Stator, motor, and method for manufacturing stator

Abstract

This stator comprises a stator core, a first phase winding, a second phase winding, a third phase winding, and a connection member. The connection member delta-connects the first phase winding, the second phase winding, and the third phase winding. The winding direction of a plurality of second wound portions is opposite to the winding direction of a plurality of first wound portions and a plurality of third wound portions. A plurality of first bridging line portions, a plurality of second bridging line portions, and a plurality of third bridging line portions are disposed on one or another side of the stator core. The connection member is disposed on the one side of the stator core.

Description

Stator, motor, and method for manufacturing stator

[0001] The present disclosure relates to a stator, a motor, and a method for manufacturing a stator. More particularly, the present disclosure relates to a stator having a delta-connected winding, a motor including the stator, and a method for manufacturing the stator.

[0002] The stator described in Patent Document 1 has a plurality of iron cores and a first-phase winding, a second-phase winding, and a third-phase winding wound around each of the plurality of iron cores. The winding directions of the first-phase winding and the third-phase winding are a first winding direction. The winding direction of the second-phase winding is a second winding direction opposite to the first winding direction. A crossover wire connecting the first-phase windings and a crossover wire connecting the third-phase winding are arranged on a first side surface of the stator. A crossover wire connecting the second-phase windings is arranged on a second surface opposite the first side surface of the stator.

[0003] In the stator described in Patent Document 1, the winding start and end positions of the second-phase winding are offset from the winding start and end positions of the first-phase winding and the third-phase winding, respectively. Therefore, a difference occurs in the length of the wiring for interconnecting the first-phase winding, the second-phase winding, and the third-phase winding, depending on the magnitude of the offset. The difference in wiring length is equal to the distance between the first side surface and the second surface. Differences in the wiring length between the windings result in differences in the resistance values ​​of the windings, which may degrade the characteristics of the stator.

[0004] Japanese Patent Application Laid-Open No. 2023-071102

[0005] An object of the present disclosure is to provide a stator, a motor, and a method for manufacturing this stator in which the difference in wiring length between windings is reduced.

[0006] A stator according to one aspect of the present disclosure includes a stator core, a first-phase winding, a second-phase winding, a third-phase winding, and a connecting member. The stator core has a plurality of teeth arranged in an annular shape around a rotation axis extending in an axial direction. The connecting member delta-connects the first-phase winding, the second-phase winding, and the third-phase winding. The first-phase winding includes a first starting end, a first ending end, a plurality of first winding portions between the first starting end and the first ending end, and a plurality of first overhead wiring portions that bridge the plurality of teeth. Each of the plurality of first winding portions is concentratedly wound around a corresponding one of the plurality of teeth. The second-phase winding includes a second starting end, a second ending end connected to the first starting end via the connecting member, a plurality of second winding portions between the second starting end and the second ending end, and a plurality of second overhead wiring portions that bridge the plurality of teeth. Each of the plurality of second winding portions is concentratedly wound around a corresponding one of the plurality of teeth. The third phase winding includes a third starting end connected to the first ending end via the connecting member, a third ending end connected to the second starting end via the connecting member, a plurality of third winding portions between the third starting end and the third ending end, and a plurality of third overhead wiring portions spanning between the plurality of teeth. Each of the plurality of third winding portions is concentratedly wound around a corresponding one of the plurality of teeth. The winding direction of the plurality of second winding portions is opposite to the winding directions of the plurality of first winding portions and the plurality of third winding portions. In a circumferential direction around an axis centered on the rotating shaft, the plurality of first winding portions are arranged adjacent to one another in the following order: a first winding portion connected to the first starting end among the plurality of first winding portions, a second winding portion connected to the second ending end among the plurality of second winding portions, a third winding portion connected to the third starting end among the plurality of third winding portions, a first winding portion connected to the first ending end among the plurality of first winding portions, a second winding portion connected to the second starting end among the plurality of second winding portions, and a third winding portion connected to the third ending end among the plurality of third winding portions. The plurality of first winding portions, the plurality of second winding portions, and the plurality of third winding portions are arranged on one side of the stator core, or the plurality of first winding portions, the plurality of second winding portions, and the plurality of third winding portions are arranged on the other side of the stator core.The connecting member is disposed on one side of the stator core.

[0007] A motor according to one aspect of the present disclosure includes the stator and a rotor that rotates relative to the stator.

[0008] A manufacturing method according to one aspect of the present disclosure is a method for manufacturing the stator, and includes a first step and a second step. In the first step, the plurality of first winding portions and the plurality of third winding portions are concentratedly wound around the corresponding teeth. In the second step, after the first step, the plurality of second winding portions are concentratedly wound around the corresponding teeth.

[0009] The present disclosure has the advantage that the difference in wiring length between windings is small.

[0010] FIG. 1 is a plan view of a motor according to an embodiment. FIG. 2 is a cross-sectional view of the motor and an enlarged view of a main part. FIG. 3 is a wiring diagram of the motor. FIG. 4 is a developed view of a stator of the motor. FIG. 5 is a plan view of a stator of the motor. FIG. 6 is a developed view of a stator according to a first comparative example. FIG. 7 is a developed view of a stator according to a second comparative example. FIG. 8 is a plan view of a stator according to the second comparative example. FIG. 9 is a plan view of a stator according to a first modified example. FIG. 10 is a plan view of a stator according to a third comparative example.

