INSULATOR, STATOR, AND ROTATING ELECTRICAL MACHINE USING THESE

A stator includes a plurality of composing split cores, an insulator that is attached to each of the split cores, a coil conductor wire that has a wound portion wound around the split cores via the insulator and a bridging portion drawn out from the wound portion, and a regulating member that regulates movement of the coil conductor wire. The insulator has an accommodating portion that accommodates the bridging portion, the accommodating portion has a first surface and a second surface that form mutually facing surfaces and opening portions that communicate with each other and are formed in each of the first surface and the second surface. The regulating member is configured of a bendable member and is inserted through the opening portion formed in the first surface and the opening portion formed in the second surface and is wound around the bridging portion accommodated in the accommodating portion.

FIELD OF THE INVENTION

The present embodiments of the present invention relate to an insulator, a stator, and a rotating electrical machine using these.

BACKGROUND OF THE INVENTION

There is a rotating electrical machine including a stator and a rotor. The stator includes, for example, a stator core with an annular shape, a plurality of teeth projecting inward in a radial direction from an inner circumferential surface of the stator core, a coil conductor wire wound around the teeth, and an insulator that is attached to the teeth and secures insulation between the teeth and the coil conductor wire.

The rotor includes, for example, a rotor core with substantially a columnar shape disposed to be rotatable inside the stator in the radial direction and a magnet provided at the rotor core. Once a current is supplied to the coil conductor wire, an interlinkage magnetic flux is generated at each of the teeth. A magnetic attracting force and repulsion force occurs between the interlinkage magnetic flux and the magnet of the rotor, and the rotor thus rotates.

Also, as a rotating electrical machine of this type, a rotating electrical machine in which a stator core is configured of a plurality of split cores to facilitate a coil conductor wire winding operation and thereby to raise a space factor is known. The split cores used in the rotating electrical machine have back yoke portions with substantially arc shapes that form an annular-shaped portion of the stator core in a mutually assembled state and teeth projecting inward in the radial direction from the back yoke portions. A plurality of winding wire blocks having the split cores are disposed in an annular shape by a ring member with an annular shape thereby to compose the stator.

An insulator configured of an insulating material is attached to each split core. The insulator has a tooth covering portion that is attached to a tooth with the coil conductor wire wound around the outer periphery thereof, and a bridging portion accommodating portion that accommodates the coil conductor wire drawn out from the tooth covering portion and the coil conductor wire drawn out from another split core and guides the coil conductor wire to a terminal connecting portion. The bridging portion accommodating portion is integrally formed with substantially an arc shape outside the tooth covering portion in the core radial direction. In the bridging portion accommodating portion, guide groove portions that guide, along a circumferential direction of the stator core, a bridging portion of the coil conductor wire drawn out from the tooth covering portion and a bridging portion of the coil conductor wire drawn out from another split core are formed. The guide groove portions are formed in a plurality of stages to be separated from each other in the core radial direction for each phase in correspondence with a plurality of phases such as a U phase, a V phase, and a W phase, for example.

SUMMARY OF THE INVENTION

The aforementioned conventional rotating electrical machine has a structure in which the bridging portion of the coil conductor wire drawn outward in the core radial direction from the tooth covering portion is simply bent to follow the corresponding guide groove portion of the bridging portion accommodating portion. Therefore, the bridging portion of the coil conductor wire drawn outward in the core radial direction from the tooth covering portion, the bridging portion of the coil conductor wire drawn out from another split core, and the like may fall off from the guide groove portion when the plurality of split coils are assembled while the coils are routed around the bridging portions of the coils at the time of assembly of the stator. In this case, there is a concern that the coil conductor wire may be out of a predetermined position and short-circuiting or the like may occur.

Thus, an insulator, a stator, and a rotating electrical machine that enable a coil conductor wire to be appropriately fixed by a simple method are provided.

A stator according to the present embodiment includes: a plurality of winding wire blocks that are disposed in an annular shape; a plurality of split cores that compose a part of the plurality of winding wire blocks and are combined with each other to compose a stator core with an annular shape; an insulator that composes a part of the plurality of winding wire blocks and is attached to each of the plurality of split cores; a coil conductor wire that composes a part of the plurality of winding wire blocks and has a wound portion wound around the split cores via the insulator and a bridging portion drawn out from the wound portion; and a regulating member that regulates movement of the coil conductor wire. The insulator has an accommodating portion that accommodates the bridging portion, the accommodating portion includes a first surface and a second surface that form mutually facing surfaces, and opening portions that communicate with each other and are formed in each of the first surface and the second surface. The regulating member is configured of a bendable member and is configured to be fixable in a state where the regulating member is inserted through the opening portion in the first surface and the opening portion in the second surface and is wound around the bridging portion accommodated in the accommodating portion.

An insulator according to the present embodiment includes: an accommodating portion that accommodates a bridging portion of a coil conductor wire. The accommodating portion has a first surface and a second surface that form mutually facing surfaces, a plurality of groove portions that are provided between the first surface and the second surface, are depressed in a same direction, and accommodate the bridging portion in a separated manner for each phase, and opening portions that communicate with each other and are formed to face the first surface and the second surface, respectively.

A rotating electrical machine according to the present embodiment includes: the stator or a stator having the insulator; and a rotor.

DESCRIPTION OF EMBODIMENT(S) OF THE INVENTION

Hereinafter, a plurality of embodiments will be described with reference to the drawings Note that the same configurations in each embodiment will be denoted by the same reference signs and description will be omitted.

