Source: https://patents.google.com/patent/US7936116B2/en
Timestamp: 2020-07-10 03:29:53
Document Index: 225161537

Matched Legal Cases: ['art 5', 'art 4', 'art 26', 'art 27', 'art 26', 'art 27', 'art 26', 'art 4', 'art 4', 'art 18', 'art 19', 'art 5', 'Application No. 2007', 'Application No. 1']

US7936116B2 - Motor stator with improved end surface insulating plate, motor including the motor stator, pump including the motor stator, and manufacturing the motor stator - Google Patents
Motor stator with improved end surface insulating plate, motor including the motor stator, pump including the motor stator, and manufacturing the motor stator Download PDF
US7936116B2
US7936116B2 US12/159,674 US15967407A US7936116B2 US 7936116 B2 US7936116 B2 US 7936116B2 US 15967407 A US15967407 A US 15967407A US 7936116 B2 US7936116 B2 US 7936116B2
US12/159,674
US20100264757A1 (en
Tougo Yamazaki
2007-02-26 Application filed by Mitsubishi Electric Corp filed Critical Mitsubishi Electric Corp
2007-02-26 Priority to PCT/JP2007/053535 priority Critical patent/WO2008105054A1/en
2008-06-30 Assigned to MITSUBISHI ELECTRIC CORPORATION reassignment MITSUBISHI ELECTRIC CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ASOU, HIROKI, ISHII, HIROYUKI, KAWAKUBO, MAMORU, YAMAMOTO, MINEO, YAMAZAKI, TOUGO
2010-10-21 Publication of US20100264757A1 publication Critical patent/US20100264757A1/en
2011-05-03 Publication of US7936116B2 publication Critical patent/US7936116B2/en
230000001012 protector Effects 0.000 claims abstract description 100
An objective is to provide a motor stator that may achieve: a reduction in parts costs by shaping coil ends so that length thereof is reduced, thereby reducing the amount of use of copper, and minimizing the amount of use of binding strings for securing the coil ends in place; a reduction in manufacturing process costs by a structure which allows a protector and a wire lead outlet part to be easily assembled; and then an improvement in quality of a stator by firmly holding the coil ends and the protector. The motor stator may include a stator core 1 including slots; a plurality of cut surfaces forming flat surfaces on the outer surface of the stator core 1; end surface insulating plates 2 formed in an approximately same shape as the shape of magnetic steel plates punched out, and assembled into the stator core 1 on both axial end surfaces thereof; projections formed in a vicinity of a peripheral portion of an end surface insulating plate 2, and engaged with the cut surfaces on the stator core 1; slot-like cutouts, a little larger in size than the slots, formed on an inner peripheral side of the each end surface insulating plate 1; and coil ends. The coil ends are shaped by pressure against the end surface insulating plates 2.
The present invention relates to a motor stator. More particularly, the present invention relates to a method of securing coil ends in place and a method of assembling components into a stator, when a stator core is insulated on the axial end surfaces, and the coil ends are shaped so that the axial length thereof is reduced.
A motor stator and a method of manufacturing a motor stator have been proposed (See Patent Document 1, for example). This disclosure is directed to a method of insulating a stator core and fixing a stator winding in order to manufacture a thin motor stator. In order to achieve the method, an insulating layer is formed on the slots and end surfaces of the stator core by integrally forming an insulating resin film with the stator core. At the same time, projecting structural parts are formed in radial positions that are out of the outer surface of the stator core. A Winding is then inserted, and shaped so that the length is reduced. Wire leads are then connected to the winding. The wire leads are then fitted to one of the projecting structural parts. The other projecting structural part formed on the opposite side is cut out. The cut out projecting structural part is placed on the wire leads so that the wire leads are sandwiched and secured. The winding is further secured by binding strings, varnishing, etc. Then, the stator core, the winding, etc. are integrally formed by insulating resin to obtain a stator part. In order to withstand the resin molding pressure, the wire lead sandwiched part formed by the projecting structural parts is molded with resin by pressure holding of a mold die.
Patent Document 1: P8-149737A
With the motor stator disclosed in the Patent Document 1, however, the coil ends of the stator are shaped to reduce the axial length thereof, and binding strings are wound around the outer surface of the stator core and the slot portion. There is nothing on the outer surface of the stator core to stop the binding strings moving in the circumferential direction. This poses a problem of allowing the binding strings to move easily in the circumferential direction on the outer surface of the stator core.
(1) to reduce parts costs by shaping coil ends so that length thereof is reduced, thereby reducing the amount of use of magnet wires, and minimizing the amount of use of binding strings for securing the coil ends in place;
(2) to reduce manufacturing process costs by a structure which allows a protector and a wire lead outlet part to be easily assembled; and
(3) to improve stator quality by firmly holding the coil ends and the protector.
