CN110870171A - Structures, Stators and Motors - Google Patents

Abstract

The structure has: a cylindrical support surface extending in a magnetic core direction of the coil; and a coil formed of a wire wound around the support surface. The support surface has a rectangular shape in which long sides and short sides are alternately arranged when viewed in the core direction. That is, the support surface has a pair of first support surfaces corresponding to the short sides and a pair of second support surfaces corresponding to the long sides. At least one of the pair of first support surfaces has a protrusion protruding toward the lead. The top of the protrusion is located inward of both ends of the first support surface in the short-side direction.

Description

Structures, Stators and Motors

technical field

The present invention relates to a structure including a coil, a stator including the structure, and a motor including the stator.

Background technique

Conventionally, the coil of a motor is formed by winding a wire around an insulator with an insulator interposed between teeth serving as a magnetic core. Inside the motor, a plurality of such coils are arranged around the central axis. In addition, in order to arrange many coils around the center axis, the cross-sectional shape of the teeth may be a rectangular shape that is long in the axial direction and short in the circumferential direction.

For example, Japanese Patent Laid-Open No. 2003-190951 and Japanese Patent Laid-Open No. 2010-519471 describe the structures of teeth, insulators, and coils included in conventional motors.

Patent Document 1: Japanese Patent Laid-Open No. 2003-190951

Patent Document 2: Japanese Patent Laid-Open No. 2010-519471

SUMMARY OF THE INVENTION

The problem to be solved by the invention

When the wire is wound around the teeth with the insulating member interposed therebetween, the wire sometimes bulges in the circumferential direction. In particular, when the cross-sectional shape of the teeth is the above-mentioned rectangular shape, the bulge (bulge) of the lead wire with respect to both end surfaces in the circumferential direction of the insulator becomes large. The thicker the wire diameter is, the more pronounced the bulge of the wire will be. In order to arrange more coils around the central axis, it is required to suppress the bulge of the wire.

An object of the present invention is to provide a structure capable of suppressing the bulge of the conducting wire with respect to the support surface in the structure including the coil.

means of solving problems

The first invention exemplified in the present application is a structure including a coil, wherein the structure has: a cylindrical support surface extending in the direction of the magnetic core of the coil; The lead wire of the support surface is constituted, when viewed along the direction of the magnetic core, the support surface has a quadrangular shape in which long sides and short sides are alternately arranged, and has a pair of first support surfaces corresponding to the short sides and a pair of first support surfaces corresponding to the short sides. On the pair of second support surfaces on the long side, at least one of the pair of first support surfaces has a protruding portion protruding toward the lead wire, and the top of the protruding portion is located more than the first support surface. Both ends in the short-side direction are located on the inner side.

Invention effect

According to the first invention exemplified in the present application, the lead wire is bent at an obtuse angle from the top of the protruding portion toward the second support surface. Thereby, compared with the case where the lead wire is bent at a right angle, the bulging of the lead wire at the second support surface can be suppressed.

Description of drawings

FIG. 1 is a longitudinal sectional view of a motor.

2 is a perspective view of a first resin member.

FIG. 3 is a plan view of a portion of the stator core and insulating members.

FIG. 4 is a cross-sectional view of the stator core and the insulator viewed from the position A-A in FIG. 3 .

FIG. 5 is a cross-sectional view of the teeth and the insulator viewed from the A-A position of FIG. 3 .

FIG. 6 is a diagram showing a comparative example in a case where there is no protrusion.

7 is a cross-sectional view of a tooth and an insulator according to a modification.

8 is a cross-sectional view of a tooth and an insulator according to a modification.

9 is a cross-sectional view of a tooth and an insulator according to a modification.

