JP4869772B2 - Stator and manufacturing method thereof - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a stator and its manufacturing method for inhibiting the flange of a stator core from being damaged due to a compression of a coil by pressing. <P>SOLUTION: A pitch of a groove 21 in an insulator 15 is extended gradually toward the radial inside A of a motor in a partial zone Da at an end of the radial inside A of the motor. A wall face 23 of an end wall 15c in the insulator 15 is inclined with respect to an outer circumference S of teeth 11a at an obtuse angle &theta;. The coil 13, other than an excluded zone E at the end of the radial inside A of the motor, is compressed by pressing. The coil 13 is compressed by pressing in a state where the excluded zone E of the coil 13 is held by a jig 27. <P>COPYRIGHT: (C)2008,JPO&amp;INPIT

Description

  The present invention relates to a stator and a manufacturing method thereof.

  As a conventional stator, there is one in which a coil is press-compressed in a state where a coil is externally mounted on a tooth portion of a stator core so as to improve a space factor of the coil (for example, Patent Documents 1 and 2). In addition, although there is no direct relationship with the present invention, there is a technique in which a coil and a powder magnetic material are loaded together in a mold and press-molded (for example, Patent Document 3).

JP 2003-244881 A JP 2004-364402 A Japanese translation of PCT publication No. 2003-507991

  However, if the coil is simply put on the teeth part of the stator core and press-compressed as in the techniques described in Patent Documents 1 and 2, the collar part of the teeth part is strongly pressed by the compressed coil, and the collar part is damaged. There is a risk. In particular, a stator core made of a dust magnetic material is more fragile than a core formed by laminating silicon steel plates, so that the brim portion is easily damaged due to press compression of the coil.

  Therefore, the problem to be solved by the present invention is to provide a stator capable of suppressing breakage of the flange portion of the stator core due to press compression of the coil, and a method for manufacturing the stator.

  In order to solve the above-mentioned problem, in the invention of claim 1, a stator disposed on the outer periphery of the rotor, the stator core having a tooth portion provided with a brim portion, and an insulating member sheathed on the tooth portion; A coil that is press-compressed in a state of being sheathed from above the insulating member, and a groove for guiding the wire of the coil is provided on the outer periphery of the insulating member, and the pitch of the groove with respect to the motor radial direction is provided. The pitch on the inner side in the motor radial direction is larger than the pitch on the outer side in the motor radial direction.

  According to a second aspect of the present invention, in the stator according to the first aspect of the present invention, the pitch of the groove with respect to the motor radial direction is at least a part of the inner side in the motor radial direction. It is gradually enlarged as it approaches the section.

  According to a third aspect of the present invention, in the stator according to the first or second aspect of the present invention, the insulating member includes an end wall interposed between the flange portion and an inner radial end portion of the coil. A wall portion on the coil side of the end wall portion is inclined so as to form an obtuse angle with respect to the outer peripheral surface of the tooth portion.

According to a fourth aspect of the present invention, in the stator according to any one of the first to third aspects, the stator core is formed of a dust magnetic material.

According to a fifth aspect of the present invention, there is provided a stator core having a tooth portion provided on the outer periphery of the rotor and provided with a flange portion, an insulating member externally mounted on the tooth portion, and a coil externally mounted on the insulating member. And a groove for guiding the wire of the coil is provided on the outer periphery of the insulating member, and the pitch on the inner side in the motor radial direction is the outer side in the motor radial direction. A method of manufacturing a stator that is larger than the pitch on the side of the stator, wherein the insulating member is sheathed on the teeth portion of the stator core, and the insulation is provided on the teeth portion from above the insulating member. According to the groove on the outer periphery of the member, the wire is wound so that the density of the wire on the inner side is lower than that on the outer side in the motor radial direction of the tooth portion. A coil sheath forming a le, to said coils fitted on the tooth portions, and a pressing step for performing press compressed toward the central axis direction of the coil.

