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

Abstract

A rotating electric machine stator (100) comprises coils (7) wound around a core (1) with an insulating portion interposed therebetween. The insulating portion comprises a first projection portion (21) projecting in one of the axial directions of the core and a second projection portion (31) projecting in the other of the axial directions of the core. The first projection portion and the second projection portion are each provided with a groove portion (9) in which a jumper wire (8) crossing between the coils is housed, wherein the jumper wire is disposed in the groove portion by changing the positions of the first projection portion and the second projection portion. This makes it possible to obtain a stator in which the interference between the jumper wires of the coils is prevented in winding a conductor wire during coil formation and a wire connection member can be reduced.

Description

[Technical Field]

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

[0002] Conventionally, stators used in rotating electrical machines such as electric motors or generators are composed of a stator core and coils fitted in slots between the teeth of the stator core. The conductor wires forming the coils are insulated, and the coils are insulated from the stator core. However, in the stators of rotating electrical machines, to ensure sufficient insulation between the coils and the stator core, an insulating section is also provided at the contact point between the stator core and the coil. (Hereinafter, the stator core will be simply referred to as the core.) In conventional stators, a coil is installed by winding a conductor wire around a core via an insulating section. For example, the insulating section shown in Patent Document 1 has a terminal storage section (cavity) that can store a crimp terminal. Then, in the stator, the conductor wire and the crimp terminal are inserted and connected between each tooth with a jumper wire. Also, for example, the stator shown in Patent Document 2 winds the conductor wire around two consecutive teeth to reduce the number of connecting sections. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] International Publication No. 2016 / 51923 [Patent Document 2] Japanese Patent Application Laid-Open No. 2008-167604 Summary of the Invention [Problem to be solved by the invention]

[0004] In general, in the manufacture of stators for rotating electrical machines, reducing material usage and shortening manufacturing time are important in order to lower costs while maintaining quality. For example, the stator described in Patent Document 1 uses insulation displacement terminals and jumper wires connecting each tooth for wiring connections. In this case, a 9-tooth stator requires 18 insulation displacement terminals and 8 jumper wires. This requires a large number of wiring components, which increases material costs and prices. Furthermore, the process of inserting the insulation displacement terminals creates strength issues in the terminal housing section of the insulating part. Furthermore, in the stator described in Patent Document 2, although the number of connecting members is reduced by winding the coils continuously, in a stator consisting of nine teeth, when winding three consecutive wires between teeth spaced two apart, if an attempt is made to place a second crossover wire, it will interfere with the first crossover wire and therefore the crossover wire cannot be placed.

[0005] The present application is intended to solve the above-mentioned problems, and aims to provide a stator for a rotating electric machine, a rotating electric machine, a method for manufacturing a stator for a rotating electric machine, and a method for manufacturing a rotating electric machine, which prevent interference between coil jumper wires when winding conductor wires during coil formation and reduce the number of connecting members. [Means for solving the problem]

[0006] The stator of a rotating electric machine according to the present application comprises a core having a yoke portion arranged in an annular shape and a plurality of teeth formed on an inner peripheral surface of the yoke portion in a radial direction and protruding radially inward at predetermined intervals in the circumferential direction, a coil formed by winding a coil wire around each of the plurality of teeth, and an insulating portion disposed between the core and the coil to insulate the core from the coil, The insulating portion is a first protrusion protruding from one side of the core in the axial direction; a second protrusion protruding in the other axial direction of the core; Equipped with The coil is made up of continuous conductor wires, including crossover wires, provided for each phase that serves as a power source for the rotating electric machine, The power supply is a three-phase AC power supply, and nine coils are provided in total, each connected to each of the three phases of the power supply. the first protruding portion and the second protruding portion have grooves for accommodating the crossover wires for the respective phases; when the crossover wires are a first crossover wire, a second crossover wire, a third crossover wire, a fourth crossover wire, a fifth crossover wire, and a sixth crossover wire in the arrangement order of the coils, each crossover wire is arranged across two coils, the first crossover wire, the second crossover wire, and the third crossover wire are provided on one of the first protruding portion and the second protruding portion, the fourth crossover wire, the fifth crossover wire, and the sixth crossover wire are provided on the other of the first protruding portion and the second protruding portion, the first protrusion and the second protrusion each have an introduction groove through which the conductor wire is introduced radially inward from the groove, and an extraction groove through which the conductor wire is extracted from the coil wound around the tooth to the groove provided radially outward, the introduction groove of the first protrusion is located closer to one end in the circumferential direction than the outlet groove of the first protrusion, The introduction groove of the second protrusion is located closer to the one end in the circumferential direction than the outlet groove of the second protrusion. the law of nature, In each of the first protrusion and the second protrusion, an axial position at which the conductor wire is led out of the lead-out groove is disposed closer to the core than an axial position at which the conductor wire connected to the destination coil is led into the lead-in groove; and The introduction groove is disposed farthest from the core in the axial direction than the grooves that house the crossover wires for each phase, In each of the first protrusion and the second protrusion, the conductor wire coming out of the lead-out groove is guided to a groove for accommodating the crossover wire for each phase and connected to the lead-in groove of the coil at the crossover destination. . [Effects of the Invention]

[0007] According to the present application, a groove portion is provided in each of the first and second protrusions protruding in the axial direction of the core to accommodate the jumper wires that cross between the coils. This allows the first and second protrusions to be switched and positioned in the groove portion, preventing interference between the jumper wires of the coils when winding the conductor wire during coil formation and reducing the number of connecting members. [Brief explanation of the drawings]

[0008] [Figure 1]3 is a diagram showing the arrangement of crossover wires in a core portion in which stators of the rotary electric machine according to the first embodiment are arranged in a straight line. FIG. [Figure 2] 1 is a perspective view of a stator of a rotary electric machine according to a first embodiment, viewed from the coil side of core portions arranged in a straight line. [Figure 3] 2 is a perspective view showing how core plates of the stator of the rotary electric machine according to the first embodiment are stacked. FIG. [Figure 4] 2 is a perspective view showing a core after core plates of the stator of the rotary electric machine according to the first embodiment have been laminated; FIG. [Figure 5] 2 is a diagram showing a core plate of a stator of the rotating electric machine according to the first embodiment; FIG. [Figure 6] 2 is a perspective view showing a first winding frame of the stator of the rotary electric machine according to the first embodiment; FIG. [Figure 7] 3 is a perspective view showing a second winding frame of the stator of the rotary electric machine according to the first embodiment. FIG. [Figure 8] 1 is a perspective view showing a core portion in which a first winding frame and a second winding frame of a stator of a rotary electric machine according to a first embodiment are combined. FIG. [Figure 9] 2 is a view of a core portion of a stator of a rotary electric machine according to the first embodiment, viewed from the radial outside. FIG. [Figure 10] 2 is a view of a core portion of a stator of a rotary electric machine according to the first embodiment, viewed from the radially inner side. FIG. [Figure 11] 1 is a view of a core portion of a stator of a rotary electric machine according to a first embodiment, viewed from the circumferential direction. [Figure 12] 1 is a view of a core portion of a stator of a rotating electric machine according to a first embodiment, as viewed from the axial direction. [Figure 13] 2 is a perspective view showing a method for manufacturing the stator of the rotating electric machine according to the first embodiment. FIG. [Figure 14] 3A to 3C are schematic views showing a method for manufacturing the stator of the rotating electric machine according to the first embodiment. [Figure 15] 3 is a diagram showing the arrangement of crossover wires of a core portion arranged in a straight line in the stator of the rotary electric machine according to the first embodiment; FIG. [Figure 16]FIG. 3 is a flowchart showing a manufacturing process of the stator of the rotating electric machine according to the first embodiment. [Figure 17] 1 is a schematic diagram showing a cross section of a rotating electric machine according to a first embodiment. [Figure 18] 1 is a schematic diagram showing a cross section of a rotating electric machine according to a first embodiment. [Figure 19] FIG. 3 is a flowchart showing a manufacturing process of the rotating electric machine according to the first embodiment. [Figure 20] 10A to 10C are schematic diagrams illustrating a method for manufacturing a stator of a rotating electric machine according to a second embodiment. [Figure 21] 10 is a diagram showing a core plate of a stator of a rotating electric machine according to a third embodiment. FIG. [Figure 22] FIG. 11 is a perspective view showing a core after core plates of a stator of a rotary electric machine according to a third embodiment have been laminated. [Figure 23] FIG. 10 is a perspective view showing a core portion of a stator of a rotating electric machine according to a fourth embodiment. [Figure 24] FIG. 10 is a perspective view showing windings around linearly arranged core portions of a stator of a rotary electric machine according to a fourth embodiment. [Figure 25] FIG. 11 is a perspective view of a core portion in which stators of a rotary electric machine according to a fifth embodiment are arranged in a straight line. [Figure 26] 10 is an exploded perspective view of a core portion in which stators of a rotary electric machine according to a fifth embodiment are arranged in a straight line, with the components being disassembled. FIG. [Figure 27] FIG. 11 is a perspective view showing a film portion of a stator of a rotating electric machine according to a fifth embodiment. [Figure 28] FIG. 13 is a perspective view showing a first winding frame of a stator of a rotary electric machine according to a fifth embodiment. [Figure 29] FIG. 13 is a perspective view showing a second winding frame of a stator of a rotary electric machine according to a fifth embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0009] Embodiment 1 FIG. 1 is a diagram showing the arrangement of linearly arranged crossover wires of a core section of a stator of a rotating electric machine according to a first embodiment. FIG. 2 is a perspective view of the core section as viewed from the coil side, which is the opposite side to that shown in FIG. 1. In FIGS. 1 and 2, a stator 100 includes a core 1, a coil 7, and an upper winding frame 2 and a lower winding frame 3 as insulating sections arranged to insulate the core 1 from the coil 7. The core 1 includes an annularly arranged yoke section 11 (however, in each drawing, the yoke section 11 is shown linearly arranged as previously shown), and a plurality of teeth 12 formed on the inner side X2 of the yoke section 11 in the radial direction X so as to protrude at predetermined intervals in the circumferential direction Z. The coils 7 are formed by winding insulatingly coated conductor wires 70 around the teeth 12.