First Embodiment

First, a first embodiment will be described with reference toFIGS.1to13. As illustrated inFIG.1, a rotating electrical machine100includes a stator10, a rotor11, and a stator case, which is not illustrated.FIG.1is a view of the rotating electrical machine100seen from one side in an axial direction in a state where the stator case is detached therefrom. In the following description, a direction that is parallel with a rotation axis Ax of the rotor11which is an orientation perpendicularly intersecting the paper surface ofFIG.1will be referred to as an axial direction, a rotation direction of the rotor11will be referred to as a circumferential direction, and a radial direction of the rotor11perpendicularly intersecting the axial direction and the rotation direction will be referred to as a radial direction. In the drawings, the axial direction will be described as A, the circumferential direction will be described as C, and the radial direction will be described as R. Note that a core axial direction that is an axial direction of a stator core14, which will be described later, coincides with a direction in which the rotation axis Ax of the rotor11extends. A core circumferential direction that is a circumferential direction of the stator core14coincides with the rotation direction, that is, a circumferential direction of the rotor11. A core radial direction that is a radial direction of the stator core14coincides with the radial direction of the rotor11.

The stator10is formed in substantially a cylindrical shape and is fitted into and fixed to an inner circumferential surface of the stator case. The rotor11is disposed on the inner side in the radial direction of the stator10and is provided to be rotatable relative to the stator10. The stator case, which is not illustrated, is formed in substantially a cylindrical shape and accommodates the stator10therein. The axial direction of the stator10and the stator case coincides with the rotation axis Ax.

The rotor11has a shaft12, a rotor core13, and a magnet, which is not illustrated. The shaft12is formed in a columnar shape and rotates about the rotation axis Ax. The rotor core13is fixed to the shaft12and includes a through-hole131formed at the center thereof in the radial direction to penetrate through the rotor core13in the axial direction. The shaft12is fixed to the through-hole131through press-fitting, for example. A plurality of magnets, which are not illustrated, are attached to be aligned in the circumferential direction near an outer circumferential portion of the rotor core13.

The stator10has the stator core14, a ring member15, an insulator30, a coil conductor wire60, and a regulating member70. The stator core14is a magnetic member, is formed in a cylindrical shape as a whole, and is configured to be splittable into a plurality of pieces. The stator core14is configured to include a plurality of, in this case, twenty four split cores16. A single stator core14with a cylindrical shape as a whole is formed by the plurality of split cores16being press-fitted into the ring member15with an annular shape and being assembled with each other. Note that the axial direction of the ring member15coincides with the rotation axis Ax.

The insulator30is formed of an insulating member and is attached to the stator core14. In this case, the insulator30covers at least a part of each split core16. The coil conductor wire60is wound around the stator core14. In the present embodiment, the coil conductor wire60is wound around the stator core14by a concentrated winding scheme. Also, the coil conductor wire60is wound around each split core16from above the insulator30. The regulating member70is a bendable insulating member and is formed in a strip shape or a string shape with a long axis. The regulating member70has a function of regulating movement of a bridging portion63, which will be described later, by surrounding a part of the coil conductor wire60, specifically, the bridging portion63and fixing the part to the insulator30.

The coil conductor wire60has a wound portion61wound around each split core16and bridging portions62and63drawn out from both sides of the wound portion61to the outer side. The first bridging portion62is a part of the coil conductor wire60drawn out from a winding start side. The second bridging portion63is a part of the coil conductor wire60drawn out from a winding termination side. Although the coil conductor wire60is a so-called flat wire with a rectangular sectional shape in the present embodiment, the coil conductor wire60is not limited thereto. In other embodiments, the coil conductor wire60may be a so-called round wire with a circular sectional shape.

The split cores16have a configuration in which a plurality of metal plates are laminated, for example. The split cores16may be formed by pressure-molding soft magnetic powder of a silicon steel plate or the like. In the present embodiment, eight split cores16in total disposed every three split cores16, that is, with two split cores16interposed therebetween from among twenty four split cores16are split cores16in a U phase. Eight split cores16in total disposed every three split cores16to be adjacent to the split cores16in the U phase are split cores16in a V phase. Eight split cores16in total disposed every three split cores16to be adjacent to the split cores16in the U phase and the split cores16in the V phase are split cores16in a W phase.

A winding wire block80is configured by winding the coil conductor wire60around each split core16via the insulator30.FIG.3is a perspective view of the winding wire block80. The winding wire block80is configured to include the split core16, the insulator30, and the coil conductor wire60. The split core16is formed in substantially a T shape in a view in the axial direction. The split core16has a tooth17and a back yoke portion18. The tooth17is formed to project inward in the radial direction from the back yoke portion18. At least a part of the tooth17is covered with the insulator30. In other words, the insulator30is attached to each split core16to cover the surroundings of the tooth17. The coil conductor wire60is wound around each tooth17from above the insulator30. The back yoke portion18forms a surface extending in the circumferential direction and the axial direction at the outer circumferential portion of the split core16. The back yoke portion18is a place forming a magnetic path with an annular shape of the stator core14when the split cores16are disposed in the annular shape by the ring member15. The back yoke portion18is formed such that an outer circumferential portion of the sectional shape perpendicularly intersecting the axial direction has an arc shape. Therefore, the stator core14has a shape in which the plurality of teeth17project inward in the radial direction from the back yoke portions18continuing in the annular shape in a view in the axial direction.

