Stator and method for manufacturing a stator

Abstract

To improve workability in winding a conductor in a winding structure having a plurality of teeth groups to be a three-teeth two-phase winding.SOLUTION: A stator includes a stator core having a plurality of teeth provided at predetermined intervals in a circumferential direction, and a stator winding having a plurality of phase windings provided for each phase. Each of the phase windings has a plurality of partial windings wound around the teeth by concentrated winding. Circumferentially consecutive three teeth of the plurality of teeth are defined as one teeth group. Among the first teeth, second teeth, and third teeth in the teeth group, a first conducting wire C1 is wound around the first teeth and the second teeth, and a second conducting wire C2 is wound around the second teeth and the third teeth, thereby a stator winding being formed. Each of the first conductive wire C1 and the second conductive wire C2 is continuously wound in two teeth groups adjacent to each other in the circumferential direction.SELECTED DRAWING: Figure 10

Description

Technical Field

[0001] The present invention relates to a stator and a method for manufacturing the stator.

Background Art

[0002] In a rotating electric machine including a stator and a rotor, in order to reduce the ripple current in the stator winding provided in the stator, it is conceivable to wind two-phase winding having different phases from each other in each of three consecutive teeth in the circumferential direction. For example, in Patent Document 1, in a rotating electric machine having a three-phase stator winding composed of a U-phase, a V-phase, and a W-phase, in a first tooth, coil bodies Ua, Va, and Wa of the U-phase, the V-phase, and the W-phase in the first stator winding are wound, in a second tooth, coil bodies Ub, Vb, and Wb of the U-phase, the V-phase, and the W-phase in the second stator winding are wound, and in a third tooth, coil bodies Uc, Vc, and Wc of any one phase of the first and second stator windings are wound. A technique is described in which the phase difference of the magnetomotive forces in each coil body between phases is within a predetermined phase range including 20 degrees in electrical angle.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in Cited Document 1 and the like, there is no description of a specific configuration in which two-phase winding is wound around each tooth group composed of three teeth continuous in the circumferential direction. Therefore, a proposal on a technique for winding two-phase winding around each of the three consecutive teeth in the circumferential direction is desired.

[0005] The present invention has been made in view of the above problems, and its purpose is to provide a stator and a method for manufacturing a stator that can improve workability when winding a conductor in a winding structure having a plurality of groups of teeth which are 3-tooth 2-phase windings. [Means for solving the problem]

[0006] The following describes the means to solve the above problems and their effects.

[0007] Method 1 is, A stator comprising a stator core having a plurality of teeth arranged at predetermined intervals in the circumferential direction, and a stator winding having a plurality of phase windings arranged for each phase, Each of the aforementioned phase windings has a plurality of partial windings that are wound around the teeth by concentrated winding, In the aforementioned plurality of teeth, three teeth that are continuous in the circumferential direction are considered as one tooth group, and in that tooth group, the first conductor is wound around the first tooth and the second tooth, and the second conductor is wound around the second tooth and the third tooth, thereby forming the stator winding. The first and second conductors are characterized in that they are wound continuously around two adjacent groups of teeth in the circumferential direction.

[0008] For example, in order to reduce ripple current in the stator, it is conceivable to wind two phase windings that are in different phases around each of the three consecutive teeth in the circumferential direction. In this case, in a group of teeth consisting of three consecutive teeth in the circumferential direction, the first conductor is wound around the first and second teeth, and the second conductor is wound around the second and third teeth, respectively. In this configuration, the first and second conductors are each wound continuously around two adjacent groups of teeth in the circumferential direction. In this case, the two conductors (the first and second conductors) are wound around six teeth, spanning two adjacent groups of teeth in the circumferential direction. In this configuration, in a winding structure having multiple groups of teeth that form a 3-tooth 2-phase winding, the stator windings for 6 teeth arranged in the circumferential direction are wound together by the first and second conductors, thereby improving workability during conductor winding.

[0009] In means 2, in two groups of teeth adjacent to each other in the circumferential direction, each tooth is numbered 1st to 6th in the circumferential direction, the first conductor is the pre-wound conductor, and the second conductor is the post-wound conductor, with the first conductor being wound in the order of 1st, 2nd, 4th, and 5th, and the second conductor being wound in the order of 6th, 5th, 3rd, and 2nd, or 5th, 6th, 2nd, and 3rd.

[0010] In the order described above, the first and second conductors are wound around two adjacent tooth groups in the circumferential direction (i.e., each of the six consecutive teeth in the circumferential direction), thereby enabling the realization of an appropriate winding structure in a stator having multiple tooth groups that form a 3-tooth 2-phase winding.

[0011] In means 3, one end in the axial direction is designated as the first coil end, and the other end in the axial direction is designated as the second coil end. In the first conductor, the first coil end is provided with the starting and ending ends of two adjacent tooth groups in the circumferential direction, and the second coil end is provided with a connecting portion between the respective tooth groups. In the second conductor, the first coil end is provided with the starting and ending ends of two adjacent tooth groups in the circumferential direction, and the second coil end is provided with a connecting portion between the respective tooth groups.

[0012] According to the above configuration, the starting and ending ends of each conductor (first conductor and second conductor) are provided on the first coil end side of the stator, and the connecting sections for each conductor are provided on the second coil end side. In this case, since the starting and ending ends and connecting sections of each conductor are distributed on both sides of the axial direction, interference between conductors is less likely to occur, and the winding work of the conductors becomes easier.

[0013] In means 4, of the first and second conductors, the first conductor is a pre-wound conductor and the second conductor is a post-wound conductor, and an insulating member is provided at the axial end of the stator core to insulate the teeth from the partial winding, and the connecting portion of the first conductor between each of the teeth is guided by the insulating member to a position radially separated from the teeth.

[0014] As described above, in a configuration where two conductors (first conductor and second conductor) with some overlap are wound around each tooth, there is a concern that the crossover portion between teeth of the first-winding conductor may interfere with the winding of the second-winding conductor. To address this, an insulating member is provided at the axial end of the stator core to guide the crossover portion of the first conductor to a position radially separated from the teeth. This suppresses the inconvenience of the crossover portion of the first-winding conductor interfering with the winding of the second-winding conductor.

[0015] In method 5, the stator winding is such that the phase windings of each phase are connected at the neutral point, and in two adjacent tooth groups in the circumferential direction, a neutral point connecting member is connected to the connecting portion from one tooth group to the other.

[0016] According to the above configuration, in two adjacent tooth groups in the circumferential direction, the first and second conductors each have two phase windings wound continuously, and a neutral point connection member is connected to the intermediate portion between the two phase windings. In this case, for example, compared to a configuration in which a neutral point connection member is connected to each of the two phase windings in each tooth group, the number of neutral point connections can be reduced. As a result, in a winding structure having multiple tooth groups with three teeth and two phase windings, it is possible to improve the workability of conductor winding while also achieving a simplified configuration for neutral point connections.

[0017] In means 6, the stator winding has two parallel phase windings for each phase, and the two parallel phase windings for each phase are connected at one neutral point. In each group of teeth, the two parallel phase windings for each phase are connected to phase windings of different phases that are separate from each other. The neutral point connection members are connected to the connecting portions between two adjacent groups of teeth in the circumferential direction, thereby connecting the one neutral point.

[0018] In the above configuration, for example, in a three-phase stator winding, the two parallel phase windings for each phase are connected in a star configuration by a single common neutral point connector. This reduces the number of connections to the neutral point connector, thereby simplifying the configuration.

[0019] In means 7, the stator winding has two parallel phase windings for each phase, and two neutral points are connected by one side of each pair of parallel phase windings and the other side of each pair of parallel phase windings. In each group of teeth, each pair of parallel phase windings is connected to a phase winding of a different phase. In some combinations of two adjacent groups of teeth in the stator winding, the connection portion by the connecting portion is separated. The two neutral points are connected to two sets of neutral point connection points, each consisting of the connecting portion between two adjacent groups of teeth and the wire end where the connecting portion is separated between two adjacent groups of teeth, by connecting the neutral point connecting member to each of these two sets of neutral point connection points.

[0020] In the above configuration, for example, in a three-phase stator winding, the two parallel phase windings for each phase are connected in a star configuration by two neutral point connecting members. This makes it possible to shorten the length of each neutral point connecting member in the circumferential direction.

[0021] Means 8 is, A method for manufacturing a stator, comprising a stator core having a plurality of teeth provided at predetermined intervals in the circumferential direction, and a stator winding having a plurality of phase windings provided for each phase, wherein each phase winding has a plurality of partial windings that are wound around the teeth by concentrated winding, The stator winding is configured such that three teeth that are circumferentially continuous in the plurality of teeth form a tooth group, and in that tooth group, the first conductor is wound around the first tooth and the second tooth, and the second conductor is wound around the second tooth and the third tooth. A first winding step in which a conductor is continuously wound around the first tooth and the second tooth of each of two adjacent tooth groups in the circumferential direction, Thereafter, using the same conductor material as in the first winding step continuously, in two adjacent tooth groups in the circumferential direction, a second winding step of continuously winding the conductor material around the second teeth and the third teeth of each of these tooth groups; A cutting step of cutting the middle portion of the conductor material wound in the first winding step and the second winding step, and making the first conductor and the second conductor continuously wound around the two adjacent tooth groups in the circumferential direction respectively in a state where they are wound around the two tooth groups; It is characterized by having the above.

