JP2014011901A - Stator, motor, and method of manufacturing stator - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a stator, a motor, and a method of manufacturing the stator which can make a jumper wire portion an appropriate tension state in a drawn-around section provided in an insulation member covering a salient pole.SOLUTION: In an insulation member 8 of a stator 4, a drawn-around section 86 is provided at a position adjacent in a radial direction to a trunk 82 around which a coil wire 6 is wound. In the drawn-around section 86, a jumper wire portion 60 of the coil wire 6 is drawn around in a circumferential direction. On a wall surface on a side of the drawn-around section 86 of a second flange 85 (partition wall) partitioning the trunk 82 and the drawn-around section 86, a recess section 850 recessed toward a side on which the trunk 82 is positioned is formed. After passing the jumper wire portion 60 through the drawn-around section 86, a part 60a of the jumper wire portion 60 is bent toward the inside of the recess section 850. Consequently, the jumper wire portion 60 is in an appropriate tension state.

Description

  The present invention relates to a stator in which a coil wire is wound around a salient pole through an insulating member, a motor including the stator, and a method for manufacturing the stator.

  A stator used in a motor or the like has a structure in which a coil wire is wound around a salient pole via an insulating member, and the insulating member is positioned at a position adjacent to the trunk portion covering the salient pole in the radial direction. A routing portion in which the crossover portion of the coil wire is routed in the circumferential direction, and a partition wall that partitions the trunk portion and the routing portion are provided. Also, the wall surface on the side of the routing portion of the partition wall is provided with a convex portion protruding on the side opposite to the side where the body portion is located, and the length of the crossover portion located on the routing portion is optimized by the convex portion. Has been proposed (see Patent Document 1).

JP 2008-253133 A

  However, even when trying to optimize the length of the crossover portion located in the routing portion by the convex portion provided on the wall surface on the routing portion side of the partition wall, depending on the tension state of the coil wire when the coil wire is routed, etc. The length of the crossover portion may vary. In such a case, the crossover portion becomes slack. As a result, the crossover portion may come into contact with the case or the like, causing a short circuit.

  In view of the above problems, an object of the present invention is to provide a stator capable of bringing the crossover portion into an appropriate tension state in the routing portion provided on the insulating member that covers the salient pole, a motor including the stator, and the stator It is in providing the manufacturing method of.

  In order to solve the above-described problems, the present invention provides a stator core having a plurality of salient poles in the circumferential direction, an insulating member having a trunk portion covering the salient poles, and around the salient poles via the trunk portion. A coil wire wound around, wherein the insulating member has a routing portion in which a connecting wire portion of the coil wire is routed in the circumferential direction at a position adjacent to the body portion in the radial direction. A partition wall that partitions the body portion and the routing portion, and a recess that is recessed toward the side where the body portion is located is formed on the wall surface of the partition wall on the routing portion side. A part is bent toward the recess and is located in the recess.

  In the present invention, the insulating member is provided with a routing portion at a position adjacent to the body portion around which the coil wire is wound in the radial direction, and the connecting wire portion of the coil wire is routed in the circumferential direction at the routing portion. Is done. Here, the wall surface on the side of the routing part of the partition wall that partitions the body part and the routing part is formed with a recess that is recessed toward the side where the body part is located, and after passing the connecting wire part through the routing part, A part of the line portion is bent toward the recess. For this reason, since the crossover part is in an appropriate tension state, the crossover part does not move carelessly. Therefore, the crossover portion and the case or the like can be appropriately separated from each other, so that problems such as a short circuit are unlikely to occur.

  In this invention, it is preferable that the said recessed part is provided in the position which overlaps with the said trunk | drum in radial direction. According to such a configuration, since the thickness of the partition wall can be reduced, sink marks or the like hardly occur on the partition wall.

  In the present invention, the insulating member includes an opposing wall on a side opposite to the partition wall with respect to the routing portion, and the opposing wall penetrates the opposing wall in a radial direction at a position overlapping the concave portion in the radial direction. It is preferable that the notch to be formed is formed. According to this configuration, after passing the crossover portion through the routing portion, a part of the crossover portion can be bent into the recess through the jig from the notch of the opposing wall. Further, it is possible to perform processing such as confirming the state in the recess through the notch, or bending a part of the crossover portion into the recess again with a jig based on the confirmation result.

  In the present invention, it is possible to adopt a configuration in which the routing portion is positioned radially outward with respect to the trunk portion.

  Further, in the present invention, a motor including the stator according to the present invention includes a rotor that is radially opposed to an end portion of the salient pole, and a motor case that accommodates the rotor and the stator inside. Yes.

  The present invention also provides a stator core having a plurality of salient poles in the circumferential direction, an insulating member having a trunk portion covering the salient poles, and a coil wound around the salient poles via the trunk portion. A wire, and the insulating member includes a routing portion in which a crossover portion of the coil wire is routed in a circumferential direction at a position adjacent to the body portion in the radial direction; A partition wall that partitions the body portion and the routing portion, and a wall surface on the routing portion side of the partition wall is provided with a recess that is recessed toward the side where the body portion is located, and the coil portion is provided with the coil After winding the wire, the coil wire is routed toward the trunk portion that covers the salient poles spaced apart in the circumferential direction, and the winding step of winding the coil wire around the trunk portion; A part of the crossover line located in the routing portion is directed into the recess by a jig. A connecting wire processing step of a state located in the inner recess bend Te, characterized in that a.

