Motor and method for manufacturing stator therefor

Patent metadata

Field	Value
Publication number	US-9748810-B2
Application number	US-201314373959-A
Country	US
Kind code	B2
Filing date	Jan 17, 2013
Priority date	Mar 13, 2012
Publication date	Aug 29, 2017
Grant date	Aug 29, 2017

Abstract

A stator core is formed by deforming a core assembly having core pieces coupled in a strip form into an annular shape, and by joining both ends of the core assembly together to make a core-fastening portion. Individual phase windings are routed from one end of the core assembly toward another end. Lead portion ( 43 v ) of phase winding ( 40 v ) and lead portion ( 43 w ) of phase winding ( 40 w ) make up respective wire terminals. Lead portion ( 43 u ) of another phase winding ( 40 u ) is extended through a plural number of the core pieces in a direction of the lead portions ( 43 v and 43 w ), and a wire terminal of the extended lead portion ( 43 u ) and the wire terminals of the other lead portions ( 43 v and 43 w ) are electrically connected to provide a neutral point of three-phase Y-connection circuit.

First claim

The invention claimed is:

1. A motor comprising a rotor having a plurality of magnetic poles around a rotary shaft, and a stator having a winding wound on a stator core formed of serially coupled twelve core pieces, each of which includes a tooth, the motor for being driven by a three-phase alternating-current power supply,
wherein:
the stator core is formed by deforming a core assembly having the core pieces coupled in a strip form into an annular shape, and by joining both ends of the core assembly together to make a core-fastening portion;
the winding comprises a first phase winding, a second phase winding and a third phase winding corresponding to respective phases;
each of the phase windings includes a winding portion wound on a designated number of the core pieces to form a plurality of coils, and a lead portion led out from the winding portion, and is routed from one end of the core assembly toward another end;
a pair of adjoining two of the coils is assigned as one coil pair of same phase, and individual coil pairs are arranged in order of the phases;
the lead portion of the first phase winding is led out from a first coil pair at one side closest to the another end of the core assembly;
the lead portion of the second phase winding is led out from a second coil pair adjacent to the first coil pair;
the stator comprises terminal pins, each having a hook;
the lead portions of the first phase winding and the second phase winding make up respective wire terminals;
a first terminal pin is disposed in place on the first coil pair, and the wire terminal of the lead portion of the first phase winding is connected to the first terminal pin;
a second terminal pin is disposed in place on the second coil pair, and the wire terminal of the lead portion of the second phase winding is connected to the second terminal pin;
the lead portion of the third phase winding is extended through a plural number of the core pieces in a direction of the other two lead portions, and is formed into an extended wire terminal; and
the extended wire terminal and the wire terminals of the other two lead portions are electrically connected by engaging the extended wire terminal in the hooks of both the first and second terminal pins to provide a neutral point of three-phase Y-connection circuit.

2. The motor of claim 1 , wherein each of the phase windings is formed by routing a single wire such that the plurality of coils are serially connected.

3. The motor of claim 1 , wherein:
the winding is wound on the core assembly via an insulator;
the insulator has a pin retainer for retaining each of the terminal pins; and
the first terminal pin is disposed on the pin retainer of the insulator of the first coil pair, and the second terminal pin is disposed on the pin retainer of the insulator of the second coil pair.

4. The motor of claim 3 , wherein the insulator has a protrusion on one face side of the core assembly for hitching the winding.

5. The motor of claim 1 , wherein:
the core pieces of the core assembly are coupled via connecting portions in the strip form, and each of connecting portions has V-shaped notch;
the lead portion which is disposed in position on the core piece wound the first phase winding is formed into the wire terminal of the first phase winding;
the lead portion which is disposed in position on the core piece wound the second phase winding is formed into the wire terminal of the second phase winding;
the lead portion of the third phase winding is formed into the extended wire terminal of the third phase winding, and is configured to be routed along a path adjacent to tip ends of the V-shaped notches and to be extended through the core pieces toward the other two lead portions; and
the extended wire terminal and each of the other two wire terminals are electrically connected to provide the neutral point by connections in two positions on each of core pieces.

6. A method for manufacturing a stator of the motor in claim 5 , comprising the steps of:
forming the core assembly by stacking a plurality of core sheet materials into layers;
forming a winding assembly by winding a winding on individual core pieces of the core assembly according to a winding pattern;
extending the lead portion of the third phase winding through a plural number of the core pieces in a direction of the other two lead portions, in such a manner that the lead portion of the third phase winding is routing along a path adjacent to tip ends of the V-shaped notches;
electrically connecting a wire terminal of the extended lead portion and wire terminals of the other two lead portions; and
deforming the winding assembly into an annular shape by using connecting portions, and joining both ends of the winding assembly together.

7. A method for manufacturing a stator of the motor in claim 1 , comprising the steps of:
forming the core assembly by stacking a plurality of core sheet materials into layers;
forming a winding assembly by winding a winding on individual core pieces of the core assembly according to a winding pattern;
extending the lead portion of the third phase winding through a plural number of the core pieces in a direction of the other two lead portions;
electrically connecting a wire terminal of the extended lead portion and wire terminals of the other two lead portions; and
deforming the winding assembly into an annular shape, and joining both ends of the winding assembly together,
wherein a pair of adjoining two of the coils is assigned as one coil pair of same phase, and individual coil pairs are arranged in order of the phases,
wherein the step of electrically connecting the wire terminals includes:
leading out the lead portion of the first phase winding from a first coil pair at one side closest to the another end of the core assembly; and
leading out the lead portion of the second phase winding from a second coil pair adjacent to the first coil pair, and then electrically connecting together the individual wire terminals,

wherein the stator includes terminal pins, each having a hook, and
wherein the step of electrically connecting the wire terminals includes:
disposing a first terminal pin in place on the first coil pair, and connecting the lead portion of the first phase winding to the first terminal pin;
disposing a second terminal pin in place on the second coil pair, and connecting the lead portion of the second phase winding to the second terminal pin; and
engaging the lead portion of the third phase winding in the hooks of both the first and second terminal pins to electrically connect the wire terminals of the three phase windings as a neutral point.

8. The method for manufacturing a stator of claim 7 , wherein the step of forming the winding assembly includes routing of a single wire such that the plurality of coils are serially connected for each of the phase windings, and then forming the winding assembly.

9. The method for manufacturing a stator of claim 7 , wherein the step of forming the winding assembly includes:
winding the winding on the core assembly via an insulator that has a pin retainer for retaining each of the terminal pins;
disposing the first and second terminal pins on the pin retainers of the insulators of the first and second coil pairs respectively; and then
electrically connecting together the individual wire terminals.

Assignees

• Panasonic Corp
• Panasonic Ip Man Co Ltd

Inventors

• Okinaga Kinjirou
• Seki Yasutake
• Iida Tomomitsu
• Yasuno Masato
• Hidaka Masahito

Classifications

• H02K3/522

  for generally annular cores with salient poles · CPC title

• H02K3/345

  between conductor and core, e.g. slot insulation · CPC title

• Y10T29/49009

  Dynamoelectric machine · CPC title

• H02K15/0081

  Electricity · mapped topic

• H02K2203/06

  Machines characterised by the wiring leads, i.e. conducting wires for connecting the winding terminations · CPC title