Patent Publication Number: US-2004051417-A1

Title: Motor stator and method of manufacturing the motor stator

Description:
TECHNICAL FIELD  
       [0001] The present invention relates to a method of manufacturing a motor stator, in which a coil is formed on each magnetic pole teeth by salient pole concentrated winding, and a stator thereof, and particularly to a manufacturing method using split cores.  
       BACKGROUND ART  
       [0002]FIG. 21 is a half section showing a typical motor. A rotor is pivotally supported on a bracket  50  via a bearing, and a stator  30  is provided so as to surround the rotor. An exciting coil  20  is wound around an insulator  31  provided on the rotor  30 .  
       [0003] Regarding salient pole concentrated winding of the above motor stator  30 , a method of winding a conductor on each of magnetic pole teeth via a nozzle has been generally performed. In order to improve a winding capability and increase a space factor of a winding in a core slot, a split core manufacturing method disclosed in JP6-105487A and so on has been widely adopted, in which a core is split to perform winding. Further, in order to reduce the cost by a decrease in man-hours, methods for continuously performing winding on split cores have been adopted. However, since exciting coils cannot be continuously wound when cores remain split, JP8-19196A adopts a continuous core, in which adjacent core segments are connected via thin portions, and discloses a continuous winding method for performing winding on the continuous core. JP9-163690A and JP10-336934A disclose a continuous winding method and so on, in which adjacent core segments are connected using a connecting tool and winding is performed on the core.  
       [0004] On the other hand, as to a structure and a manufacturing method for ensuring an insulation distance between an exciting coil and a core and insulation between adjacent out-of-phase coils in the split core manufacturing method, JP11-341747A and so on disclose a structure in which a sheet-like insulating material larger than the shape of a slot is used and the insulating material is bent to shield around a coil. Moreover, JP9-191588A and JP10-126997A disclose a method of manufacturing an insulating structural body in the continuous winding method.  
       [0005] However, the above conventional split core manufacturing method has the following problems: the continuous winding method cannot be performed, winding is interrupted, the shape of a core and so on are limited, the shape of an insulating material lacks stability, the number of man-hours is large, and cross wires and the like are hard to process.  
       DISCLOSURE OF THE INVENTION  
       [0006] The object of the present invention is to provide a structure and a manufacturing method that can ensure an insulation distance between an exciting coil and a core and insulation between out-of-phase coils with high workability at low cost without degrading high-density winding, which is the original purpose of a split core manufacturing method.  
       [0007] In order to solve the above problem, according to the present invention, in a plurality of split core segments, film-shaped insulating materials extended by a specific dimension from the ends of outer peripheral cores and inner peripheral cores of the core segments are provided in core slots, and the plurality of core segments are separated and held at specific intervals, so that winding can be continuously performed in the split cores while ensuring a winding capability. Further, the core segments are rounded and shaped into an annular form while the film-shaped insulating materials extended by the specific dimension to the outsides of the cores are sequentially bent. Thus, it is possible to manufacture a stator which can ensure an insulation distance between the exciting coil and the core and interphase insulation between the out-of-phase coils.  
       [0008] Moreover, according to the present invention, in a core segment connected body for connecting a plurality of core segments, film-shaped insulating materials extended by a specific dimension from the ends of outer peripheral cores and inner peripheral cores of the core segments are provided in core slots, the core segments are rotated about connecting portions, and the plurality of core segments are opened and held at specific intervals, so that winding can be continuously performed in the split cores while ensuring a winding capability. Further, the core segments are rotated about the connecting portions and are brought close to one another to be rounded and shaped into an annular form while the film-shaped insulating materials extended by the specific dimension to the outsides of the cores are sequentially bent. Thus, it is possible to manufacture a stator which can ensure an insulation distance between the exciting coil and the core and interphase insulation between the out-of-phase coils.  
       [0009] Besides, according to the present invention, regarding cross wires caused by continuous winding and terminal wires, a coil hanging portion protruding toward a core slot is provided outside a turning region of a nozzle for winging on the inner surface of an outer peripheral side wall of an insulator, which is provided on both ends of a core of each core segment, and a winding end line of the winding is wound and fixed on the coil hanging portion, so that loosening of a wound exciting coil can be prevented and a stator can be manufactured with high workability.  
       [0010] Further, according to the present invention, regarding cross wires caused by continuous winding and terminal wires, after the plurality of core segments are rounded to form an annular stator, a housing box made of an insulating material is provided on a coil end of an end of the stator, and cross wires provided over exciting coils where winding is continuously performed are housed in the housing box via a sheet-like insulator while being separated for respective phases, so that a plurality of cross wires with the mixed phases can be processed with fewer man-hours and high insulating quality and a stator can be manufactured with high workability.  
