Electric motor manufacturing method

Abstract

To avoid an increase in manufacturing cost of an electric motor, and increase the space factor of a winding portion while improving the reliability of a conductor wound in a first layer of the winding portion.SOLUTION: An electric motor manufacturing method performs: a first operation of winding a conductor from one end side to another end side of a winding drum in a radial direction of a yoke while leaving a gap between adjacent windings in a first layer; and a second operation of after the first operation, winding the conductor in the first layer so as to be in contact with the winding located at the other end, thereby moving at least a portion of the winding wound in the first operation toward the one end to close the gap.SELECTED DRAWING: Figure 15

Description

Technical Field

[0001] The present invention relates to a method for manufacturing an electric motor.

Background Art

[0002] As an electric motor, it includes a stator core and an insulator provided at the end of the stator core. A motor is known in which a winding portion having a plurality of layers is formed by a winding wire in which a conductor wire is wound in a concentrated winding manner around the tooth portion of the stator core and the winding cylinder portion of the insulator. In this type of electric motor, miniaturization and high efficiency are achieved by increasing the occupation ratio of the conductor wire in the winding portion.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Patent Document 3

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the electric motor described in Patent Document 1, the surface of the winding cylinder portion of the insulator is formed flat along the radial direction of the stator core. Further, the winding portion includes a first layer formed by winding the conductor wire along the surface of the winding cylinder portion from one end side (outer diameter side) to the other end side (inner diameter side) in the radial direction of the stator core, and a second layer laminated so as to overlap the first layer and formed by winding the conductor wire from the other end side (inner diameter side) to the one end side (outer diameter side) in the radial direction of the stator core.

[0005] In such an electric motor, if the winding pitch (the amount of movement of the nozzle per turn in the winding process using a winding machine) of the first layer of windings, which are wound radially around the stator core, is reduced in order to increase the space factor of the winding section, then when forming the first layer of the winding section, a portion of the windings wound later may overlap with the windings wound earlier. At this time, the windings wound later may not align with the other end (inner diameter side) of the windings wound earlier, but rather may penetrate to one end (outer diameter side) of the windings wound earlier. Because the surface of the insulating film of the conductor is slippery, the windings wound earlier may be pushed out to the other end (inner diameter side) of the stator core, a phenomenon known as "winding disorder" (hereinafter also referred to as "winding disorder"). This discovery was made by the inventors of the present invention. If winding irregularities occur, the conductors forming the winding may break as they are pulled to the inner diameter end, or the cross-sectional area of ​​the pulled conductors may decrease, increasing electrical resistance and the amount of heat generated by the conductors. In other words, the reliability of the conductors wound in the first layer of the winding may decrease. This phenomenon can occur not only when the conductors are wound in the direction from the outer diameter to the inner diameter in the radial direction of the stator core, but also when the conductors are wound in the direction from the inner diameter to the outer diameter in the radial direction of the stator core.

[0006] On the other hand, there is a structure in which grooves or the like are provided on the winding drum of the insulator to prevent the conductor wound in the first layer of the winding section from slipping (Patent Documents 2 and 3). However, this structure requires that the insulator be changed according to the outer diameter of the conductor, as grooves or the like are provided on the winding drum to match the outer diameter of the conductor, which increases the manufacturing cost of the electric motor. Furthermore, if a conductor with an outer diameter that does not match the size of the grooves or the like is wound on the winding drum, a load may be placed on the conductor that has gotten caught in the grooves or the like, potentially reducing the reliability of the conductor's current flow. In addition, a gap may be created between the grooves or the like and the conductor, which may actually reduce the space utilization ratio.

[0007] The disclosed technology has been made in view of the above, and aims to provide a method for manufacturing an electric motor that can increase the space factor of the winding section while avoiding an increase in the manufacturing cost of the electric motor and improving the reliability of the conductor wound in the first layer of the winding section. [Means for solving the problem]

[0008] One embodiment of a method for manufacturing an electric motor disclosed in the present application is a method for manufacturing an electric motor comprising: a stator core having an annular yoke portion and teeth portions extending radially from the yoke portion; an insulator having a winding drum portion attached to the teeth portion; and a winding portion having multiple layers formed by windings in which conductors are wound around the teeth portion via the winding drum portion, wherein the method involves: a first operation in which a conductor is wound radially from one end to the other of the winding drum portion while leaving a gap between adjacent windings in the first layer of the winding portion; and a second operation after the first operation in which a conductor is wound in the first layer so as to be in contact with the winding located at the other end, thereby moving at least a portion of the windings wound in the first operation to the one end and closing the gap. The winding drum portion of the insulator, when viewed in cross-section along the radial direction, has a flat surface extending along the radial direction and an inclined surface formed continuously on the other end of the flat surface and inclined with respect to the radial direction. In the second operation, when the second pitch, which is the winding pitch in the second operation, is P2, the conductor is wound so that P2=0, and the winding wound on the inclined surface slides along the inclined surface toward the flat surface, thereby moving the winding wound on the other end toward the one end. [Effects of the Invention]

[0009] According to one embodiment of the method for manufacturing an electric motor disclosed in this application, it is possible to avoid increasing the manufacturing cost of the electric motor, improve the reliability of the conductor wound in the first layer of the winding, and increase the space factor of the winding. [Brief explanation of the drawing]

[0010] [Figure 1] Figure 1 is a longitudinal cross-sectional view showing a compressor manufactured by the motor manufacturing method of the embodiment. [Figure 2] Figure 2 is a bottom view showing the stator core in the embodiment. [Figure 3] Figure 3 is a schematic perspective view showing the insulator in the embodiment. [Figure 4] Figure 4 is a bottom view showing the stator in the embodiment. [Figure 5]FIG. 5 is a cross-sectional view schematically showing the winding portion of the motor in the embodiment. [Figure 6] FIG. 6 is a cross-sectional view schematically showing the winding portion of the motor in the comparative example. [Figure 7] FIG. 7 is a cross-sectional view for explaining the case where the first-layer winding is normally wound in the winding process of the comparative example. [Figure 8] FIG. 8 is a cross-sectional view for explaining the case where the winding position of the first-layer winding is deviated in the winding process of the comparative example. [Figure 9] FIG. 9 is a side view for explaining the case where the winding position of the first-layer winding is deviated in the winding process of the comparative example. [Figure 10] FIG. 10 is a flowchart for explaining the winding process in the method for manufacturing a motor of the embodiment. [Figure 11] FIG. 11 is a flowchart for explaining the winding pitch of the winding process in the method for manufacturing a motor of the embodiment. [Figure 12] FIG. 12 is a cross-sectional view for explaining the first operation and the second operation performed in the winding process of the embodiment. [Figure 13] FIG. 13 is a cross-sectional view for explaining the case where the first-layer winding is normally wound in the first operation of the winding process of the embodiment. [Figure 14] FIG. 14 is a cross-sectional view for explaining the case where the winding position of the first-layer winding is deviated in the first operation of the winding process of the embodiment. [Figure 15] FIG. 15 is a cross-sectional view for explaining the second operation in the embodiment. [Figure 16] FIG. 16 is a cross-sectional view for explaining the first operation and the second operation performed in the winding process of the modified example.

BEST MODE FOR CARRYING OUT THE INVENTION

[0011] Hereinafter, embodiments of the method for manufacturing a motor disclosed in the present application will be described in detail based on the drawings. Note that the method for manufacturing a motor disclosed in the present application is not limited by the following embodiments.