The tooth17has a tooth main body19and a flange portion20. The tooth main body19is a part extending in the radial direction and receiving winding of the coil conductor wire60via the insulator30. The flange portion20is connected to an inner end portion of the tooth main body19in the radial direction and forms a surface projecting in the axial direction and the circumferential direction from the tooth main body19. The tooth main body19and the flange portion20are integrally molded. The tooth main body19, the flange portion20, and the back yoke portion18surround a slot that is a space where the wound portion61of the coil conductor wire60is wound.

The insulator30is configured to include a plurality of, in this case, two split members in the axial direction. In this case, the insulator30has a first insulator31and a second insulator32. The first insulator31is attached to the split core16from one side of the tooth17in the axial direction. The second insulator32is attached to the split core16from the other side of the tooth17in the axial direction. In this case, the first insulator31is attached to the split core16from above the tooth17illustrated inFIG.3, for example, and the second insulator32is attached to the split core16from below the tooth illustrated inFIG.3, for example. Once the insulator30is attached to the split core16, the first insulator31and the second insulator32are engaged with no gap therebetween, and the tooth17is not exposed to the outside from between the first insulator31and the second insulator32in this configuration. Winding of the coil conductor wire60that is wound around the tooth17from above the insulator30is started from the side of the first insulator31, and a winding termination end is drawn out from the side of the second insulator32. Note that although the side of the first insulator31in the axial direction may be referred to as a lower side and the side of the second insulator32may be referred to as an upper side in the following description, these are for convenience of explanation, and the lower side and the upper side may not coincide with the actual up-down direction.

FIGS.4and5are perspective view of the second insulator32seen from the inner side in the radial direction and the outer side in the radial direction.FIG.6is a view of the second insulator32seen from a side away from the first insulator31in regard to the axial direction.FIG.7is a view of the second insulator32seen from the outer side in the radial direction.FIG.8is a sectional view of the second insulator32seen from the axial direction along the line X8-X8inFIG.7. InFIG.8, the split core16and the coil conductor wire60are partially illustrated by dashed lines.FIG.9is a sectional view of the second insulator32seen from one side in the circumferential direction along the line X9-X9inFIG.7. The second insulator32has a covering portion33, an inner wall portion34, an outer wall portion35, and an accommodating portion40. The covering portion33is formed to have a U-shaped sectional shape in the axial direction and covers the tooth main body19from one side in the axial direction and both sides in the circumferential direction. The inner wall portion34and the outer wall portion35are molded integrally with an inner end portion and an outer end portion of the covering portion33in the radial direction and form surfaces extending in the axial direction and the circumferential direction. The inner wall portion34covers the flange portion20on the outer circumferential side. The outer wall portion35covers the back yoke portion18on the inner circumferential side.

The accommodating portion40is formed integrally with the outer wall portion35. The accommodating portion40is provided to expand outward in the radial direction from the outer wall portion35and project in the axial direction. In this case, the accommodating portion40is provided to project in an orientation away from an end portion of connection to the first insulator31in regard to the axial direction, that is, on the side opposite to the first insulator31. The accommodating portion40accommodates the second bridging portion63of the coil conductor wire60drawn out from the side of the covering portion33to the outer side in the radial direction and the second bridging portion63of the coil conductor wire60drawn out from another split core16. The accommodating portion40is formed in an arc shape such that the outer circumferential portion follows the shape of the outer circumferential portion of the back yoke portion18in a view in the axial direction.

The accommodating portion40has a base portion41, a plurality of guide walls42, a plurality of guide groove portions43, a drawing-out groove portion44, and a routing passage45. The base portion41is formed in substantially a fan shape in a view in the axial direction. The plurality of guide walls42are provided to project from the base portion41. In this case, the plurality of guide walls42extend in an orientation away from the end portion connected to the first insulator31in regard to the axial direction, that is, on the side opposite to the first insulator31from the base portion41. Also, each of the plurality of guide walls42forms a surface that is substantially perpendicular to the radial direction. The guide walls42function as a guide that guides the second bridging portions63along the guide walls42.

The plurality of, in this case, four guide walls42are aligned at equal intervals and are aligned in the order of a first guide wall421, a second guide wall422, a third guide wall423, and a fourth guide wall424from the inner side to the outer side in the radial direction. The surface of the first guide wall421on the inner side in the radial direction forms a first surface401which is a surface of the accommodating portion40on the inner side in the radial direction, that is, on the side of the tooth17. The surface of the fourth guide wall424on the outer side in the radial direction forms a second surface402which is a surface of the accommodating portion40on the outer side in the radial direction, that is, on the side of the back yoke portion18. The second guide wall422and the third guide wall423are provided between the first guide wall421on the inner side in the radial direction and the fourth guide wall424on the outer side in the radial direction.

The plurality of guide groove portions43are provided between the first surface401and the second surface402. The plurality of guide groove portions43extend in the circumferential direction and accommodate the second bridging portions63in a separated manner in the radial direction for each phase. Each guide groove portion43is formed between the adjacent guide walls42. The guide groove portions43function as passages through which the second bridging portions63pass. The drawing-out groove portion44is formed by cutting off a center portion of each guide wall42in the circumferential direction from an upper end portion to a part connected to the base portion41. Therefore, the drawing-out groove portion44establishes communication between the inside and the outside of the accommodating portion40in the radial direction. The drawing-out groove portion44functions as a passage when the second bridging portion63drawn out from the wound portion61is drawn out to the outer side in the radial direction.

