Stator, motor, and insulator

Abstract

This stator includes a stator core (21). A conductive wire (23x) wound around teeth (21b) of the stator core (21) is disposed so as to be inclined in the width direction of the teeth (21b) on both sides of the axial end portion of the teeth (21b), and uses a winding mode in which the change of winding sequence for each turn is shared on both axial sides of the teeth (21b).

Description

Stators, motors and insulators CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is based on Japanese Application No. 2024-088880, filed on May 31, 2024, the contents of which are incorporated herein by reference.

[0002] The present disclosure relates to a stator, a motor, and an insulator.

[0003] A motor stator is known in which a general round conductor is wound in multiple layers around the teeth of a stator core fitted with an insulator using aligned winding (see, for example, Patent Document 1). When multiple layers are formed by stacking an upper layer conductor that is wound later on top of a lower layer conductor that is wound earlier around the teeth, applying aligned winding of the conductor has advantages such as a high space factor.

[0004] Special Publication No. 2021-509565

[0005] In the aligned winding of the conductor, as the winding of the same layer proceeds, the conductor is shifted radially by one wire from the position where it was previously wound around one tooth to the position where it will be wound next. When such a conductor rearrangement is performed, a tensile force acts on the conductor in the winding direction as well as in the rearrangement direction. Therefore, the wound conductor is likely to collapse during rearrangement.

[0006] The collapse of the conductor winding is likely to occur when the conductor is stacked in multiple layers and during the winding process when the re-arrangement angle at which the conductor is inclined toward the next winding position is large. When winding in multiple layers, the re-arrangement angle gradually decreases as the number of layers increases, so there is a particular concern that the collapse of the conductor will occur when the conductor is stacked in the second layer, where the re-arrangement angle is the largest.

[0007] Furthermore, the wire diameter and tooth width are factors that determine the size of the reordering angle. The larger the wire diameter or the smaller the tooth width of the conductor, the larger the reordering angle must be set, which increases the risk of the conductor becoming unwound. Therefore, unless the winding mode of the conductor, including the reordering, is devised, there is a problem in that the freedom of selection of the wire diameter and tooth width of the conductor is reduced.

[0008] An object of the present disclosure is to provide a stator using a winding pattern of a conductor that allows for greater freedom in selecting the wire diameter and tooth width of the conductor, a motor using the stator, and an insulator used in the stator.

[0009] A stator according to one aspect of the present disclosure comprises a stator core having a plurality of teeth, insulators provided in a portion of the stator core including the teeth, and coils formed by winding a conductor around the teeth via the insulator, wherein the conductor is wound in multiple layers using concentrated winding while rearranging at the axial ends of the teeth, and the conductor is arranged at an angle with respect to the width direction of the teeth on both sides of the axial ends of the teeth, forming a winding pattern in which the rearranging is shared between both axial sides of the teeth.

[0010] According to the above configuration, the conductor wire wound around the teeth of the stator core is arranged at an inclination with respect to the width direction of the conductor wire on both sides of the axial end of the tooth, and the alignment change for each winding is shared between both axial sides of the tooth. In other words, when the conductor wire is arranged at an inclination during the winding process, the individual inclination angles on both axial sides of the tooth can be set small, thereby reducing the risk of the conductor wire becoming unwound. This allows for greater freedom in selecting the wire diameter and tooth width, which are correlated with the inclination angle of the conductor wire.

[0011] A motor according to one aspect of the present disclosure is configured with the above-described stator. This configuration allows for greater freedom in selecting the wire diameter of the conductors used in the stator and the tooth width of the stator core, which is expected to increase the freedom in motor configuration.

[0012] An insulator according to one aspect of the present disclosure is used in a stator having a stator core with a plurality of teeth and a coil formed by winding a conductor around the teeth, and is provided in a portion of the stator core including the teeth and wound with multiple layers of concentrated winding of the conductor, and the insulator has an arrangement groove that regulates the position of the conductor wound in the first layer so that the conductor is arranged at an incline with respect to the width direction of the tooth on both sides of the axial end of the tooth, and the winding pattern is such that the rearrangement of the conductor is shared between both axial sides of the tooth.

[0013] According to the above configuration, by winding the conductor along the arrangement groove of the insulator, which regulates the position of the conductor, it is possible to achieve a winding pattern in which the rearrangement of the conductor for each winding is shared between both axial sides of the teeth. In other words, by using the insulator, it is possible to easily achieve a winding pattern of the conductor that improves the freedom of selection of the wire diameter and tooth width.