[0011] (Embodiments) A stator 4, a motor M1, and a manufacturing method according to an embodiment will be described below with reference to the drawings. However, the following embodiment is merely one of various embodiments of the present disclosure. The following embodiment can be modified in various ways depending on the design, etc., as long as the object of the present disclosure can be achieved. Each figure described in the following embodiments is a schematic diagram. The ratios of the sizes and thicknesses of the components in the figures do not necessarily reflect the actual dimensional ratios.

[0012] Hereinafter, one side in the direction in which the axis A1 (see FIGS. 1 and 2) extends will be defined as "upper" and the other side as "lower." However, in this disclosure, "upper" and "lower" merely represent relative directions and are not intended to limit the directions in which the stator 4 and the motor M1 are used. The arrows representing up and down in FIGS. 2, 4, etc. are merely used for the purpose of explanation and have no substance.

[0013] (Overview) Fig. 1 is a plan view of a motor M1 according to an embodiment. Fig. 2 is a cross-sectional view of the motor M1 and an enlarged view of a main part. Fig. 3 is a wiring diagram of the motor M1. Fig. 4 is a developed view showing a stator 4 of the motor M1. Fig. 5 is a plan view of the stator 4 of the motor M1.

[0014] In this embodiment, a case will be described in which the stator 4 is a component of the motor M1. That is, the motor M1 of this embodiment includes the stator 4 and the rotor 5 that rotates relative to the stator 4. However, the stator 4 may also be a component of a generator.

[0015] In this embodiment, a three-phase AC current is supplied to the stator 4. The three phases are a U-phase, a V-phase, and a W-phase.

[0016] 1 and 2, the stator 4 includes a stator core 41, a first-phase winding 1X, a second-phase winding 2Y, a third-phase winding 3Z, and at least one connecting member 6. The stator core 41 has a plurality of teeth 410 arranged in an annular shape around an axis A1 that extends in the vertical direction. The at least one connecting member 6 delta-connects the first-phase winding 1X, the second-phase winding 2Y, and the third-phase winding 3Z.

[0017] One of the first, second, and third phases is a U-phase, another one is a V-phase, and the remaining one is a W-phase.

[0018] In Fig. 4, the teeth 410 arranged in an annular shape are shown unfolded and aligned in a straight line. The tooth 410 located at the left end in Fig. 4 (the tooth 410 wound with the first winding portion 15 described below) is actually adjacent to the tooth 410 located at the right end in Fig. 4 (the tooth 410 wound with the third winding portion 31 described below) (see Fig. 1).

[0019] 3 and 4 , the first-phase winding 1X includes a first starting end 1s, a first ending end 1e, a plurality of first winding portions 1c between the first starting end 1s and the first ending end 1e, and a plurality of first truncated wire portions 1b that span between the plurality of teeth 410. Each of the plurality of first winding portions 1c is concentratedly wound around a corresponding one of the plurality of teeth 410.

[0020] The second-phase winding 2Y includes a second starting end 2s, a second ending end 2e connected to the first starting end 1s via at least one connecting member 6, a plurality of second winding portions 2c between the second starting end 2s and the second ending end 2e, and a plurality of second truncated wire portions 2b spanning the plurality of teeth 410. Each of the plurality of second winding portions 2c is concentratedly wound around a corresponding one of the plurality of teeth 410.

[0021] The third-phase winding 3Z includes a third starting end 3s connected to the first starting end 1e via at least one connecting member 6, a third ending end 3e connected to the second starting end 2s via at least one connecting member 6, a plurality of third winding portions 3c between the third starting end 3s and the third ending end 3e, and a plurality of third overhead wiring portions 3b spanning between the plurality of teeth 410. Each of the plurality of third winding portions 3c is concentratedly wound around a corresponding one of the plurality of teeth 410.

[0022] The winding direction of the second winding portions 2c is opposite to the winding direction of the first winding portions 1c and the third winding portions 3c.

[0023] The number of first winding portions 1c, second winding portions 2c, and third winding portions 3c is the same. In this embodiment, as shown in FIG. 3 , the number of first winding portions 1c, second winding portions 2c, and third winding portions 3c is five. Hereinafter, the five first winding portions 1c will also be referred to as first winding portions 11, 12, 13, 14, and 15, respectively. The five second winding portions 2c will also be referred to as second winding portions 21, 22, 23, 24, and 25, respectively. The five third winding portions 3c will also be referred to as third winding portions 31, 32, 33, 34, and 35, respectively.

[0024] The first winding portion 11 is connected to the first starting end 1s. The first winding portion 15 is connected to the first ending end 1e. The five first winding portions 1c are connected in the order of first winding portions 11, 12, 13, 14, and 15, from the side electrically closest to the first starting end 1s to the side electrically farthest from the first starting end 1s. A first overhead line portion 1b is interposed between the first winding portions 11 and 12, between the first winding portions 12 and 13, between the first winding portions 13 and 14, and between the first winding portions 14 and 15.

[0025] The second winding portion 21 is connected to the second starting end 2s. The second winding portion 25 is connected to the second ending end 2e. The five second winding portions 2c are connected in the order of second winding portions 21, 22, 23, 24, and 25, from the side electrically closest to the second starting end 2s to the side electrically farthest from the second starting end 2s. Second overhead line portions 2b are interposed between the second winding portions 21 and 22, between the second winding portions 22 and 23, between the second winding portions 23 and 24, and between the second winding portions 24 and 25, respectively.

[0026] The third winding portion 31 is connected to the third starting end 3s. The third winding portion 35 is connected to the third ending end 3e. The five third winding portions 3c are connected to the third starting end 3s in the order of third winding portions 31, 32, 33, 34, and 35, from the side electrically closest to the third starting end 3s to the side electrically farthest from the third winding portion 3c. Third overhead line portions 3b are interposed between the third winding portions 31 and 32, between the third winding portions 32 and 33, between the third winding portions 33 and 34, and between the third winding portions 34 and 35.

