. The stator according to claim 7, wherein the centers of curvature of the convex and concave shapes in a cross section perpendicular to the axial direction of the yoke portion coincide with the central axes of rotation of the first connecting portion and the second connecting portion. (Appendix 9) 9. The stator according to claim 7, further comprising a molded resin portion covering the split coil winding body. (Appendix 10) 9. The stator according to claim 7 or 8, further comprising a frame that applies a preload radially inward to the outer peripheral surface of the annularly arranged split coil winding body. (Appendix 11) A stator according to any one of Supplementary Note 7 to Supplementary Note 10; a rotating electric machine including a rotor disposed radially opposite the stator with a gap therebetween; (Appendix 12) 12. The method for manufacturing a stator according to any one of Supplementary Note 7 to Supplementary Note 11, A method for manufacturing a stator in which the first connecting portion and the second connecting portion of the circumferentially adjacent split cores on which the plurality of insulators forming the stator are installed are connected, and then a flyer arm is used to wind magnet wire continuously around the tooth portion through the insulators to form the coil. [Explanation of symbols]

[0073] 1 split core, 100 rotating electric machine, 101 split coil winding body, 11 rotor, 12 stator, 13 shaft, 14 bracket, 15 bearing, 16 frame, 2 teeth portion, 3 yoke portion, 31 first contact portion, 32 second contact portion, 33 outer peripheral surface, 4 insulator, 41 columnar portion, 411 columnar portion, 412 columnar portion, 42 opening, 421 opening, 422 opening, 43 first return portion, 44 second return portion, 45 winding portion, 51 chuck portion, 511 chuck portion, 52 nozzle, 53 flyer arm, 55 discharge portion, 56 wire bobbin, 57 tensioner, 58 winding operation portion, 59 input portion, 6 molded resin portion, 7 coil, 71 magnet wire, A1 first imaginary surface, A2 Second imaginary surface, F1 direction, F2 direction, G arrow, H1 width, H2 width, T1 first central axis, T11 first central axis, T2 second central axis, T21 second central axis, T3 first rotation central axis, T31 first rotation central axis, T4 second rotation central axis, T41 second rotation central axis, R radius of curvature, R1 radius of curvature, W oscillation direction, X radial direction, X1 outer side, X2 inner side, Y axial direction, Z circumferential direction, Q rotation axis.

Claims

1. The insulator of a stator of a rotating electric machine includes a plurality of split coil windings arranged in an annular shape, each of the split coil windings having a split core, an insulator disposed on the split core, and a coil wound around the split core via the insulator, a first connecting portion at one end in a circumferential direction on a radially outer side, the first connecting portion being connected to another insulator adjacent in the circumferential direction; a second connecting portion at the other end in the circumferential direction on the radially outer side, the second connecting portion being connected to the first connecting portion of another insulator adjacent in the circumferential direction; the first connecting portion and the second connecting portion are configured by a snap-fit ​​mechanism that uses elastic deformation, a pair of the insulators adjacent to each other in the circumferential direction and connected by the first connecting portion and the second connecting portion are formed to be rotatable with respect to each other about a rotation center axis in the axial direction of the first connecting portion and the second connecting portion, the rotation center axis is located radially inward of the radially outer outer peripheral surface of the split core, The rotational axis of the first connecting portion and the rotational axis of the second connecting portion, one of the rotational axes is located circumferentially inward of a circumferential end surface of the split core, the other rotation center axis is located circumferentially outward of the circumferential end surface of the split core, a gap is formed between circumferentially opposing side surfaces of the pair of insulators connected by the first connecting portion and the second connecting portion such that circumferential end surfaces of the split cores connected by the pair of insulators are in contact with each other in a closed annular shape, The gap is an insulator formed in a space between a radially inner circumferential surface and a radially outer circumferential surface of a yoke portion extending in a circumferential direction of the split core.

2. the first connecting portion is formed by a columnar portion having a columnar shape, The insulator according to claim 1 , wherein the second connecting portion is formed as an opening having a columnar surface that engages with the columnar portion.

3. The insulator according to claim 2 , wherein the columnar portion of the first connecting portion is formed in a polygonal columnar shape or a cylindrical shape with concaves and convexes added thereto.

4. 4. The insulator according to claim 1, wherein the central axis of rotation is formed on an imaginary plane extending in the axial direction at the circumferential center of the pair of split cores adjacent in the circumferential direction.

5. one of the rotational centers is formed on a virtual plane extending in the axial direction at the circumferential center of the pair of split cores adjacent in the circumferential direction, and is spaced apart from the circumferential end surface of the split core, 4. The insulator according to claim 1, wherein the other rotational axis is formed away from the imaginary plane on a side circumferentially opposite to the circumferential end surface of the split core.

6. The first connecting portion has a first return portion that engages with the second connecting portion when the split coil winding body is arranged in a circular shape, The insulator according to claim 1 , wherein the second connecting portion includes a second folded portion that engages with the first connecting portion when the split coil winding body is arranged in a circular shape.

7. The stator using the insulator according to any one of claims 1 to 3, The split core has a yoke portion extending in a circumferential direction and teeth portions protruding radially inward from an inner peripheral surface of the yoke portion on the radially inner side, One circumferential end of the yoke portion is formed in a convex shape, The other circumferential end of the yoke portion is formed into a concave shape, The stator has curved surfaces formed with the same radius of curvature in the convex and concave shapes.

8. a center of curvature of the convex shape in a cross section perpendicular to the axial direction of the yoke portion is formed away from an imaginary plane extending in the axial direction at the circumferential center of the pair of split cores adjacent in the circumferential direction, on a side opposite in the circumferential direction to the circumferential end surface of the convex shape, 8. The stator according to claim 7, wherein a center of curvature of the concave shape in a cross section perpendicular to the axial direction of the yoke portion is formed away from the imaginary plane on a side circumferentially opposite to the circumferential end face of the concave shape.

9. 8. The stator according to claim 7, wherein the centers of curvature of the convex shape and the concave shape in a cross section perpendicular to the axial direction of the yoke portion coincide with the central rotation axes of the first connecting portion and the second connecting portion.

10. The stator according to claim 7 , further comprising a molded resin portion that covers the split coil winding body.

11. 8. The stator according to claim 7, further comprising a frame for applying a preload radially inward to the outer circumferential surface of the annularly arranged split coil winding body.

12. The stator according to claim 7; a rotating electric machine including a rotor disposed radially opposite the stator with a gap therebetween;

13. 8. The method for manufacturing a stator according to claim 7, A method for manufacturing a stator in which the first connecting portion and the second connecting portion of the circumferentially adjacent split cores on which the multiple insulators forming the stator are installed are connected, and then a flyer arm is used to wind magnet wire continuously around the tooth portion through the insulators to form the coil.

Images