A motor stator according to this invention is characterized by including a stator core that may be formed by layering magnetic steel plates punched into a predetermined shape, wherein the stator core may include a plurality of slots to hold coils; a plurality of cut surfaces that may be formed on an outer surface of the stator core in an axial direction to provide flat surfaces on the outer surface, wherein the plurality of cut surfaces may be spaced apart from one another by a predetermined distance along a circumferential direction; end surface insulating plates that may be assembled into the stator core on both axial end surfaces thereof, wherein each end surface insulating plate may be a little larger in outer diameter than the stator core, and formed in an approximately same shape as the predetermined shape of the magnetic steel plates punched out to form the stator core; a plurality of projections that may vertically extend in a vicinity of a peripheral portion of the each end surface insulating plate, wherein the plurality of projections may be engaged with the cut surfaces on the stator core when the end surface insulating plates are assembled into the stator core; slot-like cutouts that may be a little larger in size than the slots of the stator core, and formed on an inner peripheral side of the each end surface insulating plate; and coil ends, which may be portions of the coils, that may extend out of the both axial end surfaces of the stator core in the axial direction, The coil ends may be characterized by being shaped by pressure against the end surface insulating plates.
According to a motor stator of this invention, coil ends are shaped by pressure against end surface insulating plates, thereby reducing the axial length of the coil ends. This may result in reducing the amount of use of magnet wires and minimizing the amount of use of binding strings for fixing the coil ends. Hence, parts costs may be reduced.
BEST MODE FOR IMPLEMENTING THE INVENTION Embodiment 1
A first embodiment is illustrated in FIG. 1 to FIG. 5. FIG. 1 shows a perspective view of a stator 100. FIG. 2 shows an exploded perspective view illustrating structural relations of a stator core 1, end surface insulating plates 2, and a slot cell 3. FIG. 3 shows an exploded perspective view illustrating a state of the stator core 1 before a wire lead outlet part 5 and a protector protecting part 4 are assembled into the stator core 1. FIG. 4 shows a cross section of a motor 200. FIG. 5 shows a chart illustrating a manufacturing process of the motor 200.
(First Step): Magnetic steel plates are punched and layered to form the stator core 1. In parallel to this, thermoplastic resin is molded to form the end surface insulating plates 2.
(Second Step): The stator core 1 is assembled with two of the end surface insulating plates 2 on the both end surfaces thereof. In parallel to this, the slot cells 3 are produced.
(Third Step): The slot cells 3 are inserted into the stator core 1. In parallel to this, the coils (the main winding and the auxiliary winding) and the wedges 7 are produced.
(Fourth Step): The coils and the wedges are inserted into the stator core 1 at a time with the aid of a jig for coil insertion.
(Fifth Step): coil ends 6 are shaped by pressure against the end surface insulating plates. In parallel to this, thermoplastic resin is molded to form the first protector protecting part 26 and the second protector protecting part 27.
(Sixth Step): The wire leads 9 are connected to the coil end portions. In parallel to this, the protector 25 is embedded in the hollowed out space 29 of the first protector protecting part 26, and then the second protector protecting part 27 is assembled into the first protector protecting part 26.
(Seventh Step): The stator 100 is assembled with the protector protecting part 4, which holds the protector 25. The protector protecting part 4 is engaged with the predetermined one of the mounting holes 16 formed on the end surface insulating plate 2, and then bound to the coil end 6.
(Eighth Step): The coil ends are secured in place with the binding strings 8. In parallel to this, thermoplastic resin is molded to form the first wire lead outlet part 18 and the second wire lead outlet part 19.
(Ninth Step): The stator 100 is assembled with the wire lead outlet part 5.
(Tenth Step): The stator 100 is molded to produce the molded stator 39. In parallel to this, the bracket 39 and the rotor assembly 38 are produced.
(Eleventh Step): The mold stator 39, the rotor assembly 38, and the bracket 36 are assembled together to have the assembly of the motor 200.
In the above embodiment, the single-phase induction motor was thus taken as an example. The present invention is, however, also applicable to a three-phase motor (a synchronous machine, an induction machine, a synchronous induction machine, etc.).
FIG. 1 It is a diagram describing a first embodiment, which shows a perspective view of a stator 100.
US12/159,674 2007-02-26 2007-02-26 Motor stator with improved end surface insulating plate, motor including the motor stator, pump including the motor stator, and manufacturing the motor stator Active US7936116B2 (en)
PCT/JP2007/053535 WO2008105054A1 (en) 2007-02-26 2007-02-26 Stator of motor and motor and pump and method for manufacturing motor
US20100264757A1 US20100264757A1 (en) 2010-10-21
US7936116B2 true US7936116B2 (en) 2011-05-03
ID=39720901
US12/159,674 Active US7936116B2 (en) 2007-02-26 2007-02-26 Motor stator with improved end surface insulating plate, motor including the motor stator, pump including the motor stator, and manufacturing the motor stator
US (1) US7936116B2 (en)
JP (1) JP4607964B2 (en)
WO (1) WO2008105054A1 (en)
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Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:ASOU, HIROKI;KAWAKUBO, MAMORU;YAMAMOTO, MINEO;AND OTHERS;REEL/FRAME:021171/0079