[0027] As shown in FIG. 1 , in the circumferential direction around the axis A1 of the rotating shaft 52, the winding portions 11 connected to the first starting ends 1s of the plurality of first winding portions 1c, the second winding portion 25 connected to the second ending ends 2e of the plurality of second winding portions 2c, the third winding portion 31 connected to the third starting ends 3s of the plurality of third winding portions 3c, the first winding portion 15 connected to the first ending ends 1e of the plurality of first winding portions 1c, the second winding portion 21 connected to the second starting ends 2s of the plurality of second winding portions 2c, and the third winding portion 35 connected to the third ending ends 3e of the plurality of third winding portions 3c are lined up adjacent to one another in this order.

[0028] According to the above configuration, the first-phase winding 1X, the second-phase winding 2Y, and the third-phase winding 3Z are arranged so that their interconnections are close to each other. This reduces the area required for connecting the first-phase winding 1X, the second-phase winding 2Y, and the third-phase winding 3Z. Specifically, as shown in FIG. 5 , the length of the conductors (wires 62, 63, 64) used to connect the first-phase winding 1X, the second-phase winding 2Y, and the third-phase winding 3Z is sufficient if it is approximately the length between two adjacent teeth 410.

[0029] 4, the plurality of first overhead line sections 1b, the plurality of second overhead line sections 2b, and the plurality of third overhead line sections 3b are all disposed below the stator core 41. At least one connecting member 6 is disposed above the stator core 41.

[0030] With the above configuration, the difference in length between the start and end of each of the first, second, and third windings 1X, 2Y, and 3Z can be made relatively small compared to when any one of the multiple first, second, and third windings 1b, 2b, and 3b is arranged above the stator core 41 (see FIG. 6, which will be described later). Therefore, the difference in resistance value between the start and end of each of the first, second, and third windings 1X, 2Y, and 3Z can be made relatively small.

[0031] Furthermore, by connecting the first phase winding 1X, the second phase winding 2Y, and the third phase winding 3Z to each other via at least one connecting member 6, the assembly of the stator 4 can be simplified.

[0032] As described above, in the present embodiment, the plurality of first overhead line sections 1b, the plurality of second overhead line sections 2b, and the plurality of third overhead line sections 3b are all disposed below the stator core 41. In contrast to this, as a modified example, the plurality of first overhead line sections 1b, the plurality of second overhead line sections 2b, and the plurality of third overhead line sections 3b may all be disposed above the stator core 41.

[0033] (Details) The stator 4 and the motor M1 of this embodiment will be described in more detail below.

[0034] (1) Motor As shown in FIG. 2, the motor M1 includes a stator 4, a rotor 5, and a housing 7.

[0035] The housing 7 has a cover 71 and a base 72. The base 72 is a hollow member with an opening on its upper surface. The opening of the base 72 is covered by the cover 71. The stator 4 and the rotor core 51 of the rotor 5 are arranged in the space surrounded by the cover 71 and the base 72.

[0036] (2) Rotor As shown in FIG. 1 , the rotor 5 includes a rotor core 51 , a rotating shaft 52 , and a plurality of (six in FIG. 1 ) permanent magnets 53 .

[0037] The rotor core 51 includes a magnetic material. The rotor core 51 has a cylindrical shape centered on an axis A1 that extends in the up-down direction. A rotating shaft 52 is fixed to the rotor core 51. More specifically, the rotating shaft 52 is fitted into a through hole 510 provided in the center of the rotor core 51. The rotating shaft 52 includes the axis A1. The longitudinal direction of the rotating shaft 52 is the direction in which the axis A1 extends, i.e., the axial direction. As the rotor core 51 rotates, the rotating shaft 52 rotates about the axis A1.

[0038] A plurality of permanent magnets 53 are embedded in the rotor core 51 .

[0039] In the following description, the rotor 5 will be described using an interior permanent magnet rotor (IPM rotor) as shown in Fig. 1. The present disclosure can also achieve similar effects with a surface-permanent magnet rotor (SPM rotor).

[0040] (3) Overview of the Stator As shown in FIGS. 1 and 2, the stator 4 includes a stator core 41, a first-phase winding 1X, a second-phase winding 2Y, a third-phase winding 3Z, and at least one connecting member 6 (one in this embodiment).

[0041] The stator core 41 includes a magnetic material and has a cylindrical shape centered on an axis A1 extending in the up-down direction.

[0042] Stator core 41 includes a plurality of teeth 410. The plurality of teeth 410 are arranged radially around rotor core 51. The plurality of teeth 410 are connected in an annular shape when viewed from the top and bottom. As a result, stator core 41 is formed in a cylindrical shape that surrounds rotor core 51.

[0043] Each of the first-phase winding 1X, the second-phase winding 2Y, and the third-phase winding 3Z has a linear conductor and an electrically insulating coating covering the linear conductor. The first-phase winding 1X, the second-phase winding 2Y, and the third-phase winding 3Z are wound around a plurality of teeth 410. The first-phase winding 1X, the second-phase winding 2Y, and the third-phase winding 3Z are connected in series in a delta connection (see FIG. 3).

[0044] When energized, each of the first winding portions 1c of the first-phase winding 1X, the second winding portions 2c of the second-phase winding 2Y, and the third winding portions 3c of the third-phase winding 3Z generates a magnetic flux. Electromagnetic interaction between the generated magnetic flux and the permanent magnets 53 causes the rotor 5 to rotate relative to the stator 4.

