Patent Publication Number: US-2022224180-A1

Title: Coil, stator member, stator, and motor

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a U.S. national stage application under 35 U.S.C. § 371 of International Application. No. PCT/JP2020/018415, filed May 2020, which claims the priority of JP Application No. 2019-088141, filed May 8, 2019, the entire contents of each of which are incorporated herein by reference. 
    
    
     FIELD OF THE DISCLOSURE 
     The present invention relates to a coil, a stator member, a stator, and a motor. 
     BACKGROUND OF THE DISCLOSURE 
     Conventionally, edgewise coils that are composed of stacked steel plates manufactured by press punching are known. Such edgewise coils are adopted, for example, in stators of motors. 
     In this case, a stator is formed by sequentially attaching molded coils (edgewise coils) to a plurality of slots (teeth) on the inner peripheral surface of an annular stator core, and connecting one end of each of the coils, which are annularly arranged, to a busbar. 
     In more detail, each of the annularly arranged coils has a pair of terminals (long terminals). The pair of terminals is a portion in which a pair of ends, which are the beginning and end of the coil, are extended out from a helical structure portion (turn portion) along helical traveling directions. The pair of terminals are aligned on one side (e.g., one short side) of the turn portion of the coil, and one of the terminals is extended out on the side to be an inner peripheral surface of the annually arranged coils and the other is extended out on the side to be an outer peripheral surface of the annually arranged coils. Both the terminals are then connected to a rod-shaped (semi-circular) or annular busbar, which extends in a circumferential direction of the stator core, by welding or the like (refer to Patent Literature 1, for example). 
     CITATION LIST 
     Patent Literature 
     Patent Literature 1: Japanese Patent Application Laid-Open No. 2009-89456 
     SUMMARY OF THE DISCLOSURE 
     Technical Problem 
     However, in the case of attaching the conventional coils to the stator core and joining (connecting) the busbar and the terminals, a joining unit (for example, a welding device or a joining device) has to be moved between the terminals on the side to be the inner peripheral surface of the annularly arranged coils (stator core) and the terminals on the side to be the outer peripheral surface thereof, which results in complications regarding control necessary for joining, such as positioning. Furthermore, the movement range of the joining unit (welding device or the like) increases, thus preventing downsizing of the device (joining unit or stator manufacturing device) and also limiting efficiency of joining work. 
     In view of these actual circumstances, an object of the present invention is to provide a coil, a stator member, a stator, and a motor that are configured to, in the case of joining (connecting) a busbar and the coil&#39;s terminals, simplify control necessary for joining such as positioning, actualize downsizing of a device (joining unit) or stator manufacturing device), and improve efficiency of joining work. 
     Solution to Problem 
     An aspect of the present invention provides a coil including: a main body made of a conductor with a helical structure; and a first terminal and a second terminal extended out from the main body. The first terminal and the second terminal are extended out on a side of one surface of the main body. 
     An aspect of the present invention provides a stator member in which a plurality of the above-described coils is arranged. 
     An aspect of the present invention provides a stator including: the above-described coil; and a stator core to which the coil is attached. 
     An aspect of the present invention provides a motor including the above-described stator member. 
     An aspect of the present invention provides a motor including the above-described stator. 
     Advantageous Effects of Invention 
     The present invention can provide a coil, a stator member, a stator, and a motor that are configured to, in the case of joining (connecting) a busbar and the coil&#39;s terminals, simplify control necessary for joining such as positioning, actualize downsizing of a device (joining unit or stator manufacturing device), and improve efficiency of joining work. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  includes drawings illustrating a coil of the present embodiment, in which (A) is a front view, (B) is a top view thereof, (C) is a side view thereof, and (D) is a side view thereof. 
         FIG. 2  is a top view illustrating a stator member of the present embodiment. 
         FIG. 3  includes drawings illustrating a stator of the present embodiment, in which (A) is a side view illustrating a coil to which a cassette is attached, and (B) is a tip view thereof. 
         FIG. 4  is a top view illustrating another aspect of the stator member of the present embodiment. 