Detailed ways

Hereinafter, exemplified embodiments of the present invention will be described with reference to the accompanying drawings. In this application, the direction parallel to the central axis of the motor is referred to as the "axial direction", the direction perpendicular to the central axis of the motor is referred to as the "radial direction", and the direction along the circle centered on the central axis of the motor is referred to as the "axial direction". The direction of the arc is called "circumferential". In this application, the shape and positional relationship of each part will be described with the axial direction as the vertical direction and the bus bar assembly side as the upper side with respect to the stator. However, the definition of the vertical direction is not intended to limit the orientation during manufacture and use of the motor of the present invention.

The above-mentioned "parallel direction" also includes a substantially parallel direction. The above-mentioned "vertical direction" also includes a substantially vertical direction.

<1. Overall structure of the motor>

FIG. 1 is a longitudinal cross-sectional view of a motor 1 according to an embodiment of the present invention. The motor 1 of the present embodiment is mounted on, for example, an automobile, and is used as a drive source for generating a drive force of an electric power steering device. However, the motor of one embodiment of the present invention may be used for applications other than power steering. For example, the motor according to one embodiment of the present invention may be used as a drive source for other parts of an automobile, for example, a fan for cooling an engine or an oil pump. In addition, the motor according to one embodiment of the present invention may be mounted on home appliances, office automation (OA: Office Automation) equipment, medical equipment, and the like, and generate various driving forces.

As shown in FIG. 1 , the motor 1 has a stationary part 2 and a rotating part 3 . The stationary unit 2 is fixed to a casing of a device to be driven. The rotating part 3 is supported so as to be rotatable with respect to the stationary part 2 .

The stationary portion 2 of the present embodiment includes a housing 21 , a stator 22 , a bus bar assembly 23 , a lower bearing portion 24 , and an upper bearing portion 25 .

The case 21 has a cylindrical portion 211 , a bottom plate portion 212 and a cover portion 213 . The cylindrical portion 211 extends in a substantially cylindrical shape in the axial direction on the radially outer sides of the stator 22 and the bus bar assembly 23 . The bottom plate portion 212 extends substantially perpendicular to the central axis 9 at a position lower than the stator 22 and the rotor 32 to be described later. The cover portion 213 extends substantially vertically with respect to the center axis 9 at a position above the bus bar assembly 23 . The stator 22 , the bus bar assembly 23 , and the rotor 32 described later are accommodated in the inner space of the casing 21 .

The material of the cylindrical portion 211, the bottom plate portion 212, and the lid portion 213 is, for example, metal such as aluminum or stainless steel. In the present embodiment, the cylindrical portion 211 and the bottom plate portion 212 are constituted by one member, and the lid portion 213 is constituted by another member. However, the cylindrical portion 211 and the lid portion 213 may be constituted by one member, and the bottom plate portion 212 may be constituted by another member. In addition, the material of the cylindrical part 211, the bottom plate part 212, and the cover part 213 may be other materials.

The stator 22 is arranged radially outward of a rotor 32 to be described later. The stator 22 has a stator core 41 , a plurality of insulators 42 , and a plurality of coils 43 . In the present embodiment, the stator core 41 is a laminated steel sheet in which a plurality of electromagnetic steel sheets are laminated in the axial direction. The stator core 41 has an annular core back 411 and a plurality of teeth 412 protruding radially inward from the core back 411 . The core back 411 is arranged substantially coaxially with the central axis 9 . The outer peripheral surface of the core back 411 is fixed to the inner peripheral surface of the cylindrical portion 211 of the case 21 . The plurality of teeth 412 are arranged at substantially equal intervals in the circumferential direction. In addition, the stator core 41 may be a dust core or the like instead of the laminated steel sheet.

In this embodiment, the material of the insulating material 42 is resin which is an insulator. The stator 22 of this embodiment has the insulator 42 for each tooth. At least a part of the surface of the stator core 41 is covered with the insulating member 42 . Specifically, at least the upper surface, the lower surface, and both end surfaces in the circumferential direction of each of the teeth 412 on the surface of the stator core 41 are covered with the insulating material 42 . Each of the insulating members 42 has a first resin member 421 and a second resin member 422 . The second resin member 422 is located below the first resin member 421 . The first resin member 421 is attached to the stator core 41 from the upper surface side of the stator core 41 . The second resin member 422 is attached to the stator core 41 from the lower surface side of the stator core 41 .