[0022] According to the manufacturing method of the above structure, in a stator having a plurality of tooth groups that form a three-tooth two-phase winding, while taking two adjacent tooth groups in the circumferential direction (i.e., six consecutive teeth) as one unit, the conductor material can be efficiently wound. In this case, while straddling two adjacent tooth groups in the circumferential direction, two conductors (the first conductor and the second conductor) can be suitably wound around six teeth. As a result, the workability during conductor winding can be made good.

[0023] In means 9, The stator core has (6×n) of the teeth, The stator winding has {(6×n) / 3} of the tooth groups, In the first winding step, in all the tooth groups in the circumferential direction, the conductor material is continuously wound around the first tooth and the second tooth, In the second winding step, using the same conductor material as in the first winding step continuously, in all the tooth groups in the circumferential direction, the conductor material is continuously wound around the second tooth and the third tooth, In the cutting step, the middle portion of the conductor material wound in the first winding step and the second winding step is cut, and in two adjacent tooth groups in the circumferential direction, the first conductor and the second conductor are respectively in a state of being continuously wound around the two tooth groups. <00001​According to the manufacturing method described above, it is possible to properly wind the wire around the group of teeth, which will be a 3-tooth 2-phase winding, using a single continuous wire for all teeth in the circumferential direction. [Brief explanation of the drawing]

[0025] [Figure 1] A cross-sectional view of the motor. [Figure 2] Cross-sectional view of the motor. [Figure 3] A diagram showing the electrical configuration of the control device. [Figure 4] Plan view of the stator. [Figure 5] A perspective view illustrating the configuration of the stator core. [Figure 6] Winding diagram of the stator winding. [Figure 7] A diagram showing the correspondence between each section winding of the stator winding and each tooth. [Figure 8] A diagram illustrating the winding structure in the teeth group. [Figure 9] A diagram showing the winding sequence of the conductor material around the teeth. [Figure 10] A diagram showing the configuration of the neutral point connection in each stator winding. [Figure 11] A diagram showing the winding sequence of the conductor material around the teeth. [Figure 12] A diagram showing the winding sequence of the conductor material around the teeth in the second embodiment. [Figure 13] A diagram showing the winding sequence of the conductor material around the teeth in the second embodiment. [Figure 14] A diagram showing the winding sequence of the conductor material around the teeth in the third embodiment. [Figure 15] Winding diagram of the stator winding. [Figure 16] In another embodiment, this figure shows the configuration of the neutral point connection in each stator winding. [Figure 17] A diagram showing the winding configuration of the stator winding in another embodiment. [Figure 18] In another embodiment, this figure shows the configuration of the neutral point connection in each stator winding. [Modes for carrying out the invention]

[0026] (First Embodiment) The embodiments will be described below with reference to the drawings. In the following embodiments, parts that are the same or equivalent to each other are denoted by the same reference numerals in the drawings, and the explanations for such parts will be based on those same reference numerals. In the first embodiment, a motor 10 as a rotating electric machine will be described as an example.

[0027] The motor 10 shown in Figure 1 is a permanent magnet field type, specifically a permanent magnet field synchronous machine having three phase windings. In other words, the motor 10 is a brushless motor. It may have two sets of three phase windings. The motor 10 comprises a housing 20, a stator 30 fixed to the housing 20, a rotor 40 that rotates relative to the stator 30, and a rotating shaft 11 to which the rotor 40 is fixed. Hereinafter, in this embodiment, axial direction refers to the axial direction of the rotating shaft 11, radial direction refers to the radial direction of the rotating shaft 11, and circumferential direction refers to the circumferential direction of the rotating shaft 11.

[0028] The housing 20 is formed in a cylindrical shape, and the stator 30 and rotor 40 are housed inside the housing 20. The housing 20 is provided with bearings 23 and 24, which rotatably support the rotating shaft 11. The axis of the inner surface of the housing 20 is coaxial with the rotating shaft 11. An angle sensor 12 is provided on the tip side of the rotating shaft 11. The angle sensor 12 may be a magnetic sensor or a resolver.

[0029] The stator 30 is cylindrical and positioned approximately in the axial center of the housing 20, along the inner circumference of the housing 20. The stator 30 is fixed to the inner surface of the housing 20 with respect to the axis O of the rotation shaft 11. The stator 30 constitutes part of the magnetic circuit and has a ring-shaped stator core 31 arranged radially opposite to the outer circumference of the rotor 40, and stator windings 32 wound around the stator core 31.

[0030] As shown in Figure 2, the stator core 31 has an annular back yoke 33 and a plurality of teeth 34 that protrude radially inward from the back yoke 33 and are arranged at predetermined distances in the circumferential direction, with slots 35 formed between adjacent teeth 34. In the stator core 31, the teeth 34 are provided at equal intervals in the circumferential direction, and the stator windings 32 are wound around these teeth 34. As a result, the conductors of the stator windings 32 are housed in each slot 35. In this embodiment, the number of teeth 34 and the number of slots 35 are both set to "18". For the sake of explanation, each tooth 34 is assigned the designation T1 to 18 in clockwise order according to the circumferential arrangement, and when it is necessary to indicate the tooth number, the teeth 34 will also be referred to as teeth T1, T2, T3, etc. The stator windings 32 are held in a state housed in the slots 35, and magnetic flux is generated when power (AC power) is supplied.

[0031] The stator core 31 is formed by using multiple thin, magnetic steel plates (core sheets), which are stacked in the axial direction of the stator core 31. The steel plates may be formed, for example, by press-punching strip-shaped electromagnetic steel sheets.

[0032] The rotor 40 constitutes part of the magnetic circuit, has multiple magnetic poles in the circumferential direction, and is positioned radially opposite to the stator 30. In this embodiment, the rotor 40 has 14 magnetic poles (i.e., 7 magnetic pole pairs). The rotor 40 comprises a rotor core 41 made of a magnetic material and a plurality of permanent magnets 42 fixed to the rotor core 41. Specifically, as shown in Figure 2, the rotor 40 is equipped with permanent magnets 42 as magnetic parts for each magnetic pole such that the polarity alternates in the circumferential direction, and the permanent magnets 42 are embedded in housing holes provided in the rotor core 41 along the axial direction.

[0033] The rotor 40 may have a well-known configuration, and may be, for example, an IPM (Interior Permanent Magnet) type rotor or an SPM (Surface Permanent Magnet) type rotor. Alternatively, a rotor on the field winding side may be used as the rotor 40. In this embodiment, an IPM type rotor is used. The rotating shaft 11 is inserted through the rotor 40 and fixed to the rotating shaft 11 so as to rotate integrally with the rotating shaft 11 around the rotating shaft 11.

[0034] A control device 50 is connected to the motor 10. The control device 50 is mainly composed of a microcomputer equipped with a CPU, ROM, RAM, and I / O, and various functions are realized by the CPU executing a program stored in the ROM. These various functions may be realized by hardware electronic circuits, or at least a part of them may be realized by software, i.e., processing executed on a computer.

[0035] The control device 50 has functions such as converting power from an external source (e.g., a battery) and supplying it to the motor 10 to generate driving force. In addition, the control device 50 has a function to control the motor 10 (such as current control) using information about the rotation angle input from the angle sensor 12.

[0036] Figure 3 shows the electrical configuration of the control device 50 in this embodiment.

[0037] In this embodiment, the stator winding 32 is composed of a first stator winding 32a and a second stator winding 32b, and the control device 50 is provided with a first inverter circuit 51 and a second inverter circuit 52 for each of the stator windings 32a and 32b. Each inverter circuit 51 and 52 is composed of a full-bridge circuit having the same number of upper and lower arms as the number of phases in the three-phase system. The control device 50 controls the current in each phase by turning on and off switching elements provided on each arm.

[0038] More specifically, the first inverter circuit 51 comprises three phases, U-phase, V-phase, and W-phase, each equipped with a series connection of an upper arm switch Sp and a lower arm switch Sn as switching elements. In this embodiment, voltage-controlled semiconductor switching elements are used as the upper arm switch Sp and lower arm switch Sn in each phase, specifically IGBTs. MOSFETs may also be used as switching elements. Freewheeling diodes Dp and Dn are connected in antiparallel to the upper arm switch Sp and lower arm switch Sn in each phase, respectively.

[0039] The high-potential side terminal (collector) of each phase's upper arm switch Sp is connected to the positive terminal of the battery. The low-potential side terminal (emitter) of each phase's lower arm switch Sn is connected to the negative terminal (ground) of the battery. The intermediate connection point between each phase's upper arm switch Sp and lower arm switch Sn is connected to one end of the phase winding of each phase in the first stator winding 32a. The first stator winding 32a has U-phase, V-phase, and W-phase windings, and in the first inverter circuit 51, one end of each of these phase windings is connected to the intermediate connection point of the upper and lower arm switches Sp and Sn, respectively.