         FIG. 5  is an exploded side view of a motor of the present embodiment. 
     
    
    
     DETAILED DESCRIPTION OF THE DISCLOSURE 
     An embodiment of the present invention will now be described below with reference to the drawings. 
     &lt;Coil&gt; 
       FIG. 1  includes drawings illustrating a coil  10  of the present embodiment, in which  FIG. 1(A)  is a front view viewed from an axial direction of a helical structure,  FIG. 1(B)  is a top view viewed from an outlet side of the terminals (from above of  FIG. 1(A) ),  FIG. 1(C)  is a side view viewed from a left direction of  FIG. 1(A) , and  FIG. 1(D)  is a side view viewed from a right direction of  FIG. 1(A) . 
     As illustrated in  FIG. 1 , the coil  10  of the present embodiment includes a main body  11 , a first terminal  12 , and a second terminal  13 . The main body  11  is made of a conductor with a helical structure. The conductor is, for example, a flat conductor (flat rectangular conductor) whose cross section orthogonal to the traveling directions of the helical structure is substantially in the shape of a rectangle. 
     The main body  11  may be a helical structure body made by, for example, winding an elongated strip-shaped flat conductor or connecting (pressure welding, welding, or the like) a plurality of strip-shaped flat conductors (unit flat conductors) shorter than the coil  10  (complete helical structure body) continuously in the strip longitudinal directions. Specifically, in the case of connecting by pressure welding, for example, end surfaces of a plurality of unit flat conductors each having a length equal to or less than the length of a one-turn region of a welded helical structure body (or a length exceed the length of the one-turn region) can be pressed against each other along the strip longitudinal directions at a straight portion to form a turn region, and the helical structure body can be formed by connecting the turn regions. 
     Here, in this specification, a first direction along the axis of the helical structure is referred to as an axial direction C of the coil  10  (helical structure body). A second direction that is orthogonal to the axial direction C and that is along one of the traveling directions of the helical structure is referred to as a width direction W of the coil  10  (helical structure body). A third direction that is orthogonal to the first and second directions and that is along the other of the traveling directions of the helical structure is referred to as a length direction L of the coil  10  (helical structure body). 
     In an example illustrated in  FIG. 1 , the shape of the main body  11  is an approximately rectangular shape with short sides SS and long sides LS as viewed in the front view ( FIG. 1(A) ) in the axial direction C of the helical structure body (winding), in which the width direction W coincides with the extending direction of the short sides SS and the length direction L coincides with the direction of the long sides LS. 
     The helical structure body can also be a lamination body in which a plurality of approximately rectangular shaped regions for one turn (hereinafter referred to as “one-turn regions CR”), indicated by a dashed arrow in  FIG. 1(A) , are laminated (overlayed). The axial direction C coincides with a lamination direction of the one-turn region CR or a thickness direction. 
     As described above, the coil  10  in this example is a so-called edgewise coil containing the main body  11  in which the helical structure body is formed of the continuous strip-shaped flat conductor. However, not limited to this, the helical structure body may be formed by winding a round conductor (round wire conductor) whose cross section orthogonal to the traveling directions of the helical structure is approximately round, or by connecting (pressure welding, welding, or the like) a plurality of strip-shaped round conductors. That is, the shape of the main body  11  may be in the shape of an ellipse (oval) in the front view illustrated in  FIG. 1(A) . 
     The first terminal  12  and the second terminal  13  are provided as a pair in the single main body  11 . The first terminal  12  and the second terminal  13  are portions (portions indicated by dot hatching in  FIG. 1 ) in which a pair of ends, which are the beginning and end of the coil  10 , are extended out from the main body  11  (helical structure portion, turn portions) to the outside along the helical traveling directions, and both the first and second terminals  12  and  13  are extended out to the same side along the width direction W or the length direction L of the main body  11 . In the example of  FIG. 1 , the first and second terminals  12  and  13  are extended out on a side of one of the short sides SS (on a side of an upper short side SS in  FIG. 1(A) ) along the width direction W of the approximately rectangular helical structure body. The second terminal  13  includes an extending portion  14  (described later). 