[0014] The above and other objects, features, and advantages of the present disclosure will become more apparent from the following detailed description taken in conjunction with the accompanying drawings, in which Fig. 1 is a perspective view of a stator of a motor in one embodiment, Fig. 2 is an exploded perspective view of a teeth portion of the stator in the same embodiment, Fig. 3 is a side view of the teeth portion of the stator in the same embodiment, Fig. 4 is a cross-sectional view of the teeth portion of the stator in the same embodiment, Fig. 5 is an axial view of the teeth portion of the stator in the same embodiment, Fig. 6 is an axial view of the teeth portion of the stator in the same embodiment, Fig. 7 is an axial view of the teeth portion of the stator in the same embodiment, Fig. 8 is an axial view of the teeth portion of the stator in the same embodiment, and Fig. 9 is an explanatory diagram showing the effect of the winding manner of the stator in the same embodiment.

[0015] An embodiment of a stator, a motor, and an insulator will be described below. (Configuration of Motor 10) As shown in Fig. 1, the motor 10 includes a ring-shaped stator 11 and a rotor (not shown) rotatably disposed radially inside the stator 11. The stator 11 generates a rotating magnetic field on its inner circumferential surface facing the rotor when current is applied to a coil 23 (described later) attached to the stator 11. The rotor is rotated by receiving the rotating magnetic field generated by the stator 11.

[0016] (Configuration of Stator 11) As shown in Figures 1 to 4, the stator 11 includes a circular stator core 21, an insulator 22 attached to the stator core 21, and a coil 23 attached to the stator core 21 via the insulator 22.

[0017] The stator core 21 is formed by laminating magnetic metal plates, for example. The stator core 21 has an annular portion 21a on the radially outer side and teeth 21b extending radially inward from the annular portion 21a. A plurality of teeth 21b are provided at equal intervals around the circumferential direction of the annular portion 21a.

[0018] As shown in FIG. 2 , the stator 11 of this embodiment employs a split core structure. That is, the stator core 21 uses a plurality of split cores 21x, each split into a corresponding tooth 21b. The split cores 21x are set at midpoints between circumferentially adjacent teeth 21b in the annular portion 21a of the stator core 21. An insulator 22 is attached to each split core 21x. The insulator 22 is composed of a pair of a first insulator 22x and a second insulator 22y for each split core 21x. The first insulator 22x is attached to one axial side (hereinafter referred to as the upper side) of the tooth 21b. The second insulator 22y is attached to the other axial side (hereinafter referred to as the lower side) of the tooth 21b.

[0019] Before the split cores 21x are connected in an annular shape to form the stator core 21, a conductor 23x is wound around the teeth 21b from above the insulators 22 attached to the split cores 21x to form the coils 23. In this embodiment, a typical round wire with a circular cross section is used for the conductor 23x. The conductor 23x is wound around the teeth 21b of each split core 21x in a concentrated and aligned manner, with multiple layers stacked one on top of the other. The winding of the conductor 23x around the teeth 21b will be described in detail later.

[0020] After the coils 23 are attached to the teeth 21b, adjacent annular pieces 21c of the multiple split cores 21x that make up the stator 11 are connected together in an annular shape and fixed together as an annular portion 21a. The coils 23 wound around each tooth 21b are electrically connected by a three-phase wiring and are supplied with three-phase driving power from a motor control device (not shown), thereby generating a rotating magnetic field in the stator 11.

[0021] (Wounding Pattern of Conductive Wire 23x Around Teeth 21b) Figures 5 and 6 show in detail the winding pattern of the conductive wire 23x around the teeth 21b. Figure 5 shows the winding pattern around the upper side of the teeth 21b, and Figure 6 shows the winding pattern around the lower side of the teeth 21b.

[0022] In this embodiment, the winding of the conductor 23x is performed, for example, in three layers. The winding start position of the conductor 23x is set to the radially inner end position of the tooth 21b. The winding of the first layer of the conductor 23x is performed from the radially inner side of the tooth 21b to the radially outer side, while rearranging the winding so that the winding follows the outer surface of the insulator 22 attached to the tooth 21b. The winding of the second layer of the conductor 23x is performed from the radially outer side of the tooth 21b to the radially inner side, while rearranging the winding so that the winding follows the outer surface of the first layer of the conductor 23x. The winding of the third layer of the conductor 23x is performed from the radially inner side of the tooth 21b to the radially outer side, while rearranging the winding so that the winding follows the outer surface of the second layer of the conductor 23x.