In the guide groove portion43, a first guide groove portion431, a second guide groove portion432, and a third guide groove portion433are aligned in this order from the inner side to the outer side in the radial direction. The first guide groove portion431on the inner side in the radial direction is a guide groove portion43formed between the first guide wall421and the second guide wall422. The second guide groove portion432at the center portion is a guide groove portion43formed between the second guide wall422and the third guide wall423. The third guide groove portion433on the outer side in the radial direction is a guide groove portion43formed between the third guide wall423and the fourth guide wall424.

In the present embodiment, a second bridging portion63U of the coil conductor wire60in the U phase is inserted into the first guide groove portion431on the inner side in the radial direction. A second bridging portion63V of the coil conductor wire60in the V phase is inserted into the second guide groove portion432at the center portion. A second bridging portion63W of the coil conductor wire60in the W phase is inserted into the third guide groove portion433on the outer side in the radial direction. The second bridging portion63drawn out from the covering portion33and the second bridging portion63extending and coming from another winding wire block80are inserted into each guide groove portion43. In the present embodiment, four second bridging portions63at maximum are inserted into each guide groove portion43.

One or a plurality of, in this case, two routing passages45are formed by cutting off the guide wall42between the drawing-out groove portion44and the end portion of the accommodating portion40in the circumferential direction. In this case, the routing passages45are formed by cutting off the second guide wall422, the third guide wall423, and the fourth guide wall424except for the first guide wall421on the inner side in the radial direction from the upper end portions to parts connected to the base portion41. Opening portions that establish communication between the inside and the outside of the accommodating portion40are formed by the routing passages45. The routing passages45provide spaces for routing the second bridging portion63to enable a direction change when the second bridging portion63drawn out through the drawing-out groove portion44to the outer side in the radial direction is drawn out to one side in the circumferential direction through any of the guide groove portion43as illustrated inFIG.8.

Each of the guide walls421,422,423, and424is split into a plurality of pieces by the drawing-out groove portion44and the routing passage45. The first guide wall421on the inner side in the radial direction is split into two pieces in the circumferential direction by the drawing-out groove portion44. Each of the fourth guide wall424on the outer side in the radial direction and the second guide wall422and the third guide wall423at the intermediate parts is split into four pieces in the circumferential direction by the drawing-out groove portion44and the routing passage45.

The base portion41has a rising portion411. The rising portion411is formed by causing a part of the base portion41to rise in a direction away from the first insulator31in regard to the axial direction between the two routing passages45and45. Therefore, parts of the second guide wall422, the third guide wall423, and the fourth guide wall424projecting from the rising portion411, that is, the parts between the routing passages45and45have shorter length dimensions in the axial direction than parts projecting from places other than the rising portion411, that is, parts outside the routing passages45and45in the circumferential direction.

The rising portion411is split into two pieces in the circumferential direction by the drawing-out groove portion44. Also, the rising portion411has a depressed portion412. The depressed portion412is formed by depressing the rising portion411from the side of the second surface402to the inner side in the circumferential direction. The position of a bottom portion of depression of the depressed portion412in the radial direction substantially coincides with the surface of the third guide wall423on the outer side in the radial direction. The depressed portion412functions as a passage of causing the second bridging portion63drawn out through the drawing-out groove portion44to the outside of the accommodating portion40in the radial direction to be turned by about 90° in the circumferential direction and guiding the second bridging portion63to the side of the guide groove portion43as illustrated inFIGS.8and9.

FIG.8illustrates, by the dashed lines, a state where the winding termination side of the coil conductor wire60is drawn out to the accommodating portion40and the second bridging portion63is accommodated in the accommodating portion40. Also, in this case, the second bridging portion63is drawn out through the drawing-out groove portion44to the outer side in the radial direction. The second bridging portion63that has been drawn out is routed on one side in the circumferential direction around the rising portion411at the depressed portion412. The second bridging portion63that has reached the routing passage45is inserted into any of guide groove portions43, namely the first guide groove portion431, the second guide groove portion432, or the third guide groove portion433, in this case, the first guide groove portion431. The second bridging portion63that has been drawn out from the guide groove portion43extends toward the accommodating portion40of the adjacent split core16.

Note that a free end portion, that is, an end portion on the side away from the base portion41of each of the guide walls421,422,423, and424is present substantially on one plane. In other words, the height dimension of the free end portion of each of the guide walls421,422,423, and424from the base portion41in a case where the rising portion411is not taken into consideration is set to be substantially the same.

The accommodating portion40further has one or a plurality of hole portions46and one or a plurality of recessed portions47as illustrated inFIGS.4,5, and the like. Each of the hole portions46and the recessed portions47is provided in the first guide wall421on the inner side in the radial direction or the fourth guide wall424on the outer side in the radial direction. In the present embodiment, the one or plurality of hole portions46and the one or plurality of recessed portions47are provided in the first guide wall421on the inner side in the radial direction. In this case, two hole portions46are opening portions formed to penetrate through the first guide wall421in the thickness direction at a part of the first guide wall421on a side further outward in the circumferential direction than the drawing-out groove portion44. The hole portions46are formed as long holes with long axes in the axial direction. The hole portions46establish communication between the inside and the outside of the accommodating portion40. The hole portions46allow the regulating member70to be inserted thereinto and allow the regulating member70to be wound around the second bridging portion63in a state where the second bridging portion63is accommodated in the accommodating portion40.