Embodiment

[0012] (Compressor) FIG. 1 is a longitudinal sectional view showing a compressor provided with a motor manufactured by the method for manufacturing an electric motor according to an embodiment. As shown in FIG. 1, the compressor 1 is a so-called rotary compressor and includes a container 2, a shaft 3, a compression section 5, and an electric motor 6. The container 2 is formed of a metallic material and forms a sealed internal space 7. The internal space 7 is generally formed in a columnar shape. The container 2 is formed such that the central axis of the internal space 7 is parallel to the vertical direction when the container 2 is vertically placed on a horizontal plane. An oil sump 8 is formed at the lower part of the internal space 7 in the container 2. Lubricating oil for lubricating the compression section 5 is stored in the oil sump 8. A suction pipe 11 for sucking refrigerant and a discharge pipe 12 for discharging the compressed refrigerant are connected to the container 2. The shaft 3 is provided along the vertical direction and is disposed in the internal space 7 of the container 2 such that one end thereof is immersed in the oil sump 8. The shaft 3 is supported by the container 2 rotatably about the central axis of the internal space 7. By rotating, the shaft 3 supplies the lubricating oil stored in the oil sump 8 to the compression section 5.

[0013] The compression section 5 is disposed at the lower part in the internal space 7 and above the oil sump 8. The compressor 1 further includes an upper muffler cover 14 and a lower muffler cover 15. The upper muffler cover 14 is disposed above the compression section 5 in the internal space 7. The upper muffler cover 14 forms an upper muffler chamber 16 inside thereof. The lower muffler cover 15 is provided below the compression section 5 in the internal space 7 and above the oil sump 8. A lower muffler chamber 17 is formed inside the lower muffler cover 15. The lower muffler chamber 17 communicates with the upper muffler chamber 16 through a communication passage (not shown) formed in the compression section 5. A discharge hole 18 for discharging the compressed refrigerant is formed between the upper muffler cover 14 and the shaft 3, and the upper muffler chamber 16 communicates with the internal space 7 through the discharge hole 18.

[0014] The compression unit 5 compresses the refrigerant supplied from the intake pipe 11 by the rotation of a shaft 3 driven by an electric motor 6, and supplies the compressed refrigerant to the upper muffler chamber 16 and the lower muffler chamber 17. The refrigerant is compatible with lubricating oil.

[0015] (Electric motor) The electric motor 6 is located in the upper part of the compression section 5 within the internal space 7. The electric motor 6 is a three-phase motor and comprises a rotor 21 and a stator 22. The rotor 21 is fixed to the shaft 3. The stator 22 is formed in a generally cylindrical shape and is positioned on the outer circumference of the rotor 21, surrounding the rotor 21, and is fixed to the container 2. The stator 22 comprises a stator core 23, a lower insulator 25B as a first insulator, an upper insulator 25A as a second insulator, and a plurality of windings 46.

[0016] The upper insulator 25A is attached to the upper end of the stator core 23 in the axial direction of the shaft 3. The lower insulator 25B is attached to the lower end of the stator core 23 in the axial direction of the shaft 3. The upper insulator 25A and the lower insulator 25B are examples of insulating parts that insulate the stator core 23 from the windings 46. In this embodiment, the upper insulator 25A and the lower insulator 25B are formed to be the same shape, and are used as the upper insulator 25A when provided at the upper end of the stator core 23, and as the lower insulator 25B when provided at the lower end of the stator core 23. Hereinafter, in this embodiment, the upper insulator 25A and the lower insulator 25B together will be referred to as insulator 25. Note that the upper insulator 25A and the lower insulator 25B may be formed to be different shapes from each other.

[0017] Figure 2 is a bottom view showing the stator core 23 in an embodiment. As shown in Figure 2, the stator core 23 is formed by laminating a plurality of metal plates made of a soft magnetic material, such as electromagnetic steel sheets, and comprises a yoke portion 31 and a plurality of stator core teeth portions 32 (32-1 to 32-9). The yoke portion 31 is formed in a generally annular (cylindrical) shape. The first stator core tooth portion 32-1 of the plurality of stator core teeth portions 32-1 to 32-9 is formed in a generally columnar shape that extends radially in the stator core 23. The first stator core tooth portion 32-1 is formed with one end connected to the inner circumferential surface of the yoke portion 31, that is, it extends radially inward from the inner circumferential surface of the yoke portion 31. Among the multiple stator core teeth portions 32-1 to 32-9, the stator core teeth portions 32-2 to 32-9, which are different from the first stator core teeth portion 32-1, are formed in a generally columnar shape, similar to the first stator core teeth portion 32-1, and extend radially inward from the inner circumferential surface of the yoke portion 31. In the case of a 9-slot stator 22, the multiple stator core teeth portions 32-1 to 32-9 are formed on the inner circumferential surface of the yoke portion 31 so as to be arranged at equal intervals of 40° with respect to the circumferential direction of the yoke portion 31.

[0018] Figure 3 is a schematic perspective view showing the insulator 25 in the embodiment. As shown in Figure 3, the insulator 25 (upper insulator 25A and lower insulator 25B) is formed in an annular shape from an insulator exemplified by polybutylene terephthalate resin (PBT). As shown in Figure 3, the insulator 25 has an outer peripheral wall portion 41, a plurality of insulator teeth portions 42 (42-1 to 42-9) which are winding drum portions around which the conductor (winding wire 46) is wound, and a plurality of flange portions 43 (43-1 to 43-9). The outer peripheral wall portion 41 is formed in a generally cylindrical shape. The outer peripheral wall portion 41 has a plurality of slits 44 that extend from one end in the direction along the central axis of the outer peripheral wall portion 41 (the axial direction of the shaft 3) and are formed at intervals in the circumferential direction of the outer peripheral wall portion 41. Furthermore, the other end of the outer peripheral wall portion 41, in the direction along the central axis of the outer peripheral wall portion 41, is in contact with the stator core 23. In other words, the multiple slits 44 are formed extending toward the stator core 23 from one end of the outer peripheral wall portion 41 opposite to the stator core 23. The windings 46 (conductors) drawn out from the winding portion 45, which will be described later, are passed through each slit 44, so that the windings 46 drawn out from the inner circumference side to the outer circumference side of the outer peripheral wall portion 41 form connecting wires 49 stretched along the outer peripheral surface of the outer peripheral wall portion 41. Note that the insulator 25 shown in Figure 3 schematically shows the shape and arrangement of each slit 44 of the outer peripheral wall portion 41, and the details of the shape and arrangement of each slit 44 will be described later.

[0019] Of the multiple insulator teeth portions 42-1 to 42-9, the first insulator tooth portion 42-1 is formed in the shape of a straight column with a roughly semicircular cross-section. The first insulator tooth portion 42-1 is formed with one end connected to the inner surface of the outer peripheral wall portion 41, that is, it extends radially inward from the inner surface of the outer peripheral wall portion 41. The insulator tooth portions 42-2 to 42-9, which are different from the first insulator tooth portion 42-1, are also formed in the shape of a straight column with a roughly semicircular cross-section, similar to the first insulator tooth portion 42-1, and extend radially inward from the inner surface of the outer peripheral wall portion 41. Multiple insulator teeth portions 42-1 to 42-9 are formed on the inner circumferential surface of the outer circumferential wall portion 41, arranged at equal intervals of 40 degrees with respect to the circumferential direction of the outer circumferential wall portion 41. In this embodiment, the insulator teeth portion 42 is not limited to a straight column shape with a roughly semicircular cross-section, but may be formed in a straight column shape with a roughly polygonal cross-section, for example.

[0020] Multiple flange portions 43-1 to 43-9 correspond to multiple insulator tooth portions 42-1 to 42-9, and each is formed in a generally semicircular plate shape. The first flange portion 43-1, which corresponds to the first insulator tooth portion 42-1 among the multiple flange portions 43-1 to 43-9, is formed integrally with the first insulator tooth portion 42-1, and is continuous with the other end of the first insulator tooth portion 42-1. Similarly to the first flange portion 43-1, the flange portion 43, which is different from the first flange portion 43-1 among the multiple flange portions 43-1 to 43-9, is also formed integrally with each of the multiple insulator tooth portions 42-1 to 42-9, and is continuous with the other end of the multiple insulator tooth portions 42-1 to 42-9.