[0045] In FIG. 5, the winding portion is not shown.

[0046] (4) Wiring Member As shown in Fig. 5, the wiring member 6 includes a printed circuit board 61. The printed circuit board 61 has a board body 610 and a plurality of wirings 62, 63, and 64 provided on the board body 610. The board body 610 has electrical insulation properties. The plurality of wirings 62, 63, and 64 have conductivity.

[0047] The printed circuit board 61 is electrically connected to a first starting end 1s, a first ending end 1e, a second starting end 2s, a second ending end 2e, a third starting end 3s, and a third ending end 3e of the winding.

[0048] More specifically, the first starting end 1s and the second ending 2e are electrically connected to the wiring 62 of the printed circuit board 61. This electrically connects the first starting end 1s and the second ending 2e to each other. In this manner, the connecting member 6 has the wiring 62 including a connection point P2 (see FIG. 3 ) between the first starting end 1s and the second ending 2e. The shape of the wiring 62 is a straight line connecting the first starting end 1s and the second ending 2e.

[0049] The third starting end 3s and the first terminal end 1e are electrically connected to the wiring 63 of the printed circuit board 61. This electrically connects the third starting end 3s and the first terminal end 1e. In this way, the connecting member 6 has the wiring 63 including a connection point P3 (see FIG. 3 ) between the third starting end 3s and the first terminal end 1e. The shape of the wiring 63 is a straight line connecting the third starting end 3s and the first terminal end 1e.

[0050] The second starting end 2s and the third ending end 3e are electrically connected to the wiring 64 of the printed circuit board 61. This electrically connects the second starting end 2s and the third ending end 3e to each other. In this way, the connecting member 6 has the wiring 64 including a connection point P4 (see FIG. 3 ) between the second starting end 2s and the third ending end 3e. The shape of the wiring 64 is a straight line connecting the second starting end 2s and the third ending end 3e.

[0051] The shape of each of the wires 62, 63, 64 is not limited to a straight line, and may be, for example, an arc shape along the direction in which the plurality of teeth 410 are arranged.

[0052] Each of the wires 62, 63, and 64 is connected to the start and end of the winding via, for example, a through-hole H1 (see FIG. 2) provided in the printed circuit board 61. The start and end of the winding are connected to the corresponding one of the wires 62, 63, and 64 by, for example, soldering.

[0053] 2, the connecting member 6 (printed circuit board 61) is disposed above the stator core 41 with a gap therebetween in the vertical direction. The thickness direction of the printed circuit board 61 is aligned with the vertical direction.

[0054] 2, the first starting end 1s is fixed to the first winding portion 11 (1c) by a fixing member F1. That is, the stator 4 further includes a fixing member F1.

[0055] The connecting member 6 has a holding portion that positions the first starting end 1s. The holding portion includes, for example, a through-hole H1. As shown in FIG. 2, the fixing member F1 and the holding portion (through-hole H1) are aligned in the vertical direction. Therefore, the first starting end 1s is positioned along the vertical direction between the fixing member F1 and the holding portion.

[0056] Similar to the first starting end 1s, the other starting ends and ending ends are also arranged in the vertical direction by the fixing members F1 and the holding portions. That is, the stator 4 includes a plurality (six) of fixing members F1. The fixing members F1 fix the first starting end 1s, the first ending end 1e, the second starting end 2s, the second ending end 2e, the third starting end 3s, and the third ending end 3e. The first starting end 1s, the first ending end 1e, the second starting end 2s, the second ending end 2e, the third starting end 3s, and the third ending end 3e extend from the fixing members F1 in the vertical direction toward at least one connecting member 6.

[0057] The wiring 62 overlaps in the vertical direction with the first winding portion 11 connected to the first starting end 1s and the second winding portion 25 connected to the second ending end 2e.

[0058] The wiring 63 overlaps in the vertical direction with the third winding portion 31 connected to the third starting end 3s and the first winding portion 15 connected to the first terminal end 1e.

[0059] The wiring 64 overlaps in the vertical direction with the second winding portion 21 connected to the second starting end 2s and the third winding portion 35 connected to the third ending end 3e.

[0060] (5) Windings Next, the first phase winding 1X, the second phase winding 2Y, and the third phase winding 3Z will be described in detail with reference to FIGS.

[0061] The teeth 410 are arranged in a ring shape. A corresponding winding portion is wound around each tooth 410. Hereinafter, the clockwise direction in FIG. 1 (clockwise as viewed from above) is defined as "clockwise."

[0062] The tooth 410 adjacent in the clockwise direction to the tooth 410 around which the first winding portion 1c is wound is wound with the second winding portion 2c. The tooth 410 adjacent in the clockwise direction to the tooth 410 around which the second winding portion 2c is wound is wound with the third winding portion 3c. The tooth 410 adjacent in the clockwise direction to the tooth 410 around which the third winding portion 3c is wound is wound with the first winding portion 1c. In this way, the winding portions are arranged in the clockwise order of the first winding portion 1c, the second winding portion 2c, the third winding portion 3c, the first winding portion 1c, the second winding portion 2c, the third winding portion 3c, ...

[0063] More specifically, the windings are arranged clockwise in the following order: first winding portion 15, second winding portion 21, third winding portion 35, first winding portion 14, second winding portion 22, third winding portion 34, first winding portion 13, second winding portion 23, third winding portion 33, first winding portion 12, second winding portion 24, third winding portion 32, first winding portion 11, second winding portion 25, and third winding portion 31. First winding portion 15 is adjacent to third winding portion 31 in the clockwise direction.

