JP7570508B2 - Insulator, stator, rotating electric machine, method for manufacturing stator, and method for manufacturing rotating electric machine - Google Patents

Description

This application relates to an insulator, a stator, a rotating electric machine, a method for manufacturing a stator, and a method for manufacturing a rotating electric machine.

A rotating electric machine stator has been disclosed in which core pieces (split cores) divided into teeth are connected together so that they can be freely bent in a direction perpendicular to the axis (see, for example, Patent Documents 1 and 2). Adjacent teeth in the stator are close to each other on the inside in the radial direction, but with the above configuration, by changing the angle of the connecting part so that the teeth are positioned on the outer diameter side, winding can be done without interfering with adjacent core pieces, improving the coil space factor.

JP 2000-201458 A JP 2006-254569 A

However, in Patent Document 1, two types of laminated steel plates must be prepared to mesh the laminated steel plates of adjacent core pieces at the connecting portion, and there are problems such as the need for punching and crimping for connection, which increases the number of parts and complicates the process. In Patent Document 2, a mechanism is provided for insertion and removal in the axial direction for connection and rotation, but when the teeth are facing outward, a holding mechanism or the like must be prepared to prevent axial positional deviation after connection, which complicates the manufacturing process. In both Patent Documents 1 and 2, the distance between the connected teeth is determined correspondingly for each shape of the stator core, so depending on the shape of the teeth, it may not be possible to wind the windings at a high density in the winding process.

This application discloses technology to solve the problems described above, and aims to obtain a stator and motor that can wind windings at high density without increasing the number of parts and manufacturing processes.

The insulator disclosed in the present application comprises:
An insulator is attached to a stator core and electrically insulates the coil and the stator core, and comprises two arm-shaped connecting portions protruding on both circumferential sides of the stator core, a columnar portion formed on one connecting portion, a protrusion formed on one connecting portion opposite the columnar portion, and a guide portion formed on the other connecting portion for movably guiding the columnar portion, wherein the columnar portion of one insulator movably engages within the guide portion of the other adjacent insulator, making it possible to vary the distance between adjacent insulators,
The guide portion is formed with a plurality of fitting portions into which the columnar portions can be fitted,
The guide portion has a long hole portion between adjacent mating portions among the multiple mating portions, and adjacent insulators are fixed at a predetermined angle by engaging the long hole portion of one insulator with the protrusion portion of the other insulator .

In stators and motors, windings can be wound at high density without increasing the number of parts and manufacturing processes.

FIG. FIG. 2 is a perspective view of a stator core ring assembly. FIG. 2 is a perspective view of the insulator according to the first embodiment. FIG. 4 is a rear view of the insulator of FIG. 3 as viewed from the radially outer circumferential side. FIG. 4 is a top view of the insulator of FIG. 3 as viewed from above in the axial direction. 11 is a top view showing the state in which the connecting portion is reassembled into the stator core ring assembly after winding is performed on the stator core connected body of the first embodiment. FIG. 7 is a perspective view showing a fitted state through one of the insulators in the state shown in FIG. 6 . FIG. 2 is a perspective view of the insulator of the first embodiment as viewed from the radially inner periphery side. FIG. FIG. 9 is a perspective view of FIG. 8 as viewed from the axial lower side toward the upper side. 4 is a flowchart illustrating a manufacturing process of the stator according to the first embodiment. FIG. 2 is a perspective view of a stator assembly to which insulators according to the first embodiment are connected. 1 is a top view showing a state in which a flyer-type winding device is used to wind a stator core connected body of the first embodiment. FIG. 13 is a top view showing a state in which a stator core of a different size is wound by the same winding device as in FIG. 12 . 13 is a top view showing a state in which winding is performed on the stator core connected body of embodiment 1 by a winding device of a type different from that shown in FIG. 12 . 11 is a perspective view showing a state in which the connecting portion is reassembled into a position for assembling the stator core ring assembly after winding is performed on the stator core connected body of the first embodiment. FIG. FIG. 16 is a radial rear view of FIG. 15 . FIG. 4 is a top view showing a state in which the semicircular stator core connected bodies of the first embodiment are connected together. FIG. 18 is a perspective view showing a state in which the semicircular stator core connected bodies of FIG. 17 are connected together. FIG. 2 is a perspective view of the stator core ring assembly of the first embodiment. 1 is a perspective view of a completed stator in which the stator core ring assembly of the first embodiment is covered with molding resin. FIG. 1 is a cross-sectional view of a motor according to a first embodiment. FIG. 11 is a top view of an insulator according to a second embodiment. FIG. 11 is a perspective view of an insulator according to a second embodiment. FIG. 11 is a top view of a stator assembly in which insulators according to a second embodiment are connected at first fitting portions. 13 is another top view of the stator connection portion where the insulator according to embodiment 2 is connected at the first fitting portion. FIG. FIG. 11 is a top view of a stator connection portion where an insulator according to a second embodiment is connected at a second fitting portion. FIG. 11 is a perspective view of an insulator according to a third embodiment. 28 is a bottom view of the insulator of FIG. 27 as viewed from the axial lower side. FIG. 13 is a perspective view showing a state in which the connecting portion is reassembled to a stator core ring assembly after winding is performed on the stator core connected body according to embodiment 3. FIG. FIG. 30 is a perspective view of the state of FIG. 29 seen from a different angle. FIG. 11 is a cross-sectional view of a motor according to a fourth embodiment. 10 is a flowchart showing a stator manufacturing process according to the fourth embodiment. FIG. 13 is a perspective view showing a stator core insulating assembly according to embodiment 5. 13 is a top view showing a state in which a flyer-type winding device is used to wind a stator core connected body according to embodiment 6. FIG. FIG. 13 is a perspective view of an insulator according to a seventh embodiment. FIG. 13 is a perspective view of a separate connecting part according to the seventh embodiment. FIG. 13 is a perspective view of a stator assembly to which an insulator according to a seventh embodiment is connected. FIG. 13 is a top view of a stator assembly to which an insulator according to embodiment 7 is connected. 13 is a perspective view showing a state in which the connecting portion is reassembled into a position for assembling the stator core ring assembly after winding is performed on the stator core connected body of embodiment 7. FIG. FIG. 23 is an oblique view of a stator core ring assembly of embodiment 7. FIG. 23 is a perspective view of another separate connecting part according to embodiment 7. FIG. 13 is a top view of a stator assembly in which insulators according to embodiment 7 are connected by another separate connecting portion. 13 is an oblique view showing a state in which the insulator of embodiment 7 is wound around a stator core connected body connected by another separate connecting part, and then the connecting part is reassembled into a position for assembling the stator core ring assembly. FIG.