[0021] Figure 4 is a bottom view of the stator 22 in the embodiment, and is a view of the stator 22 from the lower insulator 25B side. As shown in Figure 4, each of the multiple stator core teeth 32-1 to 32-9 of the stator core 23 is wound with multiple windings 46 (U-phase windings 46-U1 to 46-U3, V-phase windings 46-V1 to 46-V3, and W-phase windings 46-W1 to 46-W3, which will be described later). As shown in Figure 4, each of the stator core teeth 32-1 to 32-9 has a winding section (coil) 45 formed by the windings 46 (conductors) of each phase. Each winding section 45 has multiple layers, for example, about 6 to 8 layers, formed by the windings 46 wound around the stator core teeth 32 via the insulator teeth 42. Each of the nine winding sections 45, forming a slot, is labeled with the numbers 1 to 9 in a clockwise order in Figure 4. The nine winding sections 45 are arranged along the circumferential direction of the stator core 23, with the three phases repeating in the same order. That is, they are arranged in a clockwise order in Figure 4, repeating the U phase, V phase, and W phase.

[0022] The motor 6 in this embodiment is a 6-pole, 9-slot concentrated winding type motor. The multiple windings (conductors) 46 include multiple U-phase windings 46-U1 to 46-U3 that form the U-phase winding section 45, multiple V-phase windings 46-V1 to 46-V3 that form the V-phase winding section 45, and multiple W-phase windings 46-W1 to 46-W3 that form the W-phase winding section 45.

[0023] Although the electric motor 6 in this embodiment is configured with 9 slots, the number of slots, i.e., the number of winding sections 45 (or the number of stator core teeth sections 32), is not limited.

[0024] Furthermore, although the stator core 23 in the embodiment has an annular yoke portion 31 integrally formed, the yoke portion may also be formed by connecting multiple arc-shaped yoke components (not shown) and assembling them in an annular shape. Also, although the stator core teeth portion 32 of the stator core 23 in the embodiment extends radially inward from the inner circumferential surface of the yoke portion 31, it may also extend radially outward from the outer circumferential surface of the yoke portion 31. Similarly, the insulator teeth portion 42 of the insulator 25 is not limited to extending radially inward from the inner circumferential surface of the outer circumferential wall portion 41, but may also extend radially outward from the outer circumferential surface of the outer circumferential wall portion 41.

[0025] (Winding section of the electric motor) Figure 5 is a schematic cross-sectional view of the winding section (coil) 45 in the electric motor 6 of the embodiment. In Figure 5, the letters "F" and "S" are used to distinguish the winding method of the first layer 1L of the winding section 45. "F" is used to indicate the winding 46 wound in the first operation described later, and "S" is used to indicate the winding 46 wound in the second operation described later. In addition, in Figure 5, the numbers "2 to 8" attached to the winding 46 of each layer of the winding section 45 indicate the second layer 2L to the eighth layer 8L.

[0026] As shown in Figure 5, in the embodiment, the conductor supplied from the nozzle N is wound in the winding section 45 at a predetermined winding pitch (the amount of movement of the nozzle N in the radial direction Y per turn) so as to be aligned in the radial direction Y of the yoke section 31 (corresponding to the radial direction Y of the outer peripheral wall section 41; hereinafter simply referred to as radial direction Y). The winding 46 wound as the first layer 1L of the winding section 45 is wound in contact with the surface of the first layer 1L of the winding section 45, i.e., the surface of the insulator teeth section 42 where the conductor is wound (hereinafter referred to as the surface of the insulator teeth section 42), in the radial direction Y. In the embodiment, the winding section 45 has an increased space factor without winding irregularities occurring in the winding 46 of the first layer 1L, and the details of this will be described later.

[0027] Here, the winding pitch refers to the amount of movement of the nozzle N relative to the radial Y direction per turn (one rotation) of the conductor (winding 46) wound around the insulator teeth 42 and stator core teeth 32 in the radial Y direction, and is different from the pitch dimension between adjacent windings 46 in the radial Y direction. For convenience, the winding pitch is sometimes shown as a pitch dimension in the drawings, but in the following explanation, the winding pitch refers to the amount of movement of the nozzle N in the radial Y direction per turn. Note that the amount of movement of the nozzle N refers to the amount of change in the relative position between the nozzle N and the insulator teeth 42. That is, when changing the relative position of the nozzle N with respect to the insulator teeth 42, the insulator teeth 42 may be fixed and the nozzle N may move, the nozzle N may be fixed and the insulator teeth 42 may move, or both the insulator teeth 42 and the nozzle N may move.

[0028] (Manufacturing method for electric motors) The manufacturing method of the electric motor in this embodiment includes a winding step in which a wire is wound around the stator core teeth 32 via the insulator teeth 42 to form a winding section (coil) 45. As shown in Figure 5, in the winding step of this embodiment, the wire is wound using a winding machine (not shown) having a nozzle N for supplying the wire. A feature of the manufacturing method of the electric motor in this embodiment is that, in the winding step, the operation of winding the wire around the first layer 1L of the winding section 45, and the amount of movement (winding pitch) of the nozzle N that supplies the wire to be wound around the first layer 1L, are controlled by a control unit C of the winding machine.

[0029] In the winding process, the winding wire 46 is supplied from a nozzle N that moves in the radial direction Y of the stator core 23, and the winding wire 46 is wound around the stator core teeth portion 32 of the stator core 23 and the insulator teeth portion 42 of the insulator 25 attached overlapping the stator core teeth portion 32. The crossover wire 49 drawn out from the winding portion 45 is wound along the outer peripheral wall portion 41 of the insulator 25. In the embodiment, when forming each winding portion 45 of three phases using a winding machine, for example, when forming the winding portion 45 for each phase using three nozzles N and forming the winding portions 45 of each phase in order, a so-called three-nozzle winding method for forming the winding portions 45 of three phases is applied.

[0030] (Winding process of the comparative example) First, in order to compare with the winding process in the manufacturing method of the motor of the embodiment, the winding process in the manufacturing method of the motor of the comparative example will be described. In the winding process in the comparison, in order to increase the occupancy ratio of the winding portion, when the outer diameter of the conductor in the state before being wound is B and the winding pitch (the amount of movement of the nozzle N in the radial direction Y per turn) of the winding wire of the first layer 1L of the winding portion is P, the conductor is wound so as to satisfy P < B (for example, P = 0.8B). Note that the outer diameter B of the conductor tends to be slightly smaller in the winding wire wound around the winding portion due to the conductor stretching in the longitudinal direction by the tension applied when the conductor is wound around the stator core teeth portion 32 via the insulator teeth portion 42.

[0031] FIG. 6 is a cross-sectional view schematically showing the winding portion 145 when the winding wire of the first layer 1L is normally wound in the motor of the comparative example. In FIG. 6, the numbers "1 to 8" attached to the winding wires 46 of each layer of the winding portion 145 indicate the first layer 1L to the eighth layer 8L. As shown in FIG. 6, in the winding portion 145 of the comparative example, for example, the winding wire 46 forms eight layers, and the winding wire is wound so that the winding pitch P of all layers from the first layer 1L to the eighth layer 8L satisfies P < B. For this reason, the first layer 1L to the eighth layer 8L of the winding portion 145 are wound so that the adjacent winding wires 46 are in close contact with each other in the radial direction Y.