[0040] The second inverter circuit 52 has the same configuration as the first inverter circuit 51, so a detailed explanation is omitted here. The second stator winding 32b has X-phase, Y-phase, and Z-phase windings, and in the second inverter circuit 52, one end of each of these phase windings is connected to the intermediate connection point of the upper and lower arm switches Sp and Sn, respectively.

[0041] The three-phase current supplied from the first inverter circuit 51 and the three-phase current supplied from the second inverter circuit 52 have a predetermined current phase difference from each other.

[0042] The specific configuration of the stator 30 is described below. Figure 4 is a plan view of the stator 30, and Figures 5(a) and 5(b) are perspective views illustrating the configuration of the stator core 31. The stator 30 shown in Figure 4 corresponds to the stator 30 shown in Figure 2.

[0043] In the stator 30, the stator core 31 is composed of a plurality of segmented cores 61, and the stator core 31 is formed into a cylindrical shape by arranging each segmented core 61 in a circumferential direction. Each segmented core 61 has a core body 62 which is a laminate of steel plates and insulating members 63, 64 which are made of an insulating resin material or the like. Figure 5(a) shows the stator core 31 with the insulating members 63, 64 attached, and Figure 5(b) shows the stator core 31 with the insulating members 63, 64 removed.

[0044] The core body 62 has teeth 34 extending radially from the stator core 31, a yoke portion 62a provided at one end, and a flange portion 62b provided at the other end. The yoke portion 62a corresponds to the back yoke 33 of the stator core 31 shown in Figure 2. In adjacent divided cores 61, the yoke portions 62a are preferably joined together by adhesive or the like. Insulating members 63 and 64 are attached to one axial end and the other end of the teeth 34. The insulating members 63 and 64 have upright portions 63a and 64a that extend axially radially outward from the teeth 34 (towards the back yoke 33). The upright portions 63a and 64a are provided with grooves 63b and 64b at two locations in the circumferential direction, through which the conductor material of the stator winding 32 can be inserted.

[0045] As each segmented core 61 is arranged in the circumferential direction, the teeth 34 and slots 35 are arranged alternately in the circumferential direction, as shown in Figure 2. In this embodiment, the stator core 31 is composed of 18 segmented cores 61. The stator winding 32 is constructed by winding conductor material around each tooth 34 in a concentrated winding manner.

[0046] An example of the electrical configuration of the stator winding 32 is shown in Figure 6. Figure 6(a) shows the configuration of the U, V, and W phase windings in the first stator winding 32a, and Figure 6(b) shows the configuration of the X, Y, and Z phase windings in the second stator winding 32b. In these stator windings 32a and 32b, the phase windings of each phase are connected to each other by a star connection (Y connection).

[0047] As shown in Figure 6(a), the first stator winding 32a has partial windings U1, U2, U3, and U4 as the U-phase winding, partial windings V1, V2, V3, and V4 as the V-phase winding, and partial windings W1, W2, W3, and W4 as the W-phase winding. The four partial windings for each phase winding are connected in parallel in pairs, and the two parallel phase windings for each phase are connected in a star configuration. In other words, the phase windings for each phase are connected to each other at the neutral point N1.

[0048] Furthermore, as shown in Figure 6(b), the second stator winding 32b has partial windings X1, X2, X3, and X4 as the phase windings for the X phase, partial windings Y1, Y2, Y3, and Y4 as the phase windings for the Y phase, and partial windings Z1, Z2, Z3, and Z4 as the phase windings for the Z phase. The four partial windings for each phase winding are connected in two parallel configurations, and the two parallel phase windings for each phase are connected in a star configuration. In other words, the phase windings for each phase are connected to each other at the neutral point N2.

[0049] The partial windings U1-U4, V1-V4, and W1-W4 of each phase in the first stator winding 32a, and the partial windings X1-X4, Y1-Y4, and Z1-Z4 of each phase in the second stator winding 32b are each wound around the teeth 34 of the stator core 31 by concentrated winding. In this embodiment, the 12 partial windings of the first stator winding 32a and the 12 partial windings of the second stator winding 32b are distributed and wound around the 18 teeth 34 of the stator core 31. This point will be explained in detail below.

[0050] In the stator core 31, all 18 teeth 34 are divided into groups of three teeth, and each group of three teeth 34 has partial windings of two phase windings that are in different phases wound around it. In other words, in the stator 30, as shown in Figure 4, all the teeth 34 (T1~T18) of the stator core 31 are divided into six tooth groups G1~G6, and each tooth group G1~G6 has two partial windings from the first stator winding 32a (U1~U4, V1~V4, W1~W4) and two partial windings from the second stator winding 32b (X1~X4, Y1~Y4, Z1~Z4) wound around it. In this case, in each tooth group G1 to G6, one of the three teeth 34 on the circumferential side is wound with a partial winding of the first stator winding 32a, and the other of the same teeth 34 is wound with a partial winding of the second stator winding 32b. In addition, the central tooth 34 of each tooth group G1 to G6 is wound with partial windings of both the first and second stator windings 32a and 32b.

[0051] Here, in each tooth group G1 to G6, if we consider the three consecutive teeth 34 in the circumferential direction as the first tooth, second tooth, and third tooth in circumferential order, then of these first to third teeth, the first and second teeth are continuously wound with a portion of the first phase winding from among the multiple phase windings, and the second and third teeth are continuously wound with a portion of the second phase winding from among the multiple phase windings. The second tooth, which is the center of the three consecutive teeth 34, is a common tooth on which both the first and second phase windings are wound. In this case, the "first phase winding" is one of the phase windings of the six phases in the first and second stator windings 32a and 32b, and the "second phase winding" is a different phase winding from the first phase winding among the six phase windings.

[0052] Figure 7 shows the correspondence between each partial winding of the stator windings 32a and 32b and each tooth T1 to T18. In Figure 7, for example, in tooth group G1, • The first tooth, tooth T1, has a partial winding Y3 of the second stator winding 32b wound around it. The second tooth T2 has a partial winding Y4 of the second stator winding 32b and a partial winding U4 of the first stator winding 32a wound around it. The third tooth, tooth T3, has a partial winding U3 of the first stator winding 32a wound around it. The other tooth groups G2 to G6 will not be explained, but each partial winding is wound in a similar manner, and each partial winding is wound around the first to third teeth of each tooth group G2 to G6 as shown in the figure.

[0053] In this embodiment, the winding structure is such that a first conductor C1 and a second conductor C2 are wound across two adjacent tooth groups G in the circumferential direction. Each conductor C1 and C2 is, for example, a covered conductor such as a round wire. In this case, in two adjacent tooth groups G in the circumferential direction, the first conductor C1 is wound around the first and second teeth of the first to third teeth, and the second conductor C2 is wound around the second and third teeth of the first to third teeth. In Figure 4, the six tooth groups G1 to G6 are divided into three groups, and two conductors C1 and C2 are wound around tooth groups G1 and G2, tooth groups G3 and G4, and tooth groups G5 and G6, respectively.

[0054] Using Figure 8, the winding structure in two adjacent tooth groups G (i.e., six teeth in the circumferential direction) will be explained below. Figure 8(a) is a plan view showing the state in which only the first conductor C1 is wound around the six circumferential teeth T1 to T6 in tooth groups G1 and G2, and Figure 8(b) is a plan view showing the state in which both the first conductor C1 and the second conductor C2 are wound around the teeth T1 to T6. The first conductor C1 is a pre-wound conductor that is wound first, and the second conductor C2 is a post-wound conductor that is wound later, and a dot is marked on the second conductor C2 of these conductors C1 and C2.

[0055] As shown in Figure 8(a), the first conductor C1 is wound around teeth T1, T2, T4, and T5, with tooth T1 being the starting tooth. The first conductor C1 is wound in opposite directions around teeth T1 and T2, and in opposite directions around teeth T4 and T5. In each of these teeth, the first conductor C1 is wound in multiple layers, and it is preferable that both the starting and ending points are located radially outward.

[0056] The section between the partial winding of tooth T1 and the partial winding of tooth T2 is a connecting section 71 that spans between teeth T1 and T2, the section between the partial winding of tooth T2 and the partial winding of tooth T4 is a connecting section 72 that spans between teeth T2 and T4, and the section between the partial winding of tooth T4 and the partial winding of tooth T5 is a connecting section 73 that spans between teeth T4 and T5. Each of the connecting sections 71 to 73 is guided to the outside of the upright section 63a, that is, on the side opposite the upright section 63a, via the groove section 63b of the insulating member 63. In other words, the connecting sections 71 to 73 of the first conductor C1 are guided to positions radially separated from each tooth. In Figure 8, for convenience, the connecting portion 72 is shown radially outward from the upright portion 63a, but it is sufficient for it to be provided along the upright portion 63a, and it is preferable for it to be positioned axially overlapping with the connecting portion 71. By guiding each connecting portion 71 to 73 to the outside of the upright portion 63a, each connecting portion 71 to 73 of the first conductor C1 does not interfere with the winding of the second conductor C2, which is wound afterward. In the first conductor C1, 74 is the conductor end on the winding start side, and 75 is the conductor end on the winding end side.