Hereinafter, a preferred embodiment of the insulator according to the present application will be described with reference to the drawings. Note that the same reference numerals are used for the same contents and corresponding parts, and detailed description thereof will be omitted. Similarly, in the following embodiments, redundant description of the configurations with the same reference numerals will be omitted.

Embodiment 1.
First, the shape of each component of this embodiment will be described.
The stator core 10 in Fig. 1 is a stator core obtained by dividing an annular stator of an inner rotor type motor (see Fig. 21) by the number of slots, and has a teeth portion 11 and a back yoke portion 12. The dividing surface 13, which is the abutment portion between adjacent teeth, is a simple flat surface, and does not have a means for joining the individual stator cores together. Since the stator core 10 has a simple shape, it is only necessary to prepare one type of mold for the stator core 10, making it easy to manufacture.

2 shows the stator core ring assembly 300 described below. In the following description, the axial direction (X), circumferential direction (θ), and radial direction (R) respectively refer to the directions shown in FIG. 2.

FIG. 3 is a perspective view of the insulator according to the first embodiment, FIG. 4 is a rear view seen from the radially outer periphery side, and FIG. 5 is a top view seen from the axial direction.
3 to 5, the insulator 20 that electrically insulates the coil and the stator core has a core fitting portion 21 that is fitted into the stator core 10, and a winding frame portion 22 that supports the wound coil. The insulator 20 in Fig. 3 shows the upper insulator (see insulator 20a in Fig. 11) that is fitted into the stator core 10 from above and below in the axial direction. The winding frame portion 22 has a portion that covers the stator core 10 and an inner circumferential flange portion 23 and an outer circumferential flange portion 24 that protrude in the axial direction, and the inner circumferential flange portion 23 and the outer circumferential flange portion 24 support the coil so that it does not protrude from the radial direction R (see Fig. 2).

The outer flange 24 has an inlet groove for introducing the coil terminal wire and an outlet groove for discharging it. The outer flange 24 has connecting portions 25a and 25b at positions facing the adjacent stator core 10 on the further outer side, and the connecting portions 25a and 25b protrude from the circumferential θ end face of the stator core 10.

The tip of the connecting portion 25a has a columnar portion 251 extending in the axial direction, and the connecting portion 25b has a guide portion that guides the columnar portion 251 of another insulator to be movable, as described later. In this embodiment, this corresponds to a slot-hole-shaped opening 252. The columnar portion 251 has a shape in which a part of a cylinder is cut out (notch portion 251a). Since the diameter of the columnar portion 251 is smaller than the width of the connecting portion 25a, a step 253 is formed at the boundary between the columnar portion 251 and the connecting portion 25a. This step 253 is preferably formed on the entire circumference of the columnar portion 251, but even if it is formed on a part of the entire circumference, it is sufficient that the step 253 is formed at a position that restricts the axial movement of the stator core 10 when it becomes a stator core connected body 200 described later. In addition, the end face of the columnar portion 251 has a protrusion 254 that protrudes outward from the cylindrical surface of the columnar portion 251.

The slot-hole-shaped opening 252 of the connecting portion 25b has a first arc portion 252a of the same diameter as the columnar portion 251 at the entrance side, which fits with the columnar portion 251 and can rotate freely around the columnar portion 251. That is, the columnar portion 251 is rotatably fitted at the first arc portion 252a, which is the fitting portion where the distance between the insulators 20 is the greatest. The opening 252 also has a second arc portion 252b of the same diameter at the end side, and is positioned so that the columnar portion 251 fits into the second arc portion 252b when the dividing surface 13 of the stator core 10 is butted against it.