The regulating member70is in a state where the regulating member70extends in a long axis direction, that is, in an open state before utilization and can be fixed in a closed state where the regulating member70is wound in an annular shape during utilization. The regulating member70regulates movement of a target in a state where the regulating member70is in contact with the target or has approached the target, by being fixed in a closed state where the surroundings of the target, movement of which is to be regulated, is wound in an annular shape as illustrated inFIGS.9to11. The regulating member70can be formed of an insulating synthetic resin such as plastic, for example. Although examples of a method for fixing the regulating member70in the closed state in the annular shape include physical fixation based on engagement between parts of the regulating member70, thermal welding, fixation using an adhesive, and the like, the method is not limited thereto. In the present embodiment, the regulating member70is simply fixed by physical fixation based on engagement between parts of the regulating member70in the closed state in the annular shape. In this case, a commercially available cable tie, for example, can be used as the regulating member70.

As illustrated inFIGS.6and7, the plurality of, in this case, two hole portions46are linearly symmetrically disposed with respect to the center of the accommodating portion40in the radial direction, in this case, the drawing-out groove portion44. It is thus possible to fix the second bridging portion63with a satisfactory balance over the entire circumferential direction of the accommodating portion40when the second bridging portion63is fixed.

As illustrated inFIGS.7,9, and the like, the hole portions46are provided near the base portion41in regard to the axial direction of the first guide wall421. In this case, the hole portions46are set to be closer to the base portion41than the midpoint of the first guide wall421in the axial direction, for example. In other words, the positions of lower end portions46aof the hole portion46, that is, end portions on the side of the base portion41or the side of the end portions connected to the first insulator31are set to be closer to the base portion41than the midpoint of the first guide wall421in the axial direction. Moreover, positions of upper end portions46bof the hole portions46, that is, end portions on the side opposite to the base portion41or the side opposite to the end portions connected to the first insulator31are set to be closer to the base portion41than the midpoint of the first guide wall421in the axial direction.

Also, the positions of the lower end portions46aof the hole portions46are set at positions closer to the base portion41than the position of an upper end surface412aof the depressed portion412, that is, an end surface on the side opposite to the first insulator31. The positions of the upper end portions46bof the hole portions46are set at positions further away from the base portion41in regard to the axial direction than the position of the upper end surface412aof the depressed portion412. Moreover, the positions of the upper end portions46bof the hole portions46are set at positions further away from the base portion41than the position of an upper end surface411aof the rising portion411, that is, the surface on the side away from the base portion41in regard to the axial direction.

In this case, the two recessed portions47are formed by cutting off, toward the base portion41, parts of the free end portion of the first guide wall421, that is, the end portion on the side away from the base portion41in regard to the axial direction and causing the parts to be recessed. The recessed portions47are provided in a region obtained by extending the hole portions46in the direction away from the base portion41in regard to the axial direction. In other words, when the regulating member70is wound around the second bridging portion63, one end portion of the regulating member70inserted into the hole portions46passes through the outside of the recessed portions47in regard to the accommodating portion40. The regulating member70fixes the second bridging portion63and the regulating member70itself to the accommodating portion40when the regulating member70is wound around the second bridging portion by passing through the inside in the radial direction of the first guide wall421on the inner side in the radial direction, that is, the outside of the first surface401in regard to the accommodating portion40.

The width dimension of the recessed portions47in the circumferential direction is set to be equal to or greater than the width dimension of the regulating member70. Preferably, the width dimension of the recessed portion47in the circumferential direction is set to be larger than the width dimension of the regulating member70. Therefore, at least a part of the regulating member70is fitted into the recessed portions47when the regulating member70is inserted into the hole portions46and surrounds the second bridging portion63. The recessed portions47regulate movement of the regulating member70in the circumferential direction in a state where the second bridging portion63is surrounded. Also, the width dimension of the recessed portions47in the circumferential direction is set to be equal to or less than 1.2 times, or preferably equal to or less than 1.1 times the width dimension of the regulating member70, for example. In this manner, movement of the regulating member70in the circumferential direction is further regulated in the state where at least a part of the regulating member70is fitted into the recessed portions47.

The depth dimension of the recessed portions47in the axial direction can be set to be equal to or greater than 25%, or preferably equal to or greater than 50% the width dimension of the regulating member70, for example. In the present embodiment, the depth dimension of the recessed portions47in the axial direction is set to be equal to or greater than the width dimension of the regulating member70. Therefore, projecting of the regulating member70to the outside of the accommodating portion40in the axial direction is curbed in the state where the regulating member70is fitted into the recessed portions47and is wound around the second bridging portion63as illustrated inFIGS.9to11.

The hole portions46and the recessed portions47are provided on the extension line of the routing passage45in the radial direction. In other words, the hole portions46and the recessed portions47are provided at positions facing the opening portion in the fourth guide wall424on the outer side in the radial direction formed by the routing passage45. Therefore, the regulating member70comes into contact with the second bridging portion63and regulates movement of the second bridging portion63outside the accommodating portion40in the radial direction, that is, on the side of the second surface402as illustrated inFIGS.9to11in the state where the regulating member70is wound around the second bridging portion63.