[0010] In the following description, each direction in the stator 100 of the rotating electric machine 1000 is indicated as the circumferential direction Z, the axial direction Y, the radial direction X, the outer side X1 of the radial direction X, and the inner side X2 of the radial direction X, based on the state in which the yoke portion 11 of the stator 100 is arranged in an annular shape. Therefore, even if multiple yoke portions 11 of the core 1 of the stator 100 are connected and arranged in a linear shape, or even if they are arranged in a reverse-warped shape in which the protruding direction of the teeth 12 is reversed, each direction will be shown and explained in each drawing based on the direction in which the yoke portion 11 of the stator 100 is arranged in an annular shape. Note that in other embodiments, the directions will be shown and explained based on the same standard.

[0011] The core 1 of the stator 100 is formed by laminating two types of core plates 6, a first core plate 601 and a second core plate 602, which are bilaterally symmetrical and are formed by punching thin magnetic steel plates as shown in Fig. 3, alternately in the axial direction Y as shown in Fig. 3. The formed core 1 is shown in Fig. 4. The shape of the core plate 6 is shown in Fig. 5. Both the first core plate 601 and the second core plate 602 have a yoke portion 11 that protrudes in the circumferential direction Z from the outer side X1 in the radial direction X and teeth 12 that protrude in the inner side X2 in the radial direction X. The first core plate 601 has a connecting hole 1111 at one end of the yoke portion 11 in the circumferential direction Z and a notch 1112 at the other end. The second core plate 602 has a notch 1112 at one end of the yoke portion 11 in the circumferential direction Z and a connecting hole 1111 at the other end, symmetrical to the first core plate 601 in the circumferential direction Z, and the yoke portion 11 of an adjacent core 1 is connected by the connecting portion 111. This connecting portion 111 is constructed by butting together and overlapping alternately the connecting hole 1111 of the first core plate 601 and the notch portion 1112 of the second core plate 602, or the connecting hole 1111 of the second core plate 602 and the notch portion 1112 of the first core plate 601, and by inserting a connecting pin into the connecting hole 1111, adjacent core portions can be connected in a deformable state. The connecting pin may be removed from the stator 100 once it has been assembled into the rotating electrical machine 1000.

[0012] Hereinafter, a portion of the yoke portion 11 having one tooth 12 will be described as a core portion 60. The core 1 is formed by connecting the yoke portions 11 of multiple core portions 60 in the circumferential direction Z with connecting portions 111. Here, the core 1 is configured by connecting nine core portions 60 with connecting portions 111. The yoke portion 11 of the core 1 can be freely bent at the connecting portions 111, and is thereby formed so as to be deformable into a straight shape or a reverse-warped shape that reverses the direction in which the teeth 12 protrude in the radial direction X. The method of connecting the core portion 60 to the yoke portion 11 is not limited to the above-described structure, and any other structure may be used as long as it allows for deformable connection.

[0013] 1, 2, and 4, the core portions 60 arranged in the circumferential direction Z are designated, from the winding start side of the conductor wire 70, as a first core portion 61, a second core portion 62, a third core portion 63, a fourth core portion 64, a fifth core portion 65, a sixth core portion 66, a seventh core portion 67, an eighth core portion 68, and a ninth core portion 69. Here, the power supply is constituted by three-phase AC of U phase, V phase, and W phase, and the wiring structure is a star connection in which different phases are arranged for each of the core portions 60 adjacent in the circumferential direction Z. The first core portion 61 is a U phase (U1), the second core portion 62 is a V phase (V1), the third core portion 63 is a W phase (W1), the fourth core portion 64 is a U phase (U2), the fifth core portion 65 is a V phase (V2), the sixth core portion 66 is a W phase (W2), the seventh core portion 67 is a U phase (U3), the eighth core portion 68 is a V phase (V3), and the ninth core portion 69 is a W phase (W3).

[0014] When there is no need to explain the order, the cores will be collectively referred to as core unit 60. Similarly, core units 61 to 69 each have a coil 7 and an upper winding frame 2 and a lower winding frame 3 as insulating units. However, each of core units 61 to 69 will be described as such regardless of whether or not the coil 7 and the upper winding frame 2 and lower winding frame 3 as insulating units are installed in that core unit 61 to 69.

[0015] Next, Fig. 5 shows one core plate 6, and the core 1 is formed by stacking these core plates 6. Each part of the core portion 60 will be described based on Fig. 5. The surface of the yoke portion 11 in the axial direction Y on the outer side X1 in the radial direction X is defined as the outer peripheral surface 113. The outer peripheral surface 113 of the yoke portion 11 is formed with a first recess 114 extending in the axial direction Y. The first recess 114 is used for positioning when attaching the core 1 to a winding machine that forms the coil 7. Furthermore, the teeth 12 each have shoe portions 13 that protrude in the circumferential direction Z at the tip of the inner side X2 in the radial direction X. The surfaces in the axial direction Y at both ends in the circumferential direction Z of the teeth 12 are referred to as first side surfaces 121, and the surfaces of the tips of the teeth 12 on the inside X2 in the radial direction X and along the axial direction Y are referred to as tip surfaces 122. The surfaces of the shoe portions 13 on the outside X1 in the radial direction X and along the axial direction Y are referred to as second side surfaces 131. The first side surfaces 121, second side surfaces 131, and tip surfaces 122 are the side surfaces of the teeth 12 along the axial direction Y. The areas surrounded by the inner circumferential surfaces 112, the first side surfaces 121, and the second side surfaces 131 are the slots 14 around which the conductor wire 70 is wound to form the coils 7.

