Stator, motor, blower, and stator manufacturing method

The present invention relates to a stator, a motor, a blower, and a stator manufacturing method.

A concentrated winding motor has a configuration in which winding wires are wound around one tooth in a concentrated manner, and thus the concentrated winding motor has a high windability and can densely wind the winding wires around the teeth. Accordingly, the concentrated winding motor can achieve downsizing of the motor, increase in the efficiency, and cost reduction. Conventionally, as an example of a single-phase, 8-slot, 4-pole concentrated winding motor, there is a motor disclosed in Patent Literature 1.

Patent Literature

Patent Literature 1: Japanese Patent Application Laid-open No. 2002-369470

Technical Problem

However, in the conventional concentrated winding motor including the motor disclosed in Patent Literature 1, in-phase winding wires are arranged on every other tooth in the case of a single phase and are arranged on every third tooth in the case of three phases, so that the winding wires on adjacent teeth are of different phases. Therefore, a crossover wire connecting the in-phase winding wires needs to cross the adjacent winding wire of a different phase, thereby causing a problem that contact with the winding wire of the different phase is likely to occur.

The present invention has been achieved to solve the above problem, and an object of the present invention is to provide a stator of a motor that can separate crossover wires of respective phases, has a high reliability and a long life, and that is inexpensive.

Solution to Problem

In order to solve the aforementioned problems, a stator according to one aspect of the present invention is configured to include: a first teeth unit including a first insulator having an annular first crossover wire guide and a plurality of first winding units radially provided at regular intervals on an outer circumference of the first crossover wire guide to cover teeth of one phase group of an alternating current, the teeth of the one phase group having upper halves fitted to the first winding units, a third insulator that covers lower halves of the teeth, and a winding wire of one phase wound around the teeth of the one phase group in a concentrated manner via the first winding units and the third insulator while allowing a first crossover wire to pass through the first crossover wire guide; a second teeth unit including a second insulator having an annular second crossover wire guide and a plurality of second winding units radially provided at regular intervals on an outer circumference of the second crossover wire guide to cover teeth of the other phase group of the alternating current, the teeth of the other phase group having upper halves fitted to the second winding units, a third insulator that covers lower halves of the teeth, and a winding wire of other phase wound around the teeth of the other phase group in a concentrated manner via the second winding units and the third insulator while allowing a second crossover wire to pass through the second crossover wire guide, the plurality of second winding units being inserted into between adjacent ones of the first winding units, respectively, and the second crossover wire guide being overlapped on the first crossover wire guide; and an annular yoke including a plurality of recesses at regular intervals on an inner circumference thereof to fit and fix the teeth of the one phase group and the teeth of the other phase group alternately to the recesses.

Advantageous Effects of Invention

The stator of the motor according to the present invention can separate crossover wires of respective phases, has a high reliability and a long life, and that is inexpensive.

FIG. 1 is a front view of a stator core of a stator according to an embodiment of the present invention.

FIG. 2 is a front view of a state where the stator core according to the embodiment is disassembled.

FIG. 3-1 is a perspective view of a state where an insulator is attached to teeth of a U-phase group.

FIG. 3-2 is a perspective view of a state where an insulator is attached to teeth of a V-phase group.

FIG. 4-1 is a perspective view of a state where a winding wire is provided around the teeth of the U-phase group via the insulator.

FIG. 4-2 is a perspective view of a state where a winding wire is provided around the teeth of the V-phase group via the insulator.

FIG. 5 is a partial sectional view of a winding unit.

FIG. 6 is a lower perspective view of a claw of a second insulator.

FIG. 7 is an exploded perspective view of the stator according to the embodiment of the present invention.

FIG. 8 is a perspective view of the stator according to the embodiment of the present invention.

FIG. 9 is a partial sectional view of a motor incorporating therein the stator according to the embodiment.

FIG. 10-1 is a front view of a ventilation fan incorporating therein the motor according to the embodiment.

FIG. 10-2 is a side view of the ventilation fan incorporating therein the motor according to the embodiment.

Exemplary embodiments of a stator, a motor, a blower, and a stator manufacturing method according to the present invention will be explained below in detail with reference to the accompanying drawings. The present invention is not limited to the embodiments.

Embodiment

FIG. 1 is a front view of a stator core of a stator according to an embodiment of the present invention. FIG. 2 is a front view of a state where the stator core according to the embodiment has been disassembled. FIG. 3-1 is a perspective view of a state where an insulator is attached to teeth of a U-phase group. FIG. 3-2 is a perspective view of a state where an insulator is attached to teeth of a V-phase group. FIG. 4-1 is a perspective view of a state where a winding wire is provided around the teeth of the U-phase group via the insulator. FIG. 4-2 is a perspective view of a state where a winding wire is provided around the teeth of the V-phase group via the insulator. FIG. 5 is a partial sectional view of a winding unit. FIG. 6 is a lower perspective view of a claw of a second insulator. FIG. 7 is an exploded perspective view of the stator according to the embodiment of the present invention. FIG. 8 is a perspective view of the stator according to the embodiment of the present invention.