[0057] Furthermore, as shown in Figure 8(b), the second conductor C2 is wound around teeth T6, T5, T3, and T2, respectively, with tooth T6 as the starting tooth. At teeth T6 and T5, the second conductor C2 is wound in opposite directions, and at teeth T3 and T2, the second conductor C2 is wound in opposite directions. At each of these teeth, the second conductor C2 is wound in multiple layers, and it is preferable that both the starting and ending points are located radially outward.

[0058] The section between tooth T6 and the section between tooth T5 is a connecting section 81 that spans between teeth T6 and T5, the section between tooth T5 and the section between tooth T3 is a connecting section 82 that spans between teeth T5 and T3, and the section between tooth T3 and the section between tooth T2 is a connecting section 83 that spans between teeth T3 and T2. Unlike the connecting sections 71 and 73, each connecting section 81 to 83 is directly connected between teeth without being guided to the outside of the upright section 63a. In the second conductor C2, 84 is the conductor end on the winding start side, and 85 is the conductor end on the winding end side.

[0059] In short, in two adjacent tooth groups G1 and G2 in the circumferential direction, if we number each tooth sequentially from 1st to 6th in the circumferential direction, the first conductor C1 is wound around the 1st, 2nd, 4th, and 5th teeth, while the second conductor C2 is wound around the 6th, 5th, 3rd, and 2nd teeth.

[0060] The following describes the procedure for winding the conductor material during the conductor winding operation as a method for manufacturing the stator 30. Figure 9 shows the winding order of the conductor material for teeth T1 to T6. In Figure 9, the first conductor C1 is shown with a solid line, and the second conductor C2 is shown with a dashed line, and the circled numbers in the figure indicate the winding order.

[0061] In Figure 9, the conductor is wound around each of the teeth in the order T1→T2→T4→T5. Between these teeth, the conductor is connected by connecting sections 71-73. As a result, partial windings Y3, Y4, Z3, and Z4 are wound continuously in this order. Using the same conductor, the conductor is then wound around each of the teeth in the order T6→T5→T3→T2. Between these teeth, the conductor is connected by connecting sections 81-83. As a result, partial windings V3, V4, U3, and U4 are wound continuously in this order. In this case, the winding order of teeth T1, T2, T4, and T5 (T1→T2→T4→T5) and the winding order of teeth T6, T5, T3, and T2 (T6→T5→T3→T2) are opposite to each other when viewed in the circumferential direction.

[0062] In this embodiment, during the wire winding process, one wire is used to perform the winding operation shown in Figure 9. Specifically, the wire is wound around each tooth T1, T2, T4, and T5 in an order that faces one direction in the circumferential direction, then folded back in the circumferential direction, and the wire is wound around each tooth T6, T5, T3, and T2 in an order that faces the other direction in the circumferential direction. After the winding operation for each of the six teeth T1 to T6 in the circumferential direction is completed, the wire is separated into a first wire C1 and a second wire C2 by cutting the end portion of the wire (part XC in the figure).

[0063] The procedure for winding the conductor material for two adjacent groups of teeth in the circumferential direction is divided into the following steps.

[0064] In the first winding process, the conductor material is continuously wound around the first and second teeth (T1, T2, T4, T5 in the diagram) of two adjacent tooth groups in the circumferential direction. Subsequently, in the second winding process, the same conductor material as in the first winding process is used to continuously wind the conductor material around the second and third teeth (T2, T3, T5, T6 in the diagram) of two adjacent tooth groups in the circumferential direction. For example, when winding the conductor material for each tooth using an automatic winding device, a single conductor material unwound from the automatic winding device will continuously wind the teeth T1→T2→T4→T5 and the teeth T6→T5→T3→T2. Then, in the cutting process, the middle portion of the conductor material wound in the first winding process and the second winding process is cut, so that in two adjacent groups of teeth in the circumferential direction, the first conductor C1 and the second conductor C2 are wound continuously around each of the two groups of teeth. According to this procedure, each set of six consecutive teeth in the circumferential direction can be easily used to complete the winding.

[0065] Furthermore, the order of the teeth to be wound is reversed between the first and second winding processes. Therefore, in the second winding process, compared to the case where the order is the same as in the first winding process, it is possible to shorten the length of the connecting section and reduce the overlap between the conductor materials.

[0066] In the winding structure diagram of Figure 6, the continuous winding of the first conductor C1 forms a series connection portion in the second stator winding 32b, for example, between the Y-phase partial windings Y3, Y4 and the Z-phase partial windings Z3, Z4. Furthermore, the continuous winding of the second conductor C2 forms a series connection portion in the first stator winding 32a, for example, between the V-phase partial windings V3, V4 and the U-phase partial windings U3, U4.

[0067] Figures 8 and 9 illustrate the wire winding structure of each tooth T1 to T6 in tooth groups G1 and G2, but the other tooth groups have a similar wire winding structure. Specifically, in tooth groups G3 and G4, the first wire C1 is wound around each tooth T7 to T12 in the circumferential direction in the order of 1st, 2nd, 4th, and 5th (i.e., teeth T7 → T8 → T10 → T11), and the second wire C2 is wound around in the circumferential direction in the order of 6th, 5th, 3rd, and 2nd (teeth T12 → T11 → T9 → T8).

[0068] Similarly, in teeth groups G5 and G6, the first conductor C1 is wound around each tooth T13 to T18 in the circumferential direction in the order of 1st, 2nd, 4th, and 5th (i.e., teeth T13 → T14 → T16 → T17), while the second conductor C2 is wound around it in the order of 6th, 5th, 3rd, and 2nd (teeth T18 → T17 → T5 → T4).

[0069] In pairs of adjacent teeth G in the circumferential direction, these tooth groups G are interconnected by connecting sections 72 of the first conductor C1 and 82 of the second conductor C2, with neutral point connections made at these connecting sections 72 and 82. In Figure 6, in the first stator winding 32a, the sections between partial windings U2-W3, W2-V1, and V4-U3 correspond to connecting sections 82. Similarly, in the second stator winding 32b, the sections between partial windings X4-Y1, Y4-Z3, and Z2-X1 correspond to connecting sections 72.

[0070] Figure 10 shows the configuration of the neutral point connection in each stator winding 32a and 32b. Figure 10(a) shows a neutral point busbar 91 that constitutes the neutral point N1 of the first stator winding 32a and a neutral point busbar 92 that constitutes the neutral point N2 of the second stator winding 32b, as busbars for neutral point connection. Each of these neutral point busbars 91 and 92 is arc-shaped overall, and radially extending arm portions 93 and 94 are provided at multiple locations (three locations in this embodiment) along its longitudinal direction. Each arm portion 93 and 94 is provided so as to extend radially outward from the busbar arc portion. The tips of each arm portion 93 and 94 of the neutral point busbars 91 and 92 are connected to positions in each stator winding 32a and 32b that are between the phase windings of each phase.

[0071] Figure 10(b) is a plan view showing the neutral busbars 91 and 92 assembled to the stator 30. In Figure 10(b), as in Figure 8(b), a dot is marked on the second conductor C2. Each neutral busbar 91 and 92 is positioned opposite the coil end portions of each stator winding 32a and 32b in the axial direction.

[0072] The tip of each arm portion 93 in the neutral busbar 91 is connected to the connecting portion 82 of the second conductor C2. More specifically, the tip of each arm portion 93 is connected to the connecting portions 82 between partial windings U2-W3, W2-V1, and V4-U3 in the first stator winding 32a. In addition, the tip of each arm portion 94 in the neutral busbar 92 is connected to the connecting portion 72 of the first conductor C1. More specifically, the tip of each arm portion 94 is connected to the connecting portions 72 between partial windings X4-Y1, Y4-Z3, and Z2-X1 in the second stator winding 32b.

[0073] In each connecting section 72, 82, for example, the insulating coating of the conductor material is partially removed, and the arms 93, 94 of the neutral point busbars 91, 92 are connected to the removed coating portion (i.e., the exposed conductor portion).

[0074] The neutral busbars 91 and 92 connect the two parallel phase windings of each phase in each stator winding 32a and 32b to a common neutral point. For example, in the first stator winding 32a, The neutral point busbar 91 is connected to the connecting section 82 between the partial windings U2-W3, thereby providing a common neutral point connection for the U-phase winding and the W-phase winding. The neutral point busbar 91 is connected to the connecting section 82 between the partial windings W2-V1, thereby providing a common neutral point connection for the W-phase winding and the V-phase winding. The neutral point busbar 91 is connected to the connecting section 82 between partial windings V4-U3, thereby providing a common neutral point connection for the V-phase winding and the U-phase winding. In this configuration, where each phase winding has two parallel connections (see Figure 6), there are a total of six neutral point ends for each phase winding. However, in this configuration, the connection of the neutral busbar 91 can be completed at three connection points. In other words, compared to a configuration where a neutral busbar is connected to each of the two parallel phase windings (a configuration where the neutral busbar is connected at six connection points), it is possible to reduce the number of neutral busbars and busbar connection points. The same applies to the second stator winding 32b.