A more detailed configuration of the insulating member 42 will be described later.

The coil 43 is composed of a lead wire 430 wound around the insulator 42 . That is, in this embodiment, the lead wire 430 is wound around the teeth 412 serving as the magnetic core with the insulating material 42 interposed therebetween. The insulating member 42 is sandwiched between the teeth 412 and the coil 43 , thereby preventing the teeth 412 and the coil 43 from being electrically short-circuited.

The bus bar assembly 23 includes a bus bar 51 made of metal such as copper as a conductor, and a resin-made bus bar holder 52 that holds the bus bar 51 . The bus bar 51 is electrically connected to the conducting wire 430 constituting the coil 43 . When the motor 1 is used, a lead wire extending from an external power source (not shown) is connected to the bus bar 51 . That is, the coil 43 and the external power source are electrically connected via the bus bar 51 . In addition, a circuit board may be provided in the housing 21 instead of the bus bar assembly 23 . Furthermore, the coil 43 and an external power source may be electrically connected via a circuit board.

The lower bearing portion 24 and the upper bearing portion 25 are arranged between the housing 21 and the shaft 31 on the side of the rotating portion 3 . In the present embodiment, the lower bearing portion 24 and the upper bearing portion 25 use ball bearings in which the outer ring and the inner ring are relatively rotated via spherical bodies. The outer ring of the lower bearing portion 24 is fixed to the bottom plate portion 212 of the housing 21 . The outer ring of the upper bearing portion 25 is fixed to the cover portion 213 of the housing 21 . The inner race of each of the lower bearing portion 24 and the upper bearing portion 25 is fixed to the shaft 31 . Thereby, the shaft 31 is rotatably supported with respect to the casing 21 . However, other types of bearings such as sliding bearings or fluid bearings may be used instead of the ball bearings.

The rotating part 3 of the present embodiment has a shaft 31 and a rotor 32 .

The shaft 31 is a columnar member extending along the central axis 9 . As the material of the shaft 31, a metal such as stainless steel is used, for example. The shaft 31 is supported by the lower bearing portion 24 and the upper bearing portion 25 described above, and is rotatable about the central axis 9 . The upper end portion 311 of the shaft 31 protrudes upward from the cover portion 213 . The upper end portion 311 of the shaft 31 is connected to a device to be driven via a power transmission mechanism such as a gear, for example. In addition, the shaft 31 does not necessarily need to protrude axially upward from the cover portion 213 . That is, a through hole may be provided in the bottom portion 212 , and the lower end portion of the shaft may protrude downward from the bottom portion 212 through the through hole. Furthermore, the shaft 31 may be a hollow member.

The rotor 32 is positioned radially inward of the stator 22 and rotates together with the shaft 31 . The rotor 32 has a rotor core 61 , a plurality of magnets 62 , and a magnet holder 63 . In the present embodiment, the rotor core 61 is a laminated steel sheet in which a plurality of electromagnetic steel sheets are laminated in the axial direction. The rotor core 61 has a through hole 60 extending in the axial direction at the center thereof. The shaft 31 is press-fitted into the through hole 60 of the rotor core 61 . Thereby, the rotor core 61 and the shaft 31 are fixed to each other. In addition, a member such as a bush may be arranged between the inner surface of the through hole 60 and the outer surface of the shaft 31 . That is, the shaft 31 and the rotor core 61 may be fixed directly or indirectly. The rotor core 61 may be a dust core or the like instead of the laminated steel plate.

The plurality of magnets 62 are fixed to the outer peripheral surface of the rotor core 61 with, for example, an adhesive. The radially outer surface of each magnet 62 is a magnetic pole surface facing the radially inner end surface of the teeth 412 . The plurality of magnets 62 are arranged in the circumferential direction so that N poles and S poles are alternately arranged. In addition, instead of the plurality of magnets 62, one annular magnet whose N pole and S pole are alternately magnetized in the circumferential direction may be used.