[0032] (Winding process of the comparative example) FIG. 7 is a cross-sectional view for explaining a case where the winding of the first layer 1L is normally wound in the winding process of the comparative example. As shown in FIG. 7, in the comparative example, in the first layer 1L, the winding 46 of the second turn 2T slides down the outer peripheral surface of the winding 46 of the first turn 1T to the other end side Y2 in the radial direction Y (the inner diameter side which is the inner side of the radial direction Y), and following the winding 46 of the first turn 1T, the winding 46 of the second turn 2T and the winding 46 of the third turn 3T are wound in sequence so that they are adjacent to each other. After the fourth turn 4T and later, since the winding pitch P satisfies P < B, the conductors are wound in alignment so that the adjacent windings 46 are in contact with each other in the radial direction Y. That is, when each winding 46 (conductor) forming the first layer 1L is normally wound, the windings 46 of the first layer 1L are wound tightly without gaps.

[0033] FIG. 8 is a cross-sectional view for explaining a case where the winding position of the winding 46 of the first layer 1L is displaced in the winding process of the comparative example. FIG. 9 is a side view for explaining a case where the winding position of the winding 46 is displaced in the winding process of the comparative example.

[0034] As shown in FIG. 8, in the winding process of the comparative example, in the first layer 1L wound on the insulator teeth portion 42, for example, the winding 46 of the second turn 2T wound following the winding 46 of the first turn 1T slides to the other end side Y2 in the radial direction Y (the inner diameter side which is the inner side of the radial direction Y) from the position adjacent to and in contact with the winding 46 of the first turn 1T, and the winding position of the winding 46 of the second turn 2T may be greatly separated from the winding 46 of the first turn 1T.

[0035] At this time, in the comparative example, since the winding pitch (the amount of movement of the nozzle N in the radial direction Y per turn) P is P < B (P = 0.8B), the winding of the winding 46 of the third turn 3T is sent by 0.8B from the winding position where the winding 46 of the second turn 2T would normally be wound. Therefore, the winding 46 of the third turn 3T cannot cross the winding 46 of the second turn 2T toward the other end side Y2 in the radial direction Y (the inner diameter side which is the inner side in the radial direction Y), and will be wound on the side of the winding 46 of the first turn 1T (the outer diameter side which is one end side Y1 in the radial direction Y) rather than the position of the winding 46 of the second turn 2T. As a result, the winding 46 of the third turn 3T enters between the winding 46 of the first turn 1T and the winding 46 of the second turn 2T, and a part of the winding 46 of the third turn 3T rides on and is wound on the winding 46 of the second turn 2T, resulting in winding disorder.

[0036] Subsequently, from the winding position of the winding 46 of the second turn 2T which is located at the winding position where the winding 46 of the third turn 3T would normally be wound, the winding 46 of the fourth turn 4T is sent by 0.8B, which is smaller than the outer diameter B of the conductor in the state before being wound. As a result, the winding 46 of the fourth turn 4T is wound adjacent to the winding 46 of the second turn 2T on the side opposite to the winding 46 of the third turn 3T (one end side Y1 in the radial direction Y) in the radial direction Y.

[0037] Also, as shown in FIG. 9, for example, when each winding 46 of the third turn 3T and the fourth turn 4T enters between the winding 46 of the first turn 1T and the winding 46 of the second turn 2T, the winding 46 of the second turn 2T continues to be displaced in the direction away from the winding 46 of the first turn 1T in the radial direction Y (the other end side Y2 which is the direction approaching the flange portion 43), along with winding disorder. In particular, the winding 46 of the second turn 2T is pulled to the other end side Y2 (the inner diameter side which is the inside in the radial direction Y) of the radial direction Y, resulting in a decrease in the cross-sectional area, an increase in the electrical resistance, and an increase in the heat generation amount of the winding 46. Further, when winding disorder occurs in the first layer 1L, the conductor wound around the second layer 2L rides on the winding 46 that has caused the winding disorder, leading to a problem that the winding portion 45 greatly bulges in the stacking direction (the winding diameter direction, for example, the axial direction of the shaft 3), and the winding portion 45 is distorted and enlarged.

[0038] As described above, in order to increase the occupation ratio of the winding portion 145, when the winding pitch P of the winding 46 (conductor) wound around the first layer 1L satisfies P < B and the conductor is wound, there is a problem that winding disorder is likely to occur in the winding 46 wound around the first layer 1L. Here, as an example, the case where the winding disorder starts when the winding 46 of the second turn 2T in the first layer 1L slides on the insulator tooth portion 42 is shown. However, in the first layer 1L where the winding 46 is wound in contact with the surface of the insulator tooth portion 42, similar winding disorder may occur at any position in the radial direction Y.

[0039] (Winding process of the embodiment) In the winding process in the manufacturing method of the motor of the embodiment, when forming the first layer 1L by continuously winding a single conductor, a first operation of winding the conductor and a second operation of winding the conductor after the first operation are performed. FIG. 10 is a flowchart for explaining the winding process in the manufacturing method of the motor of the embodiment.

[0040] As shown in Figure 10, in the first operation, a wire is wound in the first layer 1L of the winding section 45 from the outer peripheral wall 41 side, which is one end Y1 in the radial direction Y of the insulator teeth section 42, toward the flange 43 side, which is the other end Y2 in the radial direction Y, while leaving a gap G between adjacent windings 46 (step S1). In the second operation, after the first operation, the next wire is wound in the first layer 1L so as to be in contact with the winding 46 located on the flange 43 side (the other end Y2 in the radial direction Y) that was wound in the first operation, thereby moving at least a portion of the winding 46 wound in the first operation toward the outer peripheral wall 41 side (one end Y1 in the radial direction Y) and closing the gap G (step S2).

[0041] In the second operation, it is preferable that the conductor is wound so as to be in contact with the winding 46 located on the other end side Y2 (inner diameter side) of the insulator teeth portion 42 in the radial direction Y (hereinafter also referred to as the other end winding 46) among the windings 46 wound in the first operation, because the gap G can be filled from the other end side Y2 (inner diameter side) in the radial direction Y. However, it is not limited to this, and in the second operation, the conductor may be wound so as to enter and make contact between the other end winding 46 and the adjacent winding 46 on the outer peripheral wall portion 41 side of this other end winding 46, so that the adjacent winding 46 can be pushed toward the outer peripheral wall portion 41 side (one end side Y1). Furthermore, in the second operation, it is preferable that the conductor is wound so as to be in contact with the outer peripheral surface of the other end winding 46 on the flange portion 43 side (the other end side Y2 in the radial direction Y). As shown in Figure 15, which will be described later, when the winding 46(S) wound in the second operation comes into contact with the outer peripheral surface of the other end winding 46(F) wound in the first operation, on the flange side, a force f1 is applied to the other end winding 46(S) wound in the first operation, directed towards one end Y1 (outer diameter side) in the radial direction Y, and a force f2 is applied to the outer peripheral wall portion 41 in the direction of the central axis toward the stator core 23. Then, the force f1 directed towards one end Y1 (outer diameter side) in the radial direction Y, received from the winding 46(S) wound in the second operation, pushes the other end winding 46(F) wound in the first operation toward the outer peripheral wall portion 41 (the outer diameter side, which is one end Y1 in the radial direction Y).

[0042] In the second operation, if the conductor is wound so that it is in contact with the outer surface of the other end winding 46(F) on the outer surface of the outer surface of the outer surface of the outer surface of the outer surface of the outer surface of the outer surface of the outer surface of the outer surface of the outer surface of the outer surface of the outer surface of the other end winding 46(F) (one end Y1 in the radial direction Y), the winding 46(S) wound in the second operation will fit between the other end winding 46(F) wound in the first operation and the adjacent winding 46(F) on the outer surface of the outer surface of the other end winding 46 (one end Y1 in the radial direction Y), pushing this adjacent winding 46(F) toward the outer surface of the outer surface of the outer surface of the outer surface of the other end winding 46(F) (one end Y1 in the radial direction Y). In this case, a part of the winding 46(S) wound in the second operation will ride up on top of the other end winding 46(F) wound in the first operation, causing a slight winding disorder on the other end Y2 in the radial direction Y of the first layer 1L. However, such winding irregularities only occur on the other end Y2 in the radial direction Y of the first layer 1L after the winding of the winding 46 in the first layer 1L is almost complete, and are acceptable because they have little effect on the winding state of the winding section 45 and the reliability of the conductor.