According to a sixth aspect of the present invention, in the stator manufacturing method according to the fifth aspect of the present invention, in the pressing step, an excluded section on the inner side in the motor radial direction is excluded from the coil sheathed on the tooth portion. Press compression is performed in the direction of the central axis of the coil.

According to a seventh aspect of the invention, in the stator manufacturing method according to the sixth aspect of the invention, in the pressing step, the coil is excluded from the same direction as the direction in which the press compression is performed at least in the excluded section of the coil. The press compression is performed in a state where is held by a jig.

  According to the first aspect of the present invention, a groove for guiding the wire of the coil is provided on the outer periphery of the insulating member mounted on the tooth portion, and the pitch of the groove with respect to the motor radial direction is set to the inner side in the motor radial direction. Since the pitch of the coil is larger than the pitch on the outer side in the motor radial direction, if the coil wire is wound along the groove, the coil density is more in the motor radial direction than the outer side in the motor radial direction. The side (that is, the flange side) can be easily roughened. As a result, it is possible to reduce the pressure at which the inner portion of the coil in the motor radial direction expands in the motor radial direction when press-compressing the coil. The damage of the part can be suppressed.

  According to invention of Claim 2, the pitch with respect to the motor radial direction of the groove | channel provided in the outer periphery of an insulating member is a motor radial direction inner side edge part at least in the partial area of the motor radial direction inner side. Since it is gradually enlarged as it approaches, if the wire of the coil is wound along the groove, the density of the coil can be made coarser closer to the inner end in the motor radial direction, When press-compressing the coil, it is possible to more effectively reduce the pressure at which the inner portion of the coil in the motor radial direction expands in the motor radial direction.

  According to the invention described in claim 3, the insulating member is provided with the end wall portion interposed between the flange portion and the end portion on the inner side in the motor radial direction of the coil, and the coil side of the end wall portion on the coil side is provided. Since the wall surface is inclined so as to form an obtuse angle with respect to the outer peripheral surface of the tooth portion, it is possible to increase the coil winding space at the inner end in the radial direction of the motor, thereby maintaining the number of turns of the coil. However, the density of the coil at the inner end in the motor radial direction (that is, the flange end) can be easily made rough. Thereby, when press compression is performed on the coil, it is possible to more effectively reduce the pressure at which the portion on the inner side in the motor radial direction of the coil expands in the motor radial direction.

According to the fourth aspect of the present invention, since the stator core is formed of a dust magnetic material having excellent moldability, even a stator core having a three-dimensionally complicated shape can be easily manufactured. .

According to the fifth aspect of the present invention, a groove for guiding the wire material of the coil is provided on the outer periphery of the insulating member mounted on the tooth portion. Since the pitch of the coil is larger than the pitch on the outer side in the motor radial direction, if the coil wire is wound along the groove, the coil density is more in the motor radial direction than the outer side in the motor radial direction. The side (that is, the flange side) can be easily roughened. As a result, it is possible to reduce the pressure at which the inner portion of the coil in the motor radial direction expands in the motor radial direction when press-compressing the coil. The damage of the part can be suppressed.

According to the sixth aspect of the present invention, the press-compression is performed on the coil sheathed on the tooth portion in the direction of the central axis of the coil except for the exclusion section on the inner side in the motor radial direction. At this time, it is possible to reduce the pressure at which the inner portion of the coil in the radial direction of the motor expands in the radial direction of the motor, thereby suppressing the breakage of the flange portion of the stator core due to the press compression of the coil.

According to the seventh aspect of the present invention, press compression is performed in a state where the coil is pressed with a jig from the same direction as at least the press compression in the excluded section of the coil. It is possible to prevent the coil inner portion in the radial direction of the coil from being expanded in a direction away from the tooth portion and rising above the allowable limit.

  FIG. 1 is a plan view schematically showing a configuration of a stator according to an embodiment of the present invention, and FIG. 2 is a cross-sectional view showing a configuration and a manufacturing process of a split stator provided in the stator of FIG. FIG. 4 is an exploded sectional view showing a split core and an insulator provided in the split stator of FIG. 2, and FIG. 4 is a perspective view of the split core.