[0023] (Winding pattern of the first layer) On the upper side of the tooth 21b shown in Figures 5 and 2, a holding groove 22a that holds the winding start portion of the conductor 23x is provided at a position near the radially inner end of the first insulator 22x. A holding groove 22a is also provided in the second insulator 22y. The opening width of the holding groove 22a is formed slightly narrower than the wire diameter of the conductor 23x, so that the winding start portion of the conductor 23x inserted into the opening can be held. The winding start portion of the conductor 23x is held in the holding groove 22a. The winding positions of the conductor 23x on both sides of the width direction of the tooth 21b as viewed in the axial direction are numbered from "1" to "31" in Figures 5 and 6, with the winding start position of the conductor 23x held in the holding groove 22a being "1". The conductor 23x is wound in the order of "1" to "11" in the first layer, "12" to "21" in the second layer, and "22" to "31" in the third layer. At position "1", the conductor 23x is arranged along the axial direction toward the lower side of the tooth 21b shown in FIG. 6.

[0024] Below the tooth 21b shown in FIG. 6, the conductor 23x at position "1" is arranged so as to cross along the guide groove 22b provided in the second insulator 22y to position "2" on the opposite side of the tooth 21b in the width direction. The conductor 23x is arranged at position "2", which is closest to the guide portion 22c provided in the second insulator 22y. The guide portion 22c has functions such as improving the alignment of the conductor 23x wound in multiple layers. At position "2", the conductor 23x is arranged along the axial direction toward the upper side of the tooth 21b shown in FIG. 5.

[0025] 5, the conductor 23x is arranged to cross from position "2" to position "3" on the opposite side of the tooth 21b in the width direction. In this case, the conductor 23x is arranged at an angle from position "2" to position "3." At position "3," the conductor 23x is arranged along the axial direction toward the lower side of the tooth 21b shown in FIG.

[0026] 6, below the tooth 21b, the conductor 23x is arranged so as to cross from position "3" to position "4" on the opposite side of the tooth 21b in the width direction. The conductor 23x is arranged so as to be inclined at the same angle from position "3" to "4" as from position "2" to "3" described above. At position "4", the conductor 23x is arranged along the axial direction toward the upper side of the tooth 21b shown in FIG. 5. In this way, the conductor 23x is wound around the tooth 21b once from position "2" to "4", and this is repeated from position "4" onwards to complete the first layer of winding up to position "11".

[0027] Furthermore, when winding the conductor wires 23x, the conductor wires 23x are rearranged by approximately one wire per one turn around the teeth 21b so that radially adjacent conductor wires 23x are aligned with a sufficiently small gap between them. In this embodiment, the rearrangement of the conductor wires 23x is performed on both the upper side of the teeth 21b shown in FIG. 5 and the lower side of the teeth 21b shown in FIG. 6. In other words, the inclination angle on the upper side of the teeth 21b shown in FIG. 5 and the inclination angle on the lower side of the teeth 21b shown in FIG. 6 are each radially offset by approximately half the distance between adjacent conductor wires 23x (or the approximate wire diameter of the conductor wires 23x) per one turn. Therefore, it is possible to set each angle to a small value.

[0028] As a comparative example, in a typical winding pattern of the conductor 23x, the conductor 23x is realigned by approximately one wire only on either the upper side of the tooth 21b shown in FIG. 5 or the lower side of the tooth 21b shown in FIG. 6 . Therefore, it is necessary to set an inclination angle corresponding to the distance between adjacent conductors 23x in one winding on either the upper or lower side, so the set angle is approximately twice as large as in this embodiment. This is believed to be one of the major factors that lead to collapse of the conductor 23x when winding the conductor 23x. It is believed that the risk of collapse increases particularly in the second layer where the conductors 23x are stacked.

[0029] Furthermore, the first and second insulators 22x, 22y have a plurality of radially aligned protrusions 22e with a generally triangular cross section at each of the corners between the axial end faces and side faces of the teeth 21b, i.e., at each of the four corners 22d around one circumference of the conductor 23x. Each protrusion 22e has a height, for example, approximately 1 / 2 to 1 / 3 of the wire diameter of the conductor 23x. Between adjacent protrusions 22e in the radial direction, a placement groove 22f is formed to accommodate a portion of the first-layer conductor 23x and regulate its position. Each placement groove 22f has a concave groove shape that can accommodate a portion of the round conductor 23x. Each placement groove 22f positions the corresponding conductor 23x and guides the aligned winding of the conductor 23x, including rearrangement, from positions "2" to "11." Furthermore, when winding the conductor 23x around the teeth 21b, the conductor 23x is bent starting from the four corners 22d of the first and second insulators 22x and 22y, and therefore is most likely to come into contact with each of the corners 22d. Therefore, it is effective to provide the ridges 22e and the arrangement grooves 22f that guide the conductor 23x only at each of the corners 22d.