[0043] Furthermore, in the second operation, the conductor is not limited to winding only one turn (one rotation), but may be wound for multiple turns (number of turns), for example, 2 to 4 turns, depending on the size of the gap G between the windings 46(F) wound in the first operation. Increasing the number of turns in this way enhances the effect of reducing the gap G, and also increases the amount of windings 46(F, S) wound on the first layer 1L, thereby improving the space factor.

[0044] In the winding process of the embodiment, the first operation is to prevent winding irregularities that tend to occur in the winding 46 of the first layer 1L. The second operation is to close the gap G created between the windings 46(F) wound in the first operation. The second operation may also be an operation to reduce (narrow) at least one of the gaps G in multiple locations. The second operation increases the number of turns of the winding 46 in the first layer 1L and improves the alignment of the windings 46 of the second layer 2L and beyond that are superimposed on the first layer 1L, which has the gap G between the windings 46 closed.

[0045] (winding pitch of the winding wire) FIG. 11 is a flowchart for explaining the winding pitch in the winding process of the motor manufacturing method of the embodiment. FIG. 12 is a cross-sectional view for explaining the first operation and the second operation performed in the winding process of the embodiment. Hereinafter, it will be described with reference to FIGS. 11, 12, and FIG. 5. In FIG. 12, as in FIG. 5, in the first layer 1L of the winding portion 45, “F” is attached to the winding wire 46 wound in the first operation, and “S” is attached to the winding wire 46 wound in the second operation for indication.

[0046] In contrast to the winding pitch P (the amount of movement of the nozzle N in the radial direction Y per turn) of the above-described comparative example being P < B (P = 0.8B), in the first operation of the winding process of the embodiment, as shown in FIGS. 5 and 11, when the first pitch, which is the winding pitch for winding the conducting wire in the first operation, is P1 and the outer diameter of the conducting wire in the state before winding is B, the conducting wire is wound on the first layer 1L of the winding portion 45 such that the first pitch P1 satisfies P1 > B (step S3). Thereby, the winding wire 46 (F) can be wound so that winding disorder does not occur in the first layer 1L (see FIG. 14). When winding the conducting wire on the first layer 1L in the first operation, the nozzle N moves along the radial direction Y from the outer peripheral wall portion 41 side as one end side Y1 in the radial direction Y of the insulator teeth portion 42 toward the flange portion 43 side as the other end side Y2 in the radial direction Y. The first pitch P1, which is the amount of movement of the nozzle N, is controlled by the control unit C of the winding machine.

[0047] When the second pitch, which is the winding pitch for winding the conducting wire in the second operation after the first operation, is P2, in the second operation, the conducting wire is wound on the first layer 1L of the winding portion 45 such that the second pitch P2 satisfies P2 < P1 (step S4). Thereby, the gap G between the winding wires 46 (F) wound in the first operation can be filled by the winding wire 46 (S) wound in the second operation (see FIG. 15). Also in the second operation, the second pitch P2, which is the amount of movement of the nozzle N, is controlled by the control unit C of the winding machine.

[0048] When the third pitch, which is the winding pitch of the conductor wound after the second layer 2L of the winding part 45, is defined as P3, after the second operation in which the winding of the winding wire 46 in the first layer 1L is completed, the conductor is wound in the layers after the second layer 2L so that the third pitch P3 satisfies P3 < P1 (step S5). Thereby, since the number of turns of each layer after the second layer 2L can be increased, the occupation ratio of the winding part 45 can be increased. The third pitch P3, which is the moving amount of the nozzle N, is also controlled by the control unit C of the winding machine. In the embodiment, the third pitch P3 is set to a value that satisfies P2 < P3 < P1.

[0049] As described above, the nozzle N winds the conductor while reciprocating in the radial direction Y. That is, the nozzle N winds the conductor on the first layer 1L by the first operation and the second operation on the forward path of the reciprocating movement, winds the conductor on the second layer 2L on the return path of the reciprocating movement, and winds the conductor while repeating the reciprocating movement a predetermined number of times after the third layer 3L. Further, in the winding process of the embodiment, the stator core 23 and the insulator 25 are rotated around the radial direction Y in accordance with the movement of the nozzle N, and the conductor is wound around the stator core teeth portion 32 through the insulator teeth portion 42. Note that the direction in which the winding wire 46 (conductor) is wound with respect to the radial direction Y in the first layer 1L, that is, the moving direction of the nozzle N in the first layer 1L, is not limited to the direction from the outer peripheral wall portion 41 side toward the flange portion 43 side (the direction from one end side Y1 (outer side) to the other end side Y2 (inner side) of the radial direction Y), and may be the direction from the flange portion 43 side toward the outer peripheral wall portion 41 side (the direction from the other end side Y2 (inner side) to the one end side Y1 (outer side) of the radial direction Y).

[0050] In the first operation, it is preferable to wind the conductor so that the first pitch P1 satisfies P1 < 2B. When the first pitch P1 becomes 2B or more, the gap G between adjacent winding wires 46 becomes large, and there is a possibility that the gap G cannot be properly filled by the second operation. Further, when the first pitch P1 becomes 2B or more, the number of turns of the first layer 1L decreases, and the winding wire 46 of the second layer 2L easily enters the gap G between the winding wires 46 in the first layer 1L, and there is a possibility that the alignment of the winding part 45 may deteriorate. These problems can be avoided by the first pitch P1 satisfying P1 < 2B.

[0051] In the second operation, multiple turn wires are wound. In this embodiment, as an example, two turn windings 46 (wires) are wound in the second operation, but the number of turns of windings 46 in the second operation is not limited. The number of turns of windings 46 in the second operation is set to, for example, 1 to 4 turns. In the second operation, the second turn winding 46(S) is wound by feeding it by a second pitch P2 relative to the first turn winding 46(S), but the second pitch P2 may be different for each turn. In the second operation, the wires may be wound so that the second pitch P2 gradually decreases from the first turn to the last turn, for example.

[0052] Furthermore, in the second operation, the wire is wound such that the second pitch P2 satisfies 0 ≤ P2 < (B / 2). This allows the gap G between the windings 46 wound in the first operation to be properly filled.

[0053] When the second pitch P2 satisfies P2=0, the conductor will be wound around the same position on the insulator teeth portion 42 in the radial direction Y. In other words, when the second pitch P2 satisfies P2=0, the conductor wound in the second operation will be wound around the winding 46(F) located at the other end (flange portion 43 side) that was wound in the first operation, while in contact with either the flange portion 43 side (the other end side Y2 in the radial direction Y) or the outer peripheral wall portion 41 side (the one end side Y1 in the radial direction Y) of the outer peripheral surface of the other end winding 46.

[0054] In this case, from the viewpoint of moving the winding 46 at the other end toward the outer peripheral wall 41 side by the conductor wound in the second operation to close the gap G, it is desirable for the conductor to be in contact with the flange 43 side on the outer peripheral surface of the winding 46 at the other end, but it may also be in contact with the outer peripheral wall 41 side on the outer peripheral surface of the winding 46 at the other end. When the conductor wound in the second operation is wound in contact with the outer peripheral wall 41 side on the outer peripheral surface of the winding 46 at the other end, it can get between the winding 46 at the other end and the winding 46 adjacent to it, pushing the adjacent winding 46 toward the outer peripheral wall 41 side (one end Y1 in the radial direction Y) to close the gap G. At this time, a part of the winding 46 wound in the second operation rides up on top of the winding 46 at the other end, causing a slight winding disorder on the other end Y2 in the radial direction Y of the first layer 1L. However, such winding irregularities occur only on the other end Y2 in the radial direction Y of the first layer 1L after the winding of the winding 46 in the first layer 1L is almost complete, and are acceptable because they have little effect on the winding state of the winding section 45 and the reliability of the conductor. If the second pitch P2 becomes (B / 2) or greater, the conductor wound in the second operation may be wound away from the winding 46 at the other end (flange section 43 side) that was wound in the first operation, without making contact with the winding 46 at the other end, and the gap G may not be filled.