[0016] Next, the upper winding frame 2 and the lower winding frame 3 as insulating parts will be described with reference to Figures 6 to 12. As shown in Figure 6, the upper winding frame 2 is made up of a first protruding portion 21 and a first leg portion 22. As shown in Fig. 7, the lower winding frame 3 is composed of a second protruding portion 31 and a second leg portion 32. Fig. 8 is a diagram showing the upper winding frame 2 and the lower winding frame 3 placed on the core portion 60, with the first protruding portion 21 protruding from one side in the axial direction Y from the core portion 60. The second protruding portion 31 is also formed protruding from the other side in the axial direction Y from the core portion 60. The structure of each groove provided in core portion 60 is shown in Figures 9 to 12. Figure 9 is a view of core portion 60 as viewed from direction A in Figure 8, and shows that groove portion 9 is formed in multiple stages in the axial direction Y on outer peripheral surface 201 on the outer side X1 in the radial direction X of first protruding portion 21 of upper winding frame 2 and on outer peripheral surface 301 on the outer side X1 in the radial direction X of second protruding portion 31 of lower winding frame 3. Groove portion 91 of upper winding frame 2 is formed in four stages: first groove portion 911, second groove portion 912, third groove portion 913, and fourth groove portion 914, from the side farthest from core 1 in the axial direction Y. Groove portion 92 of lower winding frame 3 is formed in four stages: first groove portion 921, second groove portion 922, third groove portion 923, and fourth groove portion 924, from the side farthest from core 1 in the axial direction Y. The grooves 911, 912, 913, 914, 921, 922, 923, and 924 are formed to extend in the circumferential direction Z while inclining in the axial direction Y.

[0017] 1 and 9 , for example, a position in the axial direction Y on the second core portion 62 side adjacent in the circumferential direction Z of the fourth groove portion 914 of the first core portion 61 and a position in the axial direction Y on the first core portion 61 side adjacent in the circumferential direction Z of the third groove portion 913 of the second core portion 62 are formed to face and be close to each other. Also, a position in the axial direction Y on the second core portion 62 side adjacent in the circumferential direction Z of the third groove portion 913 of the first core portion 61 and a position in the axial direction Y on the first core portion 61 side adjacent in the circumferential direction Z of the second groove portion 912 of the second core portion 62 are formed to face and be close to each other. Furthermore, a position in the axial direction Y on the second core portion 62 side adjacent in the circumferential direction Z of the second groove portion 912 of the first core portion 61 and a position in the axial direction Y on the first core portion 61 side adjacent in the circumferential direction Z of the first groove portion 911 of the second core portion 62 are formed to face and be close to each other.

[0018] 6 , the first protrusion 21 of the upper winding frame 2 has an introduction groove 915 that continues from the first groove 911 on the side farthest from the core 1 in the axial direction Y and that is formed to communicate from the outer side X1 in the radial direction X of the first protrusion 21 to the inner side X2 in the radial direction X. The first protrusion 21 of the upper winding frame 2 has an introduction groove 916 that continues from the fourth groove 914 on the side closest to the core 1 in the axial direction Y and that is formed to communicate from the inner side X2 in the radial direction X of the first protrusion 21 to the outer side X1 in the radial direction X. Thus, the introduction groove 915 and the introduction groove 916 are formed to communicate from the outer peripheral surface 201 of the first protrusion 21 to the inner peripheral surface 202 on the inner side X2 in the radial direction X. 7, second protruding portion 31 of lower winding frame 3 has introduction groove 925 that continues from first groove 921 on the side farthest from core 1 in axial direction Y and that is formed to communicate from outer side X1 in radial direction X of second protruding portion 31 to inner side X2 in radial direction X. Second protruding portion 31 of lower winding frame 3 has introduction groove 926 that continues from fourth groove 924 on the side closest to core 1 in axial direction Y and that is formed to communicate from inner side X2 in radial direction X of second protruding portion 31 to outer side X1 in radial direction X. Thus, introduction groove 925 and introduction groove 926 are formed to communicate from outer peripheral surface 301 of second protruding portion 31 to inner peripheral surface 302 on the inner side X2 in radial direction X.

[0019] 1, 2, and 9, first grooves 911, 921, second grooves 912, 922, third grooves 913, 923, and fourth grooves 914, 924 hold crossover wires 8 that connect coils 7 of different teeth 12. The crossover wires 8 are conductor wires 70 that connect the coils 7 to one another. The introduction grooves 915, 925 hold the conductor wires 70 so that they can be introduced from the outer side X1 in the radial direction X of the core 1 to the inner side X2 in the radial direction X to be wound around the teeth 12. The extraction grooves 916, 926 hold the crossover wires 8, after the conductor wires 70 have been wound around the teeth 12 to form the coils 7, so that they can be introduced from the inner side X2 in the radial direction X of the core 1 to the outer side X1 in the radial direction X, preventing loosening.

[0020] 5 and 8, the first leg 22 of the upper winding frame 2 and the second leg 32 of the lower winding frame 3 are configured to cover the inner circumferential surface 112, the first side surface 121, and the second side surface 131 of the core portion 60. That is, the first leg 22 and the second leg 32 fit into the slot 14 to insulate the coil 7 from the core 1. Note that, although the first embodiment shows an example in which the first leg 22 and the second leg 32 are formed to have approximately the same length in the axial direction Y, this is not limitative, and it is sufficient that the first leg 22 and the second leg 32 can insulate the core 1 from the coil 7, and the lengths of the first leg 22 and the second leg 32 in the axial direction Y can be changed as appropriate. Fig. 10 is a view of the core portion 60 as viewed from direction B in Fig. 8, showing the teeth side of the introduction grooves 915, 925 and the extraction grooves 916, 926. Fig. 11 is a view of the core portion 60 as viewed from direction C in Fig. 8, showing the side of the grooves 9 provided in the first protrusion 21 and the second protrusion 31. Fig. 12 is a view of the core portion 60 as viewed from direction D in Fig. 8, showing the introduction groove 915 and the extraction groove 916 conducting from the outside X1 to the inside X2 in the radial direction X of the first protrusion 21.

[0021] Next, the arrangement of the conductor wires 70 will be described with reference to FIGS. 1, 2, and 9. The conductor wires 70 are electric wires for forming the coil 7. Here, three conductor wires 70 are used for each phase of the power supply: a first conductor wire 71, a second conductor wire 72, and a third conductor wire 73. For each of the conductor wires 71, 72, and 73, the wires from which the winding of the coil 7 begins are designated as a first winding start wire 711, a second winding start wire 721, and a third winding start wire 731, respectively. When the first winding start wire 711, the second winding start wire 721, and the third winding start wire 731 are moved from the outer side X1 to the inner side X2 in the radial direction X of the core 1 and used as power supply wires connected to the power supply, they are designated as a first power supply wire 713, a second power supply wire 723, and a third power supply wire 733. The first power supply wire 713, the second power supply wire 723, and the third power supply wire 733 are indicated by dashed lines and will be described in detail below. Furthermore, the wires of each conductor wire 71, 72, 73 where the winding of the coil 7 has finished are referred to as a first winding end wire 712, a second winding end wire 722, and a third winding end wire 732. The first winding end wire 712, the second winding end wire 722, and the third winding end wire 732 are connected together to form a neutral point 700.

[0022] Next, the crossover wires 8 will be described with reference to FIG. 1. The crossover wires 8 are formed of conductor wires 70. The crossover wires 8 include a first crossover wire 81, a second crossover wire 82, a third crossover wire 83, a fourth crossover wire 84, a fifth crossover wire 85, and a sixth crossover wire 86. The first crossover wire 81 connects the coil 7 of the first core portion 61 to the coil 7 of the fourth core portion 64, which is three core portions away from the coil 7 in the circumferential direction Z. The second crossover wire 82 connects the coil 7 of the second core portion 62 to the coil 7 of the fifth core portion 65, which is three core portions away from the coil 7 in the circumferential direction Z. The third crossover wire 83 connects the coil 7 of the third core portion 63 to the coil 7 of the sixth core portion 66, which is three core portions away from the coil 7 in the circumferential direction Z.

[0023] The fourth crossover wire 84 connects the coil 7 of the fourth core portion 64 to the coil 7 of the seventh core portion 67. The fifth crossover wire 85 connects the coil 7 of the fifth core portion 65 to the coil 7 of the eighth core portion 68, which is three core portions away in the circumferential direction Z. The sixth crossover wire 86 connects the coil 7 of the sixth core portion 66 to the coil 7 of the ninth core portion 69, which is three core portions away in the circumferential direction Z.

[0024] Next, a manufacturing method for forming the coil 7 will be described. First, as shown in FIGS. 1, 2, and 9, the first conductor wire 71 is introduced from the outside X1 to the inside X2 in the radial direction X using the introduction groove 915 of the first core portion 61. Similarly, the second conductor wire 72 and the third conductor wire 73 are introduced from the outside X1 to the inside X2 in the radial direction X using the introduction grooves 915 of the second core portion 62 and the third core portion 63, respectively. Then, as shown in FIG. 13, a nozzle unit formed by integrating three winding nozzles 51, 52, and 53 is used to simultaneously wind the wires around each of the teeth 12 in the directions of arrows 511, 521, and 531 (however, FIG. 13 illustrates an example in which the wires are wound around the seventh core portion 67, the eighth core portion 68, and the ninth core portion 69).