       [0011] Additionally, according to the present invention, as to a height of an inner peripheral side wall of an insulator provided on both ends of a core of each core segment, a core slot internal dimension up to a boundary between adjacent core slots is used as the maximum dimension, two corners outside the inner peripheral side wall is cut smaller than the outer periphery of a wound exciting coil, an obstacle is eliminated in a turning region of a nozzle for winding, and the turning locus of the nozzle is provided according to the winding shape of an exciting coil as much as possible, so that it is possible to achieve high-density winding without loosening and to ensure a set region for a coil hanging portion and so on which protrudes into the core slot. 
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0012]FIG. 1 is a plan view showing core segments on which continuous winding is performed in a three-phase brushless motor according to Example 1 of the present invention;  
     [0013]FIG. 2 is a plan view showing the core segment of Example 1;  
     [0014]FIG. 3 is a perspective view showing the core segment of Example 1;  
     [0015]FIG. 4 is a partial plan view showing the winding state of FIG. 1;  
     [0016]FIG. 5 is a plan view showing a core segment connecting body on which continuous winding is performed in a three-phase motor according to Example 2 of the present invention;  
     [0017]FIG. 6 is a partial plan view showing the winding state of FIG. 5;  
     [0018]FIG. 7 is an explanatory drawing showing manufacturing steps according to Example 3 of the present invention;  
     [0019]FIG. 8 is an explanatory drawing showing manufacturing steps according to Example 4 of the present invention;  
     [0020]FIG. 9 is an explanatory drawing showing manufacturing steps according to Example 5 of the present invention;  
     [0021]FIG. 10 is an explanatory drawing showing manufacturing steps according to Example 6 of the present invention;  
     [0022]FIG. 11 is an explanatory drawing showing manufacturing steps according to Example 7 of the present invention;  
     [0023]FIG. 12 is a perspective view showing a magnetic pole tooth for mounting an insulator having a coil hanging portion formed thereon according to Example 8 of the present invention;  
     [0024]FIG. 13 is a front view taken from the inner peripheral direction of the insulator according to Example 8 of the present invention;  
     [0025]FIG. 14 is a diagram showing a continuous winding pattern of one phase in a three-phase motor according to Example 8 of the present invention;  
     [0026]FIG. 15 is a divided perspective view showing an example of a cross wire housing box unit according to Example 9 of the present invention;  
     [0027]FIG. 16 is a perspective view showing the cross wire housing box according to Example 9 of the present invention;  
     [0028]FIG. 17 is a partial sectional view showing the cross wire housing box according to Example 9 of the present invention;  
     [0029]FIG. 18 is a sectional view showing a part of a motor for fixing the cross wire housing box according to Example 9 of the present invention;  
     [0030]FIG. 19 is a perspective view showing a cross wire housing box according to another example of the present invention;  
     [0031]FIG. 20 is a sectional view showing the cross wire housing box according to another example of the present invention;  
     [0032]FIG. 21 is a half section showing a typical motor;  
     [0033]FIG. 22 is a perspective view showing a single conventional core segment where winding is performed; and  
     [0034]FIG. 23 is an explanatory drawing showing a method of manufacturing a plurality of conventional core segments. 
    
    
     BEST MODE FOR CARRYING OUT THE INVENTION  
     [0035] A method of manufacturing a motor stator of the present invention, in which splitting is performed for each magnetic pole tooth in the circumferential direction, a plurality of core segments are fit into each other to form an annular stator after winding is performed on the plurality of core segments, each having a concave fitting portion on one end of a split surface and a convex fitting portion on the other end of the split surface, wherein a film-shaped insulating material is provided in a core slot of each core segment, the insulating material being extended by a specific dimension from the ends of an outer peripheral core and an inner peripheral core of the core segment to the outsides of the cores, the core segments are separated at specific intervals, the core segments are held in series so that the teeth are arranged substantially in parallel, and continuous winding is sequentially performed without cutting cross wires between at least two exciting coils.  
     [0036] The above manufacturing method has the following effect: winding is continuously performed on the plurality of core segments, in which film-shaped insulating materials extended by the specific dimension from the ends of the outer peripheral cores and the inner peripheral cores of the core segments to the outside are held in the core slots, by using the whole slot region with no obstacles on winding and without the necessity for connection in postprocessing.  
     [0037] A method of manufacturing a motor stator according to the present invention, in which a stator iron core is formed as a core segment connected body having a plurality of core segments connected via yokes, the core segment including one tooth, and the core segment connected body is rounded to form an annular stator after winding is performed, wherein the core segments are connected so that the teeth are opened around connecting portions from substantially parallel positions, the core segment having a core slot including a film-shaped insulating material extended by a specific dimension from the ends of an outer peripheral core and an inner peripheral core to the outsides of the cores, the core segments are held so that the film-shaped insulating materials of the adjacent core segments do not interfere with each other, and continuous winding is sequentially performed without cutting cross wires between at least two exciting coils.  
     [0038] The above manufacturing method has the following effect: winding is continuously performed on the plurality of core segments, which hold film-shaped insulating materials extended by the specific dimension from the ends of the outer peripheral cores and the inner peripheral cores of the core segments to the outside, by using the whole slot region with no obstacles on winding and without the necessity for connection in postprocessing.  