[0055] (Details of the first action) Figure 13 is a cross-sectional view illustrating the case in which the winding 46 of the first layer 1L is wound normally during the first operation of the winding process of the embodiment. As shown in Figure 13, in the first operation of the winding process of the embodiment, in the first layer 1L, the winding 46 of the first turn 1T is followed by the winding 46 of the second turn 2T and the winding 46 of the third turn 3T, in order, with a gap G between them. From the fourth turn 4T onward, the winding is continued so that the first pitch P1 satisfies P1 > B, resulting in the winding being aligned and wound with a gap G between adjacent windings 46 in the radial direction Y.

[0056] Figure 14 is a cross-sectional view illustrating the case in which the winding position of the first layer 1L winding 46 is shifted during the first operation of the winding process in the embodiment. As shown in Figure 14, in the first operation of the winding process in the embodiment, similar to the winding process of the comparative example described above (see Figure 8), in the first layer 1L, for example, the second turn 2T winding 46, which is wound following the first turn 1T winding 46, may slide radially in the Y direction on the insulator teeth portion 42 from the winding position where the second turn 2T winding 46 would normally be wound, causing the winding position of the second turn 2T winding 46 to move away from the first turn 1T winding 46.

[0057] Even in such cases, in the first operation of the winding process of the embodiment, the amount of movement of the nozzle N is properly secured by winding the conductor so that the first pitch P1 of the first layer 1L satisfies P1 > B, so that the winding 46 of the next third turn 3T can smoothly pass over the winding 46 of the second turn 2T, which is in a shifted winding position. The winding 46 of the third turn 3T is wound on the surface of the insulator teeth portion 42, for example, while in contact with the flange portion 43 side of the outer surface of the winding 46 of the second turn 2T. For this reason, the winding 46 of the third turn 3T is wound appropriately on the opposite side of the winding 46 of the second turn 2T from the winding 46 of the first turn 1T, without getting caught between the winding 46 of the first turn 1T and the winding 46 of the second turn 2T, as in the comparative example described above.

[0058] In other words, it is preferable that the first pitch P1 (amount of movement of the nozzle N) of the first layer 1L in the first operation be set to a value obtained by adding a predetermined value corresponding to the maximum amount of positional displacement of the winding position of the winding 46 assumed in the first layer 1L, that is, the maximum amount of slip of the winding 46, to the outer diameter B (upper limit of dimensional tolerance) of the conductor. Note that the first pitch P1 of the first layer 1L in the first operation should be set to a value greater than or equal to the value at which the next winding 46 is wound so as to be in contact with the outer circumferential surface (the other end Y2 on the flange 43 side of the outer circumferential surface) of the winding 46 whose winding position has been shifted. This makes it possible for the next winding 46 to overcome the winding 46 whose winding position has been shifted in the first operation of the winding process in the embodiment. Therefore, in the first operation of the winding process in the embodiment, the order of the windings 46 for each turn wound around the first layer 1L is not disrupted, and the windings 46 for each turn are wound correctly, thus preventing winding irregularities from occurring in the first layer 1L.

[0059] Similarly to the windings 46 from the 4th turn (4T) onward in the first operation, even if the winding position of the previously wound winding 46 is shifted, the next winding 46 will smoothly overtake the previously wound winding 46 as it is wound, thus preventing winding irregularities in the first layer (1L).

[0060] (Details of the second action) Figure 15 is a cross-sectional view illustrating the second operation in the embodiment. In Figure 15, in the first layer 1L of the winding section 45, the winding 46 wound in the first operation is labeled "F", and the winding 46 wound in the second operation is labeled "S".

[0061] As shown in Fig. 15, in the second operation, the conducting wire is wound such that the second pitch P2 satisfies P2 < P1, and the conducting wire (S) is wound so as to contact the winding 46(F) located at the other end in the radial direction Y among the windings 46(F) wound in the first operation. When the conducting wire (S) is wound in the second operation, the conducting wire (S) is wound around the surface of the insulator tooth portion 42 while contacting the outer peripheral surface on the side of the flange portion 43 (the other end side Y2 in the radial direction Y) of the outer peripheral surface of the winding 46(F) at the other end in the radial direction Y. As a result, a force f1 directed toward the one end side Y1 (outer diameter side) in the radial direction Y is applied to the winding 46(F) at the other end from the winding 46(S) wound in the second operation. Due to this force f1 directed toward the one end side Y1 (outer diameter side) in the radial direction Y, the winding 46(F) at the other end is pushed toward the one end side Y1 (outer diameter side) in the radial direction Y and moved toward the outer peripheral wall portion 41 side (the one end side Y1 in the radial direction Y). Thereby, the gap G between the winding 46(F) at the other end and the winding 46(F) adjacent to the winding 46(F) at the other end is filled, and the two windings 46(F) contact each other.

[0062] Subsequently, in the second operation, the next conducting wire (S) to be wound is wound such that the second pitch P2 satisfies P2 < P1, and the conducting wire (S) is wound around the surface of the insulator tooth portion 42 while contacting the outer peripheral surface on the side of the flange portion 43 (the other end side Y1 in the radial direction Y) of the winding 46(S) wound earlier in the second operation. As a result, the winding 46(S) wound earlier in the second operation is pushed and moved toward the outer peripheral wall portion 41 side (the one end side YI in the radial direction Y). Thereby, the gap G between the windings 46(F) located on the outer peripheral wall portion 41 side with respect to the winding 46(S) wound earlier in the second operation is filled. Thereafter, the same applies when the conducting wire is further wound in the second operation, and the gap G between the windings 46(F) wound on the outer peripheral wall portion 41 side is further filled.

[0063] Furthermore, in the embodiment, when viewed in cross-section along the radial direction Y, the surface of the insulator teeth portion 42 around which the conductor is wound has a flat surface 42a extending along the radial direction Y and an arc-shaped curved surface 42b as an inclined surface inclined with respect to the flat surface 42a. The flat surface 42a extends from the inner circumferential surface of the outer peripheral wall portion 41. The curved surface 42b extends from the side surface of the flange portion 43 facing the outer peripheral wall portion 41 and is smoothly continuous with the flat surface 42a on the flange portion 43 side (the other end side Y2 in the radial direction Y).

[0064] In the second operation, the winding 46 wound on the curved surface 42b of the insulator teeth portion 42 may slide along the curved surface 42b toward the flat surface 42a, thereby moving the winding 46 wound on the flange portion 43 side (the other end Y2 in the radial direction Y) of the insulator teeth portion 42 toward the outer peripheral wall portion 41 side (the one end Y1 in the radial direction Y). By utilizing the sliding force of the winding 46 wound on the curved surface 42b in this way, the gap G between the windings 46(F) wound in the first operation can be smoothly closed.

[0065] Furthermore, the inclined surface formed on the insulator teeth portion 42 is not limited to a curved surface (R surface) 42b formed with a single curvature, but may also be a C surface, a surface formed by a series of C surfaces with different inclination angles, or a surface formed by a series of R surfaces with different curvatures. In order to make the winding 46 wound around the inclined surface easier to slide, the flange portion 43 side of the insulator teeth portion 42 may be treated with a surface treatment such as a coating that reduces the coefficient of static friction.