[0030] 6, the winding of the conductor 23x shifts from position "11" in the first layer to position "12" in the second layer below the tooth 21b. The conductor 23x at position "12" is arranged so that a portion of the conductor 23x is inserted between the conductor 23x at position "10" in the first layer and the wall surface portion 22g of the second insulator 22y. The wall surface portion 22g is a portion of the second insulator 22y that covers the annular portion 21a of the stator core 21 and radially faces the guide portion 22c provided on the radially inner side.

[0031] Here, the conductor 23x at position "10" on the first layer is one position before position "11," which is closest to the wall surface 22g. In other words, the conductor 23x at position "10" is positioned slightly away from the wall surface 22g due to the inclination relationship described above. The conductor 23x at the beginning of the second layer, position "12," is stacked with a portion of itself wedged between the wall surface 22g of the second insulator 22y and the conductor 23x at position "10" on the first layer, which is slightly spaced from the wall surface 22g. Therefore, there is a risk that the conductor 23x at position "12" will be excessively wedged between the wall surface 22g and the conductor 23x at position "10," increasing the concern that the alignment of the conductors 23x will be impaired.

[0032] In consideration of this, the second insulator 22y of this embodiment is provided with a pedestal 22h between the wall surface 22g and the conductor 23x at position "10." The pedestal 22h abuts against the conductor 23x at position "12" to prevent the conductor 23x at position "12" from excessively entering between the wall surface 22g and the conductor 23x at position "10," thereby stabilizing the position of the conductor 23x at position "12" on the second layer. At position "12," the conductor 23x is axially arranged toward the upper side of the tooth 21b shown in FIG. 5 .

[0033] Above the tooth 21b shown in Fig. 5, the conductor 23x in the second layer is arranged so as to cross from position "12" to position "13" on the opposite side of the tooth 21b in the width direction. As in the first layer, the conductor 23x in the second layer is arranged at an angle from position "12" to "13". The conductor 23x at position "13" is positioned so that a portion of it enters the recess 23a between the conductors 23x at positions "9" and "11" in the first layer. At position "13", the conductor 23x is arranged axially toward the lower side of the tooth 21b shown in Fig. 6.

[0034] Again, below the tooth 21b shown in FIG. 6 , the second layer of conductor 23x is arranged to cross from position "13" to position "14" on the opposite side of the tooth 21b in the width direction. From position "13" to "14," the conductor 23x is arranged with an inclination equal to the inclination from position "12" to "13" described above. At position "14," the conductor 23x is arranged in the axial direction toward the upper side of the tooth 21b shown in FIG. 5 . In this way, the conductor 23x is wound around the tooth 21b once from position "12" to "14," and this is repeated from position "14" onward to complete the second layer of winding up to position "21" shown in FIG. 5 . At position "21," the conductor 23x is arranged in the axial direction toward the lower side of the tooth 21b shown in FIG. 6 .

[0035] The conductor 23x arranged at the start position "21" of the second layer is stacked with a portion of itself sandwiched between the guide portion 22c of the second insulator 22y and the conductor 23x at position "3" of the first layer, which is slightly spaced apart from the guide portion 22c. A pedestal portion 22i, which functions similarly to the pedestal portion 22h described above, is provided between the guide portion 22c of the second insulator 22y and the conductor 23x at position "3". The pedestal portion 22i abuts against the conductor 23x at position "21" to prevent it from excessively sandwiching between the guide portion 22c and the conductor 23x at position "3", thereby stabilizing the position of the conductor 23x at position "21" on the second layer.

[0036] (Winding pattern of the third layer) Below the tooth 21b shown in Fig. 6, the winding of the conductor 23x shifts from position "21" in the second layer to position "22" in the third layer. The conductor 23x at position "22" is positioned so that a portion of it is inserted between the conductor 23x at position "20" in the second layer and the guide portion 22c of the second insulator 22y. At position "22", the conductor 23x is positioned axially toward the upper side of the tooth 21b shown in Fig. 5.