The thus configured plurality of winding wire blocks80in the respective phases are continuously disposed in the circumferential direction in the order of the U phase, the V phase, and the W phase, for example. Each of the winding start end and the winding termination end of the coil conductor wire60drawn out from the covering portion33of the insulator30in each winding wire block80is connected. Although not illustrated in detail, the stator10is configured of three phases, namely the U phase, the V phase, and the W phase, and the coil conductor wire60is star-connected. As for the first bridging portion62on the winding start side of the coil conductor wire60drawn out from the side of the first insulator31, first bridging portions62in the three phases are connected to each other as a neutral point. In this case, end portions of the first bridging portions62of the three adjacent winding wire blocks80are connected through pressurized electric thermal welding, for example. In the present embodiment, the number of welded locations is eight in the entire stator10. The second bridging portions63on the winding termination side of the coil conductor wire60drawn out from the drawing-out groove portion44of the second insulator32are connected in the same phase and are connected to power supply terminals90U,90V, and90W in the corresponding phases as illustrated inFIG.1.

A procedure for manufacturing the stator10will be described with reference toFIGS.12and13. Once manufacturing of the stator10is started (start inFIG.12), the first insulator31and the second insulator32are attached to each split core16in Step S11. In Step S12, the wound portion61of the coil conductor wire60is wound around the tooth main body19of the split core16via the covering portion33of the insulator30. In Step S13, a part of the coil conductor wire60on the winding termination side, that is, the second bridging portion63is drawn out from the drawing-out groove portion44of the second insulator32to the side of the accommodating portion40. Note that a part of the coil conductor wire60on the winding start side, that is, the first bridging portion62is drawn out to the side of an accommodating portion311of the first insulator31, details of which are not illustrated.

In Step S14, the plurality of winding wire blocks80with the coil conductor wire60wound around are accommodated in the ring member15through press-fitting. In this manner, the split cores16are disposed in an annular shape, and the stator core14is thereby formed. In Step S15, the second bridging portion63is routed through the routing passage45and is accommodated in the guide groove portion43of the accommodating portion40. In Step S16, an end portion of the second bridging portion63is welded for each of the phases, namely the U phase, the V phase, and the W phase. In this case, the end portions of the eight second bridging portions63in each phase may be welded through pressure welding such as pressurized electric thermal welding in which the end portions are welded by heat generated by distributing power under a pressure or resistance welding, for example.

In Step S17, end portions of the first bridging portions62of the three adjacent winding wire blocks80are welded. In this manner, the coil conductor wires60on the side of the neutral point are connected. The end portions of the first bridging portions62may be welded by pressure welding such as pressurized electric thermal welding, resistance welding, or the like. In Step S18, the first bridging portion62including an unwelded part and a welded part is accommodated in the accommodating portion311on the side of the first insulator31.

In Step S19, a winding and fixing process of the regulating member70is performed. Details of the winding and fixing process are shown inFIG.13. In Step S21, the regulating member70is inserted into the accommodating portion40. At this time, the regulating member70penetrate from the side of the first surface401to the side of the second surface402in the radial direction of the accommodating portion40through the hole portions46and the routing passage45. In Step S22, the plurality of second bridging portions63accommodating in each accommodating portion40are wound together by the regulating member70. In Step S23, the regulating member70is fixed in an annular state. In this manner, the second bridging portions63are fixed to the accommodating portion40by the regulating member70being wound around the second bridging portions63. In this manner, the winding and fixing process of the regulating member70is performed. Returning toFIG.12, the stator core14is accommodated in a stator case, details of which are not illustrated, in Step S20. Specifically, the ring member15inside which the plurality of winding wire blocks80are disposed and accommodated in an annular shape is press-fitted into the stator case. In this manner, the stator10is manufactured (end).

Furthermore, the thus manufactured stator10is combined with the rotor11and the like by any known method thereby to manufacture the rotating electrical machine100.

Here, if the second bridging portions63of the coil conductor wire60sticks out from the accommodating portion40, there is a concern that collapse of winding of the coil conductor wire60may occur. Although a method of fixing the second bridging portions63with a binding thread is also known, the binding thread itself may deviate in the circumferential direction or the like, and it is not possible to sufficiently prevent the second bridging portions63from sticking out.

On the other hand, according to the present embodiment described above, the stator10includes the winding wire blocks80, the plurality of split cores16, the insulator30including the first insulator31and the second insulator32, the coil conductor wire60, and the regulating member70. The winding wire blocks80are disposed in an annular shape. The split cores16compose a part of the winding wire blocks80and are combined with each other to compose the stator core14in the annular shape. The insulator30composes a part of the winding wire blocks80and is attached to each of the plurality of split cores16. The coil conductor wire60composes a part of the winding wire blocks80and has a wound portion61wound around each split core16via the insulator30and the first bridging portion62and the second bridging portion63drawn out from the wound portion61. The regulating member70regulates movement of the coil conductor wire60. The second insulator32has the accommodating portion40that accommodates the second bridging portion63. The accommodating portion40has the first surface401and the second surface402, and the hole portions46and the routing passages45as opening portions. The first surface401and the second surface402form surfaces facing each other. The hole portions46and the routing passages45are opening portions that communicate with each other and are formed in the first surface401and the second surface402, respectively. The regulating member70is configured of a bendable member and is configured to be fixable in a state of an annular shape with the regulating member70inserted through the hole portions46that are opening portions in the first surface401and the routing passages45that are opening portions in the second surface402. In other words, the regulating member70is configured to be fixable in a state where the regulating member70is wound around the second bridging portion63accommodated in the accommodating portion40.