[0066] It is preferable that the relational expression for the outer diameter B of the conductor used in the winding process of the embodiment also holds true when this outer diameter B is set as the upper limit of the dimensional tolerance of the outer diameter of the conductor (maximum finished outer diameter). This allows the winding pitch (first pitch P1, second pitch P2, etc.) to be set optimally, thereby most appropriately obtaining the effect of preventing winding irregularities in the winding 46 wound on the first layer 1L by the first operation, and the effect of closing the gap G between the windings 46 by the second operation. The conductor (winding 46) here has a conductor 46a and an insulating film 46b covering the conductor 46a, as shown in Figure 5, and the outer diameter B of the conductor is a dimension that includes the thickness of the insulating film 46b. In the embodiment, for example, the outer diameter of the conductor 46a is 0.8 mm, and the upper limit of the dimensional tolerance of the outer diameter B of the conductor covered with insulating film 46b is set to 0.88 mm.

[0067] Furthermore, the jumper wire 49 drawn out from the winding section 45 is less prone to stretching due to tension than the winding section 46, and is therefore larger than the outer diameter of the conductor in the portion forming the winding section 46, and is close to the outer diameter B of the conductor before winding. For this reason, the outer diameter B of the conductor before winding can be approximated to the outer diameter of the conductor as the jumper wire 49 extending from the winding section 45 to the outer peripheral wall section 41. Thus, in this embodiment, the outer diameter of the conductor in the jumper wire 49 extending from the winding section 45 to the outer peripheral wall section 41 is treated as the outer diameter B of the conductor before winding.

[0068] The insulating film 46b contains, for example, polyamide-imide, and the static friction coefficient of the insulating film 46b is 0.12 or less. The insulating film 46b in the embodiment has high lubricity and a static friction coefficient of about 0.05. Therefore, the winding 46 wound in the second operation makes it easier for the winding 46 wound in the first operation to slide in the radial direction Y on the surface of the insulator teeth portion 42, and the gap G between the windings 46 can be smoothly filled. In addition, as described above, a conductor (winding 46) with a small static friction coefficient on the surface of the insulating film 46b can suppress snagging of the conductor during the winding process, but it is prone to slipping in the first layer 1L that is in contact with the surface of the insulator teeth portion 42, and the winding position of the winding 46 is prone to shifting. Therefore, when a conductor with a small static friction coefficient of the insulating film 46b is used as described above, the first pitch P1 of the first layer 1L in the first operation satisfies P1 > B, as in the embodiment, which is highly effective in preventing winding irregularities in the first layer 1L.

[0069] Furthermore, the insulator 25 in the embodiment has glass fibers added in an amount of 15% to 45% by weight, which increases the coefficient of dynamic friction on the surface of the insulator teeth 42. If the amount added is less than 15% by weight, the molding shrinkage rate of the resin material containing glass fibers increases, which is undesirable because it reduces the moldability of the insulator 25. If the amount added exceeds 45% by weight, the increase in the effect of increasing the coefficient of dynamic friction is small, and it is undesirable because it only increases the manufacturing cost. By adding glass fibers in this way, the insulator 25 prevents the winding 46 wound around the surface of the insulator teeth 42 from slipping, thereby preventing winding irregularities in the first layer 1L wound in the first operation and improving the reliability of the conductor wound around the first layer 1L.

[0070] Furthermore, in the winding process of the embodiment, by winding the conductor using a winding machine having a nozzle N, the control unit C of the winding machine controls the amount of movement of the nozzle N (first pitch P1 and second pitch P2), thereby easily forming a winding section 45 without winding irregularities at a desired first pitch P1 in the first operation, and appropriately closing the gap G between the windings 46 at a desired second pitch P2 in the second operation.

[0071] (Modified Example) In the winding process of the modified example, the number of turns of the winding 46 in the second operation is 4 turns, which is different from the winding process of the embodiment in which the number of turns of the winding 46 in the second operation is 2 turns. FIG. 16 is a cross-sectional view for explaining the first operation and the second operation performed in the winding process of the modified example. In FIG. 16, in the first layer 1L of the winding part 45, "F" is attached to the winding 46 wound in the first operation, and "S" is attached to the winding 46 wound in the second operation.

[0072] As shown in FIG. 16, in the first operation in the winding process of the modified example, similar to the embodiment, the first pitch P1 is wound around the conductor in the first layer 1L of the winding part 55 so as to satisfy P1 > B, and the winding 46 is wound so that winding disorder does not occur in the first layer 1L. In the second operation in the winding process of the modified example, the conductor is wound so that the second pitch P2 satisfies P2 < P1, whereby the gap G on the flange portion 43 side (the other end side Y2 in the radial direction Y) between the windings 46 wound in the first operation is filled.

[0073] And in the second operation of the modified example, by winding the conductor repeatedly for 4 turns with the second pitch P2, the gaps G at a plurality of locations between the windings 46 wound in the first operation are filled in order from the flange portion 43 side, and when all the gaps G are filled, the windings 56 in the first layer 1L are brought into close contact with each other. In the winding process of the modified example, similar to the embodiment, the winding part 55 is formed by winding the conductor so that the third pitch P3 satisfies P3 < P1 in the second layer 2L and subsequent layers.

[0074] (Effect of the Embodiment) As described above, the manufacturing method of the electric motor in the embodiment involves a first operation in which a conductor is wound in the first layer 1L of the winding section 45 from the outer peripheral wall 41 side (one end Y1 in the radial direction Y) toward the flange 43 side (the other end Y2 in the radial direction Y) of the insulator teeth 42, leaving a gap G between adjacent windings 46; and a second operation in which, after the first operation, the conductor is wound in the first layer 1L so as to be in contact with the winding 46 located on the flange 43 side (the other end Y2 in the radial direction Y), thereby moving at least a portion of the windings 46 wound in the first operation toward the outer peripheral wall 41 side (one end Y1 in the radial direction Y) and closing the gap G. In this way, by winding the conductor in the first layer 1L while leaving a gap G between the windings 46 in the first operation, even if the windings 46 wound in the first layer 1L slip on the surface of the insulator teeth 42, the next winding 46 can smoothly overtake the misaligned winding 46 and be wound properly, thus preventing winding irregularities in the first layer 1L. Furthermore, by winding the conductor in the first layer 1L in the second operation to close the gap G between the windings 46, the number of turns of the windings 46 in the first layer 1L can be increased, improving the alignment of the windings 46 in the second layer 2L and beyond that are superimposed on the first layer 1L with the gap G between the windings 46 closed. For this reason, according to this embodiment, for example, it is not necessary to change the insulator having grooves to prevent the windings from slipping according to the outer diameter of the conductor, thus avoiding an increase in the manufacturing cost of the electric motor 6. Furthermore, according to the embodiment, the winding 46 of the first layer 1L of the winding section 45 is prevented from stretching due to winding irregularities, thereby suppressing increases in the resistance and heat generation of the winding 46, and improving the reliability of the conductor wound in the first layer 1L.

[0075] Furthermore, in the motor manufacturing method of the embodiment, in the first operation, the conductor is wound such that the first pitch P1 satisfies P1 > B. As a result, even if the winding 46 wound on the first layer 1L slips on the surface of the insulator teeth portion 42, the next winding 46 can smoothly overtake the misaligned winding 46 and be wound properly. Therefore, the winding 46 can be wound in the first layer 1L without winding irregularities occurring.

[0076] Also, in the method for manufacturing the motor of the embodiment, in the first operation, the conductor is wound such that the first pitch P1 satisfies P1 < 2B. In other words, for the winding 46 wound around the first layer 1L of the winding portion 45, the outer diameter B and the winding pitch P satisfy 2B > P. When the first pitch P1 becomes 2B or more, the gap G between adjacent windings 46 becomes large, and there is a possibility that the gap G cannot be properly filled by the second operation. Also, when the first pitch P1 becomes 2B or more, the number of turns in the first layer 1L decreases, and it becomes easier for the winding 46 of the second layer 2L to enter the gap G between the windings 46 in the first layer 1L, and there is a possibility that the alignment of the winding portion 45 decreases. These problems are avoided by the first pitch P1 satisfying P1 < 2B.