  As shown in FIG. 1, the stator 1 includes a plurality of divided stators 3 arranged in an annular shape around the rotor. As shown in FIGS. 2 to 4, the split stator 3 includes a split core (corresponding to a stator core of the present invention) 11, a coil 13, and an insulator (insulating member) 15.

  The split core 11 includes a tooth portion 11a on which the coil 13 is externally mounted, and a yoke portion 11b provided on the outer side in the motor radial direction A of the tooth portion 11a. The yoke portion 11b protrudes from the end of the tooth portion 11a to both sides of the motor circumferential direction B and both sides of the motor axial direction C. Further, at the end portion of the teeth portion 11a on the inner side in the radial direction of the motor, a flange portion 11c that protrudes from the end portion to both sides of the motor circumferential direction B and both sides of the motor axial direction C is provided. The flange portion 11c may be configured to project only on both sides of the motor circumferential direction B and not project in the motor axial direction C.

  Such a split core 11 is composed of a metal magnetic powder or a powder magnetic material obtained by bonding a metal magnetic powder covered with a predetermined insulating film with a resin, and the powder magnetic material is made into a predetermined mold. After filling, pressurizing and compressing, it is formed by heat treatment.

  The insulator 15 includes a substantially cylindrical body portion 15a that is fitted on the outer periphery of the tooth portion 11a, and two end wall portions 15b and 15c provided at both ends of the body portion 15a, and is formed of an insulating resin. Has been. Such an insulator 15 has a shape that fits snugly into a slot portion formed on the outer periphery of the tooth portion 11 a, and the body portion 15 a is interposed between the shaft portion of the tooth portion 11 a and the coil 13. The end wall portions 15b and 15c are inserted between the end surface of the coil 13 on the outer side and the inner side in the motor radial direction A and the yoke portion 11b and the flange portion 11c.

  As shown in FIG. 5, a plurality of grooves 21 continuous in the circumferential direction for defining the winding position of the wire 13 a of the coil 13 are provided on the outer periphery of the trunk portion 15 a. When the wire 13a is wound around the body portion 15a, the wire 13a is fitted and guided in the groove 21, whereby the winding position of the wire 13a is defined, and the wire 13a is wound in an orderly manner. .

  The pitch P of the groove 21 with respect to the motor radial direction A is gradually increased as it approaches the end wall portion 15c on the inner side in the motor radial direction A in a partial section Da on the inner side in the motor radial direction A. For other sections Db, the pitch P is set to a constant value substantially equal to the outer diameter of the wire 13a. That is, in the section Da, the pitch P is gradually increased to a value larger as it approaches the end wall portion 15c, with the value slightly larger than the outer diameter of the wire 13a being the lowest value.

  Further, the wall surface 23 on the coil 13 side of the end wall portion 15c is inclined so as to form an obtuse angle θ with respect to the outer peripheral surface S of the tooth portion 11a.

  As shown in FIG. 3, the insulator 15 configured as described above is divided into two divided pairs 15 </ b> A and 15 </ b> B on a divided plane parallel to the motor axial direction C passing through the center thereof. From both sides of the motor circumferential direction B, it is fitted and attached to the teeth portion 11a. As a modification, the insulator 15 may be divided into two by a dividing plane parallel to the motor circumferential direction B.

  The coil 13 is formed by winding the wire 13a around the tooth portion 11a from above the insulator 15, and is press-compressed while being wound around the tooth portion 11a in order to improve the space factor. This press compression process will be described in detail later.

  Next, the manufacturing process of the stator 1 will be described with reference to FIG. First, as shown in FIG. 6, the insulator 15 is attached to the teeth portion 11a in the manner described above (step S1).

  Subsequently, the wire 13a of the coil 13 is wound around the tooth portion 11a from the top of the insulator 15, and the coil 13 is formed (step S2). At this time, with respect to the pitch P of the groove 21 of the insulator 15, the pitch P is set densely and uniformly in the section Db on the outer side in the motor radial direction A corresponding to the outer diameter of the wire 13a. By winding the wire 13a correspondingly, the density of the wire 13a is wound naturally and densely. On the other hand, in the section Da on the inner side in the motor radial direction A, the pitch P is formed so as to approach the end wall portion 15c and gradually increases. Therefore, the wire 13a is made to correspond to the groove 21. As a result, the gaps are naturally formed between the wires 13a, and the density is naturally rough.

