MANUFACTURING METHOD OF MOTOR AND ARMATURE

• US 20080136284A1
• Filed: 12/12/2007
• Published: 06/12/2008
• Est. Priority Date: 12/12/2006
• Status: Active Grant

• Current Assignee: Nidec Corporation
• Original Assignee: Nidec Corporation
• Inventors: SUZUKI, Hideaki, YAMADA, Yosuke, FUJII, Yoshio
• Granted Patent: US 7,830,062 B2
• Time in Patent Office: Days
• US Class Current: 310/214
• CPC Class Codes: H02K 15/064 Windings consisting of separate segments, e.g. hairpin windings H02K15/063 takes precedence
• CPC Class Codes: H02K 3/12 arranged in slots
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine

Abstract

A straight line portion of a substantially U-shaped angular wire having a substantially rectangular cross section and a straight line portion of a substantially U-shaped round wire having a substantially circular cross section are accommodated at a slot arranged at a stator of a motor. The round wire is arranged at a more radially inward portion of the slot than the angular wire is. The connecting portion of the round wire is arranged radially inwardly of the straight line portion thereof. The connecting portion of the angular wire is arranged radially outwardly of the straight line portion thereof.

Claims

1. A motor comprising:

a stator including;

a stator core having a plurality of teeth each extending in a radial direction centered about a central axis, and arranged in a circumferential direction so as to be spaced evenly apart from one another; and

a plurality of coils disposed at a plurality of slots each defined by a pair of the teeth located next to one another, and being defined by a plurality of wires electrically connected with each other and each including a portion extending in an axial direction;

wherein

the plurality of wires include an angular wire having a substantially rectangular cross section at a portion thereof corresponding to a location of the slot when viewed from one end of the axial direction and a round wire having a substantially circular cross section at a portion thereof corresponding to a location of the slot when viewed from the one end of the axial direction.

2. The motor according to claim 1 wherein, each slot has arranged therein the angular wire and the round wire in the radial direction, and the round wire is arranged radially inwardly of the angular wire.

3. The motor according to claim 2, wherein the cross section of the angular wire includes two short sides extending in the substantially radial direction and two long sides extending substantially perpendicularly from the two short sides.

4. The motor according to claim 2, wherein a side of each tooth defining the slot includes a curved portion fitting to the cross section of the round wire.

5. The motor according to claim 4, wherein each tooth includes:

an inner side tooth portion arranged radially inwardly of the curved portion, and configuring a portion of the slot accommodating the round wire; and

an outer side tooth portion arranged radially outwardly of the inner side tooth portion, and configuring a portion of the slot accommodating the angular wire;

wherein

the inner side tooth portion includes a portion that is wider than the outer side tooth portion in the circumferential direction.

6. The motor according to claim 5, wherein a circumferential width of the inner side tooth portion and a circumferential width of the outer side tooth portion increase in a radially outward direction.

7. The motor according to claim 5, wherein the side of each tooth includes at a portion thereof connecting the inner side tooth portion and the outer side tooth portion an outer side curved portion at which point the slot is narrowed.

8. The motor according to claim 2, wherein the angular wire includes a pair of straight line portions each accommodated in the slot and extending in the axial direction, and a curved connecting portion integrally connecting the pair of the straight line portions, and the round wire includes a pair of straight line portions each accommodated in the slot and extending in the axial direction, and a curved connecting portion integrally connecting the pair of the straight line portions.

9. The motor according to claim 2, wherein the angular wire and the round wire are connected to one another alternately.

10. The motor according to claim 8, wherein the connecting portion of the angular wire and the connecting portion of the round wire are curved in a direction radially away from the straight line portion of the angular wire and the straight line portion of the round wire.

11. The motor according to claim 9, wherein the connecting portion of the angular wire and the connecting portion of the round wire are arranged axially on top of one another.

12. A motor comprising:

a stator including;

a stator core having a plurality of teeth each extending in a radial direction centered about a predetermined central axis, and arranged in a circumferential direction so as to be spaced evenly apart from one another; and

a plurality of coils disposed at a plurality of slots each defined by a pair of the teeth located next to one another and defined by a plurality of wires electrically connected to each other at end portion;

wherein

the wires each include a pair of straight line portions, a connecting portion at one end portion of the straight line portions connecting the pair of straight line portions integrally, and the end portion at which the wires are electrically connected; and

a distance between the wires at the connecting portion is greater than a distance between the wires at the straight line portion.

13. The motor according to claim 12, wherein each of the wires includes an angular wire having a connecting portion that is arranged radially outwardly of the pair of straight line portions thereof, and each of the wires includes a round wire whose connecting portion is arranged radially inwardly of the pair of straight line portions thereof.

14. The motor according to claim 13, wherein each slot accommodates the angular wire and the round wire.

15. The motor according to claim 12, wherein the plurality of wires include an angular wire having a substantially rectangular cross section at the straight line portion with respect to the central axis.

16. The motor according to claim 13, wherein the plurality of wires include an angular wire having a substantially rectangular cross section at the straight line portion with respect to the central axis, and the plurality of wires include a round wire having a substantially circular cross section at the straight line portion with respect to the central axis, and the round wire is arranged radially inwardly of the angular wire in each slot.

17. The motor according to claim 16, wherein a surface of each of the pair of straight line portions of the angular wire facing opposite to one another are connected at a surface of the connecting portion opposite to an axial end surface of the stator core.

18. The motor according to claim 16, wherein each slot accommodates at least four straight line portions arranged in the radial direction.

19. A motor comprising:

a stator including;

a stator core having a plurality of teeth each extending in a radial direction centered about a predetermined central axis, and arranged in a circumferential direction so as to be spaced evenly apart from one another; and

a plurality of coils disposed at a plurality of slots each defined by the teeth next to one another, and defined by a plurality of wires each including a portion extending in an axial direction and electrically connected to each other;

wherein

the plurality of wires include a plurality of angular wires arranged in a radial direction each having a substantially rectangular cross section including two short sides and two long sides perpendicular to the short sides and corresponding to the slot;

the angular wire arranged at a radially inward portion of the slot include the long sides extending in the radial direction, and the angular wire arranged at a radially outward portion of the slot include the short sides extending in the radial direction.

20. A method of manufacturing a stator of a motor, the method comprising the steps of:

a) preparing a plurality of angular wires and a plurality of round wires each including a pair of straight line portions and a connecting portion at one end of the straight line portions connecting the pair of straight line portions integrally;

b) arranging the pair of straight line portions of the angular wire at two corresponding slots each defined by a plurality of teeth each extending in a radial direction centered about a central axis and arranged in a circumferential direction, and arranging the connecting portion of the angular wire radially outwardly of the straight line portions;

c) arranging the pair of straight line portions of the round wire at a portion of the two corresponding slots radially inwardly of the angular wire; and

d) forming a plurality of coils by connecting via a plurality of conductive terminals each angular wire and each round wire in the circumferential direction at an end portion thereof arranged opposite at an end of the straight line portion opposite from the connecting portion.

21. The manufacturing method according to claim 20, wherein the plurality of angular wires each have a substantially rectangular cross section at the straight line portion thereof with respect to the central axis, and the plurality of round wires each have a substantially circular cross section at the straight line portion thereof with respect to the central axis.

22. The manufacturing method according to claim 21, wherein the angular wire and the round wire are connected to one another alternately.

23. The manufacturing method according to claim 20, wherein the straight line portions and the connecting portions of the angular wire and the round wire are formed by pressing on a wire member having a straight shape.