[0075] In Figure 10(a), the neutral busbars 91 and 92 are formed in a roughly C-shape, but this can be changed to a configuration where the neutral busbars 91 and 92 are connected in a ring shape. By forming the neutral busbars 91 and 92 in a ring shape, the resistance difference between each phase can be eliminated.

[0076] Furthermore, in Figure 10(a), the arm portions 93 and 94 of the neutral busbars 91 and 92 are configured to extend radially outward from the arc portion, but this can be changed. The diameter of the arc portion of at least one of the neutral busbars 91 and 92 may be increased, and the arm portions 93 and 94 may be formed to extend radially inward accordingly. For example, by increasing the diameter of the arc portion of only one of the neutral busbars 91 and 92, the neutral busbars 91 and 92 can be positioned further apart from each other, and short circuits between them can be suitably suppressed.

[0077] In a configuration with six consecutive teeth in the circumferential direction, a first conductor C1 and a second conductor C2 are wound around the teeth, with two conductor ends drawn out axially from each conductor. In Figure 10(b), the conductor ends 74 and 75 of the first conductor C1 and the conductor ends 84 and 85 of the second conductor C2 are provided on one axial end of the stator 30. Power input / output busbars are preferably connected to each of these conductor ends. Power input / output busbars are conductive members that connect in-phase partial windings to each other, and preferably include six busbars: U-phase busbar, V-phase busbar, W-phase busbar, X-phase busbar, Y-phase busbar, and Z-phase busbar. In this case, in the configuration of Figure 10(b), the conductor ends 74, 75, 84, and 85 are arranged on the same virtual circle on the outer diameter side of each tooth. Therefore, connection to the busbars is simplified.

[0078] As a variation, the winding order of the conductor material can also be as shown in Figure 11. In Figure 11, as with Figure 9 described above, the first conductor C1 is shown with a solid line and the second conductor C2 is shown with a dashed line, and the circled numbers in the figure indicate the winding order.

[0079] In Figure 11, the conductor material is wound around each of the teeth in the order T1→T2→T4→T5. As a result, partial windings Y3, Y4, Z3, and Z4 are wound continuously in this order. Then, using the same conductor material, the conductor material is wound around each of the teeth in the order T5→T6→T2→T3. As a result, partial windings V4, V3, U4, and U3 are wound continuously in this order. In this case, during the conductor winding work, the winding work in Figure 11 is performed using one conductor material, and after the winding work on each of the six circumferential teeth T1 to T6 is completed, the end cut portion of the conductor material (part XC in the figure) is cut to separate it into the first conductor C1 and the second conductor C2. In the winding sequence described above, in each of the two groups of teeth on the left and right of the diagram, the conductor material is passed from left to right (i.e., in the same direction) to the adjacent teeth in the circumferential direction.

[0080] In the configuration shown in Figure 11, in two adjacent tooth groups G in the circumferential direction, the first conductor C1 is wound in the order of 1st, 2nd, 4th, and 5th in the circumferential direction, and the second conductor C2 is wound in the order of 5th, 6th, 2nd, and 3rd in the circumferential direction.

[0081] Incidentally, noise and vibration due to torque ripple are problematic in rotating electric machines. Since torque ripple mainly consists of 6th harmonic or 12th harmonic components, it is desirable to suppress these. Therefore, it is preferable to use the motor 10 with the above configuration and perform the following control in the control device 50.

[0082] In the motor 10 with the above configuration, The first teeth (T1, T4, T7, T10, T13, T16) of each tooth group are wound with the X-phase, Y-phase, and Z-phase partial windings (first coil body) of the second stator winding 32b. • On the second teeth (T2, T5, T8, T10, T14, T17) of each tooth group, a partial winding (second coil body) of either one phase from the first and second stator windings 32a and 32b is wound. The third teeth (T3, T6, T9, T12, T15, T18) of each tooth group are wound with the U-phase, V-phase, and W-phase partial windings (third coil bodies) of the first stator winding 32a.

[0083] In this configuration, the control device 50 sets the combined phase difference between the magnetomotive force generated by the partial winding of the first stator winding 32a wound around the second teeth and the magnetomotive force generated by the partial winding of the second stator winding 32b wound around the second teeth, such that the phase difference between the magnetomotive force of the second coil body of each phase and the phase difference between the magnetomotive force of the third coil body of each phase and the magnetomotive force generated by the second coil body of each phase are within a predetermined phase range including 20 degrees in electrical angle, or the phase difference between the magnetomotive force of the third coil body of each phase and the magnetomotive force generated by the partial winding of the second coil body of each phase and the magnetomotive force generated by the partial winding of the second stator winding 32b wound around the second teeth are within a predetermined phase range including 20 degrees in electrical angle. Alternatively, the control device 50 sets the combined phase difference between the current flowing through the partial winding of the first stator winding 32a wound around the second tooth and the current flowing through the partial winding of the second stator winding 32b wound around the second tooth. Details of this control are described in detail in Japanese Patent No. 7103299 filed by the applicant of this application.

[0084] According to the embodiment described in detail above, the following excellent effects can be obtained.

[0085] The stator 30 is configured such that, in a group of teeth consisting of three consecutive teeth in the circumferential direction, the first conductor C1 is wound around the first and second teeth, and the second conductor C2 is wound around the second and third teeth, respectively. In this configuration, the first conductor C1 and the second conductor C2 are each wound continuously around two adjacent groups of teeth in the circumferential direction. In this case, the two conductors (first conductor C1 and second conductor C2) are wound around six teeth, spanning two adjacent groups of teeth in the circumferential direction. In this configuration, in a winding structure having multiple groups of teeth that are 3-tooth 2-phase windings, the stator windings 32 for six teeth arranged in the circumferential direction can be wound together using the first and second conductors, thereby improving workability during conductor winding.

[0086] In each group of teeth, a two-phase winding is wound around each tooth that is arranged in a circumferential direction of three consecutive teeth. In this configuration, winding can be efficiently performed by winding the conductor material around six consecutive teeth, which are multiples of three, as a set. Furthermore, by forming two groups of teeth adjacent to each other in the circumferential direction as a set, and arranging three such sets in the circumferential direction, each stator winding 32a, 32b can be easily made into a ring.

[0087] In two adjacent tooth groups in the circumferential direction, the first conductor C1 is wound around each tooth in the circumferential direction in the order of 1st, 2nd, 4th, and 5th, while the second conductor C2 is wound around in the order of 6th, 5th, 3rd, and 2nd, or 5th, 6th, 2nd, and 3rd. This configuration enables the realization of an appropriate winding structure in a stator 30 having multiple tooth groups with 3-tooth, 2-phase windings.

[0088] In a configuration where two overlapping conductors (first conductor C1 and second conductor C2) are wound around each tooth, there is a concern that the connecting portions 71-73 between teeth of the first-winding conductor (first conductor C1) may hinder the winding of the later-winding conductor (second conductor C2). To address this, an insulating member 63 provided at the axial end of the stator core 31 is used to guide the connecting portions 71-73 of the first conductor C1 to a position radially separated from the teeth. This suppresses the inconvenience of the connecting portions 71-73 of the first-winding conductor C1 hindering the winding of the later-winding second conductor C2.

[0089] In this configuration, neutral point busbars 91 and 92 are connected to the connecting sections 72 and 82 between two adjacent tooth groups in the circumferential direction. In other words, in two adjacent tooth groups in the circumferential direction, the first conductor C1 and the second conductor C2 are each wound with two phase windings, and neutral point busbars 91 and 92 are connected to the intermediate portion between these two phase windings. In this case, the number of neutral point connections can be reduced compared to, for example, a configuration in which a neutral point busbar is connected to each of the two phase windings in each tooth group. As a result, in a winding structure having multiple tooth groups with three teeth and two phase windings, it is possible to improve the workability of conductor winding while also achieving a simplified configuration for neutral point connections.

[0090] In each stator winding 32a and 32b, in each group of teeth, the two parallel phase windings of each phase are connected to a phase winding of a different phase, and the connecting sections 72 and 82 between two adjacent groups of teeth in the circumferential direction are connected to a single neutral point busbar 91 and 92, respectively, thereby creating a single neutral point connection. In this configuration, in each of the three phase stator windings 32a and 32b, the two parallel phase windings of each phase are connected in a star configuration by a common neutral point busbar 91 and 92. This reduces the number of connections to the neutral point busbar 91 and 92, and consequently simplifies the configuration.

[0091] The manufacturing method for the stator 30 is as described above, comprising a first winding step, a second winding step, and a cutting step. According to this manufacturing method, in a stator 30 having multiple groups of teeth that form a 3-tooth 2-phase winding, the conductor material can be efficiently wound while treating two adjacent groups of teeth in the circumferential direction (i.e., 6 consecutive teeth) as one unit. In this case, two conductors (first conductor C1 and second conductor C2) can be suitably wound around the 6 teeth while straddling two adjacent groups of teeth in the circumferential direction. As a result, the workability during conductor winding can be improved.