[0037] Above the tooth 21b shown in Fig. 5, the conductor 23x in the third layer is arranged so as to cross from position "22" to position "23" on the opposite side of the tooth 21b in the width direction. As in the second layer, the conductor 23x in the third layer is arranged at an angle from position "22" to "23". The conductor 23x at position "23" is positioned so that a portion of it enters the recess 23a between the conductors 23x at positions "19" and "21" in the first layer. At position "23", the conductor 23x is arranged axially toward the lower side of the tooth 21b shown in Fig. 6.

[0038] Again, below the tooth 21b shown in FIG. 6, the third layer of conductor 23x is arranged to cross from position "23" to position "24" on the opposite side of the tooth 21b in the width direction. The conductor 23x is arranged with an inclination from position "23" to "24" the same as the inclination from position "22" to "23" described above. At position "24," the conductor 23x is arranged along the axial direction toward the upper side of the tooth 21b shown in FIG. 5. In this way, the conductor 23x is wound around the tooth 21b once from position "22" to "24," and this process is repeated from position "24" onwards to complete the third layer of winding up to position "31" shown in FIG. 5.

[0039] (Setting the reordering angle) As shown in Figures 7 and 8, in the three-layer aligned winding of the conductor 23x around the tooth 21b, when the reordering is performed in one winding of the conductor 23x, the reordering is performed on both the upper and lower sides of the tooth 21b for all of the first to third layers.

[0040] Regarding the first layer, focusing on the winding pattern of one turn of the conductor 23x from positions "2" to "4" as a representative, the inclination angle α1 of the conductor 23x from position "2" to "3" relative to the reference line L1 is set to the same angle as the inclination angle α2 of the conductor 23x from position "3" to "4." In this case, the reference line L1 is a line that passes through the center of the intermediate position "3" and is perpendicular to the radial direction.

[0041] Here, the realignment of the conductor 23x involves shifting the conductor 23x by one wire in the radial direction at the axial end of the tooth 21b during one winding around the tooth 21b. Therefore, the realignment angle of the conductor 23x can be calculated from the inter-wire distance between adjacent conductors 23x during one winding, relative to the winding diameter of the conductor 23x in the width direction of the tooth 21b as viewed in the axial direction. The calculation formula is realignment angle = arctan (inter-wire distance / winding diameter distance).

[0042] That is, the realignment angle α of the conductor wires 23x in the first layer is set from the inter-wire distance P of adjacent conductor wires 23x in one winding with respect to the winding diameter distance B1 of the conductor wires 23x in the width direction of the teeth 21b when viewed in the axial direction (for example, the inter-wire distance of the conductor wires 23x between positions "2" and "3"). In this embodiment, the realignment is performed shared between both the upper and lower sides of the teeth 21b, so the inclination angle α1 of the upper side of the teeth 21b and the inclination angle α2 of the lower side of the teeth 21b have the relationship expressed by the following equation: α = α1 + α2. Furthermore, in this embodiment, the inclination angles α1 and α2 are set to the same angle, so the relationship expressed by the following equation: α1 = α2 = α / 2 also holds.

[0043] Similarly, for the second layer, attention is focused on the winding pattern of one turn of the conductor 23x from position "16" to "18" as a representative. The inclination angle β1 of the conductor 23x from position "16" to "17" relative to the reference line L2 is set to the same angle as the inclination angle β2 of the conductor 23x from position "17" to "18". The reference line L2 is a line that passes through the center of the intermediate position "17" and is perpendicular to the radial direction.

[0044] The realignment angle β of the conductor wires 23x in the second layer is set from the inter-wire distance P of adjacent conductor wires 23x in one winding, relative to the winding diameter distance B2 of the conductor wires 23x in the width direction of the teeth 21b when viewed in the axial direction (for example, the inter-wire distance of the conductor wires 23x between positions "16" and "17"). In this embodiment, the inclination angle β1 of the upper side of the teeth 21b and the inclination angle β2 of the lower side of the teeth 21b are related by the following equation: β=β1+β2, and further, the following equation: β1=β2=β / 2.

[0045] Similarly, for the third layer, attention is focused on the winding pattern of one turn of the conductor 23x from position "28" to "30" as a representative. The inclination angle γ1 of the conductor 23x from position "28" to "29" relative to the reference line L3 is set to the same angle as the inclination angle γ2 of the conductor 23x from position "29" to "30". The reference line L3 is a line that passes through the center of the intermediate position "29" and is perpendicular to the radial direction.