The first arc portion 252a and the second arc portion 252b are connected by a long hole portion 252c that connects the arc portions, and the width of the long hole portion 252c is the same as or larger than the diameter of the columnar portion 251. The opening 252 consisting of the first arc portion 252a, the long hole portion 252c, and the second arc portion 252b has a width roughly the same as the diameter of the columnar portion 251, but as shown in Figures 5(a) and (b), the first arc portion 252a and the second arc portion 252b have protrusions 252d for forming a portion whose width is smaller than the diameter of the columnar portion 251.

The insulator 20 uses an elastic insulating material such as resin, rubber, paper, or wood, so even if the opening 252 is partially narrower than the columnar portion 251, the insulator 20 temporarily elastically deforms, allowing the columnar portion 251 to move through the first arc portion 252a and the long hole portion 252c to the second arc portion 252b. The opening side of the second arc portion 252b has a surface that fits into the notch portion 251a of the columnar portion 251. This surface is perpendicular to the direction in which the columnar portion 251 is removed from the second arc portion 252b (the opening direction).

The protrusion 255 is provided on the base side of the connecting portion 25a having the columnar portion 251. As will be described in detail later, insulators 20 are connected to form the stator core connected body 200, and the connecting portion is shown in a state where it is reassembled to be assembled to the stator core ring assembly 300 in Fig. 6 and Fig. 7. In this manner, the side surface of the protrusion 255 on the first arc portion 252a side is in a position where it contacts the end surface of the long hole portion 252c on the first arc portion 252a side when the columnar portion 251 is fitted into the second arc portion 252b, and has a guide taper such that the height of the protrusion 255 decreases toward the columnar portion 251. This shape can strengthen the retention force of the connected state.

These mechanisms allow the columnar portion 251 to fix adjacent insulators 20 and the stator core 10 at a predetermined angle at the second arc portion 252b, which is the fitting portion where the distance between the insulators 20 is closest. The fitting between the columnar portion 251 and the first arc portion 252a or the second arc portion 252b is a snap fit shape that utilizes the elastic deformation of the insulators, allowing for easy assembly. The snap fit is detachable in a plane perpendicular to the axial direction. Note that FIG. 7 shows one of the insulators in a see-through view to explain the fitting state.

As shown in Figure 8 from the radially inner side of the insulator 20, the circumferential end face of the inner flange portion 23 has inner flange fitting portions 23a, 23b that fit with adjacent insulators 20. The inner flange fitting portions 23a, 23b have a claw-like shape that opens in the axial direction when viewed from the inner side, and the inner flange fitting portions 23a, 23b do not restrict radial movement of the insulator 20 between themselves.

Figure 9 is a view of Figure 8 viewed from the axial bottom to the top, in which the insulator 20 is divided into two in the axial direction, and has wrap portions 22a and 22b where the insulators overlap each other on the winding frame portion 22. The wrap portions 22a and 22b have the function of increasing the insulation distance between the stator core 10 and the coil 30. The wrap portions 22a and 22b are stepped, and the direction of the step is the same for the wrap portion 22a on one side in the circumferential direction and the wrap portion 22b on the other side. In other words, the step on one axial end side of the insulator 20 and the step on the other axial end side are shaped to fit into each other on one or the other circumferential side.

Next, a method of assembling the stator in this embodiment shown in FIG. 10 will be described.
<Stator core insulation process S1>
As shown in Fig. 11, two insulators 20 (insulator 20a, insulator 20b) shown in Fig. 3 are assembled to one stator core 10 shown in Fig. 1 to form a stator core insulation assembly 100. The opening 252 (first arc portion 252a) of one insulator 20b faces the axially opposite side of the columnar portion 251 of the other insulator 20a, and the insulators 20a and 20b having the same shape are assembled to one stator core 10 to form the stator core insulation assembly 100.

In addition, to match the specifications of the stator, it is possible to change part of the mold parts of insulators 20a, 20b and change the shape of part of one of the insulators (for example, insulator 20a); however, in order to minimize the changes to the mold, it is better to arrange the columnar portion 251 and the opening 252 so that they face each other in the axial direction.

By orienting the step shapes of the wrap portions 22a, 22b of the insulator 20 in the same direction on one side and the other side in the circumferential direction, the insulators 20a, 20b are rotationally symmetrical with each other, so that one insulator 20a can be formed with the same shape as the other insulator 20b facing it, and the stator core insulation assembly 100 can be constructed with insulators 20 of the same shape. These wrap portions 22a, 22b may or may not be required depending on the insulation specifications of the stator, and when the wrap portions 22a, 22b are not required, it is sufficient that the requirements of the aforementioned connecting portions 25a, 25b or inner circumferential flange fitting portions 23a, 23b are met.

<Insulator connecting process S2>
As shown in Fig. 11, a plurality of stator core insulating assemblies 100 are connected to each other by fitting the columnar portions 251 and the first arc portions 252a of the insulators 20a and 20b together to form a stator core connected body 200. Since the stator core connected body 200 is connected by the columnar portions 251 and the first arc portions 252a, it can freely rotate around the columnar portions 251 as described above. The step 253 formed by the columnar portions 251 and the connecting portions 25a enters into the axial gap between the adjacent stator cores 10 and the openings 252, thereby restricting the axial movement of the openings 252. The protrusion 254 provided on the end face of the columnar portions 251 restricts the movement in the opposite direction to that restricted by the step 253.