  Further, since the wall surface 23 of the end wall portion 15c of the insulator 15 is inclined so as to form an obtuse angle θ with respect to the outer peripheral surface S of the tooth portion 11a, the coil winding space at the inner end portion in the motor radial direction A Thus, the density of the wire 13a can be easily roughened while maintaining the number of turns of the coil 13 in the vicinity of the end wall portion 15c.

  Note that the ratio of the section Da occupying the entire length of the body portion 15a of the insulator 15, the stepwise expansion ratio of the pitch P of the groove 21 in the section Da, and the inclination angle θ of the wall surface 23 are the coil 13 in the vicinity of the flange portion 11c. It is determined according to how much the density state of the wire 13a is set.

  Subsequently, press compression is performed on the coil 13 wound around the tooth portion 11a as shown in FIG. 1 to improve the space factor of the coil 13 (step S3). In this process, except for the exclusion section E on the end wall portion 15c side between the end wall portions 15b and 15c of the insulator 15, the press mold 25 is applied to the coil 13 from both sides in the motor circumferential direction B (that is, the coil side). From the direction, press compression is performed in the direction of the arrow F toward the central axis direction of the coil 13 (the press compression is not performed in the motor shaft direction C (coil end direction)). At this time, in the excluded section E, press compression is performed in a state where the coil 13 is pressed by the jig 27 from both sides in the coil side direction.

  Thus, since the press compression is performed on the coil 13 except for the excluded section E, the pressure at which the inner portion of the coil 13 in the motor radial direction A expands in the motor radial direction A during the press compression is reduced. Can be done. In addition, about the ratio of the exclusion area E which occupies the space | interval between the end wall parts 15b and 15c of the insulator 15, taking into account the density condition of the wire 13a of the coil 13 of the vicinity of the collar part 11c, the coil 13 in the case of press compression. It is determined by how much the stress acting on the brim portion 11c is set by the enlargement of.

  Moreover, in order to perform press compression with respect to the coil 13 in the state which pressed the coil 13 with the jig | tool 27 about the exclusion area E, the direction of the motor radial direction A inner side part of the coil 13 leaves | separates from the teeth part 11a by press compression. It is possible to prevent the air from rising beyond the allowable limit.

  As described above, according to the present embodiment, as described above, the pitch P of the grooves 21 of the insulator 15 is directed toward the inner side of the motor radial direction A in the partial section Da of the inner side end portion of the motor radial direction A. Therefore, if the wire 13a is wound along the groove 21, the density of the coil 13 can be made coarser as it is closer to the inner end of the motor radial direction A. As a result, the pressure at which the portion of the coil 13 on the inner side in the motor radial direction A expands in the motor radial direction A when press-compressing the coil 13 can be more effectively reduced. Thereby, the breakage of the flange portion 11a of the split core 11 due to the press compression of the coil 13 can be suppressed.

  Further, since the wall surface 23 of the end wall portion 15c of the insulator 15 is inclined so as to form an obtuse angle θ with respect to the outer peripheral surface S of the tooth portion 11a, the coil winding space at the inner end portion in the motor radial direction A is provided. As a result, while maintaining the number of turns of the coil 13, the density of the coil 13 at the inner end in the motor radial direction A (that is, the end on the flange side) can be easily roughened. Therefore, also by this point, when press-compressing the coil 13, the pressure at which the inner portion of the coil 13 in the motor radial direction A expands in the motor radial direction A can be reduced more effectively. It is possible to suppress breakage of the brim portion 11a due to the 13 press compression.

