Stator and electric motor equipped with same

Abstract

A stator (2) according to the present disclosure is provided with a core (5), windings, and an insulator (6) that insulates the core (5) from the windings. The stator (2) comprises a rotor space on the inner circumferential side thereof into which a rotor (3) is rotatably inserted. The insulator (6) comprises a substrate fixing part (20) that fixes a substrate connecting the windings. The substrate fixing part (20) comprises a bulging part (27) bulging on the inner circumferential side beyond an inner circumferential curved surface of the core (5) facing the rotor (3).

Description

[Technical Field]

[0001] The present disclosure relates to a stator and an electric motor including the stator. [Background technology]

[0002] Conventionally, a stator has been known that is manufactured by winding a main winding or an auxiliary winding around a linearly connected series of iron cores, and then connecting the ends in an annular shape (for example, Patent Document 1).

[0003] The configuration will be described below with reference to FIG.

[0004] As shown in Fig. 9, a main winding 111, an auxiliary winding 112, and a speed adjustment winding 113 (auxiliary winding) are wound around a linearly continuous iron core 101. Specifically, the main winding 111 is alternately wound around the iron core 101 from the main winding start end 111a to the main winding end 111b. Similarly, the auxiliary winding 112 is alternately wound around the iron core 101 from the auxiliary winding start end 112a to the auxiliary winding end 112b. The speed adjustment winding 113 is wound around the main winding 111 or the auxiliary winding 112 as needed. Each winding (main winding 111, auxiliary winding 112, and speed adjustment winding 113) is a pair, with a start and an end.

[0005] The speed adjustment winding 113 is an auxiliary winding that enables the rotation speed of the motor to be changed. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Japanese Patent Application Laid-Open No. 2013-215023 Summary of the Invention

[0007] In a typical electric motor, when the rotor is inserted into the rotor space of the stator in an assembled state, there is only a small gap length (gap) between the inner curved surface of the iron core and the outer curved surface of the rotor in order to improve performance.

[0008] Typically, the rotor is inserted into the stator in this state, so the insertion must be done very precisely. Even the slightest deviation in the rotor insertion causes the outer curved surface of the rotor to come into contact with the annular portion of the stator, crossing over the crossover portion of the main winding or auxiliary winding, resulting in a break in the main winding or auxiliary winding. In particular, when a straight core like the one described above is used, when the rotor comes into contact with the annular member of the stator, considerable distortion occurs in the annular portion of the stator, resulting in significant problems such as breakage of the winding.

[0009] Furthermore, there is also the problem that the use of a jig to prevent the rotor from coming into contact with the stator deteriorates workability.

[0010] The stator of the present disclosure includes a core, a winding, and an insulator that provides insulation between the core and the winding. The stator of the present disclosure includes a rotor space on the inner periphery for rotatably inserting a rotor. The insulator includes a substrate fixing portion that fixes a substrate to which the winding is connected. The substrate fixing portion includes a bulge portion that bulges outward from the inner periphery curved surface of the core that faces the rotor.

[0011] The electric motor of the present disclosure includes the stator of the present disclosure described above.

[0012] According to the present disclosure, when inserting a rotor into a stator, precise insertion is possible without using a jig or the like. [Brief explanation of the drawings]

[0013] [Figure 1] FIG. 1 is a perspective view of an electric motor according to a first embodiment of the present disclosure. [Figure 2] FIG. 2 is a perspective view of the core according to the first embodiment of the present disclosure. [Figure 3]FIG. 3 is a perspective view of the insulator and the annular connecting portion according to the first embodiment of the present disclosure. [Figure 4] FIG. 4 is a perspective view of a stator member according to the first embodiment of the present disclosure. [Figure 5] FIG. 5 is an explanatory diagram of assembly of the stator according to the first embodiment of the present disclosure. [Figure 6] FIG. 6 is a perspective view of the stator according to the first embodiment of the present disclosure. [Figure 7] FIG. 7 is a partial cross-sectional view of the substrate fixing portion when the rotor is placed in accordance with the first embodiment of the present disclosure. [Figure 8] FIG. 8 is an explanatory diagram of an assembly of a rotor and a stator according to the first embodiment of the present disclosure. [Figure 9] FIG. 9 is a schematic diagram showing a simplified state of a conventional winding. DETAILED DESCRIPTION OF THE INVENTION