  In the present invention, the insulating member is provided with a routing portion at a position adjacent to the body portion around which the coil wire is wound in the radial direction, and the connecting wire portion of the coil wire is routed in the circumferential direction at the routing portion. Is done. Here, the wall surface on the side of the routing part of the partition wall that partitions the body part and the routing part is formed with a recess that is recessed toward the side where the body part is located, and after passing the connecting wire part through the routing part, A part of the line portion is bent toward the inside of the recess by a jig. For this reason, since the crossover part is in an appropriate tension state, the crossover part does not move carelessly. Therefore, since the crossover portion and the case can be appropriately separated from each other, occurrence of a short circuit can be suppressed.

  In the present invention, the insulating member is provided with a routing portion at a position adjacent to the body portion around which the coil wire is wound in the radial direction, and the connecting wire portion of the coil wire is routed in the circumferential direction at the routing portion. Is done. Here, the wall surface on the side of the routing part of the partition wall that partitions the body part and the routing part is formed with a recess that is recessed toward the side where the body part is located, and after passing the connecting wire part through the routing part, A part of the line portion is bent toward the recess. For this reason, since the crossover part is in an appropriate tension state, the crossover part does not move carelessly. Therefore, since the crossover portion and the case can be appropriately separated from each other, occurrence of a short circuit can be suppressed.

It is a longitudinal cross-sectional view of the motor to which this invention is applied. It is explanatory drawing of the stator of the motor to which this invention is applied. It is a bottom view of the stator of the motor to which the present invention is applied. It is explanatory drawing which shows the fixing structure of the wiring board in the stator of the motor to which this invention is applied. It is explanatory drawing of the insulating member used for the stator of the motor to which this invention is applied. It is explanatory drawing which shows typically the method of winding a coil wire in the manufacturing process of the stator and motor to which this invention is applied.

  Hereinafter, embodiments for carrying out the present invention will be described with reference to the drawings. In the following description, in the motor axis direction L, the side on which the motor shaft protrudes greatly will be described as the output side L1, and the opposite side will be described as the counter-output side L2. Further, the circumferential direction is indicated by an arrow R, and one side thereof will be described as R1, and the other side will be described as R2. In the following description, the case where the present invention is applied to an inner rotor type motor will be mainly described.

(General configuration of motor)
FIG. 1 is a longitudinal sectional view of a motor to which the present invention is applied. A motor 1 shown in FIG. 1 is a three-phase inner rotor type DC brushless motor, and has a bottomed cylindrical motor case 2 whose output side L1 in the motor axial direction L is an open end, and an inner side of the motor case 2 A cylindrical stator 4 fixed by shrink fitting or the like, and a rotor 7 provided inside the stator 4. The motor case 2 includes a cylindrical case member 21 and an end plate 22 fixed to the end portion of the case member 21 on the opposite output side L2 by a method such as welding. The rotor 7 includes a rotating shaft 70 extending in the motor axial direction L, and a rotor magnet 75 (permanent magnet) fixed to the outer peripheral surface of the rotating shaft 70. The rotary shaft 70 is rotatably supported by a first bearing 76 on the output side L1 and a second bearing 77 on the non-output side L2. The first bearing 76 is held by a flange-shaped bearing holder 20 held by the motor case 2, and the second bearing 77 is held by a cylindrical portion 221 formed on the end plate 22. In this embodiment, the bearing holder 20 is used as a lid member that closes the open end of the motor case 2.

  The stator 4 includes a stator core 5 in which a plurality of split cores 50 are annularly arranged in the circumferential direction R, insulating members 8 and 9 that cover both ends of the plurality of split cores 50 in the motor axial direction L, The coil wire 6 of three phases (u phase, v phase, and w phase) wound around the salient pole 51 of the stator core 5 through nine groove-shaped coil winding portions 80 and 90 is provided. In addition, when the stator 4 supplies power to the coil wire 6, the wiring substrate 3 is used that overlaps the insulating member 8 that overlaps the opposite end portion of the stator core 5 on the opposite output side L <b> 2. In this embodiment, the coil wire 6 has a structure in which the surface of the copper wire is covered with an insulating layer.

  In this embodiment, since the stator core 5 is composed of a plurality of divided cores 50, the insulating members 8 and 9 are attached to each of the plurality of divided cores 50. Here, the insulating members 8 and 9 attached to the split cores 50 adjacent to each other in the circumferential direction R may be divided into individual members or attached to the split cores 50 adjacent to each other in the circumferential direction. Alternatively, the insulating members 8 and 9 may be connected by thin flexible portions.

(Configuration of stator 4)
FIG. 2 is an explanatory view of a stator of a motor to which the present invention is applied. FIGS. 2 (a), (b), (c), and (d) are perspective views of the stator as viewed from the non-output side L2. FIG. 3 is an exploded perspective view disassembled into a stator core side and a wiring substrate, an exploded perspective view in a state where one of the divided cores is removed from the stator core side, and an exploded perspective view of an insulating member arranged in one divided core. FIG. 3 is a bottom view of a stator of a motor to which the present invention is applied, and FIGS. 3A and 3B are bottom views of the bottom surface of the stator and the stator disassembled into a stator core side and a wiring board. . FIG. 4 is an explanatory view showing the fixing structure of the wiring board in the stator of the motor to which the present invention is applied. FIGS. It is a bottom view, a bottom view in a state where the wiring board is removed from the stator core side, and an explanatory view of an insulating member etc. for holding the wiring board.