As shown in FIGS. 1 and 2 , a stator core 10 according to the present embodiment includes an annular yoke 11 , and teeth 12 with base ends 12 a thereof fitted and fixed to recesses 11 a provided at eight positions on the inner circumference of the yoke 11 at regular intervals, respectively. The stator core 10 according to the present embodiment is a stator core of a single-phase, 8-slot, 4-pole concentrated winding motor.

Before performing winding around the stator core 10 , the stator core 10 is disassembled into the yoke 11 and the teeth 12 , and the teeth 12 are divided into a U-phase group 12 U around which a winding wire of a U phase (one of phases) of a single-phase alternating current is wound in a concentrated manner and a V-phase group 12 V around which a winding wire of a V phase (the other phase) is wound in a concentrated manner as shown in FIG. 2 .

The U-phase group 12 U is a group including one tooth 12 as a basis and three teeth 12 at positions which are different in angle by 90 degrees, respectively, starting from the basis tooth 12 . The V-phase group 12 V is a group including a tooth 12 adjacent to the basis tooth 12 and three teeth 12 at positions which are different in angle by 90 degrees, respectively, starting from the adjacent tooth 12 .

As shown in FIG. 3-1 , the four teeth 12 of the U-phase group 12 U are integrated by a first insulator 51 . The first insulator 51 includes an annular first crossover wire guide 51 a , and four (plural) first winding units 51 b radially provided on the outer circumference of the first crossover wire guide 51 a to be separated from each other by 90 degrees. The first crossover wire guide 51 a includes an annular first floor part 51 aa , and a first cylindrical part 51 ab provided on the inner circumference of the first floor part 51 aa . The first floor part 51 aa allows a first crossover wire 61 a (see FIG. 4-1 ) to run thereon, and the first cylindrical part 51 ab allows the first crossover wire 61 a to run therealong, whereby the parts 51 aa and 51 ab guide the first crossover wire 61 a.

Each of the first winding units 51 b includes a first barrel part 51 ba that covers an upper half of the relevant tooth 12 of the U-phase group 12 U, a first outer flange 51 bb provided outside of the first barrel part 51 ba , and a first inner flange 51 bc provided inside of the first barrel part 51 ba and connected to the first crossover wire guide 51 a . A first gate 51 bd that allows the first crossover wire 61 a (see FIG. 4-1 ) to pass therethrough is provided between the first crossover wire guide 51 a and the first winding unit 51 b at an upper center of the first inner flange 51 bc.

Third insulators 53 each include a barrel part 53 ba that covers a lower half of one of the teeth 12 , an outer flange 53 bb provided outside of the barrel part 53 ba , and an inner flange 53 bc provided inside of the barrel part 53 ba . Pins 53 c serving as relay points between an external power wire and the winding wire or neutral points of winding ends of the U-phase winding wire and the V-phase winding wire are attached outside of the outer flanges 53 bb , respectively.

As shown in FIG. 3-2 , the four teeth 12 of the V-phase group 12 V are integrated by a second insulator 52 . The second insulator 52 includes an annular second crossover wire guide 52 a , and four (plural) second winding units 52 b radially provided on the outer circumference of the second crossover wire guide 52 a to be separated from each other by 90 degrees. The second crossover wire guide 52 a includes an annular second floor part 52 aa , a second cylindrical part 52 ab provided on the inner circumference of the second floor part 52 aa , and four claws 52 ac protruding radially outward from an upper part of the second cylindrical part 52 ab.

The second floor part 52 aa allows a second crossover wire 62 a (see FIG. 4-2 ) to run thereon, and the second cylindrical part 52 ab allows the second crossover wire 62 a to run therealong, whereby the parts 52 aa and 52 ab guide the second crossover wire 62 a . The claws 52 ac hold the second crossover wire 62 a to prevent the second crossover wire 62 a from coming off the second crossover wire guide 52 a . Accordingly, the second crossover wire 62 a can be prevented from coming in contact with non-charged metal parts such as a frame and a cover of the motor, thereby enabling to provide a highly reliable motor.

Each of the second winding units 52 b includes a second barrel part 52 ba that covers an upper half of the relevant tooth 12 of the V-phase group 12 V, a second outer flange 52 bb provided outside of the second barrel part 52 ba , and a second inner flange 52 bc provided inside of the second barrel part 52 ba and connected to the second crossover wire guide 52 a . A second gate 52 bd that allows the second crossover wire 62 a (see FIG. 4-2 ) to pass therethrough is provided between the second crossover wire guide 52 a and the second winding unit 52 b at an upper center of the second inner flange 52 bc.