[0014] Hereinafter, embodiments of the present disclosure will be described with reference to the drawings. Note that the following embodiments are examples that embody the present disclosure and do not limit the technical scope of the present disclosure. Furthermore, the same components are designated by the same reference numerals throughout the drawings, and subsequent descriptions are omitted or simplified. Furthermore, in each drawing, detailed descriptions of each component that is not directly related to the present disclosure are omitted.

[0015] (Embodiment 1) A first embodiment of the present disclosure will be described with reference to the drawings.

[0016] First, an electric motor 1 according to the present embodiment will be described with reference to Figures 1 and 2. Figure 1 is a perspective view of the electric motor 1 according to the present embodiment. Figure 2 is a perspective view of a core 5 according to the present embodiment.

[0017] The electric motor 1 includes a stator 2 , a rotor 3 , and a substrate 4 .

[0018] The stator 2 includes an iron core 5, an insulator 6, and a winding 7.

[0019] The core 5 is integrally formed with a yoke portion 8 formed on the outer diameter side, a base portion 17 protruding from the yoke portion 8 to the inner diameter side, and teeth 9 provided at the tip of the base portion 17. The core 5 is configured in an annular shape when the stator 2 is completed.

[0020] The tooth portion 9 has, on the opposite side to the yoke portion 8, an inner peripheral curved surface 33 that faces a rotor space described below, in other words, the outer peripheral surface of the rotor 3.

[0021] The insulator 6 is configured to cover the core 5, and serves to provide electrical insulation between the core 5 and the winding 7 by winding the winding 7, which is a conductive wire made primarily of an alloy such as copper or aluminum, around multiple bases 17 via the insulator 6.

[0022] The winding 7 is wound around the core 5, which is partially covered with the insulator 6, from above the insulator 6. The ends of the winding 7 are wound around terminal pins (not shown) provided on the insulator 6 and connected to the terminal pins by solder or the like. The ends may also be connected by fusing or the like.

[0023] The rotor 3 is rotatably disposed in a rotor space located at the center of the annular shape of the stator 2, with its outer peripheral curved surface 34 (see FIG. 8) facing the inner peripheral curved surface 33 of the core 5. When current is applied to the windings 7, the rotor 3 rotates via bearings 40, which in turn rotates the rotating shaft 10. The height of the rotor 3 in the direction of the rotating shaft 10 is approximately equal to the height of the core 5 in the same direction.

[0024] The substrate 4 is electrically connected to the terminal pins connected to the windings 7. This maintains the connection between the substrate 4 and the multiple windings 7 provided.

[0025] Next, the insulator 6 and the insulator assembly including the insulator 6 will be described in detail with reference to Figures 3 and 4. Figure 3 is a perspective view of the insulator 6 and the annular connecting portion 11 according to this embodiment. Figure 4 is a perspective view of the stator member 12 in which a core is attached to the insulator 6 and the annular connecting portion 11 of Figure 3.

[0026] The insulator 6 includes an outer peripheral portion 13, an inner peripheral portion 14, a connecting portion 15, and a guide portion 24. The insulators 6 are connected by an annular connecting portion 11.

[0027] The outer peripheral portion 13 is located on the outer peripheral side of the annular insulator 6. The outer peripheral portion 13 is adjacent to the inner peripheral surface of the yoke portion 8 of the core 5 and covers the inner peripheral surface of the yoke portion 8.

[0028] The inner peripheral portion 14 is located on the inner peripheral side of the annular insulator 6. The inner peripheral portion 14 is adjacent to the outer peripheral surface of the tooth portion 9 of the core 5 and covers the outer peripheral surface of the tooth portion 9.

[0029] The connecting portion 15 connects the outer peripheral portion 13 and the inner peripheral portion 14, and covers the base portion 17 of the core 5. The connecting portion 15 includes a through hole 16 for covering the base portion 17 of the core 5.