<Winding process S3>
As shown in Fig. 12, the stator core connected body 200 is attached to the core holding mechanism 51 of the winding device 50 and wound. Because the stator core connected body 200 can freely rotate around the columnar portion 251, the stator core 10b adjacent to the stator core 10a to be wound can be held by the core holding mechanism 51 of the winding device 50 in a rotated state to a position where it does not interfere with the flyer 52. Also, as shown in Fig. 13, even stator cores 10c with different dimensions can be wound by the same winding device 50 if the positions of the columnar portions 251 of the insulators are aligned.

Even if winding is performed by moving the nozzle 53 close to the stator cores 10a and 10b in a rectangular orbit as shown in Fig. 14(a) instead of using a flyer mechanism, it is possible to wind the stator core 10c, which has different dimensions from the stator core 10a, with a common core gripping mechanism as shown in Fig. 14(b). In this case, the space between the teeth of the stator core can be made wider, so the nozzle 53 can be made thicker and the curvature of the fillet shape connecting the inner circumference of the nozzle 53 to the outlet can be increased, suppressing deterioration of the coil coating.

<Ring assembly process S4>
As shown in Figures 15 and 16, the connecting portions of the wound stator core connected body 200 are positioned to be assembled to the stator core ring assembly 300, and are connected in a ring shape as shown in Figure 17 to form the stator core ring assembly 300. At this time, as shown in Figure 18, the columnar portion 251 is slid in the direction of arrow A up to the second arc portion 252b, thereby forming a ring shape as shown in Figure 19. At this time, since the connecting portions 25a, 25b of the insulator 20 are configured to be contained inside the outer diameter of the stator core 10, the thickness of the molding resin described below can be ensured.

At this time, as described in Figure 3, the notch portion 251a of the columnar portion 251 and the surface of the second arc portion 252b engage with each other, and this surface is perpendicular to the direction in which the columnar portion 251 is removed from the second arc portion 252b (the opening direction). Therefore, even if a load is applied to disassemble the stator core connected body 200, no component force is generated to open the opening portion 252, and the stator core connected body 200 is not easily disassembled.

8, the inner flange fitting portions 23a, 23b provided on the inner flange portion 23 fit and catch on the adjacent insulator 20, thereby secondarily preventing disassembly of the stator core ring assembly 300. This increases the holding force after the stator core 10 is assembled into a ring. The inner flange fitting portions 23a, 23b are shaped so as not to restrict radial movement of the insulator (same cross-sectional shape in the radial direction), so they do not impede radial alignment of the outer connecting portions 25a, 25b.

The stator core ring assembly 300 can be easily assembled without the need for equipment such as welding or press-fitting devices. It is not easily disassembled, so no special jigs or tools are required for transporting it to subsequent processes.

<Wire connection process S5>
The terminal wires of the coil 30 are electrically connected in accordance with the stator specifications.

<Molding process S6>
The stator core ring assembly 300 with the windings and connections is placed in a resin molding die and molded. This completes the stator as shown in Fig. 20 (only the outline is shown so that the molding resin can be seen through). As shown in Fig. 21, the pressure of the resin 400 during molding presses the stator core 10 radially inward, causing the divided surfaces 13 of the stator core to butt together and form a magnetic circuit.

By assembling a rotor 60 with bearings attached on both axial sides into the stator created by the above process and fitting a bracket, a motor 70 as shown in Figure 21 can be created.

The above configuration allows winding of stator cores of different shapes without modifying or rearranging the winding machine, allows the divided stator cores to be easily connected and assembled into a ring shape, and allows some or all of the insulators divided in the axial direction to have a common shape. In addition, in the conventional insulator structure, a mechanism for gripping the teeth had to be prepared for each tooth shape and attached to the manufacturing equipment, but in this embodiment, the columnar portion and opening provided at the connecting portion of the insulator allow the distance between adjacent insulators to be variably adjusted, and multiple types of stator cores can be wound without changing the manufacturing equipment, resulting in high-performance stators and motors. Therefore, in the stators and motors, the windings can be wound at a high density without increasing the number of parts and manufacturing processes.

In addition, in Patent Document 2, the connecting portion is disposed outside the outer diameter of the stator core, and it was necessary to reduce the thickness of a portion of the yoke portion to prevent interference between adjacent yoke portions of the stator core during winding, thereby reducing the efficiency of the motor. On the other hand, in this embodiment, it is possible to obtain a stator and a motor that can ensure a magnetic path for the stator core.

Embodiment 2.
The structure of the connecting portion 25b having the same function as the guide portion of the slot-shaped opening 252 of the first embodiment will be described with reference to Figures 22 and 23. The connecting portion 25b may be formed by connecting two parallel extending arm portions 25b1 and 25b2 with a connecting portion 25b3. A protrusion 252d is formed on the arm portions 25b1 and 25b2, and a first fitting portion 25b4 and a second fitting portion 25b5 having the same function as the first arc portion 252a and the second arc portion 252b described in the first embodiment are formed. The connecting portion 25b3 may be formed at the bottom of the two arm portions 25b1 and 25b2 so as not to hinder the movement of the columnar portion 251 between the first fitting portion 25b4 and the second fitting portion 25b5. As explained in FIG. 11, since the stator core insulator is constructed by assembling the insulators 20a, 20b of the same shape on opposite axial sides, the positional relationship between the columnar portion 251 and the first mating portion 25b4, and between the columnar portion 251 and the second mating portion 25b5 in the insulators 20a, 20b are reversed, and therefore the position of the bottom is also reversed. It can also be said that the connection portion 25b3 is formed on the upper part of the two arm portions 25b1, 25b2.

