This application claims priority to Japanese Patent Application No. 2023-122509 filed on Jul. 27, 2023, the entire disclosure of which is incorporated herein by reference.
The present disclosure relates to a stator of a rotating electric machine.
A stator of a rotating electric machine includes a stator core, a coil, and an insulator, for example, as in Japanese Patent Application Publication No. 2022-150980. The stator core includes a yoke having a cylindrical shape and a plurality of teeth. Each of the plurality of teeth (i.e., a tooth) extends from an inner peripheral surface of the yoke inward in the radial direction of the yoke. The tooth has a tooth extension portion and a tooth end portion. The tooth extension portion extends from the inner peripheral surface of the yoke. The tooth end portion extends from tooth side surfaces of the tooth extension portion, which define the tooth extension portion in the circumferential direction of the yoke, along the circumferential direction of the yoke. The coil is formed of a wire wound around the stator core. The stator core has a core end surface that defines the stator core in the axial direction of the yoke, and the coil has a coil end projecting from the core end surface. The insulator faces the core end surface of the stator core. The insulator electrically insulates the core end surface from the coil end.
The insulator has an insulator base portion having a cylindrical shape, a plurality of insulator extension portions, and a plurality of insulator inner walls. The insulator base portion is located outward of the coil end and overlaps the coil end in the radial direction of the yoke. Each of the insulator extension portions extends from an inner peripheral surface of the insulator base portion inward in the radial direction of the insulator base portion. The insulator extension portion overlaps the corresponding tooth extension portion in the axial direction of the yoke. The insulator inner wall extends from the corresponding insulator extension portion, and is located inward of the coil end in the radial direction of the yoke such that the insulator inner wall overlaps the corresponding tooth end portion in the axial direction of the yoke and overlaps the coil end in the radial direction of the yoke.
Such a stator of the rotating electric machine may include a cover facing the insulator. One and the other of the cover and the insulator respectively have an engagement piece having a plate shape and extending in the axial direction of the yoke and an insertion recess into which the engagement piece is inserted, or one and the other of the cover and the yoke respectively have the engagement piece and the insertion recess into which the engagement piece is inserted. One and the other of the engagement piece and the insertion recess respectively have a first engagement portion protruding in the radial direction of the yoke and a second engagement portion engaging with the first engagement portion.
The engagement piece has side edges that define the engagement piece in the circumferential direction of the yoke, and the insertion recess has inner surfaces that define the insertion recess in the circumferential direction of the stator core. One of the side edges of the engagement piece comes into contact with one of the inner surfaces of the insertion recess. Accordingly, the cover is restrained from displacing relative to the insulator in the circumferential direction of the yoke. Furthermore, the engagement of the first engagement portion and the second engagement portion restrains the cover from displacing relative to the insulator in the axial direction of the yoke.
In such a configuration of the stator of the rotating electric machine, when the rotating electric machine vibrates, a friction may occur in the axial direction of the yoke between the side edges of the engagement piece and the inner surfaces of the insertion recess. If the friction between the engagement piece and the insertion recess progresses, the engagement piece may break. The breakage of the engagement piece may cause disengagement of the first engagement portion and the second engagement portion, and may cause the cover to come out of the insulator in the axial direction of the yoke. This may decrease the reliability of the stator of the rotating electric machine.
The present disclosure, which has been made in light of the above described problem, is directed to providing a stator of a rotating electric machine that has an increased reliability.
In accordance with an aspect of the present disclosure, there is provided a stator of a rotating electric machine. The stator includes: a stator core; a coil; an insulator; and a cover. The stator core includes a yoke having a cylindrical shape and has a core end surface defining the stator core in an axial direction of the yoke. The stator core includes a plurality of teeth each extending from an inner peripheral surface of the yoke inward in a radial direction of the yoke. Each of the plurality of teeth has: a tooth extension portion extending from the inner peripheral surface of the yoke and having tooth side surfaces that define the tooth extension portion in a circumferential direction of the yoke; and a tooth end portion extending from the tooth side surfaces of the tooth extension portion along the circumferential direction of the yoke. The coil is formed of a wire wound around the stator core. The coil has a coil end projecting from the core end surface of the stator core. The insulator faces the core end surface of the stator core, and electrically insulates the core end surface from the coil end. The insulator has: an insulator base portion having a cylindrical shape and located outward of the coil end and overlapping the coil end in the radial direction of the yoke; a plurality of insulator extension portions each extending from an inner peripheral surface of the insulator base portion inward in a radial direction of the insulator base portion, and overlapping the corresponding tooth extension portion in the axial direction of the yoke; and a plurality of insulator inner walls each extending from the corresponding insulator extension portion. Each of the insulator inner walls is located inward of the coil end in the radial direction of the yoke such that the insulator inner wall overlaps the corresponding tooth end portion in the axial direction of the yoke and overlaps the coil end in the radial direction of the yoke. The cover faces the insulator. One and the other of the cover and the insulator respectively have an engagement piece having a plate shape and extending in the axial direction and an insertion recess into which the engagement piece is inserted, or one and the other of the cover and the yoke respectively have the engagement piece and the insertion recess. One and the other of the engagement piece and the insertion recess respectively have a first engagement portion protruding in the radial direction of the yoke and a second engagement portion engaging with the first engagement portion to restrain the cover from displacing relative to the insulator in the axial direction of the yoke. The cover has an insertion plate extending in the axial direction of the yoke. The insulator inner walls adjacent to each other cooperate to have a pair of space-forming walls. One of the pair of space-forming walls is spaced from the other of the pair of space-forming walls in the circumferential direction of the yoke, and cooperates with the other of the pair of space-forming walls to define an insertion space into which the insertion plate is inserted. The insertion plate is configured to come into contact with the pair of space-forming walls with the insertion plate inserted into the insertion space.