The magnet holder 63 is a resin-made member that is fixed to the rotor core 61 . The magnet holder 63 is obtained, for example, by insert molding using the rotor core 61 as an insert member. The lower surfaces and both end surfaces in the circumferential direction of the plurality of magnets 62 are in contact with the magnet holder 63 . Thereby, the respective magnets 62 are positioned in the circumferential and axial directions. Furthermore, the rigidity of the rotor 32 as a whole is improved by the magnet holder 63 . In addition, the plurality of magnets 62 may be fixed to the rotor core 61 by molding using resin, or may be indirectly fixed to the rotor core 61 using another member.

When a drive current is supplied from an external power source to the coil 43 via the bus bar 51 , magnetic flux is generated in the plurality of teeth 412 of the stator core 41 . Then, the torque in the circumferential direction is generated by the action of the magnetic flux between the teeth 412 and the magnet 62 . As a result, the rotating part 3 rotates about the central axis 9 with respect to the stationary part 2 .

<2. About the construction of insulators and coils>

Next, the structure in which the conducting wire 430 constituting the coil 43 is wound around the insulating material 42 will be described in more detail. FIG. 2 is a perspective view of the first resin member 421 . FIG. 3 is a plan view of a part of the stator core 41 and the insulator 42 . FIG. 4 is a cross-sectional view of the stator core 41 and the insulator 42 viewed from the A-A position in FIG. 3 . In addition, in FIG. 4, the hatching which shows the cross section of the insulating material 42 is abbreviate|omitted. Hereinafter, the direction in which the teeth 412 serving as the core of the coil 43 extend will be referred to as a "core direction".

As shown in FIGS. 2 to 4 , the insulator 42 has a cylindrical support surface 70 extending in the direction of the magnetic core. The support surface 70 has a pair of first support surfaces 71 and a pair of second support surfaces 72 . The support surface 70 has a quadrangular shape in which short sides and long sides are alternately arranged around the teeth 412 when viewed in the direction of the magnetic core. The first support surface 71 is a surface corresponding to the short side. The second support surface 72 is a surface corresponding to the long side. Hereinafter, the direction along the short side will be referred to as the "short side direction", and the direction along the long side will be referred to as the "long side direction".

In the present embodiment, the upper surface and the lower surface of the insulator 42 serve as the first support surface 71 . Both end surfaces in the circumferential direction of the insulator 42 serve as the second support surfaces 72 . The first resin member 421 includes the upper surface of the insulator 42 as one of the pair of first support surfaces 71 . The second resin member 422 includes the lower surface of the insulator 42 as the other of the pair of first support surfaces 71 .

The conducting wire 430 constituting the coil 43 is wound around the support surface 70 of the insulating member 42 . The support surface 70 and the coil 43 constitute an example of the "structure" of the present invention. The wire 430 is in contact with the bearing surface 70 of an insulator 42 relative to the start of the winding of the insulator 42 . The winding end portion of the wire 430 relative to one insulating member 42 is further away from the support surface 70 than the winding start portion. The lead wire 430 is wound around the support surface 70 a plurality of times from the winding start portion toward the winding end portion.

By shortening the length of the short-side direction of the first support surface 71 , the plurality of coils 43 can be closely arranged in the circumferential direction. In addition, by increasing the length of the second support surface 72 in the longitudinal direction, the magnetic circuit inside each coil 43 can be enlarged. It is preferable that the length of the longitudinal direction of the 2nd support surface 72 is 5 times or more of the length of the transversal direction of the 1st support surface 71, for example.