[0092] The following describes other embodiments that modify some of the components of the first embodiment, focusing on the differences from the first embodiment.

[0093] (Second Embodiment) In this embodiment, the winding structure of each conductor C1 and C2 and the winding procedure of the conductor material have been modified. Here, using Figure 12, the winding structure and winding order of each conductor C1 and C2 for teeth T1 to T6 will be explained. In Figure 12, the first conductor C1 is shown with a solid line, and the second conductor C2 is shown with a dashed line, and the circled numbers in the figure indicate the winding order. Also, in Figure 12, one end in the axial direction is the first coil end CE1, and the other end in the axial direction is the second coil end CE2.

[0094] In Figure 12, similar to Figure 9 described above, the conductor material is wound around each of the teeth in the order T1→T2→T4→T5, and then the same conductor material is used to wind the conductor material around each of the teeth in the order T6→T5→T3→T2. After the winding work on each of the six teeth T1 to T6 in the circumferential direction is completed, the conductor material is separated into the first conductor C1 and the second conductor C2 by cutting the end cut portion (part XC in the figure). However, in Figure 12, the configuration of the connecting sections 72 and 82 is different from that in Figure 9, and the details are explained below.

[0095] In Figure 12, the number of turns of the wire material wound around teeth T2 and T4 in the first conductor C1 is differed by 0.5 turns from the number of turns of the wire material wound around the other teeth T1 and T5. As a result, in teeth T1 and T5 (partial windings Y3 and Z4), both the start and end of the winding are on the first coil end CE1 side, while in teeth T2 and T4 (partial windings Y4 and Z3), the start and end of the winding are on the first coil end CE1 side and the second coil end CE2 side, respectively.

[0096] Therefore, in the first conductor C1, the conductor ends 74 and 75 at the start and end of winding in two circumferentially adjacent tooth groups are provided on the first coil end CE1 side, and a connecting section 72 between teeth T2 and T4 is provided on the second coil end CE2 side. In the second conductor C2, the conductor ends 84 and 85 at the start and end of winding in two circumferentially adjacent tooth groups are provided on the first coil end CE1 side, and a connecting section 82 between teeth T3 and T5 is provided on the second coil end CE2 side.

[0097] Furthermore, in Figure 12, the connecting sections 71 and 73 of the first conductor C1 are provided on the first coil end CE1 side, and the connecting section 72 is provided on the second coil end CE2 side. Similarly, the connecting sections 81 and 83 of the second conductor C2 are provided on the first coil end CE1 side, and the connecting section 82 is provided on the second coil end CE2 side. However, it is also possible to configure the system so that all the connecting sections 71-73 of the first conductor C1 are provided on the second coil end CE2 side, and all the connecting sections 81-83 of the second conductor C2 are provided on the second coil end CE2 side.

[0098] In the winding sequence shown in Figure 12, the number of turns of the conductor material on each tooth should be as follows: In tooth T1, the number of turns of partial winding Y3 is Tm[T], In teeth T2, the number of turns of partial winding Y4 is set to Ts-0.5[T], In teeth T4, the number of turns of the partial winding Z3 is set to Tm-0.5[T], In teeth T5, the number of turns of the partial winding Z4 is Ts[T], In teeth T6, the number of turns of the partial winding V3 is Tm[T], In teeth T5, the number of turns of the partial winding V4 is set to Ts-0.5[T], In tooth T3, the number of turns of the partial winding U3 is set to Tm-0.5[T], In teeth T2, the number of turns of the partial winding U4 is denoted as Ts[T].

[0099] According to the winding structure in Figure 12, the starting and ending ends of the first conductor C1 and the second conductor C2 are provided on the first coil end CE1 side of the stator 30, and connecting portions 72 and 82 for each conductor C1 and C2 are provided on the second coil end CE2 side. In this case, the starting and ending ends of each conductor C1 and C2 and the connecting portions 72 and 82 are distributed on both sides of the axial direction, which reduces interference between the conductors and makes the winding work of the conductors easier.

[0100] As a modification of the second embodiment, the winding order of the first conductor C1 and the second conductor C2 can be as shown in Figure 13. In Figure 13, the conductor material is wound around each of the teeth in the order T1→T2→T4→T5, and then the same conductor material is used to wind around each of the teeth in the order T5→T6→T2→T3. After the winding work on each of the six teeth T1 to T6 in the circumferential direction is completed, the conductor material is separated into the first conductor C1 and the second conductor C2 by cutting the end cut portion (part XC in the figure).

[0101] Furthermore, in Figure 13, similar to Figure 12, the number of turns of the wire material wound around teeth T2 and T4 in the first conductor C1 is differed by 0.5 turns from the number of turns of the wire material wound around the other teeth T1 and T5. As a result, in the first conductor C1, the wire ends 74 and 75 for the beginning and end of winding in two circumferentially adjacent tooth groups are provided on the first coil end CE1 side, and a connecting section 72 between teeth T2 and T4 is provided on the second coil end CE2 side. Similarly, in the second conductor C2, the wire ends 84 and 85 for the beginning and end of winding in two circumferentially adjacent tooth groups are provided on the first coil end CE1 side, and a connecting section 82 between teeth T3 and T5 is provided on the second coil end CE2 side.

[0102] (Third embodiment) In this embodiment, the winding procedure for the conductor material during the conductor winding work has been modified, and the winding work is performed by continuously using one conductor material for all teeth T1 to T18 of the stator core 31.

[0103] Here, using Figure 14, we will explain the winding structure of each conductor C1 and C2 for each tooth T1 to T18, and the winding procedure of the conductor material. In Figure 14, the first conductor C1 is shown with a solid line, and the second conductor C2 is shown with a dashed line, and the circled numbers in the figure indicate the winding order.

[0104] In Figure 14, the conductor material is wound around teeth T1→T2→T4→T5→T7→T8→T10→T11→T13→T14→T16→T17 in the order of T1→T2→T4→T5→T7→T8→T10→T11→T13→T14→T16→T17 in the order of T18→T17→T15→T14→T12→T11→T9→T8→T6→T5→T3→T2 in the order of T18→T17→T15→T14→T12→T11→T9→T8→T6→T5→T3→T2 in the order of T4→T5→T6→T5→T17 in the order of T4→T5. After the conductor material has been wound around all teeth T1 to T18, the end cut portion of the conductor material (parts XC1 to XC5 in the figure) is cut, thereby separating the first conductor C1 and the second conductor C2 for every two adjacent groups of teeth in the circumferential direction.

[0105] Subsequently, in the first stator winding 32a, a neutral point busbar 91 is connected to each connecting section 82 between partial windings V4-U3, U2-W3, and W2-V1. In addition, in the second stator winding 32b, a neutral point busbar 92 is connected to each connecting section 72 between partial windings Y4-Z3, X4-Y1, and Z2-X1.

[0106] In short, in the first winding process, the conductor material is continuously wound around the first and second teeth in all tooth groups in the circumferential direction. In the second winding process, the same conductor material as in the first winding process is used again, and the conductor material is continuously wound around the second and third teeth in all tooth groups in the circumferential direction. Subsequently, in the cutting process, the middle portion of the conductor material wound in the first and second winding processes is cut, so that in two adjacent tooth groups in the circumferential direction, the first conductor C1 and the second conductor C2 are continuously wound around two tooth groups each. Then, in the neutral point connection process, in each stator winding 32a, 32b, neutral point busbars 91, 92 are connected to the connecting sections 72, 82 that connect two adjacent tooth groups in the circumferential direction.

[0107] Incidentally, looking at all teeth T1 to T18 in units of six in the circumferential direction (each of two adjacent tooth groups in the circumferential direction), in each of these units, the first conductor C1 is wound in the order of 1st, 2nd, 4th, and 5th in the circumferential direction, and the second conductor C2 is wound in the order of 6th, 5th, 3rd, and 2nd in the circumferential direction. In this case, the same winding specification as when the conductor material is wound around six consecutive teeth in the circumferential direction as one set (as in Figure 9) is achieved.

[0108] Figure 15 shows the electrical connection configuration of the stator windings 32a and 32b in this embodiment. The circled numbers in the figure indicate the winding order, as in Figure 14. As shown in Figure 15, in each stator winding 32a and 32b, all partial windings are wound continuously using a single conductor. In this embodiment, all partial windings are wound first on the first stator winding 32a, followed by all partial windings on the second stator winding 32b.

[0109] According to the manufacturing method described above, it is possible to properly wind the 3-tooth, 2-phase winding for the group of teeth, using a single continuous wire for all circumferential teeth T1 to T18.

[0110] In addition, in the stator 30 using the winding structure described in the second embodiment, it is also possible to configure it so that a single conductor is continuously wound around all teeth T1 to T18.