Other aspects and advantages of the disclosure will become apparent from the following description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the disclosure.
The disclosure, together with objects and advantages thereof, may best be understood by reference to the following description of the embodiments together with the accompanying drawings in which:
The following will describe an embodiment of a stator of a rotating electric machine with reference to accompanying
The motor housing 13 includes an end wall 13a and a peripheral wall 13b. The end wall 13a has a plate shape. The peripheral wall 13b has a cylindrical shape and extends from an outer peripheral portion of the end wall 13a. The discharge housing 12 has a cylindrical shape. The discharge housing 12 is connected to an end of the peripheral wall 13b that is distant from the end wall 13a. The inverter case 14 has a cylindrical shape. The inverter case 14 is connected to the end wall 13a of the motor housing 13. The end wall 13a of the motor housing 13 and the inverter case 14 cooperate to define an inverter chamber S1.
The motor housing 13 has a boss 13c. The boss 13c has a circular cylindrical shape. The boss 13c protrudes from the center part of an end surface of the end wall 13a toward the peripheral wall 13b. The axis of the boss 13c corresponds to the axis of the peripheral wall 13b of the motor housing 13. The end wall 13a of the motor housing 13 has a hole 13h. The hole 13h penetrates the end wall 13a of the motor housing 13 in the thickness direction of the end wall 13a. The hole 13h is located between the boss 13c and the peripheral wall 13b.
The motor housing 13 has a suction port 13d. The suction port 13d is formed in a portion of the peripheral wall 13b adjacent to the end wall 13a. The inside and the outside of the motor housing 13 are connected via the suction port 13d. A fluid, specifically, refrigerant, is introduced into the motor housing 13 through the suction port 13d from the outside of the motor housing 13.
The electric compressor 10 includes a rotary shaft 15, a compression part 16, an inverter 17, and a rotating electric machine 20. The rotary shaft 15, the compression part 16, and the rotating electric machine 20 are accommodated in the motor housing 13. That is, the housing 11 accommodates the rotating electric machine 20. The axis of the rotary shaft 15 accommodated in the motor housing 13 corresponds to the axis of the peripheral wall 13b of the motor housing 13. The inverter 17 is accommodated in the inverter chamber S1.
The compression part 16 and the rotating electric machine 20 are arranged side by side in the axial direction of the rotary shaft 15. The rotating electric machine 20 is located between the compression part 16 and the end wall 13a of the motor housing 13. The compression part 16, the rotating electric machine 20, and the inverter 17 are arranged in this order in the axial direction of the rotary shaft 15.
The electric compressor 10 includes a shaft support member 18. The shaft support member 18 is disposed between the compression part 16 and the rotating electric machine 20. Accordingly, the shaft support member 18 serves as a partition between the rotating electric machine 20 and the compression part 16. The shaft support member 18 cooperates with the end wall 13a and the peripheral wall 13b of the motor housing 13 to define a motor chamber S2. Accordingly, the housing 11 has the motor chamber S2. The motor chamber S2 accommodates the rotating electric machine 20. The refrigerant is introduced into the motor chamber S2 through the suction port 13d.
The shaft support member 18 has an insertion hole 18h. The insertion hole 18h is located at the center of the shaft support member 18. The axis of the insertion hole 18h corresponds to the axis of the boss 13c. A first end of the rotary shaft 15 is inserted through the insertion hole 18h. A radial bearing 19a is disposed between the insertion hole 18h and the first end of the rotary shaft 15. The first end of the rotary shaft 15 is rotatably supported by the shaft support member 18 via the radial bearing 19a. A second end of the rotary shaft 15 is inserted in the boss 13c. A radial bearing 19b is disposed between the boss 13c and the second end of the rotary shaft 15. The second end of the rotary shaft 15 is rotatably supported by the boss 13c via the radial bearing 19b.