Each of the pair of first support surfaces 71 has protrusions 73 . The protruding portion 73 of the first resin member 421 protrudes upward. The protruding portion 73 of the second resin member 422 protrudes downward. That is, the protruding portion 73 protrudes toward the lead wire 430 . As shown in FIG. 4 , the protrusions 73 are substantially triangular protrusions when viewed in the direction of the magnetic core. The protruding portion 73 has a top portion 730 , a first inclined surface 731 and a second inclined surface 732 . The top portion 730 is located inward of both ends in the transversal direction of the first support surface 71 . The first inclined surface 731 is located on the upstream side in the winding direction of the lead wire 430 from the top portion 730 . The second inclined surface 732 is located downstream of the top portion 730 in the winding direction of the lead wire 430 .

FIG. 5 is a cross-sectional view of the teeth 412 and the insulator 42 viewed from the position A-A in FIG. 3 . FIG. 6 is a diagram showing a comparative example in a case where there is no protrusion 73 . In FIGS. 5 and 6 , the winding direction of the conducting wire from the winding start portion to the winding end portion is indicated by the arrows of the two-dot chain line. As shown in FIG. 6 , without the protrusion 73 , the lead wire 430X is bent at a substantially right angle from the first support surface 71X toward the second support surface 72X. In this case, the bulge (swell) of the lead wire 430X at the second support surface 72X becomes large. Thereby, the width|variety of the circumferential direction of a coil becomes large.

In contrast, in the present embodiment, as shown in FIG. 5 , the lead wire 430 is bent at an obtuse angle from the top portion 730 of the protruding portion 73 toward the second support surface 72 . Therefore, compared with the case of FIG. 6 , the bulging (swelling) of the wire 430 at the second bearing surface 72 is suppressed. In other words, the lead wire 430 is intended to be bulged at the first support surface 71 , whereby the bulge of the lead wire 430 at the second support surface 72 can be suppressed. In this way, the circumferential width of the coil 43 can be reduced as compared with the case of FIG. 6 . As a result, the plurality of coils 43 can be closely arranged in the circumferential direction while preventing the conductive wires 430 of the adjacent coils 43 from contacting each other.

According to the configuration of the present embodiment, the number of times the wire 430 is wound around one tooth 412 can be increased within a limited range in the circumferential direction. In addition, the diameter of the wound wire 430 can also be increased, thereby allowing a larger current to flow. Thereby, the output of the motor 1 can be improved. In addition, according to the structure of this embodiment, the bending angle of the lead wire 430 becomes an obtuse angle in the entire circumference of the support surface 70 . Therefore, the load applied to the lead wire 430 can be reduced, and the breakage of the lead wire 430 can be suppressed.

In particular, in the protruding portion 73 of the present embodiment, the angle θ2 of the second inclined surface 732 with respect to the short-side direction is larger than the angle θ1 of the first inclined surface 731 with respect to the short-side direction. The top portion 730 of the protruding portion 73 is located on the downstream side in the winding direction of the lead wire 430 from the center in the transversal direction of the first support surface 71 . In this way, the path of the lead wire 430 from the top portion 730 of the protruding portion 73 toward the second support surface 72 can be made an obtuse angle closer to 180°. Thereby, the bulge of the lead wire 430 with respect to the 2nd support surface 72 can be suppressed further.

As shown in FIG. 5 , the wire 430 includes a first overlapping portion 431 and a second overlapping portion 432 . The first overlapping portion 431 is a portion of the lead wire 430 from the end portion on the upstream side in the winding direction of the first support surface 71 toward the top portion 730 of the protruding portion 73 . The second overlapping portion 432 is a portion of the lead wire 430 from the top portion 730 of the protruding portion 73 toward the end portion on the downstream side in the winding direction of the first support surface 71 . In this embodiment, the angle θ4 of the second overlapping portion 432 with respect to the short-side direction is larger than the angle θ3 of the first overlapping portion 431 with respect to the short-side direction. Thereby, the bulging of the lead wire 430 with respect to the second support surface 72 is further suppressed.

In the present embodiment, both of the pair of first support surfaces 71 have protrusions 73 . Therefore, the bulge of the wire 430 with respect to the one second support surface 72 and the bulge of the wire 430 with respect to the other second support surface 72 are suppressed. As a result, the circumferential width of the coil 43 can be further reduced.