[0064] In the first-phase winding 1X, the first winding portions 11, 12, 13, 14, and 15 are connected in this order from the first starting end 1s connected to the second ending end 2e, and then to the first ending end 1e. The first winding portions 11, 12, 13, 14, and 15 are arranged counterclockwise.

[0065] The third-phase winding 3Z is connected in this order from the third starting end 3s connected to the first end 1e, to the third winding portions 31, 32, 33, 34, 35, and the third end 3e. The third winding portions 31, 32, 33, 34, 35 are arranged counterclockwise.

[0066] In the second-phase winding 2Y, the second winding portions 21, 22, 23, 24, and 25 are connected in this order from the second starting end 2s connected to the third end 3e to the second end 2e. The second winding portions 21, 22, 23, 24, and 25 are arranged clockwise. As such, the winding direction of the second winding portions 2c is clockwise, which is opposite to the winding direction (counterclockwise) of the first winding portions 1c and the third winding portions 3c.

[0067] Two adjacent first winding portions 1c are connected by a first overhead line portion 1b. The first-phase winding 1X has four first overhead line portions 1b (see FIG. 3). The four first overhead line portions 1b are arranged below the stator core 41.

[0068] Two adjacent second winding portions 2c are connected by a second overhead line portion 2b. The second-phase winding 2Y has four second overhead line portions 2b (see FIG. 3). The four second overhead line portions 2b are arranged below the stator core 41.

[0069] Two adjacent third winding portions 3c are connected by a third overhead line portion 3b. The third-phase winding 3Z has four third overhead line portions 3b (see FIG. 3). The four third overhead line portions 3b are arranged below the stator core 41.

[0070] As described above, the first, second, and third overhead wire portions 1b, 2b, and 3b are all disposed below the stator core 41. At least one connecting member 6, to which the start and end of each winding is connected, is disposed above the stator core 41. Therefore, the distance L0 (see FIG. 4 ) between the connection point of the start and end of each winding with the connecting member 6 and the start and end of the winding around the teeth 410 is equal for the first-phase winding 1X, the second-phase winding 2Y, and the third-phase winding 3Z. The term "equal" as used herein does not necessarily mean perfectly equal, but also includes differences within the range of manufacturing tolerance. For example, an error of less than 5% may be considered "equal."

[0071] If there is a difference in the distance L0 between the first-phase winding 1X, the second-phase winding 2Y, and the third-phase winding 3Z, the difference will cause a difference in the resistance value of each winding, which may deteriorate the characteristics of the stator 4. In contrast, in this embodiment, the difference in resistance value can be reduced, thereby improving the characteristics of the stator 4.

[0072] (6) First Comparative Example FIG. 6 is a development view showing a stator according to a first comparative example. The stator according to the first comparative example differs from the stator 4 of the embodiment in that the plurality of second overhead wiring portions 2b are arranged above the stator core 41. In the first comparative example, the plurality of second overhead wiring portions 2b are arranged above the stator core 41. As a result, the distance L2 between the connection points of the second starting end 2s and the second ending end 2e with the connecting members 6 and the winding start and end points of the second-phase winding 2Y around the teeth 410 is relatively short. In the first comparative example, the distance L2 is shorter than the distance L1 between the connection points of the first starting end 1s and the first ending end 1e with the connecting members 6 and the winding start and end points of the first-phase winding 1X around the teeth 410. In the first comparative example, the distance L3 between the connection points of the third starting end 3s and the third ending end 3e with the connecting member 6 and the start and end points of the winding of the third phase winding 3Z around the tooth 410 is equal to the distance L1.

[0073] In the stator 4 of the embodiment, the difference in resistance value between the windings can be reduced compared to the stator of the first comparative example, and therefore the characteristics of the stator 4 can be improved.

[0074] (7) Second Comparative Example Fig. 7 is a development view showing a stator according to a second comparative example. Fig. 8 is a plan view of the stator according to the second comparative example. The stator according to the second comparative example differs from the stator 4 of the embodiment in that the winding direction of the second winding portions 2c is counterclockwise, which is the same as the winding direction of the first winding portions 1c and the third winding portions 3c.

[0075] Therefore, the multiple winding portions of the stator according to the second comparative example are arranged clockwise in the following order: first winding portion 15, second winding portion 25, third winding portion 35, first winding portion 14, second winding portion 24, third winding portion 34, first winding portion 13, second winding portion 23, third winding portion 33, first winding portion 12, second winding portion 22, third winding portion 32, first winding portion 11, second winding portion 21, and third winding portion 31. First winding portion 15 is adjacent to third winding portion 31 in the clockwise direction.

[0076] 7 and 8, in the second comparative example, the first winding portion 11 connected to the first starting end 1s and the second winding portion 25 connected to the second ending end 2e are not adjacent to each other but are arranged relatively far apart, which requires a relatively long length of the wiring 62 for electrically connecting the first starting end 1s and the second ending end 2e.

[0077] In the second comparative example, the second winding portion 21 connected to the second starting end 2s and the third winding portion 35 connected to the third ending end 3e are not adjacent to each other but are arranged relatively far apart, which requires a relatively long length of the wiring 64 for electrically connecting the second starting end 2s and the third ending end 3e.

[0078] On the other hand, in the stator 4 of the embodiment, the length of the wiring 62, 64 can be made shorter than in the stator of the second comparative example. Therefore, in the stator 4 of the embodiment, the area occupied by the wiring 62, 64 on the printed circuit board 61 can be made smaller. As a result, the printed circuit board 61 can be made smaller, or a larger area of ​​the printed circuit board 61 can be secured on which other components can be mounted.