     [0039] The method of manufacturing a motor stator of the present invention, wherein the extended portion of the film-shaped insulating material is pressed into the core slot from the outer periphery after winding is performed on the core segment, the insulating material being extended by the specific dimension from the end of the outer peripheral core of the core segment, and the plurality of core segments are brought close to one another after bending, the core segments having been separated and held at specific intervals, so that the extended portions of the bent film-shaped insulating materials are held between exciting coils of the plurality of core segments and a creepage insulation distance is ensured between the outer peripheral core and the exciting coil.  
     [0040] The above manufacturing method has the effect of readily forming a creepage insulating structural body on the outer peripheral sides of the core slots without considerably changing the winding state of the plurality of core segments where winding is continuously performed.  
     [0041] The method of manufacturing a motor stator according to the present invention, wherein the core segments are connected so as to be opened around the connecting portions from substantially parallel positions, winding is performed on the plurality of core segments which are held so as to permit no interference between the adjacent film-shaped insulating materials provided in the core slots, the plurality of core segments are rotated about the connecting portions and the core segments are brought close to one another, the core segments are rotated until the extended portions of the film-shaped insulating materials overlap each other, the insulating materials being extended by the specific dimension from the ends of the outer peripheral cores of the adjacent core segments to the outsides of the cores, the extended portions of the film-shaped insulating materials are pressed and bent into the core slots from the outer peripheral side, the film-shaped insulating materials being extended by the specific dimension from the cores, the core segments are rotated about the connecting portions again to bring the inner peripheral cores of the core segments close to one another until the extended portions of the bent film-shaped insulating materials are held between the exciting coils of the core segments, and a creepage insulation distance is ensured between the outer peripheral core and the exciting coil. The above manufacturing method has the effect of readily forming a creepage insulating structural body on the outer peripheral sides of the core slots without considerably changing the winding state of the plurality of core segments where winding is continuously performed.  
     [0042] The method of manufacturing a motor stator according to the present invention, wherein after winding is performed on the core segments, the plurality of core segments are bent into an annular shape until overlapping is made between the extended portions of the film-shaped insulating materials extended by the specific dimension from the ends of inner peripheral cores of the adjacent core segments to the outsides of the cores, the extended portions of the film-shaped insulating materials are pressed and bent in the core slots from the inner peripheral side of the annular core segments, and the inner peripheral cores of the plurality of core segments are brought close to one another again to form an annular stator, so that the extended portions of the bent film-shaped insulating materials are held between the exciting coils of the core segments and a creepage insulation distance is ensured between the inner peripheral core and the exciting coil.  
     [0043] The above manufacturing method has the following effect: by using the course of the process of forming the annular stator by rounding the plurality of core segments, on which winding is continuously performed, a creepage insulating structural body can be readily formed on the inner peripheral sides of the core slots.  
     [0044] The method of manufacturing a motor stator according to the present invention, wherein after winding is performed on the core segments, the core segments are rotated around the connecting portions of the core segments and the core segments are brought close to each other until overlapping is made between the film-shaped insulating materials extended by the specific dimension from the ends of the inner peripheral cores of the adjacent core segments to the outsides of the cores, the plurality of core segments are bent into an annular shape, the extended portions of the film-shaped insulating materials are pressed and bent into the core slots from the inner peripheral sides of the annular core segments, and the plurality of core segments are rotated about the connecting portions of the core segments again to bring the inner peripheral cores close to one another, so that the extended portions of the bent film-shaped insulating materials are held between the exciting coils of the core segments and a creepage insulation distance is ensured between the inner peripheral core and the exciting coil.  
     [0045] The above manufacturing method has the following effect: by using the course of the process of forming the annular stator by rounding the plurality of core segments, on which winding is continuously performed, a creepage insulating structural body can be readily formed on the inner peripheral sides of the core slots.  
     [0046] The method of manufacturing a motor stator according to the present invention, wherein the film-shaped insulating material has an overlapping dimension of the extended portions on the outer peripheral side and the inner peripheral side when the extended portions of the film-shaped insulating materials are bent into the core slots, the insulting materials being extended by the specific dimension from the ends of the outer peripheral cores and the inner peripheral cores to the outsides of the cores, and interphase insulation is ensured between the adjacent exciting coils when the plurality of core segments are adjacent to each other in an annular shape to form a stator.  
     [0047] The above manufacturing method has the following effect: the core segments are bent by using the course of the process of forming the annular stator by rounding the plurality of core segments, on which winding is continuously performed, so that an interphase insulating structural body can be readily formed.  
     [0048] A motor stator of the present invention that is formed into an annular shape by rounding a plurality of core segments after winding is performed on the plurality of core segments split for respective magnetic pole teeth in the circumferential direction, wherein the stator comprises a coil hanging portion protruding toward a core slot outside a turning region of a nozzle for winding on an inner surface of an outer peripheral side wall of an insulator provided on both ends of a core of the core segment, and a winding end line is wound and fixed on the coil hanging portion.  
     [0049] The above stator can readily wind and fix the winding end line without causing a failure during winding or changing the attitude of the nozzle after winding.  