     In this example, the first terminal  12  and the second terminal  13  are configured as part of the flat conductor (unit flat conductors), and each joined to the main body  11  by, for example, pressure welding. That is, welded portions CP between the flat conductor including the first terminal  12  and the main body  11  (helical structure body), also between the flat conductor including the second terminal  13  and the main body  11  (helical structure body) are provided in the straight portions of the one-turn regions CR. Each of the first terminal  12  and the second terminal  13  may be joined to the main body  11  by welding or the like. In the case of connecting by welding, as illustrated in  FIG. 1 , the first terminal  12  and the second terminal  13  may be part of the flat conductor (unit flat conductors), or the first terminal  12  and the second terminal  13  (conductors of only regions indicated by dot hatching) may be joined to the helical structure body. 
     Furthermore, the first terminal  12  and the second terminal  13  of the present embodiment are extended out on a side of a certain surface defined by the width direction W and the length direction L of the main body  11 . Specifically, in a case in which the helical structure body is a lamination body of the one-turn regions CR, both the first terminal  12  and the second terminal  13  are extended out to positions on a surface side (on a side of an uppermost surface or a lowermost surface illustrated in  FIGS. 1(B) to 1(D) ) in which one of outermost one-turn regions CR in the axial direction C (thickness direction) of the lamination body is present. 
     Specifically, in the example of  FIG. 1 , the first terminal  12  is configured to be extended out from the side of one of outermost surfaces (for example, a surface in which the one-turn region CR composing a topmost layer is present) in the axial direction C in  FIGS. 1(B) to 1(D) , and the second terminal  13  is extended out from the side of the other outermost surface (for example, a surface in which the one-turn region CR composing a bottommost layer is present), via the extending portion  14  extending along the axial direction C of the helical structure of the main body  11 , to the side of the one of the outermost surfaces (the surface in which the one-turn region CR composing the topmost layer is present). That is, the extending portion  14  is provided across a plurality of laminated one-turn regions CR in the axial direction C (thickness direction), in order to extend out the second terminal  13 , which is extended out from the side of one of the outermost surfaces (hereinafter referred to as a first surface Sf 1 ) in the lamination direction of the main body  11  (lamination body), to the side of the other outermost surface (hereinafter referred to as a second surface Sf 2 ) in the lamination direction. The first terminal  12  and the second terminal  13  are merely referred to separately for convenience of description, and the same holds true even when these are interchanged. That is, the first terminal  12  may be configured to have the extending portion  14 . 
     Similarly, the topmost layer and the bottommost layer (top surface and bottom surface) of the lamination body are merely referred to separately for convenience of description, and the same holds true even when these are interchanged. 
     As illustrated in  FIG. 1(D) , the extending portion  14  is provided so as to be extended out from one of the long sides LS of the one-turn region CR of the first surface Sf 1 , bent so as to extend in the axial direction C of the helical structure body across the plurality of laminated one-turn regions CR, and bent again on the side of the second surface Sf 2  so as to extend to the helical traveling direction (turn direction) of the helical structure body. Thereby, the first terminal  12  and the second terminal  13  are extended out so as to be aligned side by side on the side of the second surface Sf 2 . 
     &lt;Stator Member&gt; 
     With reference to  FIG. 2 , a stator member  50  of the present embodiment will be described.  FIG. 2  is a top schematic view of an annular stator member  50  viewed in an axial direction thereof. 
     The stator member  50  constitutes an annular body that is configured by arranging a plurality of the coils  10  illustrated in  FIG. 1 , in such a manner that the long sides LS are adjacent to each other. 
     Specifically, the coils  10  ( 10 A,  10 B,  10 C . . . ) are arranged so that the axes (indicated by dashed lines as virtual lines) of the respective helical structure bodies converge at a single point on a central axis CC (extending in the front and back directions of the paper) of the annular body. 