In this embodiment, the columnar portion 251 of the connecting portion 25a is not cylindrical as in the first embodiment, but is polygonal, such as a hexagonal prism. The first fitting portion 25b4 and the second fitting portion 25b5 are shaped to fit the outer periphery of the columnar portion 251. As can be seen from the top view of FIG. 22, the shape of the first fitting portion 25b4 is based on a shape that is geometrically congruent or similar to the shape of the columnar portion 251, and a triangular groove 25b7 may be formed to engage with the corners of the polygonal shape and lock the rotation so as to fit at a plurality of predetermined angles.

In addition, the columnar portion 251 can fix adjacent insulators 20 and the stator core 10 at a predetermined angle at the second fitting portion 25b5 where the distance between the insulators 20 is closest. The fitting between the columnar portion 251 and the first fitting portion 25b4 or the second fitting portion 25b5 is a snap fit shape that utilizes the elastic deformation of the insulators, allowing for easy assembly. The snap fit is detachable in a plane perpendicular to the axial direction.

As explained in Figures 11 and 12 of the first embodiment, Figure 24 shows the state after multiple stator core insulation assemblies 100 are connected by fitting the columnar portion 251 with the first fitting portion 25b4 in the insulator connecting process of this embodiment, and the stator core insulating assemblies 100 are attached to the core gripping mechanism 51 as the stator core connected body 200 in the winding process and wound. When the insulator 20 is rotated with the polygonal shape of the columnar portion 251 fitted into the first fitting portion 25b4, the opening of the first fitting portion 25b4 elastically deforms and can rotate with a rotational load of a certain level or more. This provides the function of an auxiliary mechanism that selectively holds the angle of the core in the winding process.

As explained in Fig. 15 and Fig. 16 of the first embodiment, in the present embodiment, the process for forming the connected portion of the wound stator core connected body 200 into the stator core ring assembly 300 is shown in Fig. 25 and Fig. 26. The columnar portion 251 engaged with the first engaging portion 25b4 is rotated from the state of Fig. 24 to the state of Fig. 25, and then the columnar portion 251 is moved toward the second engaging portion 25b5, so that the columnar portion 251 overcomes the protrusion 252d and engages with the second engaging portion 25b5 as shown in Fig. 26.

By shaping the connecting portions 25a and 25b as in this embodiment, it is possible to equalize the distortion that occurs during snap-fitting at the first fitting portion 25b4, where the distance between the insulators 20 is the furthest, and the second fitting portion 25b5, where the distance is the closest. Also, as in the first embodiment, the connecting portions 25a and 25b of the insulator 20 are configured to be contained inside the outer diameter of the stator core 10, so that the thickness of the molded resin described below can be ensured.

Embodiment 3.
As shown in Fig. 27 and Fig. 28, the long side of the long hole portion 252c of the insulator 20 is tangent to the arc of the second arc portion 252b, and does not have a holding means for restricting the circumferential movement of the second arc portion 252b when the stator core assembly 200 is formed. For this reason, the side surfaces of the connecting portions 25a and 25b have the locking portions 256. When the stator cores 10a and 10b are combined as shown in Fig. 29, Fig. 30 shows the locking portions 256 visible through the stator cores, and the locking portions 256 are provided at positions that lock onto the locking portions 256 of the adjacent insulators and restrict the circumferential movement of the insulators and the stator core insulating assembly. As shown in Fig. 27, the locking portions 256 of the adjacent insulators have portions that protrude from the connecting portions 25a and 25b. One or both of the engagement portions 256 are cut out on the side opposite the protruding portion so as to facilitate elastic deformation during insertion.

The side of the connecting portions 25a and 25b has an elastically deformable retaining portion 256, which restricts the circumferential movement of the stator cores 10a and 10b, and the long hole portion 252c restricts the radial movement of the stator cores 10a and 10b. In the case of the first embodiment, the second arc portion 252b is restricted to have the same dimensions as the first arc portion 252a, but in the case of the present embodiment, there is no dimensional restriction on the retaining portion 256, and it can be configured according to the required strength. In addition, the retaining portion 256 of the present embodiment can be added to the shape of the first embodiment. By forming such a retaining portion 256, the holding force after the stator core 10 is assembled into a ring is increased.

Embodiment 4.
As in the motor 70 of FIG. 31 , a frame 80 is used for the final fixation of the stator core 10, instead of the resin 400. The frame 80 is made of a structural material such as a metal, such as iron or aluminum, or reinforced plastic. The frame 80 is cylindrical, and the inner diameter of the frame is smaller than the outer diameter of the stator core assembly, so that a preload is applied to the radially inner side of the stator core when the stator core 10 is assembled with the frame 80. As shown in FIG. 19 or FIG. 26 , the connecting portions 25a and 25b of the insulator 20 are located inside the outer diameter of the stator core 10, so that the insulator can be prevented from interfering with the frame when the frame is assembled.