[0025] Then, after the coils 7 are formed on the teeth 12 of the first core portion 61, the second core portion 62, and the third core portion 63, the coils 7 are held in their respective lead-out grooves 926 to prevent loosening, and are led out from the inner side X2 to the outer side X1 in the radial direction X. Then, as shown in FIG. 14 , the winding nozzles 51, 52, and 53 are moved in the direction of arrow E, and in order to perform the next winding process, the first conductor wire 71 is moved to the fourth core portion 64, the second conductor wire 72 is moved to the fifth core portion 65, and the third conductor wire 73 is moved to the sixth core portion 66. At this time, as shown in Figures 1, 2 and 9, the first crossover wire 81 connecting the coil 7 of the first core portion 61 and the coil 7 of the fourth core portion 64 is held from the outlet groove portion 926 to the fourth groove portion 924 of the first core portion 61, held in the third groove portion 923 of the second core portion 62 connected to it in the circumferential direction Z, further held in the second groove portion 922 of the third core portion 63 connected to it in the circumferential direction Z, and further held in the first groove portion 921 of the fourth core portion 64 connected to it in the circumferential direction Z, and is introduced from the outside X1 to the inside X2 of the fourth core portion 64 in the radial direction X through the introduction groove portion 925 connected to the first groove portion 921.

[0026] Similarly, the second jumper wire 82 connecting the coil 7 of the second core portion 62 and the coil 7 of the fifth core portion 65 is held from the outlet groove portion 926 to the fourth groove portion 924 of the second core portion 62, held in the third groove portion 923 of the third core portion 63 connected in the circumferential direction Z, further held in the second groove portion 922 of the fourth core portion 64 connected in the circumferential direction Z, and further held in the first groove portion 921 of the fifth core portion 65 connected in the circumferential direction Z, and is introduced from the outside X1 to the inside X2 of the fifth core portion 65 in the radial direction X through the introduction groove portion 925 connected to the first groove portion 921. Furthermore, the third crossover wire 83 connecting the coil 7 of the third core portion 63 and the coil 7 of the sixth core portion 66 is held from the outlet groove portion 926 to the fourth groove portion 924 of the third core portion 63, held in the third groove portion 923 of the fourth core portion 64 connected in the circumferential direction Z, further held in the second groove portion 922 of the fifth core portion 65 connected in the circumferential direction Z, and further held in the first groove portion 921 of the sixth core portion 66 connected in the circumferential direction Z, and is introduced from the outside X1 to the inside X2 of the sixth core portion 66 in the radial direction X through the introduction groove portion 925 connected to the first groove portion 921.

[0027] Then, similarly to the above, as shown in FIG. 13, using three winding nozzles 51, 52, 53, the first conductor wire 71, the second conductor wire 72, and the third conductor wire 73 are simultaneously wound around the teeth 12 of the fourth core portion 64, the fifth core portion 65, and the sixth core portion 66 in the directions of arrows 511, 521, and 531, respectively. 1, 2, and 9, after the coils 7 are formed on the teeth 12 of the fourth core portion 64, the fifth core portion 65, and the sixth core portion 66, the second crossover begins by changing the position to the upper winding frame 2 having the first protrusion 21 on the opposite side of the axial direction Y from the first crossover. Thus, the first conductor wire 71, the second conductor wire 72, and the third conductor wire 73 are held in the lead-out grooves 916 of the fourth core portion 64, the fifth core portion 65, and the sixth core portion 66 to prevent loosening, and are led out from the inner side X2 to the outer side X1 in the radial direction X. Then, the winding nozzles 51, 52, and 53 are moved in the direction of arrow E, and in order to perform the next winding process, the first conductor wire 71 is moved to the seventh core portion 67, the second conductor wire 72 is moved to the eighth core portion 68, and the third conductor wire 73 is moved to the ninth core portion 69.

[0028] At this time, the fourth crossover wire 84 connecting the coil 7 of the fourth core portion 64 and the coil 7 of the seventh core portion 67 is held from the outlet groove portion 916 to the fourth groove portion 914 of the fourth core portion 64, held in the third groove portion 913 of the fifth core portion 65 connected in the circumferential direction Z, further held in the second groove portion 912 of the sixth core portion 66 connected in the circumferential direction Z, and further held in the first groove portion 911 of the seventh core portion 67 connected in the circumferential direction Z, and is introduced from the outside X1 to the inside X2 of the seventh core portion 67 in the radial direction X through the introduction groove portion 915 connected to the first groove portion 911. Similarly, the fifth crossover wire 85 connecting the coil 7 of the fifth core portion 65 and the coil 7 of the eighth core portion 68 is held from the outlet groove portion 916 to the fourth groove portion 914 of the fifth core portion 65, held in the third groove portion 913 of the sixth core portion 66 connected in the circumferential direction Z, further held in the second groove portion 912 of the seventh core portion 67 connected in the circumferential direction Z, and further held in the first groove portion 911 of the eighth core portion 68 connected in the circumferential direction Z, and is introduced from the outside X1 to the inside X2 of the eighth core portion 68 in the radial direction X through the introduction groove portion 915 connected to the first groove portion 911.

[0029] Furthermore, the sixth crossover wire 86 connecting the coil 7 of the sixth core portion 66 and the coil 7 of the ninth core portion 69 is held from the outlet groove portion 916 to the fourth groove portion 914 of the sixth core portion 66, held in the third groove portion 913 of the seventh core portion 67 connected in the circumferential direction Z, further held in the second groove portion 912 of the eighth core portion 68 connected in the circumferential direction Z, and further held in the first groove portion 911 of the ninth core portion 69 connected in the circumferential direction Z, and is introduced from the outside X1 to the inside X2 of the ninth core portion 69 in the radial direction X through the introduction groove portion 915 connected to the first groove portion 911. Then, in the same manner as described above, as shown in FIG. 13, three winding nozzles 51, 52, and 53 are used to simultaneously wind the first conductor wire 71, the second conductor wire 72, and the third conductor wire 73 around the teeth 12 of the seventh core portion 67, the eighth core portion 68, and the ninth core portion 69 in the directions of the arrows 511, 521, and 531, respectively.

[0030] Then, after forming the coils 7 on the teeth 12 of the seventh core portion 67, the eighth core portion 68, and the ninth core portion 69, the first conductor wire 71, the second conductor wire 72, and the third conductor wire 73 are cut to form the first winding end wire 712, the second winding end wire 722, and the third winding end wire 732. These winding end wires 712, 722, and 732 are then crimped together to form the star-connected neutral point 700 ( FIG. 1 ). Wire connection processes such as brazing or soldering may also be used as a method of bundling.

[0031] 16 is a flow diagram showing the manufacturing process for wiring the stator 100. In FIG. 16, in step S1, the conductor wire 70 is wound around the teeth 12 to form the coil 7. In step S2, it is determined whether the conductor wire 70 has been wound around all of the teeth 12. If there are any remaining teeth 12, in step S3, a jumper wire 8 is applied to the tooth 12 three teeth away, and the process returns to step S1. Once the winding of the conductor wire 70 around all of the teeth 12 is complete, in step S4 the neutral point 700 is connected, and the wiring process for the stator 100 is completed.

[0032] In this way, the winding of the conductor wire 70 around the core portion 60 of the stator 100 shown in FIG. under A first crossover wire 81, a second crossover wire 82, and a third crossover wire 83 are connected to the opposite side of the power source, which is the reel 3. above Although an example has been shown in which the fourth crossover wire 84, the fifth crossover wire 85, and the sixth crossover wire 86 are arranged on the connection side, which is the reel 2, as another example, as shown in Figure 15, it is also possible to arrange the first crossover wire 81, the second crossover wire 82, and the third crossover wire 83 on the connection side of the power source, which is the upper reel 2 having the first protrusion 21, and the fourth crossover wire 84, the fifth crossover wire 85, and the sixth crossover wire 86 on the anti-connection side, which is the lower reel 3 having the second protrusion 31. However, the following explanation will be given using Figure 1 as an example.