  As shown in FIG. 2, the split core 50 is formed of a laminated core in which a plurality of magnetic plates are stacked in the motor axial direction L. The outer peripheral side arc part 53 extended in the both sides of the direction and the inner peripheral side arc part 52 extended in the both sides of the circumferential direction from the inner peripheral side edge part are provided. As a result of the plurality of divided cores 50 being arranged in the circumferential direction, the side end portions of the outer circumferential arc portion 53 adjacent in the circumferential direction are connected to each other, and the outer circumferential arc portion 53 connects the annular core portion 530 of the stator 4. Configure. For this reason, the stator core 5 has a structure in which a plurality of salient poles 51 projecting radially inward from the annular core portion 530 are arranged at equal angular intervals. 52) and the rotor magnet 75 shown in FIG. 1 are opposed to each other through a gap.

  In this embodiment, since the stator core 5 is formed with three poles per phase, the stator core 5 is formed by a total of nine divided cores 50. For this reason, the split cores 50 are arranged at intervals of 40 °.

(Configuration of wiring board 3)
As shown in FIGS. 2, 3, and 4, in the motor 1 of this embodiment, the wiring board 3 includes a first arc-shaped substrate 31 that extends with an arc angle of less than 180 °, and a first arc-shaped substrate 31. On the other hand, it comprises a second arcuate substrate 32 extending at an arc angle of less than 180 ° at a position adjacent in the circumferential direction. The first arc-shaped substrate 31 and the second arc-shaped substrate 32 are both single-sided substrates. Further, each of the angle ranges θ of the first arc-shaped substrate 31 and the second arc-shaped substrate 32 is about 100 °, and the following condition (360 / (n × m)) × (m−1) < θ <(360 / (n × m)) × m
n = number of phases m = the number of poles per phase is satisfied. That is, in this embodiment, since n = 3 and m = 3, the angle ranges θ of the first arc-shaped substrate 31 and the second arc-shaped substrate 32 are as follows: 80 ° <θ <120 °
Meet.

  As shown in FIGS. 3 and 4, a common pattern 310 connected to the coil wire 6 of each phase is formed on the first arc-shaped substrate 31, and the second arc-shaped substrate 32 is connected to the coil wire 6. Thus, power line connection patterns 320u, 320v, and 320w for applying an independent potential for each phase are formed. In the present embodiment, the three power line connection patterns 320u, 320v, and 320w are drawn from positions close to each other.

  The first arc-shaped substrate 31 and the second arc-shaped substrate 32 have the same outer shape, and the first arc-shaped substrate 31 and the second arc-shaped substrate 32 are arranged in line symmetry. More specifically, the first notch 311a, the second notch 311b, and the third notch are formed on the inner peripheral edge 311 of the first arc-shaped substrate 31 in the direction around the other side R2 of the circumferential direction R. 311c are formed at equiangular intervals in this order, and the first cutout 311a, the second cutout 311b, and the third cutout 311c are all open in the radial direction. In the present embodiment, the first cutout 311a, the second cutout 311b, and the third cutout 311c are formed at 40 ° intervals.

  Here, the third notch 311c is formed at an edge in the circumferential direction, whereas the first notch 311a and the second notch 311b are formed at intermediate positions in the circumferential direction. The circumferential dimension of each of the notch 311a and the second notch 311b is larger than the circumferential dimension of the third notch 311c. In this embodiment, the circumferential dimension of each of the first notch 311a and the second notch 311b is approximately twice the circumferential dimension of the third notch 311c. The first cutout 311a, the second cutout 311b, and the third cutout 311c are formed as engaging portions into which convex portions 841 of the insulating member 8 described later fit.

  A first cutout 312a, a second cutout 312b, and a third cutout 312c are equiangular in this order on the outer peripheral edge 312 of the first arc-shaped substrate 31 in the direction around the other side R2 of the circumferential direction R. The first cutout 312a, the second cutout 312b, and the third cutout 312c are all open at the outer side in the radial direction. In the present embodiment, the first cutout 312a, the second cutout 312b, and the third cutout 312c are formed at 40 ° intervals.

  In addition, the first notch 321a, the second notch 321b, and the third notch 321c are arranged in this order on the inner peripheral edge 321 of the second arc-shaped substrate 32 in the direction around one side R1 in the circumferential direction R. The first cutouts 321a, the second cutouts 321b, and the third cutouts 321c are all open at the radially inner side. In this embodiment, the first cutout 321a, the second cutout 321b, and the third cutout 321c are formed at 40 ° intervals. The first cutout 321a, the second cutout 321b, and the third cutout 321c are formed as engaging portions into which convex portions 841 of the insulating member 8 described later fit.

  Here, the third cutout 321c is formed at the circumferential edge, whereas the first cutout 321a and the second cutout 321b are formed at intermediate positions in the circumferential direction. The circumferential dimension of each of the notch 321a and the second notch 321b is larger than the circumferential dimension of the third notch 321c. In this embodiment, the circumferential dimension of each of the first notch 321a and the second notch 321b is approximately twice the circumferential dimension of the third notch 321c.

  A first cutout 322a, a second cutout 322b, and a third cutout 322c are equiangular in this order on the outer peripheral edge 322 of the second arc-shaped substrate 32 in the direction around one side R1 in the circumferential direction R. The first cutout 322a, the second cutout 322b, and the third cutout 322c are all open at the outer side in the radial direction. In this embodiment, the first cutout 322a, the second cutout 322b, and the third cutout 322c are formed at 40 ° intervals.