The compression part 16 includes a fixed scroll 16a and a movable scroll 16b. The fixed scroll 16a is fixed to the motor housing 13. The movable scroll 16b is disposed facing the fixed scroll 16a. The compression part 16 is driven by rotation of the rotary shaft 15. The compression part 16 is configured to compress the refrigerant. The fixed scroll 16a and the movable scroll 16b cooperate to define a compression chamber S3 with variable volume. The fixed scroll 16a and the discharge housing 12 cooperate to define a discharge chamber S4. The refrigerant is compressed by the variation of the volume of the compression chamber S3, and discharged into the discharge chamber S4. The rotating electric machine 20 is configured to rotate the rotary shaft 15. The rotation of the rotary shaft 15 drives the compression part 16. The rotation of the rotary shaft 15 therefore causes the compression part 16 to compress the refrigerant.
The rotating electric machine 20 includes a rotor 21 and a stator 22. The stator 22 has a cylindrical shape. The rotor 21 is disposed inside the stator 22. The rotor 21 includes a rotor core 21a having a circular cylindrical shape, and a plurality of permanent magnets (not illustrated) disposed in the rotor core 21a. The rotor core 21a is fixed to the rotary shaft 15. The rotor core 21a is rotatable together with the rotary shaft 15.
The stator 22 includes a stator core 23. The stator core 23 is fixed to the inner peripheral surface of the peripheral wall 13b of the motor housing 13. The stator core 23 is fixed to the housing 11. For example, the stator core 23 is fitted in the inner peripheral surface of the peripheral wall 13b of the motor housing 13 by shrink fitting, so that the stator 22 is assembled to the housing 11. The axis of the stator core 23 corresponds to the axis of the rotary shaft 15. Accordingly, the axial direction of the stator core 23 corresponds to the axial direction of the rotary shaft 15.
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Each of the plurality of teeth 25 (i.e., a tooth 25) extends from an inner peripheral surface 24a of the yoke 24 inward in the radial direction of the yoke 24. The teeth 25 are spaced from each other (in this embodiment, equally spaced from each other) in the circumferential direction of the yoke 24. The circumferential direction of the yoke 24 corresponds to the circumferential direction of the stator core 23. Each of the teeth 25 (i.e., the tooth 25) extends from the inner peripheral surface 24a of the yoke 24 toward the axis of the stator core 23. According to the present embodiment, the stator core 23 includes fifteen teeth 25. The number of teeth 25 is not limited thereto, but the number of teeth is a multiple of three.
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The one end surface of the yoke 24 and the one end surface of the tooth cooperate to form a first core end surface 23a of the stator core 23 at one end of the stator core 23 in the axial direction of the yoke 24. The other end surface of the yoke 24 and the other end surface of the tooth 25 cooperate to form a second core end surface 23b of the stator core 23 at another end of the stator core 23 in the axial direction of the yoke 24. Accordingly, the stator core 23 has the first core end surface 23a and the second core end surface 23b. The first core end surface 23a and the second core end surface 23b define the stator core 23 in the axial direction of the yoke 24, and each of the first core end surface 23a and the second core end surface 23b serves as the core end surface of the present disclosure.
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The stator core 23 has a plurality of slots 30. Each of the slots 30 is formed between the teeth 25 adjacent to each other in the circumferential direction of the yoke 24. The slot 30 is defined by the inner peripheral surface 24a of the yoke 24, the tooth side surfaces 26a adjacent to each other in the circumferential direction of the yoke 24, and a surface of the tooth end portion 27 facing the yoke 24. The stator core 23 has a plurality of slot openings 31. Each of the slot openings 31 is formed between the tooth end portions 27 that are adjacent to each other in the circumferential direction of the yoke 24. The slot opening 31 is connected to the slot 30.
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Each of the insertion recesses 34 has a first engagement portion, which, in this embodiment, is a protruding engagement portion 35. The protruding engagement portion 35 protrudes from the connecting surface 34b in the radial direction of the yoke 24. The protruding engagement portion 35 has a rectangular prism shape. In a planar view of the protruding engagement portion 35, the longitudinal direction of the protruding engagement portion 35 corresponds to the circumferential direction of the yoke 24. The protruding engagement portion 35 is located away from the bottom surface 34c. The protruding engagement portion is also located away from the side surfaces 34a.
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The first insulator 50 and the second insulator 60 each have an insulator base portion 51 and a plurality of insulator teeth 52. The insulator base portion 51 has a circular cylindrical shape. The first insulator 50 and the second insulator 60 are disposed on the stator core 23 and each arranged such that the axis of the insulator base portion 51 corresponds to the axis of the yoke 24. Accordingly, the axial direction of the insulator base portion 51 corresponds to the axial direction of the yoke 24. The circumferential direction of the insulator base portion 51 corresponds to the circumferential direction of the yoke 24. The radial direction of the insulator base portion 51 corresponds to the radial direction of the yoke 24.
The first insulator 50 is disposed in contact with and facing the first core end surface 23a of the stator core 23. The second insulator 60 is disposed in contact with and facing the second core end surface 23b of the stator core 23. The outer diameter of the insulator base portion 51 is smaller than the outer diameter of the yoke 24. The insulator base portion 51 and the yoke 24 have the same inner diameter.