[0030] The guide portion 24 is provided parallel to the rotating shaft 10 on the side surface of the outer circumferential portion 13 of the insulator 6, i.e., on the connecting edge 25. When adjacent insulators 6 are installed, the guide portion 24 restricts the adjacent insulators 6 so that they can slide parallel to the rotating shaft 10. In other words, the guide portion 24 contributes to maintaining the shape of the outer circumferential side of the stator 2.

[0031] The through hole 16 is provided in the connecting portion 15 and is a space that connects the outer peripheral portion 13 and the inner peripheral portion 14, and in which the base portion 17 is located.

[0032] The state in which the cores 5 are provided on the insulators 6, that is, a set of one insulator 6 and one core 5, is called an insulator set 19 (see FIG. 6). The insulator set 19 is formed by attaching the insulators 6 to the cores 5. FIG. 4 shows a stator member 12 formed by connecting the insulator sets 19 in an annular shape at an annular connecting portion 11.

[0033] The annular connecting portion 11 is provided at one axial end of the insulator 6, and annularly connects the inner peripheral portions 14 that make up the insulator assembly 19. The annular connecting portion 11 is an integrated structure formed integrally with the insulator 6. The annular connecting portion 11 is provided parallel to and on an annular plane 18 that is virtually provided at one end of the insulator assembly 19. In other words, a plurality of insulator assemblies 19 (four downward in FIG. 3 ) are erected in the same direction with the annular plane 18 as the base. The annular connecting portion 11 includes a substrate fixing portion 20, an engaging portion 26, and a rib 32.

[0034] The substrate fixing portions 20 protrude from the annular plane 18 in the opposite direction to the insulator assembly 19, and are used to fix the substrate 4. At least three substrate fixing portions 20 are provided in the circumferential direction. Each substrate fixing portion 20 also has a bulge 27 (see FIGS. 7 and 8) on the rotor space side of the annular shape of the stator 2. The bulge 27 will be described in detail later.

[0035] The engaging portions 26 are provided on both ends of the insulator 6. Here, one end of the engaging portion 26 is referred to as engaging portion 26B, and the other end of the engaging portion 26 is referred to as engaging portion 26A. Also, an insulator space is defined as a space formed between adjacent insulator pairs 19 and having a predetermined gap.

[0036] The engaging portion 26B is formed integrally with the annular connecting portion 11 on the insulator space side of the annular connecting portion 11 and in the same direction as the insulator assembly 19 with respect to the annular plane 18.

[0037] The engaging portion 26A is provided on the inner circumferential portion 14 of the insulator 6 on the side of the protruding tip 38.

[0038] The engagement of the two engaging portions 26A and 26B fixes the positions of the protruding tip 38 of the inner circumferential portion 14 and the annular connecting portion 11, contributing to maintaining the shape of the inner circumferential side of the stator 2.

[0039] The engaging portions 26A and 26B of the engaging portion 26 have concave and convex shapes that engage with each other, thereby suppressing radial movement of the insulator 6 when engaged.

[0040] The ribs 32 are protrusions provided on at least one of the annular connecting portion 11 or the inner peripheral portion 14 to support the transition of the winding 7 to the adjacent insulator 6. The ribs 32 protrude in the opposite direction from the insulator pair 19 relative to the annular plane 18. The crossover wires constituting part of the winding 7 cross between the insulator pairs 6 via the ribs 32, allowing the crossover wires to cross along the ring of the annular connecting portion 11, preventing the winding 7 from being cut. The ribs 32 in FIGS. 3 and 4 are examples in which the ribs 32 are provided on the inner peripheral portion 14.

[0041] The insulator pairs 19 are arranged at equal intervals with respect to the annular connecting portion 11. That is, in FIG. 4 , when a central axis 21, which is a center line passing through the circumferential center of the insulator pair 19 and is parallel to the rotating shaft 10, is taken as a reference, the central axes 21 are arranged at 90-degree intervals on the ring. Furthermore, in one stator member 12, a width 22 of an insulator space formed between adjacent insulator pairs 19 is equal to a width 23 of the insulator pair 19.