[0033] Formed in this way, the first conductor wire 71 becomes, as a continuous conductor wire without being cut, the first winding start wire 711, the coil 7 of the first core portion 61, the first crossover wire 81, the coil 7 of the fourth core portion 64, the fourth crossover wire 84, the coil 7 of the seventh core portion 67, and the first winding end wire 712. The second conductor wire 72 becomes, as a continuous conductor wire without being cut, the second winding start wire 721, the coil 7 of the second core portion 62, the second crossover wire 82, the coil 7 of the fifth core portion 65, the fifth crossover wire 85, the coil 7 of the eighth core portion 68, and the second winding end wire 722. The third conductor wire 73 is a continuous conductor wire without being cut, and becomes the third winding start wire 731, the coil 7 of the third core portion 63, the third jumper wire 83, the coil 7 of the sixth core portion 66, the sixth jumper wire 86, the coil 7 of the ninth core portion 69, and the third winding end wire 732.

[0034] Next, processing is performed for use as power lines for first winding start wire 711, second winding start wire 721, and third winding start wire 731. When stator 100 is formed into a circular ring shape, these three power lines, first winding start wire 711, second winding start wire 721, and third winding start wire 731, must be removed from guide groove 915 and placed on the inside X2 in the radial direction X of stator 100 so as not to damage the power lines in the next process. After that, in the final process, a tube is placed over them to maintain insulation and the wiring process is performed.

[0035] Furthermore, according to the winding method of the present application, the winding start and end of the first and second windings are on opposite sides of each other in the axial direction Y, but the winding start and end of the third winding are common, i.e., on the same side in the axial direction Y. In other words, only the third winding has half a turn more or less than the number of turns of the first and second windings. Depending on the winding number specifications, this difference may affect the electrical characteristics. Countermeasures include changing the core shape of the tooth 12 to make the electrical characteristics common, or ending the third winding on the opposite side of the winding start and arranging the conductor wire 70 on the winding start side so that it does not affect the number of turns. These methods make it possible to make the number of turns common for all teeth.

[0036] Next, the core 1 is formed into a circular ring shape, and the ends of the core 1 are fixed together by welding or the like. Through these processes, the stator 100 is formed. Next, the entire rotating electric machine shown in FIG. 17 is assembled. FIG. 17 is a schematic diagram showing a cross section of the rotating electric machine 1000. The rotating electric machine 1000 includes the stator 100 of the first embodiment, a rotor 102 disposed on the inner circumferential side of the stator 100 with a predetermined gap therebetween, and a housing 101 that fixes the rotor 102 and the stator 100. The rotor 102 is rotatably held by fitting a shaft 1021 into an inner ring of a bearing 1011 provided in the housing 101. Fig. 18 is a schematic diagram showing the FF cross section of Fig. 17. Permanent magnets 1022 are embedded in a V-shape in rotor core 1023 fixed to the outer periphery of shaft 1021, but they may be arranged in other shapes, such as linear. Permanent magnets 1022 do not have to be embedded, and may be attached to the outer periphery of rotor core 1023 and arranged to face stator 100.

[0037] The above-described manufacturing method for the rotating electric machine 1000 is summarized in the flow diagram of Figure 19. In Figure 19, in step S11, two types of core piece groups are punched out alternately from a magnetic steel sheet, and multiple groups of each are stacked in the axial direction Y and connected at connecting portions 111 of the yoke portion 11 to form the core 1. In step S12, the upper and lower winding frames 2 and 3, which are formed by, for example, injection molding an insulating resin, are attached to the core 1. The first leg 22 of the upper winding frame 2 and the second leg 32 of the lower winding frame 3 are inserted and fitted into slots 14 from both ends of the core 1 in the axial direction Y, thereby attaching the upper and lower winding frames 2 and 3 to the core 1.

[0038] Next, in step S13, the wiring process for the stator 100 shown in Fig. 16 is performed. As a result, the coil 7 is formed in the core portion 60 of the stator 100 as shown in Fig. 1, and the wiring is completed. In step S14, the core 1 of the stator 100 formed in this manner is made into a circular ring, and the crossover wires 8 are shaped so as to be housed in the groove portions 9. In step S15, both ends of the connected cores 1 are welded, and the stator 100 is completed. Next, in step S16, the stator 100 is fixed to the housing of the rotating electric machine 1000, and in step S17, the rotor 102 is arranged opposite the stator 100, and the rotating electric machine 1000 is completed. In this embodiment 1, an example has been described in which the stator 100 has nine core portions 60, but a similar manufacturing method is possible even if the number of core portions 60 is 3×N (N is an integer greater than or equal to 2) by repeating the manufacturing method of the stator 100 every three teeth.

[0039] 18, the number of magnetic poles generated by the permanent magnets 1022 of the rotor 102 of the rotating electric machine 1000 is not limited to six as shown in FIG. 18, and may be a number corresponding to the number of teeth of the stator 100. For example, in the present invention (UVWUVW...), which requires a crossover wire to connect to a tooth two teeth away, if the number of teeth is 3×N (N is an integer equal to or greater than 2), the number of magnetic poles may be ((3±1)×N). Also, in the method (UU'UVV'VWW'W...), in which three teeth are wound consecutively around adjacent teeth, winding of the second tooth requires windings in the opposite direction to the first and third teeth, and if the number of teeth is 9×N (N is an integer equal to or greater than 1), the number of magnetic poles may be ((9±1)×N). In addition, in a method in which two adjacent teeth are wound in succession (UU'VV'WW'...), if the number of teeth is 6×N (N is an integer greater than or equal to 1), the number of magnetic poles may be ((6±1)×N).

[0040] When the number of magnetic poles of rotor 102 is ((9±1)×N), if N is 2 or more, it is necessary to wind on three consecutive teeth, then move on to the next tooth six teeth away, so a crossover operation with six teeth apart is required. When the number of magnetic poles is ((6±1)×N), it is necessary to wind on two consecutive teeth, then move on to the next tooth four teeth away, so a crossover operation with four teeth apart is required.

[0041] As described above, the stator of the rotating electric machine according to the first embodiment of the present application is a stator 100 of a rotating electric machine 1000 having a coil 7 wound around a core 1 via an insulating portion, and the insulating portion has a first protrusion 21 protruding to one side in the axial direction of the core 1 and a second protrusion 31 protruding to the other side in the axial direction of the core 1, and each of the first protrusion 21 and the second protrusion 31 is provided with a groove portion 9 in which a jumper wire 8 passing between the coils 7 is housed, and the jumper wire 8 is arranged in the groove portion 9 by swapping the positions of the first protrusion 21 and the second protrusion 31.

[0042] According to the present application, the first protrusion 21 and the second protrusion 31 protruding in the axial direction of the core 1 are each provided with a groove 9 in which the jumper wire 8 passing between the coils 7 is housed. Therefore, the positions of the first protrusion 21 and the second protrusion 31 can be changed and arranged in the groove 9, preventing interference of the jumper wire 8 of the core portion 60 when winding the conductor wire 70 during coil formation and reducing the number of connecting members. Furthermore, since the grooves 9 are formed so as to be inclined in the axial direction, the inclination of the grooves 9 can reliably prevent interference of the crossover wires 8 with the core portion 60.

[0043] The grooves 9 of the first protrusion 21 and the second protrusion 31 of the insulating part are formed in four stages, namely, first grooves 911, 921, second grooves 912, 922, third grooves 913, 923, and fourth grooves 914, 924, from the side farthest from the core 1 in the axial direction. The crossover wire 8 connects the coils 7 of the teeth 12 that are three apart in the circumferential direction, and also connects the coils 7 of the teeth 12 that are three apart in the circumferential direction from the first grooves 911, 921 to the teeth 12 that are three apart in the circumferential direction. Since the conductor wire 70 is continuously held in the second groove portions 912, 922, the third groove portions 913, 923, and the fourth groove portions 914, 924 of the first protrusion 21 or the second protrusion 31, the conductor wire 70 is wound between the teeth 12 that are spaced three apart in the circumferential direction to form the coil 7, and therefore the jumper wires 8 of other phases do not interfere with the starting wires of the conductor wires. This makes it possible to reduce the material costs and processing costs of the connecting members, while also obtaining a stator that prevents pulsation and vibration and has stable electrical characteristics.