Each of the insulator teeth 52 extends from an inner peripheral surface 51a of the insulator base portion 51 inward in the radial direction of the insulator base portion 51. The insulator teeth 52 are spaced from each other (in this embodiment, equally spaced from each other) in the circumferential direction of the insulator base portion 51. Each of the insulator teeth 52 extends along the inner peripheral surface 51a of the insulator base portion 51 in the axial direction of the insulator base portion 51. In the present embodiment, the first insulator 50 and the second insulator 60 each have fifteen insulator teeth 52. The number of insulator teeth 52 is the same as the number of teeth 25 of the stator core 23.
Each of the insulator teeth 52 has an insulator extension portion 53. That is, the first insulator 50 and the second insulator 60 each have a plurality of insulator extension portions 53. Each of the insulator extension portions 53 has a columnar shape and extends from the inner peripheral surface 51a of the insulator base portion 51 inward in the radial direction of the insulator base portion 51. The insulator extension portion 53 and the tooth extension portion 26 have the same dimension in the circumferential direction of the insulator base portion 51 and the yoke 24. The insulator extension portions 53 are in contact with the teeth 25, respectively. Accordingly, each insulator extension portion 53 overlaps the corresponding tooth extension portion 26 in the axial direction of the yoke 24.
Each of the insulator teeth 52 has an insulator inner wall 54. That is, the first insulator 50 and the second insulator 60 each have a plurality of insulator inner walls 54. Each of the insulator inner walls 54 extends from the distal end of the insulator extension portion 53, which extends from the insulator base portion 51, along the direction of the insulator base portion 51. Specifically, the insulator inner wall 54 extends from the distal end of the insulator extension portion 53 in opposite directions along the circumferential direction of the insulator base portion 51, and extends in the axial direction of the insulator base portion 51 so as to become distant away from the stator core 23. In this way, the insulator inner wall 54 extends from the insulator extension portion 53. Each insulator inner wall 54 overlaps the corresponding tooth end portion 27 in the axial direction of the yoke 24.
Each of the insulator teeth 52 (i.e., the insulator tooth 52) extending from the insulator base portion 51 has a surface 52a at the distal end of the insulator teeth 52. The tooth 25 extending from the yoke 24 has a surface 25a at the distal end of the tooth 25. The surface 52a of the insulator tooth 52 and the surface 25a of the tooth 25 are in the same plane. The surface 52a of the insulator tooth 52 is formed of a surface of the insulator inner wall 54 facing away from the insulator base portion 51. The surface 25a of the tooth 25 is formed of a surface of the tooth end portion 27 facing away from the yoke 24. The thickness of the insulator inner wall 54 is greater than the thickness of the tooth end portion 27. Accordingly, the insulator inner wall 54 closes the slot 30 at a region adjacent to the tooth end portion 27 in the axial direction of the yoke 24.
The insulator inner wall 54 has a plurality of insertion grooves 54a. Specifically, in this embodiment, the insulator inner wall 54 has two insertion grooves 54 respectively in the opposing surfaces of the insulator inner wall 54 in the circumferential direction of the insulator base portion 51. Each of the insertion grooves 54a is formed through the insulator inner wall 54 in the axial direction of the insulator base portion 51. The insertion groove 54a forms a space that serves as a part of a space between the insulator inner walls 54 adjacent to each other in the circumferential direction of the yoke 24.
The first insulator 50 has three guide grooves 55. The guide grooves 55 are arranged side by side in the axial direction of the first insulator 50. The guide grooves 55 are formed in the outer peripheral surface of the insulator base portion 51. The guide grooves 55 extend in the circumferential direction of the first insulator 50. The first insulator 50 has fifteen through grooves 56 corresponding to the three guide grooves 55. Specifically, the first insulator 50 has five through grooves 56 for each of the three guide grooves 55. The through grooves 56 are formed through the insulator base portion 51 in the radial direction.
The second insulator 60 has a plurality of insertion recesses 61. Each of the insertion recesses 61 is formed in the corresponding surface 52a of the insulator tooth 52. The insertion recess 61 is formed through the surface 52a of the insulator tooth 52 in the axial direction of the insulator base portion 51.
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The second insulating portion 48 of the insulating member 46 is disposed between the other of the adjacent tooth end portions 27 between which the slot opening 31 is located and the other of the pair of extending portions 38 of the slot insulating member 36. The second insulating portion 48 of the insulating member 46 overlaps the other of the extending portions 38 in the radial direction of the yoke 24. Accordingly, the insulating member 46 overlaps the extending portions 38 in the radial direction of the yoke 24. The second insulating portion 48 electrically insulates the other of the adjacent tooth end portions 27 from the other of the coils 28 adjacent to each other in the slot 30 in the circumferential direction of the yoke 24.