     [0050] According to the stator of the present invention, a motor stator in which a plurality of core segments are rounded and formed into an annular shape after winding is continuously performed on the plurality of core segments split for respective magnetic pole teeth in the circumferential direction without cutting cross wires between at least two exciting coils, wherein after the plurality of core segments are rounded to form an annular stator, a housing box made of an insulating material is provided on coil ends of stator ends, and cross wires provided over the exciting coils are housed in the housing box via a sheet-like insulator while being separated for respective phases, the exciting coils having been subjected to continuous winding.  
     [0051] The stator has the effect of readily separating cross wires of respective phases generated in a mixed manner and housing the cross wires for the respective phases with fewer man-hours by continuous winding.  
     [0052] According to the stator of the present invention, a motor stator in which a plurality of core segments are rounded and formed into an annular shape after winding is continuously performed on the plurality of core segments split for respective magnetic pole teeth in the circumferential direction, wherein as to a height of an inner peripheral side wall of an insulator provided on both ends of a core of the core segment, a core slot internal dimension up to a boundary between adjacent core slots is used as the maximum dimension, and two corners outside the inner peripheral side wall are cut smaller than the outer periphery of a wound exciting coil while the strength of the inner peripheral side wall is maintained.  
     [0053] The stator can minimize the turning locus of the nozzle for winding, prevent loosening during winding, achieve high-density winding, and widely use a region outside the turning region.  
     [0054] The following will describe Examples of the present invention in accordance with the accompanying drawings.  
     EXAMPLE 1  
     [0055]FIG. 1 shows that cross wires  21  between in-phase exciting coils  20  are continuously wound without being cut on split cores of a three-phase brushless motor having twelve slots.  
     [0056]FIGS. 2 and 3 show each unit of magnetic pole teeth which are split in the circumferential direction before winding. The tooth  13  has a core segment  11  formed by laminating a plurality of thin iron plates, a film-shaped insulating material  32  for insulating adjacent exciting coils, and an insulator  31 .  
     [0057] The core segment  11  has an outer peripheral core  17  and an inner peripheral core  18  which are connected to each other via a connecting portion, and core slots  12  on both sides in the laminating direction. A concave portion  14  formed on one of the ends of the outer peripheral core  17  and a convex portion  15  formed on the other end constitute a fitting portion for connecting the adjacent core segments  11 .  
     [0058] Each of the core slots  12  comprises the film-shaped insulating material  32 . An end  321  on the outer periphery of the film-shaped insulating material  32  is extended by L1 from the end of the outer peripheral core  17 , and an end  322  on the inner periphery is extended by L2 from the end of the inner peripheral core  18 . The insulator  31  is fit into both ends of the core segment  11  having the film-shaped insulator  32 .  
     [0059] Regarding the lengths L1 and L2 for extending the end  321  on the outer periphery and the end  322  on the inner periphery of the film-shaped insulating material  32  and a creepage distance for insulation, the relationship expressed by the following equation is established. The following creepage distance for insulation indicates a distance between the outer peripheral core  17  and the exciting coil  20 .  
     L1, L2&gt;creepage distance for insulation  
     [0060] As shown in FIG. 4, separation is made by a specific interval L0 from the position for connecting the adjacent core segments  11 , and the adjacent teeth  13  are held substantially in parallel. Further, the specific interval L0 is set so as to maintain a state in which the ends  321  on the outer peripheries of the adjacent film-shaped insulating materials  32  overlap each other and do not enter the core slots  12  of the adjacent core segments  11 . The specific interval L0 is an element determining a length of the cross wire  21  caused by continuous winding. It is preferable to minimize the interval L0 in consideration of simplicity of wire processing work in postprocessing and the cost.  
     [0061] Further, as shown in FIG. 4, the ends  321  on the outer peripheries of the adjacent film-shaped insulating materials  32  overlap each other like a flat surface because the insulating materials are shaped like thin films. The overlapping portions of the film-shaped insulators  32  are shaped like flat surfaces and do not protrude into the core slot  12 . Thus, the overlapping potion does not interfere with a sliding region of a nozzle  40 , so that the nozzle  40  is highly controllable over the position of the coil  22  and winding can be performed with a high density by using the whole region of the core slot  12 .  
     [0062] As described above, the positional relationship of the core segments  11  shown in FIG. 4 is maintained and the twelve core segments  11  are held in series, so that necessary exciting coils  20  can be continuously wound as shown in FIG. 1.  
     [0063] In contrast, FIG. 22 is a perspective view showing a unit of a conventional magnetic pole tooth. In FIG. 22, reference numeral  11  denotes a core segment formed by laminating a plurality of thin iron plates, reference numeral  32  denotes a film-shaped isolating material for insulating adjacent exciting coils, and reference numeral  31  denotes an insulator. In this conventional example, an exciting coil  20  is wound for each of the magnetic pole teeth and the coil  22  is cut.  