[0079] In the second comparative example, to shorten the length of the wiring 62, 64, for example, as shown in Figure 8, it is necessary to form the wiring 64 on the front surface of the printed circuit board 61 and the wiring 62 on the back surface of the printed circuit board 61, and to cross the wiring 62 and the wiring 64. In other words, it is necessary to form wiring on both surfaces of the printed circuit board 61. In contrast, in the stator 4 of the embodiment, the wiring 62, 63, 64 can be formed on the same surface of the printed circuit board 61 while minimizing the length of the wiring 62, 63, 64.

[0080] (8) Manufacturing Method Next, a method for manufacturing the stator 4 according to the embodiment will be described.

[0081] The manufacturing method includes a first step and a second step. In the first step, the first winding portions 1 c and the third winding portions 3 c are concentratedly wound around the corresponding teeth 410. In the second step, after the first step, the second winding portions 2 c are concentratedly wound around the corresponding teeth 410.

[0082] Here, the winding direction of the second winding portions 2c is opposite to the winding direction of the first winding portions 1c and the third winding portions 3c. Therefore, as shown in Fig. 4, the second overhead line portion 2b may extend obliquely near the winding start or end of the second winding portion 2c. In Fig. 4, the oblique portion 20b of the second overhead line portion 2b extends obliquely.

[0083] If the second step is performed before the first step, the diagonal portion 20b of the second-phase winding 2Y may be located near the tooth 410 around which the first winding portion 1c or the third winding portion 3c is wound. In this case, the diagonal portion 20b may interfere with the work of winding the first winding portion 1c or the third winding portion 3c around the tooth 410 in the first step.

[0084] In contrast, by performing the second step after the first step, the work can be carried out smoothly.

[0085] (First Modification) A stator 4A according to a first modification will be described below. The same components as those in the above-described embodiment will be denoted by the same reference numerals and description thereof will be omitted.

[0086] 9 is a plan view of a stator 4A according to a first modified example, in which the winding portion is not shown.

[0087] At least one connecting member 6 of the stator 4A includes at least one bus bar. In this modification, the stator 4A includes three bus bars 62A, 63A, and 64A as three connecting members 6. That is, in this modification, the first-phase winding 1X, the second-phase winding 2Y, and the third-phase winding 3Z are connected by the three bus bars 62A, 63A, and 64A instead of the printed circuit board 61.

[0088] The three bus bars 62A, 63A, and 64A are disposed above the stator core 41. The three bus bars 62A, 63A, and 64A are disposed at positions that are the same height from the stator core 41, for example.

[0089] The bus bar 62A electrically connects the first starting end 1s and the second ending end 2e, and has an arc shape that is aligned with the direction in which the teeth 410 are arranged.

[0090] The bus bar 63A electrically connects the third starting end 3s and the first terminal end 1e. The bus bar 63A has an arc shape that is aligned along the direction in which the teeth 410 are arranged.

[0091] The bus bar 64A electrically connects the second starting end 2s and the third ending end 3e, and has an arc shape that is aligned with the direction in which the teeth 410 are arranged.

[0092] The shape of each of the bus bars 62A, 63A, and 64A is not limited to an arc shape, and may be, for example, a straight line shape.

[0093] The bus bar 62A overlaps in the vertical direction with the first winding portion 11 connected to the first starting end 1s and the second winding portion 25 connected to the second terminal end 2e.

[0094] The bus bar 63A overlaps in the vertical direction with the third winding portion 31 connected to the third starting end 3s and the first winding portion 15 connected to the first terminal end 1e.

[0095] The bus bar 64A overlaps in the vertical direction with the second winding portion 21 connected to the second starting end 2s and the third winding portion 35 connected to the third terminal end 3e.

[0096] 10 is a plan view of a stator according to a third comparative example. Similar to the stator according to the second comparative example (see FIGS. 7 and 8), the stator according to the third comparative example differs from the stator 4A of the first modified example in that the winding direction of the second winding portions 2c is counterclockwise, which is the same as the winding direction of the first winding portions 1c and the third winding portions 3c.

[0097] Therefore, in the third comparative example, the first winding portion 11 connected to the first starting end 1 s and the second winding portion 25 connected to the second terminal end 2 e are not adjacent to each other but are arranged relatively far apart, and therefore the length of the bus bar 62A for electrically connecting the first starting end 1 s and the second terminal end 2 e needs to be relatively long.

[0098] Furthermore, in the third comparative example, the second winding portion 21 connected to the second starting end 2s and the third winding portion 35 connected to the third ending end 3e are not adjacent to each other but are arranged relatively far apart, so the length of the bus bar 64A for electrically connecting the second starting end 2s and the third ending end 3e needs to be relatively long.

[0099] On the other hand, in the stator 4A of the first modification, the length of the bus bars 62A, 64A can be made shorter than in the stator of the third comparative example, which reduces the material cost of the bus bars 62A, 64A and also reduces the size of the motor M1.

[0100] (Other Modifications of the Embodiment) Other modifications of the embodiment are listed below. The following modifications may be realized in appropriate combination. The following modifications may be realized in appropriate combination with the first modification described above. Hereinafter, the configuration of the above-described embodiment will be referred to as a basic example.

[0101] The holding portion that positions the first starting end 1s, the first ending end 1e, the second starting end 2s, the second ending end 2e, the third starting end 3s, and the third ending end 3e is not limited to a configuration that includes a through hole H1, and may include, for example, a terminal or a terminal block.

[0102] The stator 4 in the basic example is provided in an inner rotor type motor M1. However, the stator 4 may be provided in an outer rotor type motor. The stator 4 may be provided in an inner rotor type generator or an outer rotor type generator.