The third insulating portion 49 has a V-shape in cross section. Specifically, the third insulating portion 49 extends from one end of the first insulating portion 47 adjacent to the second insulating portion 48 toward the inner peripheral surface 24a of the yoke 24, and is bent toward the second insulating portion 48 and connected to one end of the second insulating portion 48 adjacent to the first insulating portion 47. Accordingly, the third insulating portion 49 connects the first insulating portion 47 and the second insulating portion 48. In the slot 30, the third insulating portion 49 is disposed between the coils 28 adjacent to each other in the circumferential direction of the yoke 24. The third insulating portion 49 electrically insulates one of the adjacent coils 28 from the other of the adjacent coils 28 in the slot 30. Accordingly, the third insulating portion 49 has a V-shape in cross section to connect the first insulating portion 47 and the second insulating portion 48 and electrically insulate one of the coils 28 adjacent to each other in the circumferential direction of the yoke 24 from the other of the adjacent coils 28 in the slot 30.
In this way, the insulating member 46 is disposed crossing the slot opening 31 in the circumferential direction of the yoke 24. The insulating member 46 electrically insulates the tooth end portions 27 between which the slot opening 31 is located from the coils 28.
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The first cover 65 has an end wall 65a, an outer peripheral wall 65b, and an inner peripheral wall 65c. The end wall 65a has a ring shape. The end wall 65a has a plate shape. The outer peripheral wall 65b has an edge 65e, and has a circular cylindrical shape. The outer peripheral wall 65b extends from the outer peripheral portion of the end wall 65a, and is defined by the end wall 65a and the edge 65e in the axial direction. The inner peripheral wall 65c has a circular cylindrical shape, and extends from the inner peripheral portion of the end wall 65a. The inner diameter of the outer peripheral wall 65b is greater than the outer diameter of the insulator base portion 51. The outer peripheral wall 65b surrounds the insulator base portion 51 of the first insulator 50. The inner peripheral wall 65c faces the insulator inner walls 54 of the first insulator 50 in the axial direction of the yoke 24. The end wall 65a faces the first coil ends 32 in the axial direction of the yoke 24. The end wall 65a has a plurality of insertion holes 65h.
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The second cover 70 has a main body 71 having a circular cylindrical shape and an extending wall 72 having a plate shape. The main body 71 faces the insulator inner walls 54 of the second insulator 60 in the axial direction of the yoke 24. The extending wall 72 extends from a part of the outer peripheral edge of the main body 71 outward in the radial direction of the yoke 24. The extending wall 72 has a thin plate shape. The extending wall 72 has a storage 73 that has electrical insulation properties. The storage 73 has, for example, a rectangular cylindrical shape. The storage 73 stores a neutral point connector (not illustrated), which serves as a neutral point at which the ends of lead wires 74 for the U phase, the V phase, and the W phase drawn out from the second coil ends 33 are electrically connected to each other.
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The engagement piece 75 has a first engagement portion, which, in this embodiment, is a protruding engagement portion 76. The engagement piece 75 has a radially outer surface in the radial direction of the main body 71, and the protruding engagement portion 76 extends from the radially outer surface at the distal end of the engagement piece 75 in the radial direction of the yoke 24. The protruding engagement portion 76 has a sloped surface 76a, which is a radially outer surface of the protruding engagement portion 76 in the radial direction of the main body 71. The sloped surface 76a is inclined inward in the radial direction of the main body 71 toward the distal end of the engagement piece 75.
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In this way, the second cover 70 has the engagement piece 75, and the insulator inner wall 54 of the second insulator 60 has the insertion recess 61. The second cover 70 is attached to the second insulator 60 with the circumferential direction and the axial direction of the main body 71 respectively corresponding to the circumferential direction and the axial direction of the yoke 24.
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The second cover 70 has a plurality of insertion plates 78. Each of the insertion plates 78 extends in the axial direction of the yoke 24 from the inner peripheral edge of the main body 71 of the second cover 70. The insertion plates 78 are equally spaced from each other in the circumferential direction of the main body 71 on the main body 71 of the second cover 70. Each of the insertion plates 78 has an elongated plate shape. The longitudinal direction of the insertion plate 78 corresponds to the axial direction of the yoke 24. The insertion plate 78 has side edges that define the insertion plate 78 in the circumferential direction of the yoke 24. The side edges of the insertion plate 78 extend in the axial direction of the yoke 24 and are parallel to each other.
The insertion plate 78 is inserted into the insertion recess 61 into which the engagement piece 75 is not inserted. Specifically, the insertion plate 78 is inserted into an insertion space 80 that is defined by a pair of space-forming walls 81. The pair of space-forming walls 81 are spaced from each other in the circumferential direction of the yoke 24, and form the pair of side surfaces 61a of the insertion recesses 61 into which the engagement piece 75 is not inserted. Accordingly, any two circumferentially adjacent insulator inner walls 54 of the second insulator 60 cooperate to have the pair of space-forming walls 81. One and the other of any two adjacent insulator inner walls 54 respectively have one and the other of the pair of space-forming walls 81. One of the pair of space-forming walls 81 is spaced from the other of the pair of space-forming walls 81 in the circumferential direction of the yoke 24, and cooperates with the other of the pair of space-forming walls 81 to define the insertion space 80 into which the insertion plate 78 is inserted. The insertion plate 77 is not disposed in a space between the teeth 25 adjacent to each other in the circumferential direction of the yoke 24, and is located away from the stator core 23 in the axial direction of the yoke 24. The dimension of the insertion plate 78 is slightly greater than the dimension of the engagement piece 75 in the circumferential direction of the yoke 24.