[0042] Next, a procedure for forming the stator 2 will be described with reference to Figures 5 and 6. Figure 5 is an explanatory diagram of the assembly of the stator 2 according to this embodiment. Figure 6 is a perspective view of the stator 2 according to this embodiment.

[0043] When assembling the stator 2, two stator members 12A and 12B are prepared with windings 7 wound around the insulators 6. The two stator members 12A and 12B are positioned so that their central axes 21 are offset by 45 degrees and so that the annular connecting portions 11 (annular connecting portions 11A and 11B) are located at the far ends of each other's stator members 12. In this state, the insulator pair 19 faces the insulator space of the opposing stator member 12.

[0044] In this state, as stator members 12A and 12B are brought closer together in the directions of arrows 30A and 30B, corresponding guide portions 24A and 24B on insulator 6 slide against each other, connecting stator members 12A and 12B while maintaining the annular shape. When stator members 12A and 12B are connected, engaging portion 26A on protruding tip 38 of insulator 6 engages engaging portion 26B on annular connecting portion 11. With engaging portion 26A and engaging portion 26B engaged, substrate 4 is placed on substrate fixing portion 20, and terminal pins to which windings 7 are fixed are connected to substrate 4, completing stator 2. Note that the substrate 4 is not shown in FIG. 6 .

[0045] In this state, as shown in Fig. 6, adjacent insulator pairs 19 are arranged on the same circumference. Furthermore, the annular connecting portion 11A is arranged at one end (upper end) of the insulator pair 19. The annular connecting portion 11B is arranged at the other end (lower end) of the insulator pair 19. That is, the annular connecting portion 11A and the annular connecting portion 11B are arranged at both ends of the stator 2, facing each other. In other words, the stator 2 has an assembled structure in which the insulator pairs 19 are assembled by alternately positioning them so as to fill predetermined gaps between each other.

[0046] The stator 2 having such a shape can be wound with a winding machine from the outer periphery of the annular insulator 6 on one stator member 12. This allows the winding machine to be made smaller.

[0047] Furthermore, it is only necessary to manufacture two stator members 12 of the same shape, which contributes to a reduction in the number of parts.

[0048] Furthermore, the two stator members 12 are engaged with the inner periphery 14 at the engaging portion 26 and with the outer periphery 13 at the guide portion 24. Therefore, the annular shape of the stator 2 can be firmly maintained at the inner periphery and the outer periphery.

[0049] Next, the configuration of the bulging portion and the procedure for assembling the rotor 3 and the stator 2 will be described with reference to Figures 7 and 8. Figure 7 is a partial cross-sectional view of the substrate fixing portion 20 when the rotor 3 according to this embodiment is placed. Figure 8 is an explanatory diagram of the assembly of the rotor 3 and the stator 2 according to this embodiment.

[0050] As shown in FIG. 7, the substrate fixing portion 20 has a bulging portion 27.

[0051] When the stator 2 and the rotor 3 are assembled, the bulging portion 27 bulges radially toward the rotor space beyond the inner circumferential curved surface 33 of the core 5. The bulging degree of the bulging portion 27 is such that the innermost end 36 of the bulging portion 27 is located inside the inner circumferential curved surface 33 of the core 5 and contacts the outer circumferential curved surface 34 of the rotor 3. In other words, the bulging portion 27 bulges inward from the inner circumferential curved surface 33 by approximately a gap length 35, which is the distance between the inner circumferential curved surface 33 and the outer circumferential curved surface 34, and the innermost end 36 is located on the same circumference as the circumference formed by the outer circumferential curved surface 34 in an axial view. Note that the innermost end 36 of the bulging portion 27 may bulge further inward than the same circumference as the outer circumferential curved surface 34.

[0052] When the stator 2 and the rotor 3 are combined, the rotational axis direction end 28 of the rotor 3 and the rotational axis direction end 37 of the core 5 are substantially aligned in the rotational axis direction. The bulge 27 is located outside the rotational axis direction end 28 of the rotor 3 (above the rotational axis direction end 28 in FIG. 7).