[0044] In addition, the first protrusion 21 and the second protrusion 31 of the insulating part are continuous with the groove portion 9 on the side closest to the core 1 in the axial direction, and are formed so as to communicate from the radial outside to the radial inside of the first protrusion 21 and the second protrusion 31, and have introduction groove portions 915, 925 that hold the conductor wire 70, so that the conductor wire 70 can be easily guided toward the teeth 12. In addition, the first protrusion 21 and the second protrusion 31 of the insulating part are continuous with the groove portion 9 on the side farthest from the core 1 in the axial direction, and have guide groove portions 916, 926 that are formed continuously from the radial inside to the radial outside of the first protrusion 21 and the second protrusion 31 and hold the jumper wire 8, so that the jumper wire 8 can be easily guided to the location where the groove portion 9 of the first protrusion 21 and the second protrusion 31 is formed.

[0045] Furthermore, in each of the first protrusion 21 and the second protrusion 31, the position in the axial direction Y at which the conductor wire 70 is led out of the lead-out groove 916 is closer to the core 1 than the position in the axial direction Y at which the conductor wire 70 connected to the coil 7 at which the conductor wire 70 is connected is led into the lead-in groove 915. This allows the conductor wire 70 of each phase to be led from the lead-in groove to the tooth portion without interfering with the conductor wires 70 of other phases. This also allows the conductor wires 70 of multiple phases to be wound around the coil 7 simultaneously, and the jumper wires 8 leading out of the lead-out grooves 916, 926 to be led into the lead-in grooves 915, 925 at the destination from the side farther from the core 1 in the axial direction.

[0046] In addition, the first protrusion 21 and the second protrusion 31 of the insulating part have the power line in the groove 9 on the side farthest from the core 1 in the axial direction, so that the power line can be easily guided radially inward of the core 1. Furthermore, since the yoke portion 11 is formed so as to be deformable into a linear shape, the winding of the conductor wire 70 around the teeth 12 of the core 1 can be facilitated.

[0047] Furthermore, according to the manufacturing method of the stator 100 of the rotating electric machine 1000, the yoke portion 11 of the core 1 is deformed and aligned in a straight line, and three conductor wires 70 are simultaneously wound using three winding nozzles along paths that follow the shapes of three circumferentially consecutive teeth 12 to form the coils 7 around the three teeth 12. After that, the three conductor wires 70 are held as crossover wires 8 in the grooves 9 of the first protrusions 21 or second protrusions 31 of the three teeth 12 and moved to the tooth 12 that is three teeth away in the circumferential direction, so that the coils 7 can be formed by winding consecutive conductor wires 70 for each phase around three circumferentially consecutive teeth 12. This reduces the number of connecting members and suppresses product costs.

[0048] Embodiment 2 In the above-described first embodiment, the yoke portion 11 of the core 1 is deformed into a linear shape and aligned, and the conductor wire 70 is wound around the teeth 12 to form the coil 7. However, this is not limited to this method. As another method, the following will be described in which the yoke portion 11 of the core 1 is deformed into a reverse-bow shape using the connecting portion 111 to reverse the direction in which the teeth 12 protrude in the radial direction X. 20 is a schematic diagram showing a manufacturing method of stator 100 according to the second embodiment. Except for the winding method, this is the same as stator 100 according to the first embodiment. Winding machine 400 has hexagonal chuck mechanism 40. Chuck mechanism 40 has six chucks: chucks 41, 42, 43, 44, 45, and 46. Winding nozzles 54, 55, and 56 for winding conductor wire 70 are installed at positions of chuck mechanism 40 facing chucks 41, 42, and 43. The winding nozzles 54, 55, and 56 are rotated on the rotation axes T1, T2, and T3 to wind the conductor wire 70 around the teeth 12, respectively.

[0049] First, as shown in FIG. 20 , the first core portion 61, the second core portion 62, and the third core portion 63 of the core 1 are fixed to the chucks 41, 42, and 43, respectively. Then, the winding nozzles 54, 55, and 56 are rotated about the rotation axes T1, T2, and T3, and the conductor wire 70 is wound around each tooth 12 to form the coil 7. After the first winding is completed, the winding nozzles 54, 55, and 56 are moved back and forth and up and down, and the chuck mechanism 40 is rotated, so that the crossover wire 8 is connected to a predetermined core portion 60, as in the first embodiment. At this time, the chuck mechanism 40 rotates at 60° intervals. That is, the fourth core portion 64 rotates three times at 60° intervals to the position of the chuck 41 where the first core portion 61 was fixed during the first winding. The other core portions 60 also move simultaneously. Since the core portion 60 is ejected from the position of the chuck 46, the core portion 60 is not fixed at the position of the chuck 45.

[0050] According to the method for manufacturing the stator 100 of the rotating electric machine 1000 of the second embodiment, the yoke portion 11 of the core 1 is deformed into a reverse-warped shape, and three conductor wires 70 are simultaneously wound using three winding nozzles along paths that follow the shapes of three circumferentially consecutive teeth 12 to form coils 7 around the three teeth 12. Thereafter, the chuck mechanism 40 is rotated, and the three conductor wires are held as crossover wires 8 in the grooves 9 of the first protrusions 21 or second protrusions 31 of the three teeth 12, respectively, and moved to the tooth 12 that is three teeth away in the circumferential direction. This allows the conductor wires 70 for each phase to be wound around the three circumferentially consecutive teeth at high speed to form coils. This reduces the number of connecting members and suppresses product costs.

[0051] Furthermore, this method allows the coils 7 to be formed by winding the conductor wire 70 around the teeth 12 while ensuring a wide gap between adjacent teeth 12 in the circumferential direction Z. That is, as shown in FIG. 20 , the rotation axes T1, T2, T3 of the winding nozzles 54, 55, 56 can be always directed toward the teeth 12 during winding. This allows the conductor wire 70 to be wound around the teeth 12 at high speed, thereby shortening the winding cycle time. The method for manufacturing the stator of the rotating electric machine shown in the second embodiment can also be used in the third embodiment.

[0052] Embodiment 3 Hereinafter, a rotating electrical machine stator 100 according to the third embodiment and a method for manufacturing the same will be described with reference to the drawings, focusing on the differences from the first embodiment. FIG. 21 is a diagram showing a core plate of a stator according to embodiment 3. As shown in FIG. 21, core plate 603 has a structure in which the circumferential ends of yoke portions 11 are connected by thin-walled connecting portions 116. In this embodiment 3, one core plate 603 is formed by connecting nine sets of yoke portions 11 and teeth 12. The structure other than connecting portions 116 between core portions 60 is the same as that of FIG. 5 in embodiment 1. First Since it is the same as the core plate 601, a detailed description will be omitted.

[0053] Fig. 22 is a perspective view showing the core 1 after laminating the core plates 603 used in the stator 100 according to the third embodiment. Fig. 22 corresponds to Fig. 4 in the first embodiment, but the core portions 60 are connected by thin-walled connections using connecting portions 116. The core portions 60 connected in this manner are formed by laminating a plurality of core plates 603 formed by punching thin magnetic steel plates in the axial direction Y. At this connecting portion 116, the yoke portion 11 of the core portion 60 cannot be bent freely, but can be connected and held in a straight state. After the winding is completed, the connecting portion 116 is plastically deformed and bent into an annular shape, and the stator 100 is completed.

[0054] According to the third embodiment, the core portions 60 are connected to each other simply by stacking the core plates 603, which simplifies the connection structure and reduces manufacturing costs. Furthermore, the core portion 60 according to the present embodiment 3 can also be provided with the insulating member shown in the embodiment 1, and the insulating member can be attached in a linear arrangement and the conductor wire 70 can be wound around it, making it possible to manufacture the stator 100 in the same manner as in the embodiment 1, and obtaining the same effects as in the embodiment 1.