The method of assembling the frame 80 to the stator includes a method of heat-fitting the frame 80 to expand its diameter by thermal expansion and fitting it, and then cooling the frame 80 to shrink and fix it in place by shrink fitting, or a method of press-fitting the frame 80 without heating the frame 80. There is also a method of splitting the frame 80 into multiple parts and fastening them together by screws, welding, or adhesive.
With this configuration, a mold or molding machine is not required, and the stator can be manufactured using simpler manufacturing equipment.

Embodiment 5.
As shown in Figure 33, the insulator 20 is not divided in the axial direction, and the stator core 10 is inserted into a resin molding die and insert molded. This ensures the insulation distance without having to consider the step in the wrap portion. If there is a step in the wrap portion, the thin side of the step must be the minimum thickness for resin molding, and the thickness of the insulator where there is no wrap portion is twice the minimum thickness. On the other hand, since there is no wrap portion in this embodiment, the thickness of the insulator can be the minimum thickness for resin molding, which increases the space for accommodating the coil and reduces the copper loss of the stator.

Embodiment 6.
As shown in Fig. 34, more than one stator is connected to form a stator core connected body 200, which is then attached to multiple core holding mechanisms 51, allowing multiple flyers 52 to continuously wind the coils of each phase without cutting the wires midway. This shortens the time required to cut the wires during the cycle time of the winding device, improving the operating rate of the winding device. In addition, the stator core insulating assemblies 100 can be supplied one by one during winding, eliminating the waiting time for work supply and improving the operating rate.

The stator cores that have been completely wound are moved in the direction of the arrow in Fig. 34, and are assembled into a ring shape beforehand when they are discharged. When all the stator cores for one stator are assembled, they are separated from the stator core connected body 200 that is being wound, and the stator core ring assembly 300 is formed, which eliminates the need to rearrange the stator cores for each phase. Note that Fig. 34 shows a configuration in which two coils of different phases are arranged between coils of the same phase, such as a 9-pole, 12-slot configuration, but even in cases where two coils of the same phase are adjacent to each other, such as a 10-pole, 12-slot configuration, and two pairs of coils of different phases are placed between two pairs of coils of the same phase, the number of stator cores between different flyers can be changed to an appropriate number to achieve winding in a similar configuration.

Embodiment 7.
The connecting parts 25a, 25b in the first to fifth embodiments are provided in the insulator 20, but in the present embodiment, a separate connecting part is provided in addition to the insulator. Fig. 35 is a perspective view of the insulator 20 in the present embodiment. Fig. 36 is a perspective view of the separate connecting part 25c. The insulator 20 has protrusions 27a, 27b on which columnar parts 26a, 26b are formed. The separate connecting part 25c has openings 252e, 252f, and as shown in Fig. 37, the columnar part 26b formed in the protrusion 27b of the insulator 20a fits into the opening 252e of the separate connecting part 25c, and the columnar part 26a formed in the protrusion 27a of the insulator 20b adjacent to the insulator 20a fits into the opening 252f of the separate connecting part 25c, thereby rotatably connecting the insulators 20a and 20b.

As a result, as shown in FIG. 38, the stator core connected body 200 is configured to be freely rotatable around the columnar parts 26a and 26b, as in FIG. 11. With this configuration, as shown in FIG. 12 or FIG. 34, the stator core adjacent to the stator core to be wound can be rotated to a position where it does not interfere with the flyer 52 and held by the core holding mechanism 51 of the winding device 50, and can be wound by the winding device 50. Then, as shown in FIG. 39, the connecting part of the wound stator core connected body 200 is placed in a position to be assembled to the stator core annular assembly 300, and connected to form an annular shape as shown in FIG. 40. At this time, the separate connecting part 25c of the insulator 20 may be configured to be located inside the outer diameter of the stator core 10, and with this configuration, the thickness of the molded resin can be ensured, as in the first embodiment.

In the above-described configuration, there is an opening in the separate connecting portion 25c and two columnar portions in the insulator 20, but the same effect can be obtained by providing a columnar portion in the separate connecting portion 25c and an opening in the insulator 20.

In addition, the separate connecting portion 25c is rotatably connected to both of the two columnar portions 26a, 26b, but it may also be configured so that only one of them is rotatably connected.

Also, as shown in Fig. 41, the openings 252e and 252f formed in the separate connecting portion 25c may have a third arc portion 252g and a fourth arc portion 252h. By configuring in this way, as shown in Figs. 42 and 43, by adjusting the length of the separate connecting portion for each model, the distance between adjacent stator cores during winding can be made common, and they can be manufactured without setup using common manufacturing equipment.

As described above, by connecting the insulator 20 with the separate connecting portion 25c, the separate connecting portion 25c fits within the core outer diameter in the state of the stator core ring assembly 300, so high-density winding is possible with the same assembly method as in the first and third embodiments. In addition, the fitting portion that rotatably connects the columnar portions 26a, 26b of the insulator 20 to the openings 252e, 252f of the separate connecting portion 25c can be positioned at any position relative to the insulator and the stator core, so that multiple types of stator cores can be wound without changing the manufacturing equipment, as in the first embodiment, and high-performance stators and motors can be obtained. This allows high-density winding in the stator and motor without increasing the number of parts and manufacturing processes.