     As described above, each of the coils  10  includes the first terminal  12  and the second terminal  13  that are extended out on a side of a certain surface (for example, the side of the second surface Sf 2 ) of the main body  11 . That is, all the first terminals  12  and the second terminals  13  of the plurality of coils  10  are extended out on the side of the same peripheral surface (in this example, the side of an outer peripheral surface Sf 2 ) of the annular stator member  50 . In other words, the coils  10  are arranged so that an outlet direction of the first terminal  12  and the second terminal  13  of each coil  10  is positioned on the same side (outer peripheral side in  FIG. 2 ) in the length direction L (direction along the central axis CC of the annular body) of each coil  10 . 
     In conventional coils and stator members configured therewith, first terminals are extended out, for example, on an outer peripheral surface side of the stator member, which is an annular body, and second terminals are extended out on an inner peripheral surface side of the stator member. Accordingly, when connecting the first and second terminals to a busbar or the like, a connecting unit (e.g., joining (pressure welding) device (welding device)) to the busbar must be moved between the inner peripheral surface side and the outer peripheral surface side of the stator member, which results in cumbersome or complicated control necessary for connecting (for example, control for positioning or the like). Furthermore, movement range of the joining unit (welding device) increases, thus preventing downsizing of the device (joining device (welding device), a stator (member) manufacturing device, or the like) and also hindering improvement in efficiency of connecting work. 
     However, in the present embodiment, the first terminals  12  and the second terminals  13  of all the plurality of coils  10  are extended out on the same peripheral side (e.g., the side of the outer peripheral surface Sf 2 ) of the stator member  50 , which is the annular body. In the case of joining the terminals (connecting) to a busbar, this results in simplifying control necessary for joining, such as positioning, actualizes downsizing of the device (joining device (welding device), a stator (member) manufacturing device, or the like), and also improves efficiency of joining work. 
     Furthermore, in the present embodiment, the first terminals  12  and the second terminals  13  that are adjacent to each other in a circumferential direction (arranged in the circumferential direction) of the plurality of coils  10  are arranged to be approximately equally spaced. Specifically, the distance between the first terminal  12  and the second terminal  13  of one of the coils  10  is equal to (approximately the same space) the distance between the first terminal  12  of the one of the coils  10  and the second terminal  13  of another coil  10  adjacent thereto. 
     For example, with reference to  FIG. 1(D) , the second terminal  13  is extended out from the helical structure body to the outside, in such a manner that the extending portion  14  is provided so as to extend out from one long side LS 2  of the one-turn region CR of the first surface Sf 1  (e.g., the inner peripheral surface in the case of annular arrangement as the stator member  50 ) to the extending direction of the long side LS 2  (the right direction of  FIG. 1(D) ), bent so as to extend in the axial direction C of the helical structure body across the plurality of laminated one-turn regions CR to the side of the second surface Sf 2  (e.g., the outer peripheral surface in the case of annular arrangement as the stator member  50 ), and bent again on the side of the outer peripheral surface Sf 2  so as to extend to the helical traveling directions (turn direction) of the helical structure body (so as to extend along the long side LS 2  corresponding to the one-turn region CR on the outer peripheral surface side). 
     As illustrated in  FIGS. 1(A) and 1(C) , the first terminal  12  is extended out from the long side LS 1  (the long side LS 1  opposite the long side LS 2  from which the second terminal  13  is extended out) of the one-turn region CR of the second surface (outer peripheral surface) Sf 2  to the extending direction of the long side LS 1 . 
     As illustrated in  FIG. 2 , the distance (distance along the circumferential direction of the annular body) D 2  between a first terminal  12 B and a second terminal  13 B of a certain coil  10 B is configured to be spaced approximately equal to the distance (distance along the circumferential direction of the outer periphery of the annular body) D 1  between the second terminal  13 B of the coil  10 B and a first terminal  12 A of a coil  10 A adjacent thereto. Similarly, the distance (distance along the circumferential direction of the outer periphery of the annular body) D 3  between the first terminal  12 B of the coil  10 B and a second terminal  13 C of a coil  10 C adjacent thereto is configured to be spaced approximately equal to the distance D 1 , D 2  (same for all coils  10 ). 