[0103] The numbers of the first winding portions 1c, the second winding portions 2c, and the third winding portions 3c in the basic example are merely examples and can be changed as appropriate.

[0104] (Summary) The above-described embodiments and the like disclose the following aspects.

[0105] A stator (4; 4A) according to a first aspect includes a stator core (41), a first-phase winding (1X), a second-phase winding (2Y), a third-phase winding (3Z), and a connecting member (6). The stator core (41) has a plurality of teeth (410) arranged in an annular shape around a rotation axis (52) extending in the axial direction (vertical direction). The connecting member (6) delta-connects the first-phase winding (1X), the second-phase winding (2Y), and the third-phase winding (3Z). The first-phase winding (1X) includes a first starting end (1s), a first ending end (1e), a plurality of first winding portions (1c) between the first starting end (1s) and the first ending end (1e), and a plurality of first truncated wire portions (1b) spanning the plurality of teeth (410). Each of the plurality of first winding portions (1c) is concentratedly wound around a corresponding one of the plurality of teeth (410). The second phase winding (2Y) includes a second starting end (2s), a second ending end (2e) connected to the first starting end (1s) via a connecting member (6), a plurality of second winding portions (2c) between the second starting end (2s) and the second ending end (2e), and a plurality of second overhead wiring portions (2b) spanning between the plurality of teeth (410). Each of the plurality of second winding portions (2c) is concentratedly wound around a corresponding one of the plurality of teeth (410). The third-phase winding (3Z) includes a third starting end (3s) connected to the first ending end (1e) via a connecting member (6), a third ending end (3e) connected to the second starting end (2s) via the connecting member (6), a plurality of third winding portions (3c) between the third starting end (3s) and the third ending end (3e), and a plurality of third overhead wiring portions (3b) spanning the plurality of teeth (410). Each of the plurality of third winding portions (3c) is concentratedly wound around a corresponding one of the plurality of teeth (410). The winding direction of the plurality of second winding portions (2c) is opposite to the winding directions of the plurality of first winding portions (1c) and the plurality of third winding portions (3c).In the circumferential direction around the axis (A1) of the rotating shaft (52), the first winding portion (11) connected to the first starting end (1s) of the plurality of first winding portions (1c), the second winding portion (25) connected to the second ending end (2e) of the plurality of second winding portions (2c), the third winding portion (31) connected to the third starting end (3s) of the plurality of third winding portions (3c), the first winding portion (15) connected to the first ending end (1e) of the plurality of first winding portions (1c), the second winding portion (21) connected to the second starting end (2s) of the plurality of second winding portions (2c), and the third winding portion (35) connected to the third ending end (3e) of the plurality of third winding portions (3c) are arranged adjacent to one another in this order. The plurality of first overhead line sections (1b), the plurality of second overhead line sections (2b), and the plurality of third overhead line sections (3b) are arranged on one side (upper side) of the stator core (41), or the plurality of first overhead line sections (1b), the plurality of second overhead line sections (2b), and the plurality of third overhead line sections (3b) are arranged on the other side (lower side) of the stator core (41). The connecting member (6) is arranged on one side (upper side) of the stator core (41).

[0106] According to the above configuration, the first phase winding (1X), the second phase winding (2Y), and the third phase winding (3Z) are arranged so that their interconnected portions are close to each other. This reduces the area required for connecting the first phase winding (1X), the second phase winding (2Y), and the third phase winding (3Z). Furthermore, according to the above configuration, the difference in length between the start and end of each of the first phase winding (1X), the second phase winding (2Y), and the third phase winding (3Z) can be made relatively small. This reduces the difference in resistance value between the start and end of each of the first phase winding (1X), the second phase winding (2Y), and the third phase winding (3Z).

[0107] Furthermore, the stator (4; 4A) according to the second aspect is the same as that of the first aspect, but further includes a plurality of fixing members (F1). The plurality of fixing members (F1) fix the first starting end (1s), the first terminal end (1e), the second starting end (2s), the second terminal end (2e), the third starting end (3s), and the third terminal end (3e). Each of the first starting end (1s), the first terminal end (1e), the second starting end (2s), the second terminal end (2e), the third starting end (3s), and the third terminal end (3e) extends from the plurality of fixing members (F1) along the axial direction toward the connecting member (6).

[0108] According to the above configuration, the difference in length between the start and end of each of the first phase winding (1X), the second phase winding (2Y), and the third phase winding (3Z) can be further reduced.

[0109] In the stator (4) according to the third aspect, in the first or second aspect, the connecting member (6) includes a printed circuit board (61). The first starting end (1s), the first terminal end (1e), the second starting end (2s), the second terminal end (2e), the third starting end (3s), and the third terminal end (3e) are electrically connected to the printed circuit board (61).

[0110] According to the above configuration, the first phase winding (1X), the second phase winding (2Y), and the third phase winding (3Z) can be connected on a single printed circuit board (61). Furthermore, the first phase winding (1X), the second phase winding (2Y), and the third phase winding (3Z) are arranged so that their interconnections are close to each other. This reduces the area of ​​the printed circuit board (61) required for the connections.

[0111] In addition, in a stator (4A) according to a fourth aspect, in any one of the first to third aspects, the connecting member (6) includes a bus bar (62A, 63A, 64A).

[0112] According to the above configuration, the first phase winding (1X), the second phase winding (2Y), and the third phase winding (3Z) are arranged so that their interconnections are close to each other, thereby enabling the bus bars (62A, 63A, 64A) to be made smaller.