[0055] Embodiment 4 Hereinafter, a rotating electrical machine stator 100 according to the fourth embodiment and a method for manufacturing the same will be described with reference to the drawings, focusing on the differences from the first embodiment. FIG. 23 is a perspective view showing a core of a stator according to the fourth embodiment. The core portion 60 shown in FIG. 23 is formed by laminating a plurality of core plates 604 formed by punching thin magnetic steel plates in the axial direction Y, and each core portion 60 is in a divided core state, with no function of connecting with other core portions 60. The core plate 604 has a structure that does not have a connecting portion in the circumferential direction of the yoke portion 11. The other structure is the same as that of FIG. 5 in the first embodiment. First Since it is the same as the core plate 601, detailed description will be omitted. First The recessed portion described as the first recessed portion 114 in the description of the core plate 601 is used to enable the core portion 60 after lamination to be fixed to a fixing jig.

[0056] 24 is a perspective view showing the divided core portions 60 arranged in a straight line and fixed to a fixing jig 401, covered with an insulating member, and wound with a conductor wire 70. The fixing jig 401 for the core portion 60 is fixed using the first recess 114. The core portion 60 is fixed by fitting the first recess 114 into a rail-shaped protrusion (not shown) provided on the fixing jig 401, but the yoke portion 11 of the core portion 60 is also fixed by fitting the first recess 114 into the rail-shaped protrusion (not shown) provided on the fixing jig 401. jig Any other method may be used as long as it is a method for reliably fixing the wire 401 to the wire 401. jig With the core 60 attached to the rotor, an insulating member is placed on the core 60 and wound.

[0057] For winding, core portions 60 are arranged and held in a straight line on fixing jig 401, and the winding is performed continuously in the same manner as in embodiment 1. After the winding process is complete, core portions 60 are removed from fixing jig 401, and the nine teeth are arranged in a circular ring shape. Each core portion 60 is then fixed to form stator 100. Core portions 60 are fixed together by welding, shrink fitting, or the like. Alternatively, instead of using the fixing jig 401, an insulating member may be used to connect and hold the components.

[0058] According to the fourth embodiment, the core plates 604 can be punched out in the same shape from a magnetic steel plate, and the die for punching the core plates 604 can be realized with one small die, thereby reducing manufacturing costs. Furthermore, the core portion 60 according to this embodiment 4 can also be provided with the insulating member shown in embodiment 1, and the insulating member can be attached in a linear arrangement and the conductor wire 70 can be wound around it, making it possible to manufacture the stator 100 in the same manner as in embodiment 1, and achieving the same effects as in embodiment 1.

[0059] Embodiment 5. FIG. 25 is a perspective view of stator 100 for a rotating electric machine according to embodiment 5, in which yoke portion 11 of core 1 has been deformed and arranged in a straight line. This shows the state in which upper winding frame 20, lower winding frame 30, and film portion 230, which serve as insulating portions, have been attached. FIG. 26 is an exploded perspective view showing the state before upper winding frame 20, lower winding frame 30, and film portion 230, which are the components of FIG. 25, are attached to core 1. FIG. 27 is a perspective view showing the state in which only film portion 230 has been removed. FIG. 28 is a perspective view of upper winding frame 20 in embodiment 5, and FIG. 29 is a perspective view of lower winding frame 30. 25 to 28, parts that are the same as those in the above-described first embodiment are given the same reference numerals, and descriptions thereof will be omitted. As shown in Fig. 25, stator 100 in the fifth embodiment differs from that in the first embodiment in the configuration of upper winding frame 20 and lower winding frame 30 that serve as an insulating section that insulates core 1 from coil 7. In the fifth embodiment, the insulating section for insulating core 1 from coil 7 is composed of upper winding frame 20, lower winding frame 30, and film section 230.

[0060] 28 and 29, upper winding frame 20 and lower winding frame 30 have first protrusion 21 of upper winding frame 2 and second protrusion 31 of lower winding frame 3 in embodiment 1, but do not have portions corresponding to first leg 22 and second leg 32. Furthermore, first protrusion 21 has claws 211, 212, and 213 for securing film portion 230, which will be described later. Furthermore, second protrusion 31 has claws 311, 312, and 313 for fixing film portion 230. Furthermore, upper winding frame 20 and lower winding frame 30 have protrusions 215 and 315. Core 1 has second recesses 115 formed in teeth 12 in axial direction Y. Second recesses 115 may either penetrate through core 1 in axial direction Y, or may not penetrate through core 1 but are machined from above and below to the required depth. Upper winding frame 20 and lower winding frame 30 are installed by fitting protrusions 215 and 315 into second recesses 115 of core 1.

[0061] The film portion 230 is formed of a thin, insulating film material, for example, a film material with a thickness of 0.125 mm. The film material is then folded into a shape as shown in FIG. 27 . Due to these folds, the film portion 230 includes a first side surface 231 covering the inner circumferential surface 112, which is the side surface in the axial direction Y on the inner side X2 of the radial direction X of the yoke portion 11; a second side surface 232 covering the first side surface 121 and the second side surface 131, which are the side surfaces in the axial direction Y of the teeth 12; and a third side surface 233 covering the tip end surface 122, which is the side surface in the axial direction Y of the teeth 12 (see FIG. 5 for the corresponding part of the teeth 12). As shown in FIGS. 25 and 26 , when the film portion 230 is attached to the core 1, it is connected to the first protrusion 21 and the second protrusion 31 in the axial direction Y. The film portion 230 is continuously formed corresponding to all of the core portions 61 to 69 of the core 1. After the coil 7 is wound, the third side surface 233 is cut in the axial direction Y near the center of the arc shape, and the cut third side surface 233 is folded into the slot 14 and arranged to cover the outermost layer of the coil 7.

[0062] Specifically, the connection of the film portion 230 in the axial direction Y to the first protruding portion 21 of the upper winding frame 20 and the second protruding portion 31 of the lower winding frame 30 is formed so that, at both ends of the film portion 230 in the axial direction Y, it is longer than the length of the core 1 in the axial direction Y. The portions of the film portion 230 that are longer than both ends of the core 1 in the axial direction Y are fixed to the claw portions 211, 212, 213 of the upper winding frame 20 and the claw portions 311, 312, 313 of the lower winding frame 30, respectively. The other configurations and the method of manufacturing the stator 100 of the rotating electric machine 1000 are the same as those in the first embodiment.

[0063] The insulating portion of the stator of the rotating electric machine of the fifth embodiment configured as described above includes first protrusions 21 and second protrusions 31 that protrude from the other axial side of core 1, and film portion 230 that covers the axial side surfaces of teeth 12 and the radially inner axial side surfaces of yoke portion 11. This allows the insulating portion to be configured with thin film portion 230, which simplifies the configuration of the insulating portion and reduces costs. Also, the same effects as those of the first embodiment can be achieved.

[0064] 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 the present specification, 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 components of another embodiment. [Explanation of symbols]

[0065] 1 core, 11 yoke portion, 111 connecting portion, 1111 connecting hole, 1112 notch portion, 112 inner peripheral surface, 113 outer peripheral surface, 114 first recess, 115 second recess, 116 connecting portion, 12 teeth, 121 first side surface, 13 shoe portion, 131 second side surface, 122 tip surface, 14 slot, 2, 20 upper winding frame, 21 first protrusion portion, 22 first leg portion, 201 outer peripheral surface, 202 inner peripheral surface, 211, 212, 213 claw portion, 215 protrusion portion, 230 film portion, 231 first side surface, 232 second side surface, 233 third side surface, 3, 30 lower winding frame, 31 second protrusion portion, 32 second leg portion, 301 outer peripheral surface, 302 Inner peripheral surface, 311, 312, 313 claw portion, 315 convex portion, 40 chuck mechanism, 41, 42, 43, 44, 45, 46 chuck, 400 winding machine, 401 fixing jig, 51, 52, 53, 54, 55, 56 winding nozzle, 511, 521, 531 arrow direction, 6 core plate, 60 core portion, 61 first core portion, 62 second core portion, 63 third core portion, 64 fourth core portion, 65 fifth core portion, 66 sixth core portion, 67 seventh core portion, 68 eighth core portion, 69 ninth core portion, 601 first core plate, 602 second core plate, 603, 604 core plate, 7 coil, 70 conductor wire, 71 first conductor wire, 72 Second conductor wire, 73 Third conductor wire, 700 Neutral point, 711 First winding start wire, 721 Second winding start wire, 731 Third winding start wire, 712 First winding end wire, 722 Second winding end wire, 732 Third winding end wire, 713 First power supply wire, 723 Second power supply wire, 733 Third power supply wire, 8 Crossover wire, 81 First crossover wire, 82 Second crossover wire, 83 Third crossover wire, 84 Fourth crossover wire, 85 Fifth crossover wire, 86 Sixth crossover wire, 9, 91, 92 Groove portion, 911, 921 First groove portion, 912, 922 Second groove portion, 913, 923 Third groove portion, 914, 924 Fourth groove portion, 915, 925 Lead-in groove portion, 916, 926 Outlet groove portion, 100 stator, 101 housing, 1011 bearing, 102 rotor, 1021 shaft, 1022 permanent magnet, 1023 rotor core, 1000 rotating electric machine.