     Configured in this way, in the case of joining (connecting) the coils to a busbar, it is possible to further simplify control necessary for joining such as positioning, and improve efficiency of joining work. 
     The outlet shape of the first terminal  12  and the second terminal  13  in the example above is merely an example, and can be configured as appropriate, in accordance with the shape of the coils  10 , so that the distances D 1 , D 2 , D 3  . . . , between the first terminal  12  and the second terminal  13  of the coils  10  constituting the stator member  50 , are equally spaced. Thus, for example, the first terminal  12  may have an extending portion along the short side SS of the helical structure body, and may be configured so as to extend out from the helical structure body after being bent at one end along the short side SS of the helical structure body. The extending portion  14  of the second terminal  13  may be extended out from the helical structure body after being bent along the short side SS so as to be close to or separated from the first terminal  12 . The respective extending portions of the first terminal  12  and the second terminal  13  may be extended out from the helical structure body after being bent in the direction of the short side SS with respect to each other. 
     All the first terminals  12  and the second terminals  13  of the plurality of coils  10  may be configured to be extended out on the side of the first surface Sf 1  (inner peripheral surface) of the stator member  50 . However, since the circumference of the inner peripheral surface Sf 1  is smaller than that of the outer peripheral surface Sf 2 , flexibility in arranging for equal distances between the first terminal  12  and the second terminal  13  is reduced. The distance between the first terminal  12  and the second terminal  13  is also narrowed, and in general, a traveling distance of the joining unit (joining (pressure welding) device or welding device) to the busbar arranged outside the stator member  50  is increased. For this reason, the first terminals  12  and the second terminals  13  are preferably extended out on the side of the outer peripheral surface Sf 2  of the stator member  50 . On the other hand, in the case of disposing a joining unit inside the stator member  50 , the first terminals  12  and the second terminals  13  may be extended out on the side of the inner peripheral surface Sf 1  of the stator member  50 . 
     &lt;Stator&gt; 
       FIG. 3  is a drawing illustrating an outline of a stator  60  utilizing the coils  10  (stator member  50 ) of the present embodiment.  FIG. 3(A)  is a drawing illustrating an example of a method for attaching the coil  10 , which is a side view of the coil  10  viewed from a peripheral direction of the stator  60 .  FIG. 3(B)  is a top schematic view viewed from an axial direction of the stator  60 . 
     The stator  60  of the present embodiment is formed, not by winding a strip-shaped conductor on a stator core  61 , but by sequentially attaching the molded coils (edgewise coils)  10  to a plurality of cassettes (also referred to as slots or teeth)  62  provided in an inner peripheral surface of the annular (cylindrical) stator core  61  or integrally attaching the stator member  50 , and by connecting one end of each of the annularly arranged coils  10  to the busbar (not illustrated). 
     Specifically, as illustrated in  FIG. 3(A) , cassettes  62  are attached to each of the plurality of coils  10 . 
     For example, the cassettes  62  are prepared in pairs for each of the plurality of coils  10  (for a single coil  10 ) constituting the stator member  50 . The pair of cassettes  62  ( 62 A and  62 B) have flange portions  62 C and  62 D on the side of the first surface Sf 1  and on the side of the second surface Sf 2  of the coil  10 , respectively. The single coil  10  is inserted from the side of one cassette  62 A, the side on which the flange portion  62 C is not formed, and the other cassette  62 B is overlapped from the side of the cassette  62 B, the side on which the flange portion  62 D is not formed, to engage the both, thus attaching the cassettes  62  to the coil  10 . The cassettes  62  are similarly attached to every coil  10  constituting the stator member  50 . Thereafter, as illustrated in  FIG. 3(B) , the coils  10  with the cassettes  62  are attached to the stator core  61 . The cassettes  62  are engaged (fitted) in the stator core  61  at not-illustrated engagement portions (fitting portions). 
     Alternatively, for example, in the stator member  50  in which the plurality of annularly arranged coils  10  are connected and integrated by the not-illustrated busbar or the like, the cassettes  62  are attached as described above to each of the coils  10 , and the stator member  50  with the cassettes  62  is attached to the stator core  61 . 