  In this embodiment, as shown in FIG. 3A, the first notch 312a, the second notch 312b, and the third notch 312c formed on the outer peripheral edge 312 of the first arc-shaped substrate 31 are respectively The coil wire 6 is formed as a coil wire support portion through which the winding start of the coil wire 6 (coil wires 6u1, 6v1, 6w1) passes, and the coil wires 6u1, 6v1, 6w1 of each phase are respectively a first notch 312a and a second notch. It is connected to the common pattern 310 while being positioned in the circumferential direction by the 312b and the third notch 312c.

  On the other hand, the first cutout 322a, the second cutout 322b, and the third cutout 322c formed on the outer peripheral edge 322 of the second arc-shaped substrate 32 are respectively the end of winding of the coil wire 6 (coil wire 6u2 6v2, 6w2) through which the coil wires 6u2, 6v2, 6w2 of each phase are respectively surrounded by a first notch 322a, a second notch 322b, and a third notch 322c. The power line connection patterns 320u, 320v, and 320w are connected in a state of being positioned in the direction. Further, power lines 60u, 60v, 60w are connected to the power line connection patterns 320u, 320v, 320w. In this embodiment, three power lines 60u, 60v, 60w are drawn from between the coil wires 6u2, 6v2.

  The first cutouts 312a and 321a, the second cutouts 312b and 322b, and the third cutouts 312c and 322c formed on the inner peripheral edges 311 and 321 of the first arcuate substrate 31 and the second arcuate substrate 32 are as follows. As described below, each is used as an engaging portion into which the convex portion 841 of the insulating member 8 is fitted, and is used for positioning the first arc-shaped substrate 31 and the second arc-shaped substrate 32.

(Configuration of insulating member 9)
FIG. 5 is an explanatory view of an insulating member used for a stator of a motor to which the present invention is applied. FIGS. 5 (a), (b), (c), (d), and (e) are bottom views of the insulating member. Figure, side view of insulating member viewed from one side R1 in the circumferential direction R, front view of insulating member viewed from the outside in the radial direction, perspective view of the insulating member viewed from one side R1 in the circumferential direction R, and circumferential direction of the insulating member It is the perspective view seen from the other side R2 of R. The insulating member 8 on the counter-output side L2 and the insulating member 9 on the output side L1 shown in FIG. 1 have the same configuration. In this embodiment, the insulating member 8 on the counter-output side L2 uses the insulating member 8 on the counter-output side L2. Fixing and connection between the end of the coil wire 6 and the wiring board 3 are performed. Therefore, the configuration and the like will be described focusing on the insulating member 8 on the non-output side L2. In this embodiment, the insulating member 8 is a resin molded product.

  As shown in FIG. 5, the insulating member 8 covers the outer end surface of the salient pole 51 in the motor axial direction L (the plate-shaped body portion 82 that covers the end surface and the side surface of the counter-output side L <b> 2) and the inner circumferential arc portion 52. A plate-shaped inner peripheral side plate-like portion 81 and an outer peripheral side plate-like portion 83 covering the outer peripheral side arc portion 53 (annular core portion 530) are provided. A plurality of grooves 820 that define the position of the coil wire 6 when wound are formed.

  The insulating member 8 has a first flange 84 (wall) connected to the inner peripheral side end (one side end) of the body 82 on the opposite output side L2 in the motor axial direction L with respect to the inner peripheral side plate-shaped portion 81. Part / inner peripheral side flange part), while being connected to the outer peripheral side end part (the other side end part) of the body part 82 on the opposite output side L2 in the motor axial direction L with respect to the outer peripheral side plate-like part 83. A second flange 85 (partition wall / outer peripheral flange) is provided. For this reason, the 1st collar part 84 is facing the 2nd collar part 85 (partition wall) on both sides of the trunk | drum 82. FIG. A coil winding portion 80 is formed by the body portion 82, the first flange portion 84, and the second flange portion 85 configured as described above. Further, on the side (outer peripheral side) opposite to the body portion 82 with respect to the second flange portion 85, a routing portion in which the crossover portion 60 (see FIG. 3A) of the coil wire 6 is routed in the circumferential direction. 86 is formed, and the second flange portion 85 is configured as a partition wall that partitions the body portion 82 (coil winding portion 80) and the routing portion 86. The insulating member 8 includes an opposing wall 87 on the side opposite to the second flange portion 85 (partition wall) with respect to the routing portion 86. Here, the second flange portion 85 is formed with a notch 851 through which the coil wire 6 is passed from the routing portion 86 to the body portion 82 (coil winding portion 80) side on the other side R2 in the circumferential direction R. On one side R1 of R, a notch 852 through which the coil wire 6 is passed from the side of the body portion 82 (coil winding portion 80) to the routing portion 86 is formed. In this embodiment, the cutout 851 is cut to a deeper position toward the output side L1 in the motor axis L direction as the surface of the body 82 opens, and the cutout 852 is output in the motor axis L direction. It is cut out to a shallow position toward the side L1.