     [0064] In the conventional method of manufacturing a stator, a required number of magnetic pole teeth are produced and are arranged like FIG. 23( a ), and the core segments  11  are connected like an annular shape as shown in FIG. 23( b ). The in-phase coils  22  are connected later. The conventional method requires more man-hours for connection as compared with the present example and thus automation becomes difficult.  
     EXAMPLE 2  
     [0065]FIG. 5 shows that cross wires  21  between in-phase exciting coils  20  are continuously wound without being cut on the connecting cores of a three-phase brushless motor having twelve slots. As shown in FIG. 6, in this example, core segments  11  are connected so that teeth  13  are opened around a connecting portion  162 , and the adjacent core segments  11  are held with a specific angle of θ 0 . The specific angle θ 0  is set so as to maintain a state in which no interference occurs between extended portions on outer peripheral ends  321  of adjacent film-shaped insulating materials  32 . Since the extended portions on the ends of the film-shaped insulating materials  32  do not interfere with each other, the flatness is not degraded on the outer peripheral ends  321  of the film-shaped insulating materials  32  (virtual lines of FIG. 6) and any obstructions are not found in a sliding region of a nozzle  40 . Thus, winding can be performed with a high density while the nozzle  40  is highly controllable over the position of the coil  22  and the whole region of the core slot  12  is used.  
     [0066] As described above, the positional relationship of the core segments  11  of FIG. 6 is maintained and the twelve core segments  11  are held, so that required exciting coils  20  can be continuously wound as shown in FIG. 5.  
     EXAMPLE 3  
     [0067]FIG. 7 shows a part of a line having a plurality of core segments  11 , on which winding is performed as shown in FIG. 1, and the steps of forming a creepage insulating structural body between outer peripheral cores  17  and exciting coils  20  of the core segments  11 .  
     [0068] As shown in FIG. 4, the core segments  11  are separated from one another at specific intervals L0, adjacent teeth  13  are held substantially in parallel, and winding is performed (FIG. 7( a )). Then, the extended portions on ends  321  of film-shaped insulating materials, which are extended by a specific dimension from the ends of the outer peripheral cores  17  of the core segments  11 , are pressed and bent into core slots  12  by blades  41  from the outer peripheral sides (FIG. 7( b )). The outer peripheral cores  17  of the plurality of core segments  11 , which have been separately held at the specific intervals L0, are brought close to each other until contact occurs, so that the extended portions on the ends  321  of the bent film-shaped insulating materials are folded inward and are held to form a creepage insulating structural body (FIG. 7( c )).  
     [0069] As described above, without changing the series configuration after winding, with a simple method for readily performing automation, in which the extended portions on the ends  321  of the film-shaped insulating materials are pressed inward by the plurality of blades  41  from the outer peripheral sides and the outer peripheral cores  17  of the core segments  11  are brought close to each other until contact occurs, it is possible to ensure a creepage distance for insulation between the outer peripheral cores  17  and the exciting coils  20 .  
     [0070] In the process of bringing the core segments  11  into contact with each other after bending the extended portions on the outer peripheral sides of the film-shaped insulating materials, the outer peripheral cores  17  of the core segments  11  do not need to make contact with each other. The adjacent core segments  11  only need to be brought close to each other by a moving distance permitting the function of holding the extended portions  321  on the outer peripheral sides of the bent film-shaped insulating materials.  
     EXAMPLE 4  
     [0071]FIG. 8 shows a part of a line having a plurality of connecting cores, on which winding is performed as shown in FIG. 5, and the steps of forming a creepage insulating structural body between outer peripheral cores  17  and exciting coils  20  of core segments  11 .  
     [0072] As shown in FIG. 6, the core segments  11  are connected so as to be opened around connecting portions  162 . The adjacent core segments  11  are held with a specific angle of θ 0  and winding is performed (FIG. 8( a )). Then, the core segments  11  are rotated about the connecting portions  162  and inner peripheral cores  18  are brought close to each other. The core segments  11  are rotated until ends  321  of film-shaped insulating materials overlap each other. The film-shaped insulating materials have been extended by a specific dimension from the ends of the outer peripheral cores  17  to the outsides of the cores. Blades  41  are pressed into core slots  12  from openings between the core segments connected via the connecting portions  162 , and the extended portions on the ends  321  of the film-shaped insulators are bent (FIG. 8( b )). Furthermore, the core segments  11  are rotated about the connecting portions  162  and the inner peripheral cores  18  are brought close to one another until teeth  13  of the core segments  11  are arranged substantially in parallel. In this way, the extended portions on the ends  321  of the bent film-shaped insulating materials are folded inward and are held to form a creepage insulating structural body (FIG. 8( c )).  
     [0073] As described above, with the simple method for readily performing automation, in which the plurality of core segments  11  are rotated about the connecting portions  162 , the plurality of blades  41  are pressed inward from the outer peripheral sides, and the core segments  11  are rotated to bring the inner peripheral cores  18  close to each other, it is possible to ensure a creepage distance for insulation between the outer peripheral cores  17  and exciting coils  20 .  