Claims

1. A stator for a rotating electric machine comprising: a core having a yoke portion arranged in an annular shape; a plurality of teeth formed on an inner peripheral surface of the yoke portion in a radial direction, the inner teeth protruding radially inward at predetermined intervals in the circumferential direction; coils formed by winding coil wires around the teeth; and an insulating portion disposed between the core and the coil to insulate the core from the coil, The insulating portion is a first protrusion protruding from one side of the core in the axial direction; a second protrusion protruding in the other axial direction of the core; Equipped with The coil is made up of continuous conductor wires, including crossover wires, provided for each phase that serves as a power source for the rotating electric machine, The power supply is a three-phase AC power supply, and nine coils are provided in total, each connected for each of the three phases of the power supply. the first protruding portion and the second protruding portion have grooves for accommodating the crossover wires for the respective phases; when the crossover wires are a first crossover wire, a second crossover wire, a third crossover wire, a fourth crossover wire, a fifth crossover wire, and a sixth crossover wire in the arrangement order of the coils, each crossover wire is arranged across two coils, the first crossover wire, the second crossover wire, and the third crossover wire are provided on one of the first protruding portion and the second protruding portion, the fourth crossover wire, the fifth crossover wire, and the sixth crossover wire are provided on the other of the first protruding portion and the second protruding portion, the first protrusion and the second protrusion each have an introduction groove through which the conductor wire is introduced radially inward from the groove, and an extraction groove through which the conductor wire is extracted from the coil wound around the tooth to the groove provided radially outward, the introduction groove of the first protrusion is located closer to one end in the circumferential direction than the outlet groove of the first protrusion, the introduction groove of the second protrusion is located closer to the one end in the circumferential direction than the outlet groove of the second protrusion, In each of the first protrusion and the second protrusion, an axial position at which the conductor wire is led out of the lead-out groove is disposed closer to the core than an axial position at which the conductor wire connected to the coil at the destination of the conductor wire is led into the lead-in groove; and the introduction groove portion is disposed farthest from the core in the axial direction than the groove portion that accommodates the crossover wire for each phase, A stator for a rotating electric machine, characterized in that in each of the first protrusion and the second protrusion, the conductor wire coming out of the outlet groove is guided to the groove that houses the jumper wire for each phase and connected to the introduction groove of the coil to which it is connected.

2. In one of the first protrusion and the second protrusion, an axial position at which the conductor wire connected to the coil at the destination of the first crossover wire is introduced into the introduction groove is disposed at a position farther from the core than axial positions of the second crossover wire and the third crossover wire at the same circumferential position as the introduction groove; and an axial position at which the conductor wire connected to the coil at the destination of the second jumper wire is introduced into the introduction groove is disposed at a position farther from the core than an axial position of the third jumper wire at the same circumferential position as the introduction groove; On the other of the first protrusion and the second protrusion, an axial position at which the conductor wire connected to the coil at the destination of the fourth crossover wire is introduced into the introduction groove is disposed at a position farther from the core than axial positions of the fifth crossover wire and the sixth crossover wire at the same circumferential position as the introduction groove; and 2. The stator of claim 1, wherein the axial position at which the conductor wire connected to the coil at the destination of the fifth jumper wire is introduced into the introduction groove is located farther from the core than the axial position of the sixth jumper wire at the same circumferential position as the introduction groove.

3. 2. The stator of claim 1, wherein the conductor wire coming out of the outlet groove of the second protrusion is guided as the crossover wire into the groove of the second protrusion and is connected to the introduction groove at the second protrusion at the crossover destination, which is located circumferentially closer to the one end than the outlet groove at the crossover destination of the crossover wire.

4. 2. The stator of claim 1, wherein the conductor wire is introduced into the introduction groove located on the one circumferential end side of the outlet groove at the second protrusion at the destination of the jumper wire, and exits from the introduction groove located on the other circumferential end side opposite the one circumferential end side of the outlet groove at the first protrusion.

5. 2. The stator of claim 1, wherein the first protrusion and the second protrusion insulate the teeth from the coils, and the grooves house the jumper wires radially outward, and the grooves are provided in four stages for each phase of the power supply, extend circumferentially while inclining axially, and are configured to face the grooves of adjacent coils circumferentially.

6. 6. The stator of claim 5, wherein the insulating portion includes a film portion covering a side surface of the tooth between the first protrusion and the second protrusion.

7. 6. The stator of claim 5, wherein the core has a structure that allows a plurality of the cores to be linearly connected at the yoke portion.

8. 6. The stator of claim 5, wherein the core has a structure that allows a plurality of the teeth to be connected at the yoke portion in a reversely curved shape facing outward.

9. The core is formed by stacking first core plates and second core plates that are symmetrical to each other in the circumferential direction, in a staggered arrangement, the first core plate and the second core plate each have the yoke portion protruding radially outward in the circumferential direction and the teeth protruding radially inward, the first core plate has a first connecting hole at one circumferential end of the yoke portion and a first notch at the other circumferential end, the second core plate has a second notch portion at one circumferential end of the yoke portion and a second connecting hole at the other circumferential end, the second notch portion being circumferentially symmetrical to the first core plate; 5. A stator for a rotating electric machine according to claim 1, characterized in that in the yoke portion of a core adjacent to the core, the first connecting hole of the first core plate and the second notch portion of the second core plate, or the second connecting hole of the second core plate and the first notch portion of the first core plate, are butted and overlapped to enable connection.

10. 6. The stator of claim 5, wherein the core is formed by stacking core plates in which the circumferential tips of the adjacent yoke portions are connected to form a thin wall.

11. 6. The stator of a rotating electric machine according to claim 5, wherein the core has a recess on the radially outer side of the yoke portion that can be fixed to a fixing jig, and has a structure that allows multiple cores to be connected in a linear manner to the fixing jig for continuous winding.

12. A stator for a rotating electric machine as described in Claim 1, characterized in that the conductor wire coming out of the outlet groove portion of the second protrusion is guided as the crossover wire into the groove portion of the second protrusion, and at the second protrusion at the destination of the crossover wire, is inclined in a direction away from the core toward the outlet groove portion at the destination of the crossover wire.

13. A rotating electric machine comprising: the stator of claim 1; and a rotor disposed opposite the stator with a gap therebetween.

14. A method for manufacturing a stator for a rotating electric machine according to claim 7, comprising the steps of: A plurality of the cores are connected and arranged in a straight line, The three conductor wires for each phase are simultaneously wound using three winding nozzles along paths that follow the shapes of the three circumferentially adjacent teeth to form the coils around the three teeth. A method for manufacturing a stator for a rotating electric machine, characterized in that three of the conductor wires are held as crossover wires in the grooves of the first protrusions or the second protrusions of three of the teeth, and moved to a tooth three teeth away in the circumferential direction.

15. 9. A method for manufacturing a stator for a rotating electric machine according to claim 8, comprising the steps of: A plurality of the cores are connected and arranged around the chuck mechanism in a reverse-warped manner, The three conductor wires for each phase are simultaneously wound using three winding nozzles along paths that follow the shapes of the three circumferentially adjacent teeth to form the coils around the three teeth. A method for manufacturing a stator for a rotating electric machine, characterized in that three of the conductor wires are held as crossover wires in the grooves of the first protrusions or the second protrusions of three of the teeth, and the chuck mechanism is rotated to move to a tooth that is three teeth away in the circumferential direction.

16. 16. A method for manufacturing a rotating electric machine, comprising: disposing a rotor opposite to a stator manufactured by the method for manufacturing a stator for a rotating electric machine according to claim 14 or 15, with a gap therebetween.

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