  In the insulating member 8 configured as described above, the opposite end surface L2 of the first flange portion 84 in the motor axis L direction on the opposite end side L2 in the motor axis L direction on both sides in the circumferential direction of the first flange portion 84. A cylindrical convex portion 841 projecting toward is formed. The convex portions 841 are formed on both sides of the body portion 82 in the circumferential direction R, and are not formed at positions that overlap the body portion 82 in the radial direction. In this embodiment, the outer diameter (diameter) of the convex portion 841 is set such that the first cutouts 312a and 321a formed on the inner peripheral edges 311 and 321 of the first arcuate substrate 31 and the second arcuate substrate 32 are the second cutouts. It is below the dimension (depth dimension) of the circumferential direction of 312b, 322b and the 3rd notch 312c, 322c. The first flange 84 has a radially curved inner circumferential surface located inside in the radial direction, whereas the outer surface facing the second flange 85 is linear in the circumferential direction. It is a flat surface that extends to. Therefore, the first flange portion 84 is a thick portion 849 whose both radial sides are thicker in the radial direction than the inner side in the circumferential direction (see FIG. 5A). A convex portion 841 is formed on the end face of the non-output side L2. For this reason, the convex part 841 can be formed in a cylindrical shape having a large outer diameter (diameter) and a high strength.

  Further, in the insulating member 8, the outer peripheral surface (wall surface on the side of the routing portion 86) of the second flange portion 85 is directed to the substantially central portion in the circumferential direction R and toward the radially inner side (the side where the body portion 82 is located). A concave portion 850 is formed, and the concave portion 850 is formed at a position overlapping the body portion 82 in the radial direction. Here, a notch 851 is formed on the other side R2 of the recess 850 in the circumferential direction R, and a notch 856 is formed on the one side R1 of the recess 850 in the circumferential direction R. In this embodiment, the depth dimension (diameter dimension) of the recess 850 is larger than the thickness of the coil wire 6 and power lines 60u, 60v, 60w described later.

  Further, the opposing wall 87 is formed with a notch 870 that penetrates the opposing wall 87 in the radial direction at a position overlapping the concave portion 850 on the radially outer side. In this embodiment, the circumferential dimension of the notch 870 is smaller than the circumferential dimension of the recess 850. In the opposing wall 87, a notch 877 through which the coil wire 6 is passed between the outside and the routing portion 86 is formed at the position adjacent to the notch 870 on the other side in the circumferential direction R. ing.

(Manufacturing method of stator 4 and motor 1 and detailed configuration)
FIG. 6 is an explanatory view schematically showing a method of winding the coil wire 6 in the manufacturing process of the stator 4 and the motor 1 to which the present invention is applied. FIGS. 6 (a) and 6 (b) are coil wires. FIG. 6 is an explanatory view showing a planar state when winding 6 and an explanatory view showing a state where the coil wire 6 is wound as viewed from the outside in the radial direction.

  Hereinafter, a detailed configuration will be described while explaining a method of manufacturing the stator 4 and the motor 1 to which the present invention is applied.

  In order to manufacture the stator 4 and the motor 1 of this embodiment, in the winding process shown in FIGS. 6A and 6B, the insulating members 8 and 9 are attached to each of the plurality of divided cores 50, and then the plurality of divisions are performed. The cores 50 are arranged linearly. Next, coil wire 6 (u-phase coil wire 6u) is wound around divided core 50 corresponding to u phase and insulating members 8 and 9 among a plurality of divided cores 50, and divided core 50 corresponding to v-phase and The coil wire 6 (v-phase coil wire 6v) is wound around the insulating members 8 and 9, and the coil wire 6 (w-phase coil wire 6w) is wound around the split core 50 and the insulating members 8 and 9 corresponding to the w-phase. To do.

  At that time, the coil wire 6 is routed to the split core 50 and the insulating members 8 and 9 of the corresponding phase so as to straddle the split core 50 and the insulating members 8 and 9 of the other phases. In addition, the coil wire 6 straddling the other-phase split core 50 and the insulating members 8 and 9 passes the routing portion 86 of the insulating member 8 as a crossover portion 60 as shown by a solid line in FIG.

  Next, the divided cores 50 are arranged in a circle. At that time, slack occurs in the crossover portion 60, and when the slack portion comes into contact with the motor case 2 when the stator 4 is accommodated in the motor case 2 shown in FIG. 1, the withstand voltage decreases. In particular, when the stator 4 is fixed to the motor case 2 by shrink fitting, the heat may damage the insulating layer of the coil wire 6 and cause a short circuit.

  Therefore, in this embodiment, in the crossover processing step, as shown in FIG. 5A, the jig S is inserted from the notch 870 formed in the facing wall 87, and the crossover portion 60 is formed in the second flange portion 85. Into the recessed portion 850. At this time, the portion corresponding to the edge of the recessed portion 850 in the second flange portion 85 surely bends the connecting wire portion 60, so that the portion 60 a of the connecting wire portion 60 surely enters the recessed portion 850. Therefore, since the connecting wire portion 60 is in an appropriate tension state, when the stator 4 is accommodated in the motor case 2, the connecting wire portion 60 and the motor case 2 can be separated from each other. Here, the circumferential width dimension of the recess 850 is larger than the circumferential width dimension of the notch 870, and the circumferential opening width of the notch 870 is narrower than the circumferential opening width of the recess 850. Therefore, as shown in FIG. 5A, when the connecting wire portion 60 is pressed into the recess 850 by the jig S, the connecting wire portion 60 located at the center portion in the circumferential direction of the recess 850 is placed in the recess 850. However, on both sides of the circumferential method, the crossover portion 60 is gently curved and pulled out, so the crossover portion 60 is not easily damaged. That is, when the crossover portion 60 is pushed into the entire circumferential direction of the concave portion 870, the crossover portion 60 may be strongly hit against the corner portion located on the radially outer side of the concave portion 870, but may be damaged. The occurrence of such a situation can be avoided.