[0113] In addition, in the stator (4; 4A) according to the fifth aspect, in any one of the first to fourth aspects, a plurality of first winding portions (1c) and a plurality of third winding portions (3c) are wound in a concentrated manner around the corresponding teeth (410), and then a plurality of second winding portions (2c) are wound in a concentrated manner around the corresponding teeth (410).

[0114] According to the above configuration, it is possible to reduce the possibility that the second winding portion (2c) will interfere with the first winding portion (1c) or the third winding portion (3c) and interfere with the work of winding the first winding portion (1c) or the third winding portion (3c) around the tooth (410).

[0115] The configurations other than the first aspect are not essential for the stator (4; 4A) and can be omitted as appropriate.

[0116] A motor (M1) according to a sixth aspect includes a stator (4; 4A) according to any one of the first to fifth aspects, and a rotor (5) that rotates relative to the stator (4; 4A).

[0117] According to the above configuration, it is possible to provide a motor (M1) in which the area required for connecting the first phase winding (1X), the second phase winding (2Y), and the third phase winding (3Z) is reduced.

[0118] A manufacturing method according to a seventh aspect is a manufacturing method for the stator (4; 4A) according to any one of the first to fifth aspects, and includes a first step and a second step. In the first step, a plurality of first winding portions (1c) and a plurality of third winding portions (3c) are concentratedly wound around the corresponding teeth (410). In the second step, after the first step, a plurality of second winding portions (2c) are concentratedly wound around the corresponding teeth (410).

[0119] According to the above configuration, it is possible to reduce the possibility that the second winding portion (2c) will interfere with the first winding portion (1c) or the third winding portion (3c) and interfere with the work of winding the first winding portion (1c) or the third winding portion (3c) around the tooth (410).

[0120] 1b First overhead line section 1c, 11, 12, 13, 14, 15 First winding section 1e First end 1s First starting end 1X First phase winding 2b Second overhead line section 2c, 21, 22, 23, 24, 25 Second winding section 2e Second end 2s Second starting end 2Y Second phase winding 3b Third overhead line section 3c, 31, 32, 33, 34, 35 Third winding section 3e Third end 3s Third starting end 3Z Third phase winding 4; 4A Stator 5 Rotor 6 Connecting member 41 Stator core 52 Rotating shaft 61 Printed circuit board 62A, 63A, 64A Bus bar 410 Teeth A1 Shaft center F1 Fixing member M1 Motor

Claims

1. A stator core having a plurality of teeth arranged in an annular shape around a rotation axis extending in the axial direction, a first phase winding, a second phase winding, a third phase winding, and a connecting member that delta-connects the first phase winding, the second phase winding, and the third phase winding, wherein the first phase winding includes: a first starting end, a first ending end, a plurality of first winding sections between the first starting end and the first ending end, and a plurality of first overhead wiring sections that bridge between the plurality of teeth, and each of the plurality of first winding sections is concentratedly wound on a corresponding one of the plurality of teeth, and the second phase winding includes: a second starting end, a second ending end that is connected to the first starting end via the connecting member, a plurality of second winding sections between the second starting end and the second ending end, and a plurality of second overhead wiring sections that bridge between the plurality of teeth, each of the plurality of second winding portions is concentratedly wound around a corresponding one of the plurality of teeth, and the third phase winding includes: a third starting end connected to the first ending end via the connecting member; a third ending end connected to the second starting end via the connecting member; a plurality of third winding portions between the third starting end and the third ending end; and a plurality of third overhead line portions spanning between the plurality of teeth, and each of the plurality of third winding portions is concentratedly wound around a corresponding one of the plurality of teeth, and the winding direction of the plurality of second winding portions is opposite to the winding directions of the plurality of first winding portions and the plurality of third winding portions, and in a circumferential direction centered on an axis of the rotating shaft, The first winding portions are arranged adjacent to one another in the following order: a first winding portion connected to the first end of the plurality of first winding portions; a second winding portion connected to the second start of the plurality of second winding portions; and a third winding portion connected to the third end of the plurality of third winding portions;A stator, wherein the plurality of first overhead line sections, the plurality of second overhead line sections, and the plurality of third overhead line sections are arranged on one side of the stator core, or the plurality of first overhead line sections, the plurality of second overhead line sections, and the plurality of third overhead line sections are arranged on the other side of the stator core, and the connecting member is arranged on one side of the stator core.

2. A stator as described in claim 1, further comprising a plurality of fixing members that fix the first starting end, the first terminal end, the second starting end, the second terminal end, the third starting end, and the third terminal end, and each of the first starting end, the first terminal end, the second starting end, the second terminal end, the third starting end, and the third terminal end extends from the plurality of fixing members along the axial direction toward the connecting member.

3. A stator according to claim 1 or 2, wherein the connecting member includes a printed circuit board to which the first starting end, the first terminal end, the second starting end, the second terminal end, the third starting end, and the third terminal end are electrically connected.

4. The stator according to claim 1 or 2, wherein the connecting member includes a bus bar.

5. A stator according to claim 1 or 2, wherein the plurality of first winding portions and the plurality of third winding portions are each concentratedly wound around the corresponding teeth, and then the plurality of second winding portions are each concentratedly wound around the corresponding teeth.

6. A motor comprising: a stator according to claim 1 or 2; and a rotor that rotates relative to the stator.

7. A method for manufacturing a stator as set forth in claim 1 or 2, comprising: a first step of concentrating winding the plurality of first winding portions and the plurality of third winding portions around the corresponding teeth; and a second step, after the first step, of concentrating winding the plurality of second winding portions around the corresponding teeth.

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