     [0074] Additionally, in the process of rotating the core segments  11  again and bringing the core segments  11  close to each other after bending the extended portions on the ends  321  of the film-shaped insulators, it is not necessary to bring the core segments  11  close to each other until the teeth  13  are arranged substantially in parallel. Rotation needs to be performed only with an angle permitting the function of holding the extended portions on the ends  321  of the bent film-shaped insulating materials.  
     EXAMPLE 5  
     [0075]FIG. 9 shows the steps of forming a creepage insulating structural body between inner peripheral cores  18  and exciting coils  20  of a line having a plurality of core segments  11 , on which a creepage insulating structural body of FIG. 7 has been formed between outer peripheral cores  17  and the exciting coils  20 , after winding is performed on the core segments  11  as shown in FIG. 1.  
     [0076] Prior to the step of FIG. 9( a ), as shown in FIG. 7( c ) in a state in which teeth  13  are kept in parallel, the outer peripheral cores  17  are brought close to each other until contact occurs, and a creepage insulating structural body is formed between the outer peripheral cores  17  and the exciting coils  20 .  
     [0077] The plurality of core segments  11  shown in FIG. 7( c ) are fixed on holding tools (not shown) which can freely rotate about contact points  161  between the core segments  11 . The plurality of core segments  11  held on the holding tools are rotated about the contact points  161  until overlapping is made between the extended portions on inner peripheral ends  322  of film-shaped insulating materials which are extended from the ends of the inner peripheral cores  18  (FIG. 9( a )).  
     [0078] Then, the extended portions that have overlapped each other on the ends  322  of the film-shaped insulating materials are pressed into core slots  12  by blades  41  from the inner peripheral sides of the cores and are bent therein (FIG. 9( b )).  
     [0079] Further, the plurality of core segments  11  are rotated about the contact points  161  and the inner peripheral cores  18  are brought close to each other and make contact with each other, so that an annular stator  30  is formed. The extended portions on the ends  322  of the film-shaped insulating materials are bent into the core slots  12  and are held to form a creepage insulating structural body.  
     [0080] As described above, with the method of rotating the plurality of core segments  11  about the contact points  161 , pressing the plurality of blades  41  inward from the inner peripheral side, bending the extended portions on the ends  322  of the film-insulating materials to the core slots  12 , and rotating the core segments  11  again to bring the inner peripheral cores  18  close to each other, it is possible to readily perform manufacturing using tools. With the simple method permitting automation, it is possible to form the annular stator  30  while ensuring a creepage distance for insulation between the inner peripheral cores  18  and the exciting coils  20 .  
     EXAMPLE 6  
     [0081]FIG. 10 shows the steps of forming a creepage insulating structural body between inner peripheral cores  18  and exciting coils  20  of a line having a plurality of core segments  11  shown in FIG. 8 after winding is performed on the core segments  11  as shown in FIG. 5.  
     [0082] From a state in which teeth  13  of FIG. 8( c ) are kept substantially in parallel, the core segments  11  are rotated about connecting portions  162  to bring the inner peripheral cores  18  close to each other, and overlapping is made between the extended portions of ends  322  on the inner peripheral side of film-shaped insulating materials, which are extended by a specific dimension from the ends of the adjacent inner peripheral cores  18  (FIG. 10( a )).  
     [0083] Then, the extended portions that overlap each other on the ends  322  of the film-shaped insulating materials are pressed into core slots  12  by blades  41  from the inner peripheral sides of the cores and are bent therein (FIG. 10( b )).  
     [0084] Further, the plurality of core segments  11  are rotated about the contact points  161  and the inner peripheral cores  18  are brought close to each other to make contact with each other, so that an annular stator  30  is formed. The extended portions on the ends  322  of the film-shaped insulating materials are bent into the core slots  12  and are held to form a creepage insulating structural body.  
     [0085] As described above, with the method of rotating the plurality of core segments  11  about the contact points  161 , pressing the plurality of blades  41  inward from the inner peripheral sides, bending the extended portions on the ends  322  of the film-shaped insulating materials into the core slots  12 , and rotating the core segments  11  again to bring the inner peripheral cores  18  close to each other, it is possible to perform manufacturing using tools. With the simple method permitting automation, it is possible to form the annular stator  30  while ensuring a creepage distance for insulation between the inner peripheral cores  18  and the exciting coils  20 .  
     EXAMPLE 7  
     [0086]FIG. 11 shows a part of a line having a plurality of core segments according to the present example. When extended portions of ends  321  on the outer peripheral sides of the film-shaped insulating materials and extended portions of ends  322  on the inner peripheral sides are bend into core slots  12 , the present example has dimensions of the extended portions of ends  321  and the ends  322  that overlap each other. Moreover, after winding is performed on the plurality of core segments  11 , the extended portions of the ends  321  and the extended portions of the ends  322  are caused to overlap each other, and the plurality of core segments  11  are rounded to form an annular core.  