A stator assembled in this manner may be used to manufacture a rotating electric motor 70 using the method described in embodiment 1 or embodiment 3.

Although the present application describes various exemplary embodiments and examples, the various features, aspects, and functions described in one or more embodiments are not limited to application to a particular embodiment, but may be applied to the embodiments alone or in various combinations.
Therefore, countless modifications not exemplified are assumed within the scope of the technology disclosed in the present specification, including, for example, modifying, adding, or omitting at least one component, and further, extracting at least one component and combining it with a component of another embodiment.

10: stator core, 11: teeth portion, 12: back yoke portion, 13: division surface, 20: insulator, 21: core fitting portion, 22: winding frame portion, 23: inner circumferential flange portion, 23a, 23b: inner circumferential flange fitting portion, 24: outer circumferential flange portion, 25a, 25b: connecting portion, 25b3: connection portion, 25b4: first fitting portion, 25b5: second fitting portion, 25c: separate connecting portion, 26a, 26b: columnar portion, 30: coil, 50: winding device, 51: core gripping mechanism , 52: flyer, 53: nozzle, 60: rotor, 70: motor, 80: frame, 100: stator core insulation assembly, 200: stator core connected body, 251: columnar portion, 252, 252e, 252f: opening, 252a: first arc portion, 252b: second arc portion, 252c: long hole portion, 252g: third arc portion, 252h: fourth arc portion, 253: step, 254, 255: protrusion, 300: stator core ring assembly, 400: resin

Claims (18)