Because the four third insulators 53 that cover lower halves of the teeth 12 of the V-phase group 12 V are the same as the four third insulators 53 that cover the lower halves of the teeth 12 of the U-phase group 12 U, explanations thereof are omitted.

Winding wires 61 of one phase are wound around the four teeth 12 of the U-phase group 12 U in a state where the four teeth 12 , the first insulator 51 , and the four third insulators 53 are integrated as shown in FIG. 3-1 . As shown in FIG. 4-1 , a winding start end of a winding wire 61 is first entwined around one of the pins 53 c , and then concentrated winding and crossover are repeated in such a manner that the winding wire 61 is wound around one of the teeth 12 in a concentrated manner via the corresponding first winding unit 51 b and the corresponding third insulator 53 , and the first crossover wire 61 a is guided to the adjacent first winding unit 51 b through the first gate 51 bd and the first crossover wire guide 51 a . Accordingly, the winding wires 61 of one phase are wound in series around the four teeth 12 of the U-phase group 12 U in the concentrated manner. A winding end of the winding wires 61 is entwined around the other pin 53 c as the neutral point. A first teeth unit 81 is completed by the above winding operations.

Winding wires 62 of the other phase are wound around the four teeth 12 of the V-phase group 12 V in a state where the four teeth 12 , the second insulator 52 , and the four third insulators 53 are integrated as shown in FIG. 3-2 . As shown in FIG. 4-2 , a winding start end of a winding wire 62 is entwined around the pin 53 c , and then concentrated winding and crossover are repeated in such a manner that the winding wire 62 is wound around one of the teeth 12 in the concentrated manner via the corresponding second winding unit 52 b and the corresponding third insulator 53 , and the second crossover wire 62 a is guided to the adjacent second winding unit 52 b through the second gate 52 bd and the second crossover wire guide 52 a . Accordingly, the winding wires 62 of the other phase are wound in series around the four teeth 12 of the V-phase group 12 V in the concentrated manner. A winding end of the winding wire 62 is entwined around the other pin 53 c of the first teeth unit 81 as the neutral point. A second teeth unit 82 is completed by the above winding operations.

Winding operations of the first and second teeth units 81 and 82 are performed from the outer circumference sides of the first and second teeth units 81 and 82 by a winding machine, respectively. After the first and second winding wires 61 and 62 are wound around one tooth 12 in the concentrated manner, the first and second crossover wires 61 a and 62 a run on the first and second floor parts 51 aa and 52 aa , to move to the concentrated winding around the corresponding adjacent teeth 12 , respectively. At this time, because the first and second barrel parts 51 ab and 52 ab are provided, the first and second crossover wires 61 a and 62 a can move to the corresponding adjacent teeth 12 along the first and second barrel parts 51 ab and 52 ab only by rotating the first and second teeth units 81 and 82 by 90 degrees, respectively. Therefore, the first and second crossover wires 61 a and 62 a do not protrude into inside of the first and second crossover wire guides 51 a and 52 a.

At the time of the end of the concentrated winding of the winding wires 61 and 62 around the teeth 12 , the winding wires 61 and 62 have the same height as that of the first and second floor parts 51 aa and 52 aa . However, because the height of the first and second inner flanges 51 bc and 52 bc on the opposite sides of the first and second gates 51 bd and 52 bd is set to be higher than the height of the first and second floor parts 51 aa and 52 aa , the first and second crossover wires 61 a and 62 a do not come off from the first and second gates 51 bd and 52 bd , respectively, which facilitates the winding operation.

As shown in FIG. 5 , central parts of the first and second inner flanges 51 bc and 52 bc are made to be inclined surfaces, with the upper parts thereof being inclined inwardly and connected to the first and second floor parts 51 aa and 52 aa , respectively. Therefore, the first and second crossover wires 61 a and 62 a can be smoothly guided from the first and second floor parts 51 aa and 52 aa to the winding start positions of the first and second barrel parts 51 ba and 52 ba along the inclined surfaces of the first and second inner flanges 51 bc and 52 bc.

As shown in FIG. 6 , a rear side of the claw 52 ac is an inclined surface like a triangular pyramid, and even if the position of the second crossover wire 62 a is misaligned at the time of the winding operation by the winding machine, the second crossover wire 62 a slides on the inclined surface of the claw 52 ac and is surely set at a base of the claw 52 ac.

As shown in FIG. 7 , each of the four second winding units 52 b of the second teeth unit 82 is inserted into between adjacent ones of the four first winding units 51 b of the first teeth unit 81 , and the second crossover wire guide 52 a is overlapped on the first crossover wire guide 51 a to integrate the first teeth unit 81 and the second teeth unit 82 .