In the present embodiment, the protrusion 73 provided on one of the pair of first support surfaces 71 and the protrusion 73 provided on the other of the pair of first support surfaces 71 are symmetrical with respect to the center line of the support surface 70 configuration. In this way, the shape of the first resin member 421 and the shape of the second resin member 422 can be made the same, and the components can be made common. Thereby, the manufacturing cost of the motor 1 can be reduced. However, the protrusion 73 provided on one of the pair of first support surfaces 71 and the protrusion 73 provided on the other of the pair of first support surfaces 71 may be asymmetrical with respect to the center line of the support surface 70 .

In addition, the motor 1 of the present embodiment is a so-called inner rotor type motor in which the rotor 32 is located radially inward of the stator 22 . In the case of the inner rotor type, the coils 43 adjacent in the circumferential direction are easily approached to each other. However, according to the structure of this embodiment, the lead wire 430 can be prevented from bulging in the circumferential direction. Therefore, the conductive wires 430 of the adjacent coils 43 can be suppressed from contacting each other.

<3. Modifications>

One embodiment of the present invention has been described above, but the present invention is not limited to the above-described embodiment.

FIG. 7 is a cross-sectional view of the teeth 412A and the insulator 42A according to a modification. In FIG. 7 , the winding direction of the conducting wire 430A from the winding start portion to the winding end portion is indicated by the double-dot chain arrow.

In FIG. 7, a pair of 71 A of 1st support surfaces also respectively have the protrusion part 73A which protrudes toward the lead wire 430A. However, in the example of FIG. 7, the 1st support surface 71A becomes the triangular protrusion part 73A as a whole. That is, the 1st inclined surface 731A of each protrusion part 73A extends from the top part 730A of the protrusion part 73A toward the upstream end part of the winding direction of the 1st support surface 71A. The second inclined surface 732A of each projection portion 73A extends from the top portion 730A of the projection portion 73A toward the end portion on the downstream side in the winding direction of the first support surface 71A.

In FIG. 7, the wire 430A is also bent at an obtuse angle from the top 730A of the protrusion 73A toward the second support surface 72A. Therefore, bulging (swelling) of the conducting wire 430A at the second bearing surface 72A is suppressed. Therefore, the circumferential width of the coil can be reduced. As a result, the plurality of coils can be closely arranged in the circumferential direction while preventing the conductive wires 430A of adjacent coils from contacting each other.

In addition, in FIG. 7 , the first overlapping portion 431A of the wire 430A extends along the first inclined surface 731A, and the second overlapping portion 432A of the wire 430A extends along the second inclined surface 732A. Therefore, the positions of the first overlapping portion 431A and the second overlapping portion 432A can be stabilized. As a result, winding collapse of the coil and damage to the lead wire 430A can be further suppressed. In addition, in FIG. 7, the boundary part of 731 A of 1st inclined surfaces and 72 A of 2nd support surfaces is a gently continuous curved surface. Thereby, damage to the lead wire 430A is further suppressed.

FIG. 8 is a cross-sectional view of a tooth 412B and an insulator 42B of another modification. In FIG. 8 , the winding direction of the conducting wire 430B from the winding start portion to the winding end portion is indicated by the double-dot chain arrow.

In FIG. 8, a pair of 1st support surface 71B has the 1st protrusion part 73B and the 2nd protrusion part 74B, respectively. The second protruding portion 74B is located on the downstream side in the winding direction relative to the first protruding portion 73B. In such a configuration, the wire 430B also bends at an obtuse angle from the top 740B of the second protrusion 74B toward the second bearing surface 72B. Therefore, the bulging (swelling) of the conducting wire 430B at the second bearing surface 72B is suppressed. Therefore, the circumferential width of the coil can be reduced. As a result, the plurality of coils can be closely arranged in the circumferential direction while preventing the conductive wires 430B of adjacent coils from contacting each other.