According to this, the regulating member70itself is also fixed to the accommodating portion40by being inserted through the hole portions46, and movement of the regulating member70in the circumferential direction is regulated. Therefore, falling-off of the second bridging portion63is effectively curbed by the regulating member70, and the stator10can reduce occurrence of short-circuiting or the like. Also, since it is only necessary to cause the regulating member70to be inserted through the hole portions46and the routing passages45and to fix the regulating member70in the annular shape, it is possible to considerably easily curb falling-off of the second bridging portion63. Moreover, it is possible to use a member that can be easily obtained, such as a cable tie, for example, as the regulating member70. Therefore, the stator10that enables the coil conductor wire60to be appropriately fixed by the simple method is provided.

Note that the stator10includes the stator core14, the ring member15, the plurality of split cores16, the insulator30including the first insulator31and the second insulator32, the coil conductor wire60, and the regulating member70. The stator core14is formed in an annular shape. The split cores16compose the stator core14. The ring member15is formed in an annular shape and accommodates the plurality of split cores16therein in an aligned manner in an annular shape.

The accommodating portion40has the recessed portions47that receive the regulating member70at an end portion of at least one of the first surface401and the second surface402. In the present embodiment, the recessed portions47are provided at a free end portion of the first surface401.

Movement of the regulating member70itself in the circumferential direction is further curbed by the regulating member70being fitted into the recessed portion47. Therefore, it is possible to curb loosening of the regulating member70. Therefore, it is possible to further effectively curb falling-off of the second bridging portion63from the accommodating portion40.

Here, if the number of slots in the stator10increases, the maximum number of second bridging portions63to be accommodated in the accommodating portion40increases. With this, it is not possible to accommodate the second bridging portions63in the accommodating portion40unless the volume of the accommodating portion40is sufficiently large, that is, unless the first surface401and the second surface402are sufficiently wide. In a case of a configuration in which the guide groove portions43are formed to be depressed in the radial direction of the stator10, for example, there is a concern that the accommodating portion40excessively projects outward in the radial direction of the stator10. In a case where the accommodating portion40largely projects on the side further outward than the back yoke portions18of the split cores16in the radial direction, the diameter of the rotating electrical machine100should increase. Furthermore, in such a case, there is a concern that the regulating member70may become interruption when the split cores16are press-fitted into the ring member15or the regulating member70may be damaged due to frictional heat generated at the time of the press-fitting.

On the other hand, the first surface401forms the surface of the accommodating portion40on the inner side in the radial direction of the stator core14. The second surface402forms the surface of the accommodating portion40on the outer side in the radial direction of the stator core14. The accommodating portion40has the first guide groove portion431, the second guide groove portion432, and the third guide groove portion433as the plurality of groove portions that are provided between the first surface401and the second surface402, are formed by being depressed in the axial direction of the stator core14, and accommodate the second bridging portions63.

According to this, there is no need to cause the accommodating portion40to excessively project outward in the radial direction even of the number of slots increases, by forming the guide groove portions43to be depressed in the axial direction of the stator core14, and it is thus possible to curb an increase in diameter of the rotating electrical machine100. For this reason, it is possible to reduce interruption of the regulating member70and damage thereof due to frictional heat generated at the time of the press-fitting when the split cores16are press-fitted into the ring member15. Therefore, the stator10that enables the coil conductor wire60to be appropriately fixed by the simple method is provided.

The hole portions46that are opening portions formed in the first surface401are through-holes formed to penetrate through the first surface401in the thickness direction. The recessed portions47are provided in a region obtained by extending the hole portions46in the axial direction.

According to this, the hole portions46and the recessed portions47are provided on a straight line that is parallel with the axial direction. Therefore, it is possible to minimize the length of the part of the regulating member70extending outside the first surface401, that is, inside the accommodating portion40in the radial direction by the regulating member70passing through the hole portions46and the recessed portions47. Accordingly, loosening of the regulating member70is unlikely to occur. Therefore, the stator10that enables the coil conductor wire60to be appropriately fixed by the simple method is provided.

Here, if the diameter or the width dimension of the coil conductor wire60differs, the dimension of the entire bridging portions accommodated in the accommodating portion40in the axial direction varies. For example, a case where the diameter or the width dimension of the coil conductor wire60is small and the dimension in the axial direction of all the plurality of second bridging portions63accommodated in the accommodating portion40is small will be examined. In this case, if the positions of the hole portions46are fixed, there is a concern that a large gap is placed between the regulating member70and the second bridging portions63even if the regulating member70inserted into the hole portions46is wound around the second bridging portions63. Therefore, the sticking out of the second bridging portions63may not be able to be effectively curbed by the regulating member70depending on the diameter of the coil conductor wire60.

On the other hand, in the present embodiment, the hole portions46that are opening portions in the first surface401are formed such that the length dimension in the axial direction of the stator core14is a long diameter while the length dimension in the circumferential direction is a short diameter. In the present embodiment, the hole portions46are long holes having a long diameter in the axial direction. In other embodiments, the hole portions46may have an oval shape having a long diameter in the axial direction or have a rectangular or a rounded rectangular shape having a long side in the axial direction, for example.