[0046] The realignment angle γ of the conductor 23x in the third layer is set from the inter-wire distance P of adjacent conductors 23x in one winding with respect to the winding diameter distance B3 of the conductor 23x in the width direction of the tooth 21b when viewed in the axial direction (for example, the inter-wire distance of the conductor 23x between positions "28" and "29"). In this embodiment, the inclination angle γ1 of the upper side of the tooth 21b and the inclination angle γ2 of the lower side of the tooth 21b are related by the following equation: γ=γ1+γ2, and further, the following equation: γ1=γ2=γ / 2.

[0047] Furthermore, since the winding radial distances B1, B2, and B3 of the conductor 23x from the first to the third layer satisfy the relationship of the following equation: B1<B2<B3, the reordering angles α, β, and γ satisfy the relationship of the following equation: α>β>γ. That is, as can be seen from the calculation formula for the reordering angle described above, the reordering angles α, β, and γ gradually decrease as the number of layers increases. It is believed that collapse of the winding of the conductor 23x is particularly likely to occur when the conductor 23x is stacked and when winding in the second layer, where the reordering angle is the largest.

[0048] That is, when the conductor wire 23x in the first layer is wound with a large reordering angle α, it is wound directly onto the resin insulator 22, and the insulator 22 also has an arrangement groove 22f, so it is believed that the conductor wire 23x in the first layer is less likely to collapse. Furthermore, when the conductor wire 23x in the third layer is wound with a small reordering angle γ, the small angle allows the conductor wire 23x in the third layer to more stably fit into the center of the recess 23a between the conductor wires 23x in the second layer below, so the conductor wire 23x in the third layer is less likely to collapse. In this embodiment, the conductor wires 23x are stacked in three layers, but even when the number of layers is three or more, the arrangement position of the conductor wire 23x becomes more stable and the winding is less likely to collapse as the number of layers increases. In contrast, the winding of the second layer of the conductor 23x, which is wound onto the conductor 23x and has a large row reordering angle β, is the most likely to cause the conductor 23x to collapse out of all three layers, and there are concerns about the winding of the second layer of the conductor 23x collapsing.

[0049] (Operation of this embodiment) The operation of this embodiment will be described. Based on the above, in this embodiment, the inclination angles β1 and β2 that constitute the rearrangement angle β of the second layer are set in consideration of the limit value at which winding collapse is likely to occur. Next, the inclination angles α1 and α2 that constitute the rearrangement angle α of the first layer and the inclination angles γ1 and γ2 that constitute the rearrangement angle γ of the third layer are set.

[0050] 9 shows the results of a comparison between the present invention, in which the winding pattern performs realignment on both the upper and lower sides of the teeth 21b, and a comparative example, in which the winding pattern performs realignment on only one of the upper and lower sides of the teeth 21b. It can be seen that the inclination angles β1 and β2 that contribute to the realignment angle β of the second layer in this embodiment are sufficiently large relative to the limit value at which winding collapse easily occurs for a given diameter of the conductor 23x. In other words, since there is sufficient margin for the inclination angles β1 and β2 even when the diameter of the conductor 23x is increased, it can be said that there is a high degree of freedom in selecting the wire diameter.

[0051] Furthermore, although not shown, as the winding radial distance B2 of the conductor 23x in the width direction of the teeth 21b when viewed in the axial direction (see FIG. 7, etc.) decreases, the realignment angle β of the second layer increases. However, it can be inferred that the inclination angles β1 and β2 that contribute to the realignment angle β, as in this embodiment, have a sufficient margin relative to the limit value at which winding collapse is likely to occur for a given wire diameter of the conductor 23x. In other words, it can be inferred that there is a sufficient margin for the inclination angles β1 and β2 even if the winding radial distance B2 of the conductor 23x is reduced, i.e., the width dimension of the teeth 21b is reduced, and it can be said that there is a high degree of freedom in selecting the tooth width.

[0052] (Advantages of the Present Embodiment) The advantages of the present embodiment are described below. (1) The conductor 23x wound around the teeth 21b of the stator core 21 is arranged at an inclination with respect to the width direction of the conductor 23x on both sides of the axial end of the tooth 21b, and the axial direction of the conductor 23x is used to share the realignment for each winding. In other words, when the conductor 23x is arranged at an inclination during the winding process, the individual inclination angles on both sides of the axial direction of the tooth 21b, such as the inclination angles β1 and β2 of the second layer, which are a high risk of winding collapse, can be set small, thereby reducing the risk of winding collapse of the conductor 23x. This improves the flexibility in selecting the wire diameter and tooth width of the conductor 23x, which are correlated with the inclination angles β1 and β2 of the conductor 23x. This is also expected to improve the flexibility in designing the motor 10.

