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US 10,566,867 B2Granted
Stator and method of manufacturing stator
AssigneeAisin Aw Co., Ltd.
InventorsKiyotaka Koga, Shingo Hashimoto, Shingo Sato
Life of this patent
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Abstract
A stator that includes a core formed by stacking annular steel sheets on each other and having teeth and slots provided between the teeth; and a plurality of continuous coils each continuously formed from a single conductor wire and each having a plurality of slot housed portions to be housed in the slots which are different from each other, a coil end portion on one side in an axial direction that connects the slot housed portions to each other, and a coil end portion on the other side in the axial direction that connects the slot housed portions to each other.
Claims11
A stator comprising:
- a core formed by stacking annular steel sheets on each other and having teeth and slots provided between the teeth;
- and
- a plurality of continuous coils each continuously formed from a single conductor wire and each having a plurality of slot housed portions to be housed in the slots that are different from each other, a coil end portion on one side in an axial direction that connects the slot housed portions to each other, and a coil end portion on the other side in the axial direction that connects the slot housed portions to each other, wherein:
- the coil end portion of a first continuous coil and the coil end portion of a second continuous coil to be housed in the slots that are adjacent to each other in a circumferential direction, of the plurality of continuous coils, are each provided with an offset portion in which the conductor wire is bent in a radial direction of the stator so as to be offset in the radial direction by a width corresponding to one conductor wire;
- a clearance in the circumferential direction between the slot housed portion of the first continuous coil and the slot housed portion of the second continuous coil after the first continuous coil and the second continuous coil are housed in the slots is larger than a clearance in the circumferential direction between the slot housed portion of the first continuous coil and the slot housed portion of the second continuous coil before the first continuous coil and the second continuous coil are housed in the slots;
- and
- in the case where a length from a center of the core to end portions of the teeth on a radially inner side as viewed in the axial direction is defined as R, a width of the coil end portion in the radial direction as viewed in the axial direction is defined as B, the number of the slots is defined as n1, and the number of turns of the continuous coils that are disposed in the slots is defined as n2, a width A of the offset portion in the circumferential direction meets the following formula (2):
- A≤2×π×(R−(B×(n2−1)))/n1 (2).
5 more elements
A method of manufacturing a stator, comprising the steps of:
- disposing a first continuous coil and a second continuous coil on a radially inner side of a core, the core being formed by stacking annular steel sheets on each other and having teeth and slots provided between the teeth, the first continuous coil and the second continuous coil each being continuously formed from a single conductor wire to be housed in the slots that are adjacent to each other in a circumferential direction and each including a plurality of slot housed portions to be housed in the slots that are different from each other, a coil end portion on one side in an axial direction that connects the slot housed portions to each other, and a coil end portion on the other side in the axial direction that connects the slot housed portions to each other, and the coil end portions each being provided with an offset portion in which the conductor wire is bent in a radial direction of the stator so as to be offset in the radial direction by a width corresponding to one conductor wire;
- and
- moving the first continuous coil and the second continuous coil from the radially inner side toward a radially outer side to be inserted into the slots that are adjacent to each other in the circumferential direction such that a clearance in the circumferential direction between the slot housed portion of the first continuous coil and the slot housed portion of the second continuous coil after the first continuous coil and the second continuous coil are housed in the slots is larger than a clearance in the circumferential direction between the slot housed portion of the first continuous coil and the slot housed portion of the second continuous coil before the first continuous coil and the second continuous coil are housed in the slots, while maintaining a state in which an overall width of the offset portion is disposed in a range of a sector centered on a center of the core and having a center angle θ determined by the following formula (4) as viewed in the axial direction in the case where the number of the slots is defined as n:
- θ=360/n (4)
- wherein the step of disposing the first continuous coil and the second continuous coil on the radially inner side of the core is configured such that, in the case where a length from the center of the core to an end surface, on an outer side in the radial direction, of the coil end portion disposed on an innermost peripheral side of the first continuous coil or the second continuous coil as viewed in the axial direction with the first continuous coil and the second continuous coil disposed on the radially inner side of the core is defined as r, a width A of the offset portion in the circumferential direction meets the following formula (5):
- A≤2×Π×r/n (5).
3 more elements
Dependencies are inferred from the claim text.