The insulator is attached to a stator core and electrically insulates the coil from the stator core, and includes two arm-shaped connecting portions protruding from both sides in the circumferential direction of the stator core, a columnar portion formed on one of the connecting portions, a protrusion formed on the one connecting portion opposite the columnar portion, and a guide portion formed on the other connecting portion for movably guiding the columnar portion,
The columnar portion of one insulator is movably engaged within the guide portion of the other adjacent insulator, thereby making the distance between the adjacent insulators variable;
The guide portion is formed with a plurality of fitting portions into which the columnar portion can be fitted,
The guide portion has an elongated hole portion between adjacent ones of the plurality of fitting portions, and adjacent insulators are fixed at a predetermined angle by engaging the elongated hole portion of one insulator with the protrusion portion of the other insulator . 2. The insulator as described in claim 1, wherein when the columnar portion is engaged with the second engaging portion where the distance between the insulators is closest, the side surface of the protrusion portion on the first engaging portion side different from the second engaging portion contacts the end surface of the long hole portion on the first engaging portion side. The insulator is attached to a stator core and electrically insulates the coil from the stator core. The insulator comprises two arm-shaped connecting portions protruding from both sides in the circumferential direction of the stator core, a columnar portion formed on one connecting portion, and a guide portion formed on the other connecting portion for movably guiding the columnar portion.
The columnar portion of one insulator is movably engaged within the guide portion of the other adjacent insulator, thereby making the distance between the adjacent insulators variable;
The guide portion is formed with a plurality of fitting portions into which the columnar portion can be fitted,
The guide portion has an elongated hole portion between adjacent ones of the plurality of fitting portions,
an insulator in which each of the guide portions at both ends of the elongated hole portion has a protrusion that forms a portion whose width is smaller than the width of the elongated hole portion; 4. The insulator according to claim 1, characterized in that the guide portion has a plurality of fitting portions formed between two circumferentially extending members having a gap therebetween that allows the columnar portion to move, and a connection portion that connects the two members is formed in the long hole portion between the fitting portions at a location that does not hinder movement of the columnar portion. 5. The insulator according to claim 1 , wherein the columnar portion is rotatably fitted to a first fitting portion where the distance between the insulators is the greatest. 6. The insulator according to claim 1, wherein the columnar portion and the fitting portion are detachably attached to each other by a snap fit. The insulator is attached to a stator core and electrically insulates the coil from the stator core. The insulator comprises two arm-shaped connecting portions protruding from both sides in the circumferential direction of the stator core, a columnar portion formed on one connecting portion, and a guide portion formed on the other connecting portion for movably guiding the columnar portion.
The columnar portion of one insulator is movably engaged within the guide portion of the other adjacent insulator, thereby making the distance between the adjacent insulators variable;
the guide portion is a slot-hole-shaped portion having a plurality of fitting portions formed therein into which the columnar portion can be fitted,
An insulator characterized in that a notch is formed in the columnar portion, and a protrusion that fits into the notch is formed in the mating portion where the insulators are closest to each other. The insulator is attached to a stator core and electrically insulates the coil from the stator core. The insulator comprises two arm-shaped connecting portions protruding from both sides in the circumferential direction of the stator core, a columnar portion formed on one connecting portion, and a guide portion formed on the other connecting portion for movably guiding the columnar portion.
The columnar portion of one insulator is movably engaged within the guide portion of the other adjacent insulator, thereby making the distance between the adjacent insulators variable;
The guide portion has a plurality of fitting portions formed between two members extending in a circumferential direction having a gap allowing the columnar portion to move, and a connection portion connecting the two members is formed between the fitting portions at a location that does not impede the movement of the columnar portion,
The insulator is characterized in that the columnar portion is a rectangular prism having a polygonal cross section, and is rotatably fitted into a first fitting portion where the distance between the insulators is the greatest, and a groove portion is formed in the first fitting portion that engages with a corner of the rectangular prism and prevents the columnar portion from rotating. The insulator according to any one of claims 1 to 8, characterized in that it has flanges formed on the inner and outer circumferential sides of the insulator to regulate the coil, and a notch is formed on the circumferential side of the inner flange to fit with an adjacent insulator. A stator comprising: an insulator according to claim 1 ; a coil wound around the insulator; and a stator core attached to the insulator; the stator core is connected in an annular shape and molded with resin. 10. A stator comprising: an insulator according to claim 1; a coil wound around the insulator and attached to a stator core; the stator core is connected in an annular shape; and an outer periphery of the stator core is covered with a frame to apply a radial pressure. The insulator is attached to a stator core and electrically insulates the coil from the stator core. The insulator has two protrusions formed in the circumferential direction of the stator core and protruding radially outward, and a separate connecting portion that fits into a fitting portion formed on the two protrusions.
The separate connecting portion rotates about the fitting portion to vary the distance between adjacent insulators,
the fitting portion is a fitting portion between a columnar portion formed on the protrusion and an opening portion formed on the separate connecting portion, or a fitting portion between an opening portion formed on the protrusion and a columnar portion formed on the separate connecting portion,
A plurality of the openings and the columnar portions are formed,
The opening has an elongated hole between adjacent fitting portions,
A coil is wound around the insulator and attached to a stator core,
The stator cores are connected in an annular shape and molded with resin or the outer periphery of the stator core is covered with a frame and a radial pressure is applied thereto.
A stator, characterized in that the separate connecting portion is located inside the outer periphery of the stator core . The insulator is attached to a stator core and electrically insulates the coil from the stator core. The insulator comprises two arm-shaped connecting portions protruding from both sides in the circumferential direction of the stator core, a columnar portion formed on one connecting portion, and a guide portion formed on the other connecting portion for movably guiding the columnar portion.
The guide portion is formed with a plurality of fitting portions into which the columnar portion can be fitted,
The guide portion has an elongated hole portion between adjacent ones of the plurality of fitting portions,
The columnar portion of one insulator is movably engaged within the guide portion of the other adjacent insulator, thereby making the distance between the adjacent insulators variable;
A coil is wound around the insulator and attached to the stator core, and the stator core is connected in an annular shape and molded with resin or the outer periphery of the stator core is covered with a frame and a radial pressure is applied thereto,
A stator, wherein the connecting portion is located inside the outer periphery of the stator core. The insulator is attached to a stator core and electrically insulates the coil from the stator core. The insulator comprises two arm-shaped connecting portions protruding from both sides in the circumferential direction of the stator core, a columnar portion formed on one connecting portion, and a guide portion formed on the other connecting portion for movably guiding the columnar portion.
The guide portion is formed with a plurality of fitting portions into which the columnar portion can be fitted,
The guide portion has an elongated hole portion between adjacent ones of the plurality of fitting portions,
The columnar portion of one insulator is movably engaged within the guide portion of the other adjacent insulator, thereby making the distance between the adjacent insulators variable;
A coil is wound around the insulator and attached to the stator core, and the stator core is connected in an annular shape and molded with resin or the outer periphery of the stator core is covered with a frame and a radial pressure is applied thereto,
A stator characterized in that two of the insulators are assembled in the axial direction of the teeth portion of the stator core, and a guide portion is arranged on one of the two assembled insulators on the axially opposite side, corresponding to the columnar portion of the other insulator . The stator according to claim 14, characterized in that the two insulators are assembled and fitted together, and one of the insulators has two first wrap portions on the left and right in the circumferential direction of the core fitting portion, and the other insulator on the axially opposite side has two second wrap portions on the left and right in the circumferential direction of the core fitting portion, the first wrap portions and the second wrap portions are formed by steps, and the direction of the steps is the same on the left and right . A rotating electric machine comprising: the stator according to claim 10 ; and a rotor disposed radially opposite the stator. In a manufacturing method of a stator including an insulator attached to a stator core and electrically insulating the stator core from a coil, the insulator includes two protrusions formed in a circumferential direction of the stator core and protruding radially outward, and a separate connecting portion that fits into a fitting portion formed on the two protrusions,
one insulator and another adjacent insulator are rotatably engaged with each other at the separate connecting portion, and the distance between the adjacent insulators is variable;
the insulator or the separate connecting portion is formed with a plurality of fitting portions, the fitting portion is moved according to the size of the stator core, and the insulator is attached to a winding device in a state where the insulator is fitted into one of the plurality of fitting portions;
the fitting portion is a fitting portion between a columnar portion formed on the protrusion and an opening portion formed on the separate connecting portion, or a fitting portion between an opening portion formed on the protrusion and a columnar portion formed on the separate connecting portion,
The method for manufacturing a stator, wherein the opening has a slot between adjacent fitting portions. 18. A method for manufacturing a rotating electric machine, comprising the steps of: disposing a rotor radially opposite the manufactured stator;

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