The integrated first teeth unit 81 and second teeth unit 82 are inserted into the yoke 11 , and the teeth 12 of the U-phase group 12 U and the teeth 12 of the V-phase group 12 V are fitted and fixed alternately to the recesses 11 a in the yoke 11 , so that a stator 80 according to the present embodiment shown in FIG. 8 is completed.

An axial position of the second crossover wire guide 52 a is higher than an axial position of the first crossover wire guide 51 a , and thus the second crossover wire guide 52 a can be overlapped on the first crossover wire guide 51 a.

Slot widths of the first and second winding units 51 b and 52 b are wider on the side of the first and second outer flanges 51 bb and 52 bb than on the side of the first and second inner flanges 51 bc and 52 bc , respectively. Therefore, when the winding wires 61 and 62 of the first and second winding units 51 b and 52 b are wound all over the slot widths, the winding wires 61 and 62 on the first and second winding units 51 b and 52 b have fan shapes, respectively. Accordingly, the winding wires 61 and 62 on the side of the first and second outer flanges 51 bb and 52 bb are higher than on the side of the first and second inner flanges 51 bc and 52 bc , respectively. The first and second inner flanges 51 bc and 52 bc are set to be lower than the first and second outer flanges 51 bb and 52 bb , respectively, and the first floor part 51 aa is also set to be lower than the first and second outer flanges 51 bb and 52 bb.

Accordingly, when the second teeth unit 82 is overlapped on the first teeth unit 81 , the first floor part 51 aa falls within the heights of the first and second outer flanges 51 bb and 52 bb . Therefore, the first floor part 51 aa does not project upward from the first and second outer flanges 51 bb and 52 bb , and thus the size of the stator 80 in the height direction (the axial direction) can be reduced, thereby enabling to downsize the motor.

As explained above, in the stator 80 according to the present embodiment, the first crossover wire 61 a of one phase is led to pass through the first crossover wire guide 51 a and the second crossover wire 62 a of the other phase is led to pass through the second crossover wire guide 52 a to separate the first and second crossover wires 61 a and 62 a of the respective phases. Consequently, the stator has a high reliability against short circuit and a long life and is inexpensive.

FIG. 9 is a partial sectional view of a motor incorporating therein the stator according to the embodiment. FIG. 10-1 is a front view of a ventilation fan incorporating therein the motor according to the embodiment. FIG. 10-2 is a side view of the ventilation fan incorporating therein the motor according to the embodiment.

As shown in FIG. 9 , a motor 90 according to the present embodiment includes a frame 91 in which a front-bearing holding part 91 a is formed at the center of a front end plate, the stator 80 according to the present embodiment fitted in a cylindrical barrel part of the frame 91 , a cover 92 in which a front-end outer circumference thereof is fitted to the stator 80 and connected to the frame 91 and a rear-bearing holding part 92 a is formed at the center of a rear end plate, and a rotor 93 in which a front bearing 93 a fitted to a rotation shaft 93 c and held by the front-bearing holding part 91 a of the frame 91 and a rear bearing 93 b fitted to the rotation shaft 93 c and held by the rear-bearing holding part 92 a are arranged in the stator 80 . Because the motor 90 incorporates the stator 80 according to the present embodiment, the motor 90 has a high reliability and a long life and is inexpensive.

As shown in FIGS. 10-1 and 10-2 , in a ventilation fan 100 according to the present embodiment as a blower, the motor 90 according to the present embodiment that drives a fan 102 is mounted on a frame 101 . Because the ventilation fan 100 as the blower includes the motor 90 according to the present embodiment, the ventilation fan 100 has a high reliability and a long life and is inexpensive. Although not shown, the motor 90 according to the present embodiment can be mounted on an electric fan as the blower.

10 stator core

11 yoke

11 a depressed portion

12 tooth

12 a base end

12 U U-phase group

12 V V-phase group

51 first insulator

51 a first crossover wire guide

51 aa first floor part

51 ab first cylindrical part

51 b first winding unit

51 ba first barrel part

51 bb first outer flange

51 bc first inner flange

51 bd first gate

52 second insulator

52 a second crossover wire guide

52 aa second floor part

52 ab second cylindrical part

52 ac claw

52 b second winding unit

52 ba second barrel part

52 bb second outer flange

52 bc second inner flange

52 bd second gate

53 third insulator

53 ba barrel part

53 bb outer flange

53 bc inner flange

53 c pin

61 winding wire

62 winding wire

61 a first crossover wire

62 a second crossover wire

80 stator

81 first teeth unit

82 second teeth unit

90 motor

91 frame

91 a front-bearing holding part

92 cover

92 a rear-bearing holding part

93 rotor

93 a front bearing

93 b rear bearing

93 c rotation shaft

100 ventilation fan (blower)

101 frame

102 fan