[0077] Also, in the method for manufacturing the motor of the embodiment, in the second operation, the conductor is wound such that the second pitch P2 satisfies P2 < P1. Thereby, the gap G between the windings 46 wound in the first operation can be filled by the winding 46 wound in the second operation.

[0078] Also, in the method for manufacturing the motor of the embodiment, in the second operation, the conductor is wound such that the second pitch P2 and the outer diameter B of the conductor satisfy 0 ≦ P2 < (B / 2). Thereby, the gap G between the windings 46 wound in the first operation can be properly filled.

[0079] Also, in the method for manufacturing the motor of the embodiment, in the second operation, the conductor is wound by repeating a plurality of turns. By increasing the number of turns in this way, the effect of reducing the gap G is enhanced, and the number of windings 46 wound around the first layer 1L can be increased.

[0080] Also, in the method for manufacturing the motor of the embodiment, the conductor is wound such that the third pitch P3 of the winding 46 wound after the second layer 2L of the winding portion 45 satisfies P3 < P1. Thereby, the number of turns of each layer after the second layer 2L can be increased, and the occupation ratio of the winding portion 45 can be increased.

[0081] Furthermore, the outer diameter B of the conductor used in the motor manufacturing method of the embodiment is the upper limit of the dimensional tolerance. This allows the winding pitch (first pitch P1, second pitch P2, etc.) to be optimally set, thereby most effectively preventing winding irregularities in the winding 46 wound on the first layer 1L during the first operation, and closing the gap G between the windings 46 during the second operation.

[0082] Furthermore, the insulator teeth portion 42 of the insulator 25 used in the motor manufacturing method of the embodiment has, when viewed in cross-section along the radial direction Y, a flat surface 42a extending along the radial direction Y and a curved surface 42b formed continuously with respect to the radial direction Y on the flange portion 43 side (the other end Y2 in the radial direction Y) of the flat surface 42a. Then, in the second operation, the winding 46 wound on the curved surface 42b slides along the curved surface 42b toward the flat surface 42a, thereby moving the winding 46 wound on the flange portion 43 side toward the outer peripheral wall portion 41 side (one end Y1 in the radial direction Y). By utilizing the sliding force of the winding 46 wound on the curved surface 42b in this way, the gap G between the windings 46 wound in the first operation can be smoothly closed.

[0083] Furthermore, the insulating film 46b of the conductor (winding 46) used in the motor manufacturing method of the embodiment contains polyamide-imide. As a result, the insulating film 46b has high lubricity, making it easier for the winding 46 wound in the second operation to slide the winding 46 wound in the first operation in the radial direction Y on the surface of the insulator teeth portion 42, and allowing the gap G between the windings 46 to be smoothly filled. In addition, although the high lubricity of the insulating film 46b suppresses snagging of the conductor during the winding process, the first layer 1L in contact with the surface of the insulator teeth portion 42 is prone to slipping, making it easy for the winding position of the winding 46 to shift. For this reason, as in the embodiment, satisfying P1>B for the first pitch P1 of the first layer 1L in the first operation is highly effective in preventing winding irregularities in the first layer 1L.

[0084] Furthermore, the insulator 25 used in the motor manufacturing method of the embodiment has glass fibers added in an amount of 15% to 45% by weight. This increases the coefficient of dynamic friction on the surface of the insulator teeth 42, and prevents the winding 46 wound around the surface of the insulator teeth 42 from slipping. This has the effect of preventing winding irregularities in the first layer 1L wound in the first operation and improving the reliability of the conductor wound around the first layer 1L.

[0085] Furthermore, the manufacturing method of the electric motor in the embodiment involves winding the conductor using a winding machine having a nozzle N for supplying the conductor. As a result, the control unit C of the winding machine controls the amount of movement of the nozzle N (first pitch P1, second pitch P2), which allows for the easy formation of a winding section 45 without winding irregularities at a desired first pitch P1 in the first operation, and for the gap G between the windings 46 to be appropriately closed at a desired second pitch P2 in the second operation. [Explanation of Symbols]

[0086] 6 Electric motor 23 Stator Core 25 (25A, 25B) Insulator 31 York section 32 (32-1~32-9) Stator core teeth section (teeth section) 41 Outer wall 42 (42-1~42-9) Insulator teeth section (winding drum section) 42a flat surface 45, 55 Winding section 46 windings 46a Conductor 46b Insulating film 49 Crossover B Outer diameter of the conductor G Gap P1 First pitch (winding pitch in the first operation) P2 Second pitch (winding pitch in the second operation) P3 Winding pitch from the second layer onwards 1L, 1st layer 2L~8L 2nd to 8th layer M length N Nozzle Y radial direction

Claims

1. A stator core having an annular yoke portion and teeth portions extending radially from the yoke portion, An insulator having a winding drum portion attached to the teeth portion, A method for manufacturing an electric motor, comprising: a winding section having multiple layers formed by windings in which conductors are wound around the teeth section via the winding drum section, A first operation involves winding the conductor in the first layer of the winding portion from one end to the other of the winding drum in the radial direction, while leaving a gap between adjacent windings. After the first operation, a second operation is performed in which the conductor is wound around the first layer so as to be in contact with the winding located on the other end, thereby moving at least a portion of the winding wound in the first operation toward the one end and closing the gap. The winding drum portion of the insulator, when viewed in cross-section along the radial direction, has a flat surface extending along the radial direction and an inclined surface formed continuously with respect to the radial direction on the other end of the flat surface. A method for manufacturing an electric motor, wherein in the second operation, when the second pitch, which is the winding pitch in the second operation, is P2, the conductor is wound so that P2 = 0, and the winding wound on the inclined surface slides along the inclined surface toward the flat surface, thereby moving the winding wound on the other end toward the one end.

2. The winding drum portion of the insulator has a flange portion formed at the inner diameter end of the winding drum portion in the radial direction. The inclined surface is formed spanning the flat surface and the flange portion. A method for manufacturing an electric motor according to claim 1.

3. The flange portion is formed such that, in the radial direction, the end face on the outer diameter side of the flange portion extends in a direction perpendicular to the flat surface. The inclined surface is located on the outer diameter side of the outer diameter end face of the flange portion in the radial direction. A method for manufacturing an electric motor according to claim 2.

4. In the first operation, when the first pitch, which is the winding pitch in the first operation, is P1 and the outer diameter of the conductor is B, The wire is wound such that P1 > B. A method for manufacturing an electric motor according to claim 1.

5. In the first operation, The wire is wound such that P1 < 2B. A method for manufacturing an electric motor according to claim 2.

6. In the second operation described above, the wire is wound around multiple turns. A method for manufacturing an electric motor according to claim 1.

7. When the third pitch, which is the winding pitch of the conductor wound in the second and subsequent layers of the aforementioned winding section, is defined as P3, The wire is wound such that P3 < P1. A method for manufacturing an electric motor according to claim 4.

8. The outer diameter B of the aforementioned conductor is the upper limit of the dimensional tolerance for that outer diameter. A method for manufacturing an electric motor according to claim 4.

9. The aforementioned wire comprises a conductor and an insulating film covering the conductor. The insulating film includes polyamide-imide, A method for manufacturing an electric motor according to any one of claims 1 to 8.

10. The insulator contains glass fibers in an amount of 15% to 45% by weight. A method for manufacturing an electric motor according to any one of claims 1 to 8.

11. The wire is wound using a winding machine having a nozzle for supplying the wire. A method for manufacturing an electric motor according to any one of claims 1 to 8.