[0053] The bulge 27 also has an insertion slope 29 and a removal slope 39 .

[0054] The insertion gradient 29 is a gradient (inclination) that extends from the tip 31 of the substrate fixing portion 20, which is located on the outer side in the direction of the rotation axis, toward the inner circumferential direction as it moves toward the rotor space.

[0055] The removal gradient 39 is a gradient (inclination) that increases inward in the rotational axis direction from the rotor space side toward the outside in the rotational axis direction (above the rotational axis direction end 28 in FIG. 7). The removal gradient 39 has an end 41 on the rotor space side in the rotational axis direction that is located outer than the inner peripheral curved surface 33 of the core 5. The inner end of the insertion gradient 29 in the rotational axis direction and the outer end of the removal gradient 39 in the rotational axis direction intersect at the innermost peripheral end 36.

[0056] The above is the configuration of the bulging portion 27.

[0057] In the assembled state where the rotor 3 is inserted into the rotor space of the stator 2, a gap length 35 is provided between the inner circumferential curved surface 33 of the core 5 and the outer circumferential curved surface 34 of the rotor 3. The smaller the gap length 35, the higher the performance of the electric motor, and in some electric motors the gap length 35 is less than 1 mm. In other words, there is only a gap of the gap length 35 between the outer circumferential curved surface 34 of the rotor 3 and the inner circumferential curved surface 33 of the stator.

[0058] Normally, when assembling the electric motor 1 in this state, the rotor 3 is inserted into the rotor space of the stator 2, so the insertion of the rotor 3 must be done very precisely. If there is even the slightest deviation in the insertion of the rotor 3, the outer circumferential curved surface 34 will come into contact with the annular connecting portion 11, crossing over the crossover wire routed between the ribs 32 of the annular connecting portion 11, i.e., the crossover wire will break.

[0059] In contrast, the stator 2 according to this embodiment has a bulge 27. When the rotor 3 is inserted into the stator 2, the rotor 3 is inserted into the stator 2 from either the top or bottom direction with respect to the axial center 30 of the rotor space until both the rotational axis direction end 28 of the rotor 3 and the rotational axis direction end 37 of the core 5 are positioned on the same plane. At this time, the outer peripheral curved surface 34 of the rotor 3 comes into contact with the bulge 27, and furthermore, the insertion slope 29 guides the rotational axis 10 of the rotor 3 onto the same line as the axial center 30 of the rotor space.

[0060] This ensures precise positioning when inserting the rotor 3. Therefore, even if a crossover wire is routed on the annular plane 18 and the crossover wire approaches the rotor space due to slack, the bulge 27 guides the rotor 3 precisely to the center. This makes it possible to prevent the rotor 3 from crossing the crossover wire due to improper insertion.

[0061] Furthermore, the bulging portion 27 is located outside the end portion 28 in the direction of the rotation axis. Therefore, even when the rotor 3 is driven to rotate, the bulging portion 27 can operate without coming into contact with the rotor 3.

[0062] Furthermore, during the assembly process of inserting the rotor 3 into the rotor space in the stator 2, the bearing 40 may occasionally be damaged by impact or other factors, causing abnormal noise. Furthermore, even in the field, depending on the external environment, dust or sand may get into the bearing 40, causing abnormal noise. In such cases, the rotor 3 must be removed and the bearing 40 replaced. In this case, by providing the removal slope 39 and locating the starting point of the removal slope 39 on the outer periphery side of the inner curved surface 33 of the core 5, the rotation axis direction end 28 of the rotor 3 can smoothly contact the removal slope 39 when the rotor 3 is removed. This facilitates the removal of the rotor 3 and prevents damage to parts due to forceful removal.

[0063] In this embodiment, the bulges 27 are arranged evenly around the circumference, but they may be arranged unevenly, and it is sufficient to provide at least three points for the purpose of guiding the rotor 3 to the center.

[0064] The shape of the bulging portion 27 may also be any shape that can support the outer circumferential curved surface 34 of the rotor 3 .

[0065] In addition, in this embodiment, four insulator pairs 19 are connected to one stator member 12, but the number is not limited to four as long as there is a plurality. In an AC motor, due to the characteristics of the windings, it is preferable to provide one stator member 12 with an even number of insulator pairs 19.