In the main body 71 of the second cover 70, the engagement pieces 75, the insertion plates 77, and the insertion plates 78 are spaced from each other and arranged in the order of the engagement piece 75, the insertion plate 77, the insertion plate 78, the insertion plate 77, the insertion plate 78, the insertion plate 77, and the engagement piece 75 repeatedly in the circumferential direction of the main body 71, for example.
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The insertion plate 68 and the insertion plate 77 each have a holding portion 86. The holding portion 86 of the insertion plate 68 projects outward in the radial direction of the yoke 24 from a center part of a radially outer surface of the insertion plate 68. The holding portion 86 of the insertion plate 77 projects outward in the radial direction of the yoke 24 from a center part of a radially outer surface of the insertion plate 77. The holding portion 86 of the insertion plate 68 is integrally formed with the insertion plate 68. The holding portion 86 of the insertion plate 77 is integrally formed with the insertion plate 77. Each holding portion 86 is disposed between the first insulating portion 47 and the second insulating portion 48 of the insulating member 46 in the circumferential direction of the yoke 24. The holding portion 86 is in contact with the opposite end portions of the third insulating portion 49 respectively adjacent to the first insulating portion 47 and the second insulating portion 48. The insulating member 46 has the first connecting point 46a, and the second connecting point 46b. The third insulating portion 49 is connected to the first insulating portion 47 at the first connecting point 46a and connected to the second insulating portion 48 at the second connecting point 46b. The holding portion 86 secures an opening angle of the third insulating portion 49, thereby ensuring a distance between the first connecting point 46a and the second connecting point 46b in the circumferential direction of the yoke 24.
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The stator 22 includes three lead wires 43 respectively for the U phase, the V phase, and the W phase. The lead wires 43 are drawn out from the rotating electric machine 20. In this embodiment, each of the lead wires 43 is drawn out from the second coil end 33 of any one of the coils 28 of the corresponding phase. For the sake of explanation,
The stator 22 includes a cluster block 44. The cluster block 44 accommodates three connection terminals 45. The cluster block 44 has electrical insulation properties. The cluster block 44 is made of a resin material, for example. The cluster block 44 accommodates three connection terminals 45 respectively for the U phase, the V phase, and the W phase. Each of the 20 conductive members 41 is electrically connected to the corresponding lead wire 43 via the corresponding connection terminal 45.
The inverter 17 supplies power to the rotating electric machine 20 via the conductive members 41, the connection terminals 45, and the lead wires 43. Accordingly, the rotating electric machine 20 is driven. In other words, the inverter 17 drives the rotating electric machine 20.
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The following will describe the operation of the stator of the rotating electric machine according to the present embodiment.
For example, when the rotating electric machine 20 vibrates, a friction occurs in the axial direction of the yoke 24 between the insertion plate 68 in the insertion space 58 and one of the pair of space-forming walls 59. The occurrence of the friction between the insertion plate 68 and one of the pair of space-forming walls 59 suppresses the friction between the engagement piece 66 and the insertion recess 34 in the axial direction of the yoke 24. Particularly, in a situation that the insertion plate 68 is in contact with one of the pair of space-forming walls 59, a clearance is formed between each of the circumferential side edges 66a of the engagement piece 66 and the circumference inner surface (i.e., the corresponding side surface 34a) of the insertion recess 34 in the circumferential direction of the yoke 24. This configuration prevents the occurrence of the friction between the side edge 66a of the engagement piece 66 and the corresponding side surface 34a of the insertion recess 34. This therefore suppresses the progression of the friction between the engagement piece 66 and the insertion recess 34. This therefore prevents a breakage of the engagement piece 66, thereby preventing disengagement of the protruding engagement portion 35 and the hook piece 67b of the engagement claw 67. This therefore prevents the first cover 65 from coming out of the first insulator 50 in the axial direction of the yoke 24.