     [0087] In winding of the split cores shown in FIG. 1, in order to ensure interphase insulation between adjacent exciting coils  20 , as shown in FIG. 11, the present example has dimensions of the extended portions of the outer peripheral ends  321  and the extended portions of the inner peripheral ends  322  that overlap each other. Winding is performed on the plurality of core segments having the film-shaped insulating materials  32  on the core slots  12 . At this point, a specific interval L0 between the adjacent core segments  11  is set so that the extended portions on the ends  321  of the adjacent film-shaped insulating materials  32  overlap each other and can be kept from entering the core slots  12  of the adjacent core segments  11  as in Example 1.  
     [0088] The process of forming the annular shape after winding is the same as those of Examples 3 and 5. As with the case of forming the above creepage insulating structural bodies, it is possible to form an annular stator  30  while ensuring interphase insulation between the exciting coils  20  with a simple method permitting automation.  
     [0089] Besides, regarding a method of extending the extended portions  321  on the ends  321  and the extended portions on the ends  322  of the film-shaped insulating materials until the extended portions overlap each other, the extended dimension of the extended portion  322  on the inner peripheral side and the extended dimension of the extended portion  321  on the outer peripheral side have the following relationship:  
     extended dimension of the extended portion on the inner peripheral side&gt;extended dimension of the extended portion on the outer peripheral side  
     [0090] With the above dimensions, it is possible to minimize the extension of the specific interval L0 between the core segments and achieve simplified wire processing work on cross wires and in postprocessing.  
     EXAMPLE 8  
     [0091]FIG. 12 is a perspective view showing that winding is performed on a core segment  11 , which comprises an insulator  31  having a coil hanging portion formed thereon, by a nozzle  40  for winding. FIG. 13 shows a configuration in which a coil hanging portion  312  protruding toward a core slot  12  is provided outside a region for turning the nozzle  40  for winding on the inner surface of the outer peripheral side wall of the insulator. Further, FIG. 14 is a diagram showing a winding pattern of one phase using the coil hanging portion.  
     [0092] Referring to FIG. 14, the present example will be discussed below. First, after winding is performed on V 1  of the core segment  11 , a winding end line  23  is wound around the coil hanging portion  312  and is fixed thereon, the winding is shifted to V 2  of the subsequent core segment  11  via a cross wire  21 , and winding performed on V 2 . In this way, winding is sequentially performed on V 3  and V 4  of the core segment.  
     [0093] Fixing the winding end line  23  on the coil hanging portion is an important condition for reducing the man-hours in wire processing on the cross wires  21  and the like in postprocessing. It is possible to readily perform wire processing without changing the winding state.  
     [0094] Moreover, outside the region for turning the nozzle  40  for winding, the coil hanging portion  312  is provided on an inner surface region of an outer peripheral side wall  311  of the insulator. The inner surface region is in an interval of the exciting coil  20  and is not used. Thus, the coil hanging portion  312  does not interfere with the nozzle  40  for winding when winding is performed. Additionally, the coil hanging portion  312  is protruded into the core slot  12 , so that the winding end line  23  can be readily wound and fixed without changing the attitude of the nozzle  40  after winding is performed.  
     EXAMPLE 9  
     [0095]FIG. 15 is an exploded perspective view showing a cross wire housing box unit provided on a stator of the present example. In this example, after a plurality of core segments  11  are rounded to assemble an annular stator  30 , a housing box  33   a  made of an insulating material is provided on an end of the stator  30 , cross wires  21  provided over exciting coils  20 , on which winding is continuously performed, are separated for respective phases via a sheet-like insulator  35  and are housed in three stages in the housing  33   a , and housed members such as the cross wire  21  are contained in the housing box  33   a  by a lid  34   a  for fixation. Besides, although the two sheet-like insulators  35  are necessary in a three-phase motor, one of the insulators is omitted in FIG. 15.  
     [0096]FIG. 16 is a perspective view showing the housing box  33   a . The housing box  33   a  is positioned and held on the insulators  31  by mounting arms  334  which protrude toward the outer periphery.  
     [0097] Further, on an outer peripheral wall  331  of the housing box  33   a , slits  332  for the cross wires  21  are provided in accordance with the positions of coil hanging portions  312  and the positions of winding start grooves  315  of the insulators  31  provided on the core segments  11 , so that the cross wires  21  fixed on the coil hanging portions  312  can be housed with high workability.  
     [0098] Besides, FIGS.  17 ( a ) to  17 ( c ) are partial sectional views showing the housing box  33   a . Every time the cross wire  21  of each phase is housed in the housing box  33   a , the cross wire  21  is covered with the sheet-like insulator  35  for interphase insulation. Two kinds of steps  333  on different positions are provided on an outer peripheral wall  331  of the housing box  33   a , the outer peripheral edges of the sheet-like insulator  35  are locked into the steps  333 , and two sheet-like insulators  35  can be fixed as interphase insulation among three phases.  
     [0099] Moreover, as shown in FIG. 15, the lid  34   a  for fixation is positioned and held on the insulators  31  by mounting arms  341  protruding toward the outer periphery. The lid  34   a  for fixation can be fixed in the housing box  33   a  in a fitting manner. The lid  34   a  contains housed members in the housing box  33   a  and insulates the housed members from the outer periphery including a bracket  50 .  