In addition, in FIG. 8, the height of the 2nd protrusion part 74B is higher than the height of the 1st protrusion part 73B. In this way, the path of the lead wire 430B from the top portion 740B of the second protrusion portion 74B toward the second support surface 72B can be made an obtuse angle closer to 180°. As a result, the lead wire 430B can be further suppressed from bulging with respect to the second support surface 72B.

9 is a cross-sectional view of a tooth 412C and an insulator 42C according to another modification. In FIG. 9 , the winding direction of the conducting wire 430C from the winding start portion to the winding end portion is indicated by the arrows of the two-dot chain line.

In FIG. 9 , one of the pair of first support surfaces 71C has a protruding portion 73C. The other of the pair of first support surfaces 71C is an inclined surface 75C gradually protruding from the upstream end portion toward the downstream end portion in the winding direction. In this way, the protruding portion 73C may be provided only on either one of the pair of first support surfaces 71C. Even in this case, the bulging (swelling) of the lead wire 430C in at least one of the pair of second support surfaces 72C is suppressed. Therefore, the circumferential width of the coil can be reduced.

In the above-described embodiments and modifications, the insulator is composed of two members: the first resin member including one of the pair of first support surfaces, and the second resin member including the pair of first support surfaces the other side. However, the insulator may have one cylindrical resin member including both of the pair of first support surfaces.

In the above-described embodiments and modifications, the conductive wires are wound around the teeth of the stator core with the insulating material interposed therebetween. Therefore, the cylindrical support surface which supports a lead wire is provided in the insulating material. However, it is also possible to omit the insulating material, and to directly wind the wire around the teeth of the stator core whose surface is insulated and painted. In this case, it is sufficient that the teeth themselves have a bearing surface having the same shape as the bearing surface of the above-described insulator.

In the above-mentioned embodiment and modification, the so-called inner rotor type motor in which the rotor is positioned radially inward of the stator has been described. However, the structure, the stator, and the motor of the present invention can also be applied to a so-called outer rotor type motor in which the rotor is positioned radially outward of the stator.

In the above-mentioned embodiment and modification, the structure included in the motor has been described. However, the structure of the present invention may be included in devices other than motors such as generators.

In addition, the plurality of magnets do not necessarily need to be located on the outer peripheral surface of the rotor core. At least a part of the magnet may be embedded in the rotor core.

In addition, the motor may have a control board that controls energization to the stator. In this case, the control substrate is electrically connected to the bus bar. In addition, the motor may not have the bus bar assembly. In this case, the lead wire is electrically connected to a connector or the like connected to an external power source. Furthermore, when the motor has the control board, the motor may not have the bus bar assembly. In this case, the wires are electrically connected to the control board without passing through the bus bar assembly.

The shape of the detail of each member may differ from the shape shown in each figure of this application. The respective elements appearing in the above-described embodiments or modifications may be appropriately combined within a range that does not cause inconsistency.

Industrial Availability

The present invention can be applied to a structure including a coil, a stator including the structure, and a motor including the stator.

Label description

1: motor; 2: stationary part; 3: rotating part; 9: central axis; 21: housing; 22: stator; 23: bus bar assembly; 24: lower bearing part; 25: upper bearing part; 31: shaft; 32: rotor; 41: stator core; 42, 42A, 42B, 42C: insulating part; 43: coil; 70: bearing surface; 71, 71A, 71B, 71C: first bearing surface; 72, 72A, 72B, 72C : second bearing surface; 73, 73A, 73C: protrusion; 73B: first protrusion; 74B: second protrusion; 75C: inclined surface; 411: iron core back; 412, 412A, 412B, 412C: teeth; 421: first resin part; 422: second resin part; 430, 430A, 430B, 430C: lead wires; 431, 431A: first lap; 432, 432A: second lap; Top; 731, 731A: first inclined surface; 732, 732A: second inclined surface.