     Although the illustration of the busbar is omitted, for example, a circular wiring portion and coil connection ends are integrally configured by punching of a metal material (e.g., a copper plate) or the like. The coil connection ends are joined to the first terminals  12  and the second terminals  13  of the coils  10  by pressure welding, welding, screwing, or the like. 
       FIG. 4  is a top view illustrating another aspect of the stator member  50  of the present embodiment. In  FIG. 4 , the illustration of the cassettes  62  is omitted. The form of the helical structure body of the coil  10  of the present embodiment is not limited to that illustrated in  FIG. 1 . For example, as illustrated in  FIG. 4 , the helical structure body may be configured in an approximately trapezoidal shape, that is, an approximately quadrangular pyramid trapezoidal form viewed from the top. In this case, the coil  10  may be made of a flat conductor whose width (length in a direction which intersects the helical traveling direction) gradually decreases along the helical traveling direction, while whose thickness (length in the axial direction of the helical structure body) gradually increases, and a cross-sectional area perpendicular to the helical traveling direction is equal in the helical traveling direction. 
     In this example, the first terminals  12  and the second terminals  13  need only be aligned and extended out to the same peripheral surface (e.g., outer peripheral surface) of the annular body, and the distance between the first terminal  12  and the second terminal  13  of one coil  10  may or may not be the same as the distance between the first terminal  12  of the one coil  10  and the second terminal  13  of another adjacent coil  10 . 
     &lt;Motor&gt; 
       FIG. 5  is an exploded side view illustrating an outline of a motor  70  utilizing the stator  60  (or the stator member  50 ) of the present embodiment. 
     As illustrated in the drawing, a rotor  73  is assembled to the above-described stator  60  and made to be rotatable, to obtain a motor (single-phase motor, three-phase motor, or the like)  70 . Specifically, the motor  70  has, for example, a shaft  71 , a housing  72 , the rotor  73 , the stator  60  (illustrated in  FIG. 3 ), and the like. The shaft  71  is a columnar member, and rotates about its central axis while being supported by a bearing  74  provided in, for example, the housing  72 . To one end of the shaft  71 , a device (not illustrated) to be driven is coupled via a power transmission mechanism such as a gear. 
     The rotor  73  has magnets (not illustrated) disposed in its circumferential direction, and rotates together with the shaft  71 . The stator  60  is disposed, for example, outside the rotor  73  in a radial direction, and generates a force to rotate the rotor  73 . An external terminal (not illustrated) of the stator  60  is connected to a drive circuit or a power supply (both are not illustrated) that supplies power to the motor via a lead, for example. 
     Upon applying a drive current to the coils  10  through the busbar (not illustrated), the motor  70  generates magnetic fluxes in the cassettes  62  of the stator  60 . Then, torque is generated in the circumferential direction by the action of the magnetic flux between the cassette  62  and magnet (not illustrated). As a result, the rotor  73  rotates about the central axis with respect to the stator  60 . 
     Although not illustrated, the motor  70  of the present embodiment is not limited to one configured with the stator  60  as illustrated in  FIG. 3 , as long as the motor  70  is configured so as to include the coil  10  illustrated in  FIG. 1  or the stator member  50  illustrated in  FIG. 2 . 
     The present invention is not limited to the embodiment described above, but, as a matter of course, various modifications may be made within a range without deviating from the gist of the present invention. 
     INDUSTRIAL APPLICABILITY 
     The present invention can be applied to stators and motors. 
     REFERENCE SIGNS LIST 
     
         
         
           
             ( 10 A,  10 B,  10 C . . . ) coil 
               11  main body 
               12 ,  12 A,  12 B first terminal 
               13 ,  13 A,  13 B second terminal 
               14  extending portion 
               50  stator member 
               60  stator 
               61  stator core 
               62 ,  62 A,  62 B cassette 
               62 C,  62 D flange portion 
               70  motor 
               71  shaft 
               72  housing 
               73  rotor 
               74  bearing