[0111] When a single wire is continuously wound around all teeth T1 to T18 of the stator core 31, as described above, in the first winding step, the wire is continuously wound around all tooth groups in the circumferential direction toward one side in the circumferential direction (for example, the right side in Figure 14), and in the second winding step, the wire is similarly continuously wound around all tooth groups in the circumferential direction toward the other side in the circumferential direction (for example, the left side in Figure 14).

[0112] Alternatively, in the first winding step, the conductor material may be continuously wound in the circumferential direction toward one side (for example, the right side in Figure 14) for all tooth groups in the circumferential direction, and similarly in the second winding step, the conductor material may be continuously wound in the circumferential direction toward one side (for example, the right side in Figure 14) for all tooth groups in the circumferential direction.

[0113] (Other embodiments) The above embodiment may be modified as follows, for example.

[0114] The configuration of the neutral point connections in each stator winding 32a and 32b may be changed as follows. Figures 16(a) and (b) show modified examples of the neutral point busbars 91 and 92. Figures 17(a) and (b) also show the configuration of the electrical connections of each stator winding 32a and 32b.

[0115] As shown in Figures 17(a) and (b), the first stator winding 32a has two star connections in each of the two parallel phase windings. In this case, one end of the series connection of partial windings U3 and U4 is connected to one end of the series connection of partial windings V3 and V4, and one end of the series connection of partial windings W3 and W4 is connected to one another at neutral point N1a, while one end of the series connection of partial windings U1 and U2 is connected to one end of the series connection of partial windings V1 and V2, and one end of the series connection of partial windings W1 and W2 is connected to one another at neutral point N1b. In other words, the first stator winding 32a has two parallel phase windings for each phase, and two neutral points N1a and N1b are formed by connecting one side of each of the two parallel phase windings and the other side of each of the two parallel phase windings.

[0116] Similarly, in the second stator winding 32b, two star connections are made in the two parallel phase windings for each phase. In this case, one end of the series connection of partial windings X3 and X4, one end of the series connection of partial windings Y3 and Y4, and one end of the series connection of partial windings Z3 and Z4 are connected to each other at neutral point N2a, and one end of the series connection of partial windings X1 and X2, one end of the series connection of partial windings Y1 and Y2, and one end of the series connection of partial windings Z1 and Z2 are connected to each other at neutral point N2b. In other words, the second stator winding 32b has two parallel phase windings for each phase, and two neutral points N2a and N2b are made by connecting one side of each parallel phase winding to each other and the other side to each other.

[0117] In this configuration, the first stator winding 32a has two neutral point busbars 91A and 91B that are divided in the circumferential direction as the neutral point busbar 91. The second stator winding 32b also has two neutral point busbars 92A and 92B that are divided in the circumferential direction as the neutral point busbar 92.

[0118] In the first stator winding 32a, the neutral busbar 91A constitutes the neutral point N1a between the partial windings U3, V4, and W3, and the neutral busbar 91B constitutes the neutral point N1b between the partial windings U2, V1, and W2 (see Figure 17(a)). In Figures 16(a) and (b), the neutral busbar 91A connects the jumper section 82 between teeth T3-T5 (between partial windings U3-V4) to the conductor end of partial winding W3 wound around tooth T9. Also, the neutral busbar 91B connects the jumper section 82 between teeth T15-T17 (between partial windings V1-W2) to the conductor end of partial winding U2 wound around tooth T11. In this embodiment, the connecting section 82 between teeth T9 and T11 is cut, and the cut ends of the conductors are individually connected to the neutral point busbars 91A and 91B.

[0119] In short, in the first stator winding 32a, in some combinations of two adjacent tooth groups in the circumferential direction, the connection portion by the connecting section 82 is interrupted. Then, two neutral point connection points, N1a and N1b, are connected to the two neutral point busbars 91A and 91B, respectively, which consist of the connecting section 82 between two adjacent tooth groups in the circumferential direction and the wire end where the connecting section 82 is interrupted between two adjacent tooth groups in the circumferential direction.

[0120] Furthermore, in the second stator winding 32b, the neutral busbar 92A constitutes the neutral point N2a between the partial windings X4, Y4, and Z3, and the neutral busbar 92B constitutes the neutral point N2b between the partial windings X1, Y1, and Z2 (see Figure 17(b)). In Figures 16(a) and (b), the neutral busbar 92A connects the jumper 72 between teeth T2-T4 (between partial windings Y4-Z3) to the conductor end of partial winding X4 wound around tooth T8. Also, the neutral busbar 92B connects the jumper 72 between teeth T14-T16 (between partial windings Z2-X1) to the conductor end of partial winding Y1 wound around tooth T10. In this embodiment, the connecting section 72 between teeth T8 and T10 is cut, and the cut ends of the conductors are individually connected to the neutral point busbars 92A and 92B.

[0121] In short, in the second stator winding 32b, in some combinations of two adjacent tooth groups in the circumferential direction, the connection portion by the connecting section 72 is interrupted. Then, the two neutral point busbars 92A and 92B are connected to two sets of neutral point connection points, each consisting of a connecting section 72 between two adjacent tooth groups in the circumferential direction and a conductor end where the connecting section 72 is interrupted between two adjacent tooth groups in the circumferential direction, thereby connecting the two neutral points N2a and N2b.

[0122] In the above configuration, in each of the three phase stator windings 32a and 32b, the two parallel phase windings for each phase are connected in a star configuration by two neutral busbars 91A, 91B, 92A, and 92B. This makes it possible to shorten the length of each neutral busbar in the circumferential direction.

[0123] Figure 18 shows another example of the configuration of the neutral points N1a and N1b of the first stator winding 32a and the neutral points N2a and N2b of the second stator winding 32b. As shown in Figure 18, in the first stator winding 32a, the connection of the neutral point N1a is made by connecting the jumper section 82 between teeth T3 and T5 (between partial windings U3 and V4) and the conductor end of the partial winding W3 wound around tooth T9 with a neutral point connection wire 101A. In addition, the connection of the neutral point N1b is made by connecting the jumper section 82 between teeth T15 and T17 (between partial windings V1 and W2) and the conductor end of the partial winding U2 wound around tooth T11 with a neutral point connection wire 101B.

[0124] On the other hand, in the second stator winding 32b, the connection point N2a is made by connecting the junction 72 between teeth T2-T4 (between partial windings Y4-Z3) with the wire end of partial winding X4 wound around tooth T8 using a neutral point connection wire 102A. Also, the connection point N2b is made by connecting the junction 72 between teeth T14-T16 (between partial windings Z2-X1) with the wire end of partial winding Y1 wound around tooth T10 using a neutral point connection wire 102B. The above neutral point connection wires 101 and 102 may be insulated wires such as round wires rather than busbars. The neutral point connection wires 101 and 102 correspond to the neutral point connection members.

[0125] In the above configuration, in a winding structure where two neutral points are provided for each stator winding 32a, 32b, two of the three phase conductor ends are connected by connecting sections 72, 82, and the connecting sections 72, 82 are connected to the conductor end of the remaining phase by a neutral point connection wire. In this case, neutral point connection can be suitably performed without using a busbar.

[0126] In the stator core 31, each segmented core 61 may have multiple teeth 34. For example, a segmented core 61 may have three teeth 34. Alternatively, the stator core 31 may have a configuration that is not a segmented core structure, i.e., a single, indivisible annular structure in the circumferential direction.

[0127] The number of teeth of the stator core 31 may be other than 18. However, in this case, the number of teeth should be 6 × n. Also, the stator winding 32 should have {(6 × n) / 3} groups of teeth. In the motor 10, the number of magnetic poles of the rotor 40 should be (18 ± 4) × m, and the number of slots should be 18 × m (where m is an integer).

[0128] • The rotating electric machine may be an outer rotor type instead of an inner rotor type.