[0053] (2) When rearranging the conductor 23x, the inclination angles β1, β2, etc. on both axial sides of the teeth 21b are set to the same angle, which is expected to make it easier to wind the conductor 23x.

[0054] (3) By winding the conductor 23x along the arrangement groove 22f of the insulator 22, which regulates the position of the conductor 23x, it is possible to achieve a winding pattern in which the rearrangement of the conductor 23x for each winding is shared between both axial sides of the teeth 21b. In other words, the above-described winding pattern of the conductor 23x can be easily achieved by using the insulator 22.

[0055] (4) The arrangement grooves 22f of the insulator 22 are provided only at the four corners 22d around the teeth 21b around which the conductor 23x is wound. When winding the conductor 23x around the teeth 21b, the conductor 23x is bent starting from the four corners 22d of the insulator 22, and therefore is most likely to come into contact with each corner 22d. In other words, providing the arrangement grooves 22f that guide the conductor 23x only at each corner 22d is effective, and is expected to have the effect of improving the degree of freedom in the shape of the insulator 22 in parts other than the corners 22d.

[0056] (5) The insulator 22 has a holding groove 22a for holding the conductor 23x, and the winding start portion of the conductor 23x is held in the holding groove 22a. This is expected to have the effect of facilitating winding of the conductor 23x.

[0057] (6) The insulator 22 has pedestal portions 22h, 22i that prevent the second-layer conductor 23x from excessively entering the first layer, and the position of the conductor 23x is restricted by contact with the pedestal portions 22h, 22i. This stabilizes the position of the second-layer conductor 23x and improves the alignment of the conductor 23x.

[0058] (Modifications) This embodiment can be modified as follows: This embodiment and the following modifications can be combined and implemented within the scope of technical compatibility.

[0059] The above-described configuration of the insulator 22 is merely an example and may be modified as appropriate. For example, the arrangement grooves 22 f of the insulator 22 are provided only at the four corners 22 d around the teeth 21 b around which the conductor wires 23 x are wound, but the shape and position of the arrangement grooves 22 f may be modified as appropriate, or may even be omitted.

[0060] Furthermore, the insulator 22 is provided with a holding groove 22a for holding the conductor 23x at the start of winding, but the shape and position of the holding groove 22a may be changed as appropriate, or the holding groove 22a may be omitted. Furthermore, the insulator 22 is provided with pedestals 22h, 22i for preventing the second layer conductor 23x from excessively entering the first layer, but the shape and position of the pedestals 22h, 22i may be changed as appropriate, or the holding groove 22a may be omitted.

[0061] Although the insulator 22 is divided into two axially, that is, the first and second insulators 22x and 22y, in the above embodiment, an insulator that is not divided in the axial direction may be used. Furthermore, although the insulator 22 is attached to the stator core 21, the insulator 22 may be integrally formed with the stator core 21.

[0062] When rearranging the conductors 23x, the inclination angles β1, β2, etc. are set to the same angle on both axial sides of the teeth 21b, but the angles may also be different on the upper and lower sides of the teeth 21b to share the rearrangement angle.

[0063] Although the split cores 21x are used in the stator core 21, a non-split core that is pre-formed into an annular shape may be used. In this case, the insulators 22 may be provided for each tooth 21b, or may be integral with the stator core 21 in the circumferential direction.

[0064] In addition to the above, the configuration of the motor 10 may be modified as appropriate. While the present disclosure has been described with reference to the exemplary embodiments, it is understood that the present disclosure is not limited to those exemplary embodiments or structures. The present disclosure also encompasses various modifications and modifications within the scope of equivalents. In addition, various combinations and forms, including only one element, more than one element, or less than one element, are also within the scope and spirit of the present disclosure.

[0065] (Supplementary Note) The technical ideas that can be understood from the above embodiment and modified examples will be described. [1] A stator (11) comprising: a stator core (21) having a plurality of teeth (21 b), insulators (22, 22 x, 22 y) provided in a portion of the stator core including the teeth, and coils (23) formed by winding a conductor wire (23 x) around the teeth via the insulators, wherein the conductor wire is wound in multiple layers using concentrated winding while rearranging at axial ends of the teeth, and the conductor wire is arranged at an angle with respect to the width direction of the teeth on both sides of the axial ends of the teeth, and the rearranging is shared between both axial sides of the teeth.