[0066] Alternatively, the core 5, insulator 6, and annular connecting portion 11, i.e., the insulator assembly 19, may be integrally molded. A plurality of cores 5 are placed in a mold, and the resin that forms the insulators 6 and annular connecting portion 11 is poured into the mold to form the insulator assembly 19. The shape of the insulator assembly 19 thus produced makes it possible to confirm that it is integrally formed as a finished product.

[0067] Furthermore, although the core 5 is configured to have an annular shape in the completed shape of the stator 2, it may be linear at the time of manufacturing. In particular, a linear core 5 is prone to distortion when made into an annular shape, and therefore the effect of the present invention is significant.

[0068] The stator 2 configured in this manner can be used in the electric motor 1, and the electric motor 1 can be suitably used in a blower. [Industrial Applicability]

[0069] A stator according to the present disclosure is useful as it can improve the manufacturing efficiency of electric motors. [Explanation of symbols]

[0070] 1 electric motor 2 Stator 3 rotor 4 boards 5 cores 6 Insulator 7 windings 8 Yoke section 9 Teeth 10 Rotation axis 11, 11A, 11B Annular joint 12, 12A, 12B Stator members 13 Outer periphery 14 Inner circumference 15 Connection 16 through holes 17 Base 18 Circular Plane 19 Insulator assembly 20 Board fixing part 21 Center axis 22, 23 width 24, 24A, 24B guide part 25 connecting edges 26, 26A, 26B engaging part 27 Bulge 28 Rotational shaft end 29 Insertion Gradient 30 axis center 31 Tip 32 Ribs 33 Inner curved surface 34 Peripheral curved surface 35 Gap Length 36 Innermost edge 37 Rotational shaft end 38 Protruding tip 39 Extraction gradient 40 bearings 41 End 101 Iron Core 111 Main Winding 111a Main winding start end 111b Main winding termination 112 Auxiliary Winding 112a Auxiliary winding start end 112b Auxiliary winding termination 113 Speed ​​adjustment winding

Claims

1. A stator including a core, a winding, and an insulator that insulates between the core and the winding, and including a rotor space on an inner circumferential side for rotatably inserting a rotor, The insulator is a substrate fixing portion that fixes a substrate to which the winding is connected, The substrate fixing portion is a bulging portion that bulges outward from an inner circumferential curved surface of the core that faces the rotor, The bulging portion has an insertion gradient that extends from the outside in the rotation axis direction toward the rotor space toward the inner circumferential direction.

2. A stator including a core, a winding, and an insulator that insulates between the core and the winding, and including a rotor space on an inner circumferential side for rotatably inserting a rotor, The insulator is a substrate fixing portion that fixes a substrate to which the winding is connected, The substrate fixing portion is a bulging portion that bulges outward from an inner circumferential curved surface of the core that faces the rotor, The bulging portion has a withdrawal gradient that increases from the rotor space side in the rotational axis direction toward the outer side in the rotational axis direction toward the inner circumferential direction.

3. The stator according to claim 1 , wherein the bulging portion is positioned outward from an end portion of the rotor in the rotation axis direction.

4. 3. The stator according to claim 1, wherein the innermost periphery of the bulging portion is located on the same circumference as an outer circumferential curved surface of the rotor facing the core, or the bulging portion bulges outward from the same circumference to a periphery further inward.

5. 5. The stator according to claim 4, wherein the bulging portion bulges inward from the inner circumferential curved surface of the core by a gap length that is a distance between the inner circumferential curved surface of the core and the outer circumferential curved surface of the rotor.

6. the substrate fixture is one of at least three substrate fixtures; The stator according to claim 1 , wherein the at least three substrate fixing portions are provided in the circumferential direction of the insulator.

7. The stator according to claim 2 , wherein the removal gradient is such that an end portion of the stator on the rotor space side in the rotation axis direction is positioned on the outer circumferential side of the inner circumferential curved surface.

8. An electric motor comprising the stator according to claim 1 or 2.

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