  Further, since the press compression is performed on the coil 13 except for the excluded section E at the inner side end portion in the motor radial direction A, the inner portion of the coil 13 in the motor radial direction A is the motor radial direction A during the press compression. The pressure to expand can be reduced. Therefore, also by this point, the breakage of the brim portion 11a due to the press compression of the coil 13 can be suppressed.

  Further, in the excluded section E, since the coil 13 is pressed and compressed from both sides in the coil side direction with the jig 27, the portion of the coil 13 on the inner side in the motor radial direction A is lifted by the press compression. Thus, the space factor of the coil 13 is improved.

  Moreover, since the split core 11 is formed of a compacted magnetic material having excellent moldability, even the split core 11 having a three-dimensionally complicated shape can be easily manufactured.

  In the above-described embodiment, the split core 11 is formed of a powder magnetic material. However, the split core 11 may be formed by stacking electromagnetic steel plates.

It is a top view which shows typically the structure of the stator which concerns on one Embodiment of this invention. It is sectional drawing which shows the structure and manufacturing process of the division | segmentation stator with which the stator of FIG. 1 is equipped. It is sectional drawing which decomposes | disassembles and shows the division | segmentation core and insulator with which the division | segmentation stator of FIG. 2 is equipped. It is a perspective view of a split core. It is sectional drawing which shows typically the structure of the principal part of an insulator. It is process drawing which shows the manufacturing process of a stator.

Explanation of symbols

1 Stator 3 Split Stator 11 Split Core 13 Coil 13a Wire 15 Insulator 15a Body 15b, 15c End Wall 21 Groove 23 Wall 25 Press Mold 27 Jig A Motor Radial Direction B Motor Circumferential Direction C Motor Axial Direction Da, Db Section E Excluded section P Pitch θ Obtuse angle

Claims (7)

A stator disposed on the outer periphery of the rotor,
A stator core having a teeth portion provided with a brim portion;
An insulating member sheathed on the teeth portion;
A coil that is press-compressed in a state of being sheathed from above the insulating member;
With
A groove for guiding the wire of the coil is provided on the outer periphery of the insulating member,
Regarding the pitch of the groove with respect to the motor radial direction, the pitch on the inner side in the motor radial direction is larger than the pitch on the outer side in the motor radial direction. The stator according to claim 1,
A stator in which the pitch of the groove with respect to the motor radial direction is gradually increased as it approaches the inner end in the motor radial direction at least in a partial section on the inner side in the motor radial direction. The stator according to claim 1 or 2,
The insulating member is provided with an end wall portion interposed between the brim portion and the motor radial direction inner side end portion of the coil,
The stator is characterized in that the coil side wall surface of the end wall portion is inclined so as to form an obtuse angle with respect to the outer peripheral surface of the tooth portion.   The stator according to any one of claims 1 to 3,
  The stator, wherein the stator core is made of a dust magnetic material.   A stator core disposed on the outer periphery of the rotor and having a teeth portion provided with a flange portion;
  An insulating member sheathed on the teeth portion;
  A coil sheathed from above the insulating member;
With
  A groove for guiding the wire of the coil is provided on the outer periphery of the insulating member, and the pitch of the groove with respect to the motor radial direction is greater than the pitch on the motor radial outer side than the pitch on the motor radial outer side. Is a method of manufacturing a stator,
  An insulating member sheathing step of sheathing the insulating member on the teeth portion of the stator core;
  According to the groove on the outer periphery of the insulating member from above the insulating member, the density of the wire on the inner side is lower than the outer side in the motor radial direction of the tooth portion. A coil sheathing step of winding the wire to form the coil;
  A pressing step for press-compressing the coil sheathed on the teeth portion toward the central axis of the coil; and
A method for manufacturing a stator, comprising:   In the manufacturing method of the stator according to claim 5,
  In the pressing step, the coil mounted on the teeth portion is subjected to press compression toward the central axis direction of the coil except for an excluded section on the inner side in the motor radial direction. Method.   In the manufacturing method of the stator according to claim 6,
  In the pressing step, the press compression is performed in a state where the coil is pressed with a jig from the same direction as the direction in which the press compression is performed at least in the excluded section of the coil. Production method.

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