According to this, since the position of the regulating member70can move within a range of the long axis of the hole portions46, the diameter of the annular shape formed when the regulating member70is wound around the second bridging portions63can be variable in accordance with the diameter or the width dimension of the coil conductor wire60. Therefore, the stator10according to the present embodiment can curb a large gap placed between the regulating member70and the second bridging portions63and to effectively curb sticking-out of the second bridging portions63regardless of the diameter or the width dimension of the coil conductor wire60. Also, the stator10according to the present embodiment can also address a change in thickness dimension of the regulating member70. Therefore, the stator10that enables the coil conductor wire60to be appropriately fixed by the simple method is provided.

The stator core14has a plurality of, in this case, two regulating members70for each split core16. The first surface401has the hole portions46as a plurality of, in this case, two opening portions disposed symmetrically from the center of the accommodating portion40in regard to the circumferential direction of the stator core14.

According to this, it is possible to fix the second bridging portions63by the plurality of regulating members70with a satisfactory balance and thereby to more effectively prevent falling-off of the second bridging portions63. Therefore, the stator10that enables the coil conductor wire60to be appropriately fixed by the simple method is provided.

The insulator30according to the present embodiment includes the accommodating portion40that accommodates the second bridging portions63of the coil conductor wire60. The accommodating portion40has the first surface401and the second surface402, the first guide groove portion431, the second guide groove portion432, and the third guide groove portion433as the plurality of groove portions, and the hole portions46and the routing passages45as the opening portions. The first surface401and the second surface402form mutually facing surfaces. The first guide groove portion431, the second guide groove portion432, and the third guide groove portion433are provided between the first surface401and the second surface402, are depressed in the same direction, and accommodate the second bridging portions63in a separated manner for each phase. The hole portions46and the routing passages45are opening portions that communicate with each other and are formed to face the first surface401and the second surface402.

According to this, the insulator30can fix the second bridging portions63at the accommodating portion40and regulate movement of the regulating member70in the circumferential direction by inserting the regulating member70such as a cable tie, for example, into the hole portions46. Therefore, falling-off of the second bridging portions63is effectively curbed by using the regulating member70, and the stator10can reduce occurrence of short-circuiting or the like. Additionally, since it is only necessary to cause the regulating member70to be inserted into the hole portions46and the routing passages45and to fix the regulating member70in the annular shape, the insulator30can considerably easily curb falling-off of the second bridging portions63. Therefore, the insulator30that enables the coil conductor wire60to be appropriately fixed by the simple method is provided.

Furthermore, according to the present embodiment, the rotating electrical machine100includes the stator10or the stator10including the insulator30, and the rotor11. According to this, the rotating electrical machine100that enables the coil conductor wire60to be appropriately fixed by the simple method is provided as described above.

Other Embodiments

Note that the hole portions46are long holes in the above embodiment, the hole portions46are not limited thereto. For example, the hole portions46can be formed as long holes, ovals, long square holes, or the like in other embodiments. The aforementioned effects are achieved in these cases as well. Also, the hole portions46may have a circular shape, a rectangular shape, a rounded rectangular shape, a polygonal shape, or a rounded polygonal shape. Although a range in which a change in diameter of the coil conductor wire60can be addressed is narrowed in this case, the other effects described above can be achieved even in such embodiments.

Moreover, although the first surface401and the second surface402form the surface on the inner side in the radial direction and the surface on the outer side in the radial direction of the accommodating portion40in the aforementioned embodiment, the first surface401and the second surface402are not limited thereto. For example, the first surface401and the second surface402may be configured to form one surface in the axial direction and another surface in the axial direction of the accommodating portion40. In this case, the first guide groove portion431, the second guide groove portion432, and the third guide groove portion433are formed to be depressed in the radial direction between the first surface401and the second surface402. Although the diameter of the rotating electrical machine100may increase when the number of slots is caused to increase, for example, in such an embodiment, the other effects described above can be achieved.

Furthermore, although the aforementioned embodiment in which the regulating member70fixes the second bridging portions63accommodated in the accommodating portion40of the second insulator32has been described, the fixation is not limited thereto. For example, the first bridging portions62accommodated in the accommodating portion311of the first insulator31may be fixed with the regulating member70. In this case, it is possible to provide opening portions that are formed in the surface on the inner side and the surface on the outer side of the accommodating portion311in the radial direction and communicate with each other although details are not illustrated. The regulating member70can be inserted into the opening portions formed in the surface on the inner side and the surface on the outer side in the radial direction and can be fixed in a state of the annular shape surrounding the first bridging portions62. It is thus possible to regulate movement of the first bridging portions62accommodated in the accommodating portion311. Also, it is possible to achieve the fixation with a satisfactory balance over the entire circumferential direction of the accommodating portion311when the regulating member70fixes the first bridging portions62by providing a plurality of opening portions linearly symmetrically from the center of the accommodating portion311in the circumferential direction at this time. Furthermore, it is possible to regulate movement of the regulating member70and to achieve further reliable fixation of the first bridging portions62by providing recessed portions for receiving the regulating member70at an end portion of at least one of the surface on the inner side and the surface on the outer side of the accommodating portion311in the radial direction.

Although the plurality of embodiments of the present invention have been described above, the embodiments have been proposed as examples and are not intended to limit the scope of the invention. These novel embodiments can be implemented in other various forms, and various omissions, replacements, and changes can be made without departing from the gist of the invention. These embodiments and modifications thereof are included in the scope and the gist of the invention and are also included in the inventions described in the claims and the scope equivalent thereto.