Claims (18)

1. A structure comprising a coil, wherein,

the structure has:

a cylindrical support surface extending in a core direction of the coil; and

the coil is composed of a wire wound around the support surface,

the support surface has a quadrilateral shape in which long sides and short sides are alternately arranged when viewed in the core direction, and has a pair of first support surfaces corresponding to the short sides and a pair of second support surfaces corresponding to the long sides,

at least one of the pair of first support surfaces has a protrusion protruding toward the lead,

the top of the protrusion is located inward of both ends of the first support surface in the short direction.

2. The construct of claim 1 wherein,

the conductive wire is wound around the support surface in a winding direction from a winding start portion that is in contact with the support surface toward a winding end portion that is farther from the support surface than the winding start portion,

the apex portion is located on a downstream side in the winding direction from a center in the short side direction of the first support surface.

3. The construct of claim 2 wherein,

the protrusion has:

a first inclined surface located on an upstream side in the winding direction from the top portion; and

a second inclined surface located on a downstream side in the winding direction from the top portion,

an angle of the second inclined surface with respect to the short side direction is larger than an angle of the first inclined surface with respect to the short side direction.

4. The construct of claim 3 wherein,

the second inclined surface extends from the apex portion toward an end portion of the first support surface on a downstream side in the winding direction.

5. The construct of claim 3 or 4,

the first inclined surface extends from the apex portion toward an end portion on an upstream side in the winding direction of the first support surface.

6. The construct of any of claims 2 to 5, wherein,

the wire includes:

a first overlapping portion that faces the apex portion from an end portion on an upstream side in the winding direction of the first supporting surface; and

a second overlapping portion facing from the top portion to an end portion on a downstream side in the winding direction of the first support surface,

the angle of the second lap portion with respect to the short side direction is larger than the angle of the first lap portion with respect to the short side direction.

7. The construct of any of claims 2 to 6, wherein,

both of the pair of first supporting surfaces have the protruding portion,

the projection portion of one of the pair of first supporting surfaces and the projection portion of the other of the pair of first supporting surfaces are arranged symmetrically with respect to a center line of the supporting surface.

8. The construct of claim 1 wherein,

both of the pair of first supporting surfaces have the protruding portion,

the projection portion of one of the pair of first support surfaces and the projection portion of the other of the pair of first support surfaces are disposed asymmetrically with respect to a center line of the support surface.

9. The construct of any of claims 2 to 6, wherein,

one of the pair of first support surfaces has the protrusion,

the other of the pair of first support surfaces is an inclined surface that gradually protrudes from an upstream end toward a downstream end in the winding direction.

10. The construct of any of claims 1 to 9, wherein,

at least one of the pair of first support surfaces has a first protrusion and a second protrusion as the protrusion, the second protrusion being located on a downstream side in the winding direction from the first protrusion,

the second protrusion has a height greater than a height of the first protrusion.

11. The construct of any of claims 1 to 10 wherein,

the length of the second support surface in the long side direction is 5 times or more the length of the first support surface in the short side direction.

12. A stator comprising the structure of any one of claims 1 to 11,

the stator has:

a stator core;

a resin insulator covering at least a part of the stator core; and

the coil is provided with a plurality of coils,

the insulator has the bearing surface.

13. The stator according to claim 12,

the insulating member has:

a first resin member including one of the pair of first supporting surfaces; and

and a second resin member including the other of the pair of first supporting surfaces.

14. The stator according to claim 12,

the insulating member has a cylindrical resin member including both the pair of first supporting surfaces.

15. A stator comprising the structure of any one of claims 1 to 11,

the stator has:

a stator core, the surface of which is coated with insulation; and

the coil is provided with a plurality of coils,

the stator core has the bearing surface.

16. A motor, comprising:

the stator of any one of claims 12 to 15; and

a rotor that rotates relative to the stator.

17. The motor of claim 16,

the rotor is located radially inward of the stator.

18. The motor according to claim 16 or 17,

the motor is a driving source of the electric power steering apparatus.

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