Similarly, when the rotating electric machine 20 vibrates, a friction occurs in the axial direction of the yoke 24 between the insertion plate 77 in the insertion space 62 and one of the pair of space-forming walls 63 and between the insertion plate 78 in the insertion space 80 and one of the pair of space-forming walls 81. The occurrence of the friction between the insertion plate 77 in the insertion space 62 and one of the pair of space-forming walls 63 and between the insertion plate 78 in the insertion space 80 and one of the pair of space-forming walls 81 suppresses the friction between the engagement piece 75 and the insertion recess 61 in the axial direction of the yoke 24. Particularly, in a situation that the insertion plate 77 and the insertion plate 78 are respectively in contact with one of the pair of space-forming walls 63 and one of the pair of space-forming walls 81, a clearance is formed between each of the circumferential side edges 75a of the engagement piece 75 and the circumferential inner surface (i.e., the corresponding side surface 61a) of the insertion recess 61 in the circumferential direction of the yoke 24. This configuration prevents the occurrence of the friction between the side edge 75a of the engagement piece 75 and the corresponding side surface 61a of the insertion recess 61. This therefore suppresses the progression of the friction between the engagement piece 75 and the insertion recess 61. This therefore prevents a breakage of the engagement piece 75, thereby preventing disengagement of the protruding engagement portion 76 and the third connecting surface 61d of the insertion recess 61. This therefore prevents the second cover 70 from coming out of the second insulator 60 in the axial direction of the yoke 24.
The insertion plate 68 and the insertion plate 77 each have a support surface 85 that is located in the space between the insulator inner walls 54 adjacent to each other in the circumferential direction of the yoke 24, and located inward of the insulating member 46 to support the insulating member 46 in the radial direction of the yoke 24. The support surface 85 is located radially outward of the slot opening 31, which is disposed between the tooth end portions 27, in the radial direction of the yoke 24 when viewed in the axial direction of the yoke 24. This configuration restrains the insulating member 46 from approaching the slot opening 31. This configuration therefore easily secures an insulation distance between the tooth end portions 27 and the coils 28.
The aforementioned embodiment provides the following advantageous effects. The following (1) to (3) will focus on advantageous effects related to the second cover 70, and will not elaborate advantageous effects related to the first cover 65 since they are the same as the advantageous effects related to the second cover 70.
(1) The second cover 70 has the insertion plate 77 and the insertion plate 78 extending in the axial direction of the yoke 24. Any two circumferentially adjacent insulator inner walls 54 of the second insulator 60 cooperate to have the pair of space-forming walls 63. One and the other of any two adjacent insulator inner walls 54 respectively have one and the other of the pair of space-forming walls 63. One of the pair of space-forming walls 63 is spaced from the other of the pair of space-forming walls 63 in the circumferential direction of the yoke 24, and cooperates with the other of the pair of space-forming walls 63 to define the insertion space 62 into which the insertion plate 77 is inserted. Furthermore, any two circumferentially adjacent insulator inner walls 54 of the second insulator 60 cooperate to have the pair of space-forming walls 81. One and the other of any two adjacent insulator inner walls 54 respectively have one and the other of the pair of space-forming walls 81. One of the pair of space-forming walls 81 is spaced from the other of the pair of space-forming walls 81 in the circumferential direction of the yoke 24, and cooperates with the other of the pair of space-forming walls 81 to define the insertion space 80 into which the insertion plate 78 is inserted. The insertion plate 77 is configured to come into contact with the pair of space-forming walls 63 with the insertion plate 77 inserted into the insertion space 62. The insertion plate 78 is configured to come into contact with the pair of space-forming walls 81 with the insertion plate 78 inserted into the insertion space 80. For example, when the rotating electric machine 20 vibrates, a friction occurs in the axial direction of the yoke 24 between the insertion plate 77 in the insertion space 62 and one of the pair of space-forming walls 63 and between the insertion plate 78 in the insertion space 80 and one of the pair of space-forming walls 81. The occurrence of the friction between the insertion plate 77 in the insertion space 62 and one of the pair of space-forming walls 63 and between the insertion plate 78 in the insertion space 80 and one of the pair of space-forming walls 81 suppresses the friction between the engagement piece 75 and the insertion recess 61 in the axial direction of the yoke 24. This therefore suppresses the progression of the friction between the engagement piece 75 and the insertion recess 61. This therefore prevents a breakage of the engagement piece 75, thereby preventing disengagement of the protruding engagement portion 76 and the third connecting surface 61d of the insertion recess 61. This therefore prevents the second cover 70 from coming out of the second insulator 60 in the axial direction of the yoke 24. As a result, this increases the reliability of the stator 22 of the rotating electric machine 20.
(2) In a situation that the insertion plate 77 and the insertion plate 78 are respectively in contact with one of the pair of space-forming walls 63 and one of the pair of space-forming walls 81, a clearance is formed between each of the circumferential side edges 75a of the engagement piece 75 and the circumferential inner surface (i.e., the corresponding the side surface 61a) of the insertion recess 61 in the circumferential direction of the yoke 24. This configuration prevents the occurrence of the friction between the side edge 75a of the engagement piece 75 and the corresponding side surface 61a of the insertion recess 61.
(3) The insertion space 62 is a space between the insulator inner walls 54 adjacent to each other in the circumferential direction of the yoke 24. The pair of space-forming walls 63 are side walls of the insulator inner walls 54 that are adjacent to each other in the circumferential direction of the yoke 24. This configuration allows the progression of the friction between the engagement piece 75 and the insertion recess 61 to be suppressed simply by the presence of the insertion plate 77 inserted into the space between the insulator inner walls 54 adjacent to each other in the circumferential direction of the yoke 24. This therefore simplifies the configuration of the stator 22.