[0129] The technical concepts extracted from the above-described embodiments are described below. [Configuration 1] A stator (30) comprising a stator core (31) having a plurality of teeth (34) arranged at predetermined intervals in the circumferential direction, and a stator winding (32) having a plurality of phase windings provided for each phase, Each of the aforementioned phase windings has a plurality of partial windings that are wound around the teeth by concentrated winding, In the aforementioned plurality of teeth, three teeth that are continuous in the circumferential direction are considered as one tooth group, and in that tooth group, the first conductor (C1) is wound around the first tooth and the second tooth, and the second conductor (C2) is wound around the second tooth and the third tooth, thereby forming the stator winding. A stator in which the first and second conductors are each continuously wound around two adjacent groups of teeth in the circumferential direction. [Configuration 2] In two adjacent groups of teeth in the circumferential direction, each tooth is designated as the 1st to 6th in the circumferential direction, the first conductor is designated as the pre-wound conductor, and the second conductor is designated as the post-wound conductor. The first conductor is wound in the order of 1st, 2nd, 4th, and 5th, The stator according to configuration 1, wherein the second conductor is wound in the order of 6th, 5th, 3rd, 2nd, or 5th, 6th, 2nd, 3rd. [Configuration 3] The axial end is designated as the first coil end, and the axial end is designated as the second coil end. In the first conductor, the first coil end is provided with the starting and ending ends of two adjacent tooth groups in the circumferential direction, and the second coil end is provided with a connecting portion (72) between the respective tooth groups. The stator according to configuration 1 or 2, wherein the second conductor is provided with the starting and ending ends of two adjacent tooth groups in the circumferential direction on the first coil end side, and a connecting portion (82) between the tooth groups is provided on the second coil end side. [Structure 4] Of the first and second conductors, the first conductor is a pre-wound conductor and the second conductor is a post-wound conductor. The axial ends of the stator core are provided with insulating members (63, 64) that insulate the teeth from the partial windings. A stator according to any one of configurations 1 to 3, wherein the connecting portions (71 to 73) between each of the teeth in the first conductor are guided by the insulating member to a position radially separated from the teeth. [Composition 5] The stator winding is such that the phase windings of each phase are connected at the neutral point. A stator according to any one of configurations 1 to 4, wherein in two adjacent tooth groups in the circumferential direction, a neutral point connecting member (91, 92, 101, 102) is connected to a connecting portion (72, 82) that connects one tooth group to the other tooth group. [Composition 6] The stator winding has two parallel phase windings for each phase, and the two parallel phase windings for each phase are connected at a single neutral point. In each of the aforementioned tooth groups, the two parallel phase windings of each phase are connected to the phase windings of different phases, The stator according to configuration 5, wherein the neutral point connecting member is connected to each of the connecting portions between two adjacent groups of teeth in the circumferential direction, thereby connecting one neutral point. [Composition 7] The stator winding has two parallel phase windings for each phase, and the two parallel phase windings for each phase are connected at two neutral points, one to the other and the other to the other. In each of the aforementioned tooth groups, the two parallel phase windings of each phase are connected to the phase windings of different phases, In the stator winding, among the combinations of two adjacent tooth groups in the circumferential direction, in some combinations the connection portion by the connecting part is separated. The stator according to configuration 5, wherein the two neutral points are connected by connecting the neutral point connecting member to each of two sets of neutral point connection locations, each set consisting of a connecting portion between two circumferentially adjacent groups of teeth and a wire end where the connecting portion is interrupted between two circumferentially adjacent groups of teeth. [Structure 8] A method for manufacturing a stator (30) comprising a stator core (31) having a plurality of teeth (34) provided at predetermined intervals in the circumferential direction, and a stator winding (32) having a plurality of phase windings provided for each phase, wherein each phase winding has a plurality of partial windings wound around the teeth by concentrated winding, The stator winding is configured such that three teeth that are circumferentially continuous in the plurality of teeth form a tooth group, and in that tooth group, the first conductor (C1) is wound around the first tooth and the second tooth, and the second conductor (C2) is wound around the second tooth and the third tooth. A first winding step in which a conductor is continuously wound around the first tooth and the second tooth of each of two adjacent tooth groups in the circumferential direction, Subsequently, using the same conductor material as in the first winding step, a second winding step is performed in which the conductor material is continuously wound around the second and third teeth of each of two adjacent tooth groups in the circumferential direction. A cutting step in which the intermediate portion of the conductor material wound in the first winding step and the second winding step is cut, so that in two adjacent groups of teeth in the circumferential direction, the first conductor and the second conductor are wound continuously around the two groups of teeth, respectively. A method for manufacturing a stator, comprising: [Composition 9] The stator core has (6 × n) teeth, The stator winding has {(6×n) / 3} groups of teeth, In the first winding step, the conductor material is continuously wound around the first tooth and the second tooth in all the tooth groups in the circumferential direction. In the second winding step, the same conductor material as in the first winding step is used again, and the conductor material is continuously wound around the second and third teeth in all the tooth groups in the circumferential direction. The method for manufacturing a stator according to configuration 8, wherein in the cutting step, the intermediate portion of the conductor material wound in the first winding step and the second winding step is cut, so that in two adjacent groups of teeth in the circumferential direction, the first conductor and the second conductor are wound continuously around each of the two groups of teeth. [Explanation of Symbols]

[0130] 30...stator, 31...stator core, 32...stator winding, 34...teeth, C1...first conductor, C2...second conductor.

Claims

1. A stator (30) comprising a stator core (31) having a plurality of teeth (34) provided at predetermined intervals in the circumferential direction, and a stator winding (32) having a plurality of phase windings provided for each phase, Each of the aforementioned phase windings has a plurality of partial windings that are wound around the teeth by concentrated winding, In the aforementioned plurality of teeth, three teeth that are continuous in the circumferential direction are considered as one tooth group, and in that tooth group, the first conductor (C1) is wound around the first tooth and the second tooth, and the second conductor (C2) is wound around the second tooth and the third tooth, thereby forming the stator winding. A stator in which the first and second conductors are each continuously wound around two adjacent groups of teeth in the circumferential direction.

2. In two adjacent groups of teeth in the circumferential direction, each tooth is designated as the 1st to 6th in the circumferential direction, the first conductor is designated as the pre-wound conductor, and the second conductor is designated as the post-wound conductor. The first conductor is wound in the order of 1st, 2nd, 4th, and 5th, The stator according to claim 1, wherein the second conductor is wound in the order of 6th, 5th, 3rd, 2nd, or 5th, 6th, 2nd, 3rd.

3. The axial end is designated as the first coil end, and the axial end is designated as the second coil end. In the first conductor, the first coil end is provided with the starting and ending ends of two adjacent tooth groups in the circumferential direction, and the second coil end is provided with a connecting portion (72) between the respective tooth groups. The stator according to claim 1, wherein the second conductor is provided with the starting and ending ends of two adjacent tooth groups in the circumferential direction on the first coil end side, and a connecting portion (82) between the tooth groups is provided on the second coil end side.

4. Of the first and second conductors, the first conductor is a pre-wound conductor and the second conductor is a post-wound conductor. The axial ends of the stator core are provided with insulating members (63, 64) that insulate the teeth from the partial windings. The stator according to claim 1, wherein the connecting portions (71-73) between each of the teeth in the first conductor are guided by the insulating member to a position radially separated from the teeth.

5. The stator winding is such that the phase windings of each phase are connected at the neutral point. A stator according to any one of claims 1 to 4, wherein in two adjacent tooth groups in the circumferential direction, a neutral point connecting member (91, 92, 101, 102) is connected to a connecting portion (72, 82) that connects one tooth group to the other tooth group.

6. The stator winding has two parallel phase windings for each phase, and the two parallel phase windings for each phase are connected at a single neutral point. In each of the aforementioned tooth groups, the two parallel phase windings of each phase are connected to the phase windings of different phases, The stator according to claim 5, wherein the neutral point connecting member is connected to each of the connecting portions between two adjacent groups of teeth in the circumferential direction, thereby connecting one of the neutral points.

7. The stator winding has two parallel phase windings for each phase, and the two parallel phase windings for each phase are connected at two neutral points, one to the other and the other to the other. In each of the aforementioned tooth groups, the two parallel phase windings of each phase are connected to the phase windings of different phases, In the stator winding, among the combinations of two adjacent tooth groups in the circumferential direction, in some combinations the connection portion by the connecting part is separated. The stator according to claim 5, wherein the two neutral points are connected by connecting the neutral point connecting member to each of two sets of neutral point connection locations, each set of neutral point connection locations, which consist of a connecting portion between two circumferentially adjacent groups of teeth and a wire end where the connecting portion is interrupted between two circumferentially adjacent groups of teeth.

8. A method for manufacturing a stator (30) comprising a stator core (31) having a plurality of teeth (34) provided at predetermined intervals in the circumferential direction, and a stator winding (32) having a plurality of phase windings provided for each phase, wherein each phase winding has a plurality of partial windings that are wound around the teeth by concentrated winding, The stator winding is configured such that three teeth that are circumferentially continuous in the plurality of teeth form a tooth group, and in that tooth group, the first conductor (C1) is wound around the first tooth and the second tooth, and the second conductor (C2) is wound around the second tooth and the third tooth. A first winding step in which a conductor is continuously wound around the first tooth and the second tooth of each of two adjacent tooth groups in the circumferential direction, Subsequently, using the same conductor material as in the first winding step, a second winding step is performed in which the conductor material is continuously wound around the second and third teeth of each of two adjacent tooth groups in the circumferential direction. A cutting step in which the intermediate portion of the conductor material wound in the first winding step and the second winding step is cut, so that in two adjacent groups of teeth in the circumferential direction, the first conductor and the second conductor are wound continuously around the two groups of teeth, A method for manufacturing a stator.

9. The stator core has (6 × n) teeth, The stator winding has {(6 × n) / 3} groups of teeth, In the first winding step, the conductor material is continuously wound around the first tooth and the second tooth in all the tooth groups in the circumferential direction. In the second winding step, the same conductor material as in the first winding step is used again, and the conductor material is continuously wound around the second and third teeth in all the tooth groups in the circumferential direction. The method for manufacturing a stator according to claim 8, wherein in the cutting step, the intermediate portion of the conductor material wound in the first winding step and the second winding step is cut, so that in two adjacent groups of teeth in the circumferential direction, the first conductor and the second conductor are wound continuously around each of the two groups of teeth.

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