     [0100] Further, protrusions  342  for fixation are provided on the mounting arms  341  protruding toward the outer periphery of the lid  34   a  for fixation. As shown in FIG. 18, the protrusions  342  for fixation are pressed onto the stator  30  by the bracket  50  via the insulators  31  when a motor is assembled, so that the housing box  33   a  can be fixed on the stator  30  without the necessity for a fastening component.  
     [0101] Besides, it is needless to say that when interphase insulation between the cross wires  21  of respective phases is not necessary, the cross wires  21  of the respective phases generated in a mixed manner can be readily housed as they are by using the whole housing box  33   a , without the necessity for the sheet-like insulator  35 .  
     [0102] Further, FIG. 19 shows another example of the housing box and FIG. 20 is a partial sectional view showing the housing box. A housing box  33   b  of FIG. 20 is an example in which two separation walls  335  are provided on the bottom of the housing box  33   b  in parallel with the outer peripheral wall and the inner peripheral wall of the housing box so as to permit separation for each phase. The two separation walls  335  and the slits  332  on the outer peripheral wall are changed in depth, so that interphase insulation can be provided on the wiring of the cross wires to the housing box  33   b . In FIG. 20, the height of the separation wall  335  and the slits of the inner peripheral wall are formed so as to correspond to each other. Furthermore, a step suitable for the height of the separation wall  335  is provided on the bottom of the lid  34   b  for fixation of FIG. 20, so that each phase can be separated without the necessity for the sheet-like insulator.  
     EXAMPLE 10  
     [0103] Referring to FIGS. 12 and 13, Example 10 will be discussed below. In this example, the shape of an internal side wall  313  is limited on an insulator  31  provided on both ends of a core of each core segment, so that a nozzle  40  can be controlled with a small turning locus.  
     [0104] First, as to a height H0 of the internal peripheral side wall  313  of the insulator, as shown in FIG. 2, when it is assumed that a dimension L3 is provided between the inner peripheral base of the inner peripheral side wall  313  of the insulator and a boundary between adjacent core slots  12  (line connecting an end of an outer peripheral core  17  and an end of an inner peripheral core  18 ), since an exciting coil is not wound as large as the inner peripheral dimension L3 of the core slot, the height H0 is limited like H0&lt;L3 and is not increased more than necessary.  
     [0105] Further, corners  314  on both external sides of the inner peripheral side wall  313  of the insulator are cut like trapezoids smaller than the outer peripheral edge of a wound exciting coil  20  so that the strength of the inner peripheral side wall  313  can be maintained. Thus, an obstacle is eliminated in a turning region of a nozzle  40  for winding. The turning locus of the nozzle  40  is provided according to the winding shape of the exciting coil  20  as much as possible, so that loosening of a coil  22  is suppressed and high-density winding is achieved without uneven winding.  
     [0106] Moreover, since the turning locus of the nozzle  40  limited to a minimum, it is possible to widely use a region outside the turning region of the nozzle and sufficiently ensure a region for setting a coil hanging portion  312  which protrudes into a core slot as shown in Example 8.  
     [0107] With the above configuration, the present invention can obtain the following effect: by using split cores or connecting cores, a coil is wound around a core segment having a film-shaped insulating material on a core slot, the insulating material being extended by a specific dimension from the ends of an outer peripheral core and an inner peripheral core of the core segment, the whole slot region is used with a high density, which is the original purpose of the split cores, and continuous winding can be performed without the necessity for a connecting operation in the postprocessing of winding.  
     [0108] Moreover, according to the present invention, the following effect can be achieved: without largely changing the winding state of the plurality of core segments on which continuous winding is performed using split cores or connecting cores, a creepage insulating structural body can be readily formed on the outer peripheral sides of the core segments.  
     [0109] Additionally, according to the present invention, the following effect can be achieved: by using the course of the process of forming an annular stator by rounding a plurality of core segments, on which winding is continuously performed using split cores or connecting cores, a creepage insulating structural body can be readily formed on the inner peripheral sides of the core segments.  
     [0110] Further, according to the present invention, it is possible to obtain the effect of readily forming an interphase insulating structural body by using the course of the process of rounding a plurality of core segments, on which winding is continuously performed, to form an annular stator.  
     [0111] Besides, according to the present invention, the following effect can be achieved: a winding end line can be readily wound and fixed without causing a failure during winding and man-hours can be reduced for wire processing of cross wires and so on in postprocessing.  
     [0112] Further, according to the present invention, the following effect can be achieved: cross wires of respective phases generated in a mixed manner can be readily separated and housed for the respective phases with fewer man-hours by continuous winding, so that the man-hours for wire processing can be remarkably reduced while ensuring interphase insulation.  
     [0113] Additionally, according to the present invention, the following effects can be achieved: a turning locus of a nozzle for winding is minimized, loosening is prevented during winding, high-density winding is achieved, and a region outside a turning region can be widely used.