  Next, the wiring substrate 3 (the first arc-shaped substrate 31 and the second arc-shaped substrate 32) is overlaid on the opposite side of the insulating member 8 in the motor axial direction L. At that time, as shown in FIGS. 2 (a), 3 (a), and 4 (a), the convex portion 841 formed on the first flange portion 84 of the insulating member 8 has the first arc-shaped substrate 31 and The first notches 311a and 321a, the second notches 311b and 321b, and the third notches 311c and 321c formed in the inner peripheral edges 311 and 321 of the second arcuate substrate 32 are fitted. At this time, one convex portion 841 fits in the third cutouts 311c and 321c, whereas the first cutouts 311a and 321a and the second cutouts 311b and 321b are adjacent in the circumferential direction R. Two convex portions 841 formed on each of the two second flange portions 84 are fitted. Here, since the first cutouts 311a and 321a, the second cutouts 311b and 321b, and the third cutouts 311c and 321c are open radially inward, the first arcuate substrate 31 and the second arcuate substrate 32 is shifted in the radial direction, and the first arc-shaped substrate 31 and the second arc-shaped substrate 32 are arranged at appropriate positions. In this embodiment, the outer diameter (diameter) of the convex portion 841 is set such that the first cutouts 312a and 321a formed on the inner peripheral edges 311 and 321 of the first arcuate substrate 31 and the second arcuate substrate 32 are the second cutouts. It is below the dimension (depth dimension) of the circumferential direction of 312b, 322b and the 3rd notch 312c, 322c. Therefore, the convex portion 841 is completely inside the first cutouts 312a and 321a, the second cutouts 312b and 322b, and the third cutouts 312c and 322c of the first arcuate substrate 31 and the second arcuate substrate 32. It will be in the state where it entered.

  In this way, after the first arc-shaped substrate 31 and the second arc-shaped substrate 32 are arranged at appropriate positions, the tip end portion of the convex portion 841 is heated and melted as indicated by a dotted line in FIG. After that, it is crushed and expanded in diameter to form a retaining portion 841a for the first arc-shaped substrate 31 and the second arc-shaped substrate 32. Note that an adhesive is applied to the portions of the convex portion 841 that protrude from the first arc-shaped substrate 31 and the second arc-shaped substrate 32 so as to straddle the first arc-shaped substrate 31 and the second arc-shaped substrate 32. Then, it may be cured and the retaining portion may be constituted by an adhesive. Further, after the tip portion of the convex portion 841 is heated and melted and then crushed to form the retaining portion 841a, the retaining portion 841a and the first arc-shaped substrate 31 and the second arc-shaped substrate 32 are straddled. After applying the adhesive, it may be cured.

  Next, as described with reference to FIG. 3A, in the first arc-shaped substrate 31, the coil wires 6 u 1, 6 v 1, 6 w 1 of each phase are respectively provided with the first notch 312 a, the second notch 312 b, And it connects with the pattern 310 for common with solder | solder in the state positioned in the circumferential direction by the 3rd notch 312c. In the second arcuate substrate 32, the power is applied in a state where the coil wires 6u2, 6v2, 6w2 of each phase are positioned in the circumferential direction by the first notch 322a, the second notch 322b, and the third notch 322c, respectively. The line connection patterns 320u, 320v, and 320w are connected by solder. In the second arc-shaped substrate 32, the power lines 60u, 60v, and 60w are connected to the power line connection patterns 320u, 320v, and 320w by soldering.

  Thereafter, the stator 4 is accommodated in the motor case 2. In this embodiment, a part 60a of the crossover portion 60 is pushed into the recess 850 of the second flange 85 before the wiring board 3 is stacked on the insulating member 8, but after the wiring board 3 is fixed to the insulating member 8. The part 60 a of the crossover part 60 may be pushed into the recess 850 of the second flange 85.

(Main effects of this form)
As described above, in the stator 4 and the motor 1 of the present embodiment, the insulating member 8 is provided with the routing portion 86 at a position adjacent to the body portion 82 around which the coil wire 6 is wound in the radial direction. In the routing portion 86, the crossover portion 60 of the coil wire 6 is routed in the circumferential direction. Here, a concave portion 850 that is recessed toward the side where the body portion 82 is located is formed on the wall surface on the side of the routing portion 86 of the second flange portion 85 (partition wall) that partitions the body portion 82 and the routing portion 86. After passing the crossover portion 60 through the routing portion 86, a part 60 a of the crossover portion 60 is bent toward the recess 850. For this reason, since the crossover part 60 is in an appropriate tension state, the crossover part 60 does not move carelessly. Therefore, the crossover portion 60 and the motor case 2 and the like can be appropriately separated from each other, so that problems such as a short circuit hardly occur.

  In addition, the insulating member 8 includes an opposing wall 87 on the opposite side to the second flange portion 85 with respect to the routing portion 86, and a notch 870 is formed in the opposing wall 87 at a position overlapping the concave portion 850 in the radial direction. ing. For this reason, after passing the crossover portion 60 through the routing portion 86, a part 60 a of the crossover portion 60 can be bent into the recess 850 from the notch 870 of the opposing wall 87 through the jig S. Further, even after the wiring substrate 3 (the first arc-shaped substrate 31 and the second arc-shaped substrate 32) is attached, the state in the recess 850 is confirmed through the notch 870, and the jig is determined based on the confirmation result. In S, it is possible to perform a process such as bending a part of the crossover portion 60 into the recess 840 again.