(4) The second cover 70 has the engagement piece 75, and the insulator inner wall 54 of the second insulator 60 has the insertion recess 61. The insertion plate 77, the pair of space-forming walls 63, the engagement piece 75, and the insertion recess 61 are located radially inward of the second coil end 33 in the radial direction of the yoke 24. This configuration allows the engagement piece 75 and the insertion recess 61 to be located as close to the insertion plate 77 and the pair of space-forming walls 63 as possible, compared with a configuration in which the engagement piece 75 and the insertion recess 61 are located radially outward of the second coil end 33 in the radial direction of the yoke 24. This configuration is unlikely to cause tolerance accumulation of the engagement piece 75, the insertion recess 61, the insertion plate 77, and the pair of space-forming walls 63. This configuration therefore suitably suppresses a friction between the engagement piece 75 and the insertion recess 61 caused by a friction between the insertion plate 77 and the space-forming wall 63.
(5) The insertion plate 68 and the insertion plate 77 each have the support surface 85 that is located in the space between the insulator inner walls 54 adjacent to each other in the circumferential direction of the yoke 24, and located inward of the insulating member 46 to support the insulating member 46 in the radial direction of the yoke 24. The support surface 85 is located radially outward of the slot opening 31, which is disposed between the tooth end portions 27, in the radial direction of the yoke 24 when viewed in the axial direction of the yoke 24. This configuration restrains the insulating member 46 from approaching the slot opening 31. This configuration therefore easily secures an insulation distance between the coils 28 and the tooth end portions 27 between which the slot opening 31 is located. This configuration therefore suppresses the occurrence of electric insulation failures between the tooth end portions 27 and the coils 28, thereby increasing the reliability of the stator 22 of the rotating electric machine 20.
(6) The insulating member 46 overlaps the extending portions 38 of the slot insulating member 36 in the radial direction of the yoke 24. This configuration easily allows extension of the insulation distance between the tooth end portions 27 and the coils 28, compared with a configuration in which the slot insulating member 36 does not have the extending portions 38. This configuration therefore further suppresses the occurrence of electric insulation failures between the tooth end portions 27 and the coils 28, thereby further increasing the reliability of the stator 22 of the rotating electric machine 20.
(7) The insulating member 46 has the first connecting point 46a, and the second connecting point 46b. The third insulating portion 49 is connected to the first insulating portion 47 at the first connecting point 46a and connected to the second insulating portion 48 at the second connecting point 46b. The insertion plate 68 and the insertion plate 77 each have the holding portion 86 that secures an opening angle of the third insulating portion 49. The holding portion 86 therefore secures a distance between the first connecting point 46a and the second connecting point 46b in the circumferential direction of the yoke 24. This configuration allows extension of the distance between the slot opening 31 and the distal edge of the first insulating portion 47 extending from the third insulating portion 49 and the distance between the slot opening 31 and the distal edge of the second insulating portion 48 extending from the third insulating portion 49 as much as possible. This configuration therefore easily allows extension of the insulation distance between the tooth end portions 27 and the coils 28. This configuration therefore further suppresses the occurrence of electric insulation failures between the tooth end portions 27 and the coils 28, thereby further increasing the reliability of the stator 22 of the rotating electric machine 20.
(8) Each of the insertion plate 68 and the insertion plate 77 is not disposed in a space between the teeth 25 adjacent to each other in the circumferential direction of the yoke 24, and is located away from the stator core 23 in the axial direction of the yoke 24. In this configuration, the support surface 85 of each of the insertion plate 68 and the insertion plate 77 is located inward of the insulating member 46 to support only a part of the insulating member 46 protruding from the slot 30 into a space between the circumferentially adjacent insulator inner walls 54. The insertion plate 68 and the insertion plate 77 are located away from the stator core 23. This configuration prevents contact and therefore prevents a friction between the insertion plates 68 and 77 and the stator core 23, for example, when the rotating electric machine 20 vibrates. This 30 configuration therefore increases durability of the stator 22 of the rotating electric machine 20, thereby further increasing the reliability of the stator 22 of the rotating electric machine 20.
The aforementioned embodiment may be modified as below. The embodiment and the following modifications may be combined with each other within technically consistent range.
As illustrated in
The aforementioned embodiment includes configurations described in the following appendices.
A stator of a rotating electric machine, the stator comprising:
The stator of the rotating electric machine according to Appendix 1, wherein
The stator of the rotating electric machine according to Appendix 1 or 2, wherein
The stator of the rotating electric machine according to any one of Appendices 1 to 3, wherein
The stator of the rotating electric machine according to Appendix 3, wherein
Number | Date | Country | Kind |
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2023-122509 | Jul 2023 | JP | national |