[0066] [2] The stator according to [1] above, wherein the inclination angles (β1, β2, etc.) of the conductors on both axial sides of the teeth are set to the same angle when the rows are rearranged.

[0067] [3] The stator according to the above [1] or [2], wherein a rearrangement angle (β, etc.) when rearranging the conductors is calculated using rearrangement angle = arctan (wire distance / winding diameter distance), and the rearrangement angle (β) calculated from the wire distance (P) of adjacent conductors in one winding and the winding diameter distance (B2) of the conductors in the second layer in the width direction of the teeth is set to be smaller than a limit value.

[0068] [4] The stator according to any one of the above [1] to [3], wherein the insulator has an arrangement groove (22f) that regulates the position of the conductor, and the conductor is wound along the arrangement groove of the insulator.

[0069] [5] The stator according to the above [4], wherein the arrangement grooves of the insulator are provided only at four corners (22d) around the teeth around which the conducting wires are wound.

[0070] [6] The stator according to any one of the above [1] to [5], wherein the insulator has a holding groove (22a) for holding the conductor, and the winding start portion of the conductor is held in the holding groove of the insulator.

[0071] [7] The stator according to any one of the above [1] to [6], wherein the insulator has a base portion (22h, 22i) that prevents the second layer of the conductor from excessively entering the first layer, and the conductor is configured so that its position can be controlled by abutting against the base portion of the insulator.

[0072] [8] A motor configured with the stator (11) according to any one of [1] to [7] above.

[0073] [9] An insulator (22, 22x, 22y) used in a stator (11) including a stator core (21) having a plurality of teeth (21b) and a coil (23) formed by winding a conductor (23x) around the teeth, the insulator being provided in a portion of the stator core including the teeth and wound with a plurality of layers by concentrated winding of the conductor, wherein the insulator has arrangement grooves (22f) that regulate the position of the conductor wound in the first layer so that the conductor is arranged at an angle with respect to the width direction of the teeth on both sides of the axial end of the teeth, and a winding pattern in which the rearrangement of the conductor is shared between both axial sides of the teeth.

Claims

1. A stator (11) comprising: a stator core (21) having a plurality of teeth (21b); insulators (22, 22x, 22y) provided in a portion of the stator core including the teeth; and coils (23) formed by winding a conductor (23x) around the teeth via the insulators, wherein the conductor is wound in multiple layers using concentrated winding while rearranging at the axial ends of the teeth, and the conductor is arranged at an angle with respect to the width direction of the teeth on both sides of the axial ends of the teeth, and the rearranging is shared between both axial sides of the teeth.

2. A stator according to claim 1, wherein the inclination angles (β1, β2, etc.) of the conductor wires on both sides of the axial direction of the teeth are set to the same angle when the rows are rearranged.

3. A stator according to claim 1, wherein the reordering angle (β, etc.) when the conductors are reordered is calculated using the formula: reordering angle = arctan (wire-to-wire distance / winding diameter distance), and the reordering angle (β) calculated from the wire-to-wire distance (P) of adjacent conductors in one winding and the winding diameter distance (B2) of the conductors in the second layer in the width direction of the teeth is set to be smaller than a limit value.

4. A stator according to claim 1, wherein the insulator has an arrangement groove (22f) for regulating the position of the conductor, and the conductor is wound along the arrangement groove of the insulator.

5. A stator according to claim 4, wherein the arrangement grooves of the insulator are provided only at four corners (22d) around the teeth around which the conductor wires are wound.

6. A stator according to claim 1, wherein the insulator has a retaining groove (22a) for retaining the conductor wire, and the winding start portion of the conductor wire is retained in the retaining groove of the insulator.

7. A stator as described in claim 1, wherein the insulator has a base portion (22h, 22i) that prevents the second layer of conductor wire from entering excessively into the first layer, and the conductor wire is configured so that its position can be controlled by abutting against the base portion of the insulator.

8. A motor comprising a stator (11) according to any one of claims 1 to 7.

9. An insulator (22, 22x, 22y) used in a stator (11) having a stator core (21) with a plurality of teeth (21b) and a coil (23) formed by winding a conductor (23x) around the teeth, the insulator (22, 22x, 22y) being provided in a portion of the stator core including the teeth and wound with multiple layers of concentrated winding of the conductor, the insulator having arrangement grooves (22f) that regulate the position of the conductor wound in the first layer so that the conductor is arranged at an angle with respect to the width direction of the tooth on both sides of the axial end of the tooth, and a winding pattern in which the rearrangement of the conductor is shared between both axial sides of the tooth.

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