  Further, the concave portion 850 is provided at a position overlapping the body portion 82 in the radial direction. For this reason, since the thickness of the partition wall 85 can be reduced, sink marks or the like hardly occur in the second flange portion 85 (partition wall). Therefore, since unevenness due to sink marks is unlikely to occur on the surface of the second flange portion 85 (partition wall) on the body portion 82 side, it is possible to avoid a situation in which the winding amount is reduced due to the unevenness.

  In addition, the wiring board 3 (the first arc-shaped substrate 31 and the second arc-shaped substrate 32) is arranged on the insulating member 8 so as to overlap with each other, and a convex portion 841 formed on the first flange portion 84 of the insulating member 8 is formed. , Engaging portions (first cutouts 312a and 321a, second cutouts 312b and 321b, and third cutout 312c) formed on the inner peripheral edges 311 and 321 of the first arcuate substrate 31 and the second arcuate substrate 32. , 321c). Therefore, the first arc-shaped substrate 31 and the second arc-shaped substrate 32 can be easily positioned. Even when a force for displacing the wiring board 3 is applied from the coil wire 6 or the like, the wiring board 3 is positioned at a predetermined position on the insulating member 8. Therefore, it does not take much time to assemble the stator 4 and the motor 1.

  Further, when a force directed radially inward is applied to the convex portion 841, stress tends to concentrate on the root portion, but in this embodiment, the convex portion 841 has a cylindrical shape and the root portion has a cylindrical shape. For this reason, compared with the case where the convex part 841 is a quadrangular prism, since force is disperse | distributed, the convex part 841 is hard to bend. Further, the convex portion 841 is formed on the end face on the counter-output side L2 of the thick portion 849 having a larger radial thickness than a portion adjacent in the circumferential direction in the first flange portion 84 (wall portion). For this reason, the convex part 841 can be formed in a cylindrical shape with a large outer diameter (diameter). Therefore, the convex portion 841 is not easily broken.

  In addition, since the first cutouts 312a and 321a, the second cutouts 312b and 321b, and the third cutouts 312c and 321c are open radially inward, the first arcuate substrate 31 and the second arcuate substrate 32 are provided. The first arc-shaped substrate 31 and the second arc-shaped substrate 32 can be arranged at appropriate positions by shifting the position in the radial direction.

  Further, after the first arc-shaped substrate 31 and the second arc-shaped substrate 32 are arranged at appropriate positions, the tip end portion of the convex portion 841 is heated and melted and then crushed to constitute a retaining portion 841a. Therefore, the first arc-shaped substrate 31 and the second arc-shaped substrate 32 can be prevented from coming off with a simple configuration.

  In this embodiment, as the wiring substrate 3, arc-shaped substrates (the first arc-shaped substrate 31 and the second arc-shaped substrate 32) extending with an arc angle of less than 180 ° are used, and the arc shape having such a configuration is used. If it is a board | substrate, if the extraction position from a large sized board | substrate is devised, the number of extraction from a large sized board | substrate can be increased compared with an annular | circular shaped board | substrate. Therefore, since the cost of the wiring board 3 can be reduced, the cost of the stator 4 and the motor 1 can be reduced.

In particular, in the motor 1 of this embodiment, each of the angle ranges θ of the first arc-shaped substrate 31 and the second arc-shaped substrate 32 is about 100 °, and the following condition (360 / (n × m)) × (M−1) <θ <(360 / (n × m)) × m
n = number of phases m = the number of poles per phase is satisfied. That is, in this embodiment, since n = 3 and m = 3, the angle ranges θ of the first arc-shaped substrate 31 and the second arc-shaped substrate 32 are as follows: 80 ° <θ <120 °
Meet. According to such a configuration, the first arc-shaped substrate 31 and the second arc-shaped substrate 31 can be reduced to the necessary minimum size, the number of large substrates can be increased, and the coil wires 6 of each phase can be easily formed. It can be connected to the first arc-shaped substrate 31 and the second arc-shaped substrate 32. That is, in order to connect the coil wire 6 of each phase to the first arc-shaped substrate 31 and the second arc-shaped substrate 32, at least an arc angle equal to or larger than an angle range corresponding to (the number of poles per phase m−1). The first arc-shaped substrate 31 and the second arc-shaped substrate 32 are required, but the first arc-shaped substrate 31 and the second arc-shaped substrate 32 having an arc angle in an angular range corresponding to the number of poles m per phase are required. If there is, it is sufficient to connect the coil wire 6 of each phase to the first arc-shaped substrate 31 and the second arc-shaped substrate 32.

  If a plurality of arc-shaped substrates (the first arc-shaped substrate 31 and the second arc-shaped substrate 32) are used as the wiring substrate 3, the surface on which the pattern is formed can be changed for each substrate. Therefore, since single-sided substrates can be used as the arc-shaped substrates (the first arc-shaped substrate 31 and the second arc-shaped substrate 32), the cost can be further reduced and the single-sided substrate is used as the arc-shaped substrate. Even in this case, there is no problem in connecting the coil wire 6 and the like.

  The first arc-shaped substrate 31 is formed with a common pattern 310 connected to the coil wire 6 of each phase, and the second arc-shaped substrate 32 has an independent potential for each phase with respect to the coil wire 6. Power line connection patterns 320u, 320v, and 320w to be applied are formed. That is, the first arc-shaped substrate 31 and the second arc-shaped substrate 32 are arranged at positions corresponding to the winding start portion and the winding end portion of the coil wire 6. For this reason, the dimension of the circumferential direction R of the 1st circular arc-shaped board | substrate 31 and the 2nd circular arc-shaped board | substrate 32 can be shortened. Therefore, since the number of mold substrates can be increased, the cost of the wiring board 3 can be reduced. Moreover, since the first arc-shaped substrate 31 and the second arc-shaped substrate 32 have the same outer shape, they can be efficiently removed from the large-sized substrate.

  Further, the first arc-shaped substrate 31 and the second arc-shaped substrate 32 are provided with first cutouts 312a and 322a, second cutouts 312b and 322b, and third cutouts 312c and 322c through which the coil wire 6 passes. Although formed as a support, it is line symmetric. Therefore, when the first arc-shaped substrate 31 and the second arc-shaped substrate 32 are arranged, the first notches 312a and 322a, the second notches 312b and 322b, and the third notches 312c and 322c (coil wire support portions) ) And the coil wire 6, it can be determined whether or not the first arc-shaped substrate 31 and the second arc-shaped substrate 32 are arranged at appropriate positions. Therefore, even if the first arc-shaped substrate 31 and the second arc-shaped substrate 32 have the same shape or similar shapes, the first arc-shaped substrate 31 and the second arc-shaped substrate 32 are prevented from being exchanged. be able to.

(Other embodiments)
In the above embodiment, the first cutouts 311a and 321a, the second cutouts 311b and 321b, and the third cutouts 311c and 321c are formed as the engaging portions into which the convex portions 841 are fitted. A through hole may be formed as a joint.

  In the above embodiment, the first cutouts 312a and 322a, the second cutouts 312b and 322b, and the third cutouts 312c and 322c are formed as the coil wire support portions that support the coil wire 6. You may form a through-hole as a coil wire support part which supports this.

  In the above embodiment, the common pattern 310 is formed on one surface of the first arc-shaped substrate 31, and the power line connection patterns 320u, 320v, and 320w are formed on one surface of the second arc-shaped substrate 32. As the first arc-shaped substrate 31 and the second arc-shaped substrate 32, common arc-shaped substrates in which the common pattern 310 is formed on one surface and the power line connection patterns 320u, 320v, and 320w are formed on the other surface are used. It may be used. According to such a configuration, the two shared arc-shaped substrates are respectively turned upside down, and the arc-shaped substrate with one surface facing the counter-output side L2 out of the two shared arc-shaped substrates is first. An arc-shaped substrate that is used as the arc-shaped substrate 31 and whose other surface faces the opposite output side L <b> 2 may be used as the second arc-shaped substrate 32. According to such a configuration, it is not necessary to prepare the first arc-shaped substrate 31 and the second arc-shaped substrate 32 as substrates having different configurations, so that the component cost can be reduced.

DESCRIPTION OF SYMBOLS 1 Motor 3 Wiring board 4 Stator 6 Coil wire 8 Insulating member 31 1st arc-shaped board 32 2nd arc-shaped board 60 Junction part 60a Junction part 82 Body part 84 First collar part (wall part)
85 Second collar (partition wall)
86 Leading-out part 87 Opposite wall 870 Notch 311a-311c of opposing wall, 321a-321c Notch (engagement part)
312a-312c, 322a-322c Notch (coil wire support)
310 Common pattern 320u, 320v, 320w Power line connection pattern 841 First flange convex portion 849 First collar thick portion 850 Second collar concave portion

Claims (6)

A stator having a stator core having a plurality of salient poles in the circumferential direction, an insulating member having a trunk portion covering the salient poles, and a coil wire wound around the salient poles via the trunk portion. Because
The insulating member includes a routing portion in which a connecting wire portion of the coil wire is routed in a circumferential direction at a position adjacent to the trunk portion in the radial direction, and a partition wall that partitions the trunk portion and the routing portion. ,
On the wall surface of the partition wall on the side of the routing portion, a recess is formed that is recessed toward the side where the body portion is located,
A part of the crossover portion is bent toward the recess and is located in the recess.   The stator according to claim 1, wherein the concave portion is provided at a position overlapping with the body portion in a radial direction. The insulating member includes an opposing wall on the side opposite to the partition wall with respect to the routing portion,
The stator according to claim 1, wherein the opposing wall is formed with a notch penetrating the opposing wall in a radial direction at a position overlapping the concave portion in the radial direction.   The stator according to any one of claims 1 to 3, wherein the routing portion is located radially outside the body portion. A motor comprising a stator as defined in any one of claims 1 to 4,
A motor comprising: a rotor opposed to an end portion of the salient pole in a radial direction; and a motor case that accommodates the rotor and the stator inside. A stator having a stator core having a plurality of salient poles in the circumferential direction, an insulating member having a trunk portion covering the salient poles, and a coil wire wound around the salient poles via the trunk portion. A manufacturing method of
The insulating member includes a routing portion in which a connecting wire portion of the coil wire is routed in a circumferential direction at a position adjacent to the trunk portion in the radial direction, and a partition that partitions the trunk portion and the routing portion. Set up
A winding step of winding the coil wire around the body portion, then winding the coil wire around the body portion covering the salient poles spaced apart in the circumferential direction, and winding the coil wire around the body portion; ,
A connecting wire processing step of bending a part of the connecting wire portion located in the routing portion of the coil wire toward the inside of the recessed portion with a jig to be positioned in the recessed portion,
A method of manufacturing a stator, comprising:

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