CA2297534C - Insulating structure in stator for outer rotor-type multi-pole generator - Google Patents
Insulating structure in stator for outer rotor-type multi-pole generator Download PDFInfo
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- CA2297534C CA2297534C CA 2297534 CA2297534A CA2297534C CA 2297534 C CA2297534 C CA 2297534C CA 2297534 CA2297534 CA 2297534 CA 2297534 A CA2297534 A CA 2297534A CA 2297534 C CA2297534 C CA 2297534C
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- coil
- bobbin
- stator
- coils
- salient poles
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- 230000005405 multipole Effects 0.000 title abstract description 8
- 238000003780 insertion Methods 0.000 description 32
- 230000037431 insertion Effects 0.000 description 32
- 239000004020 conductor Substances 0.000 description 18
- WABPQHHGFIMREM-UHFFFAOYSA-N lead(0) Chemical compound [Pb] WABPQHHGFIMREM-UHFFFAOYSA-N 0.000 description 11
- 230000000717 retained effect Effects 0.000 description 5
- 239000002184 metal Substances 0.000 description 4
- 230000007935 neutral effect Effects 0.000 description 4
- 239000011800 void material Substances 0.000 description 4
- 229920003002 synthetic resin Polymers 0.000 description 3
- 239000000057 synthetic resin Substances 0.000 description 3
- 230000002093 peripheral effect Effects 0.000 description 2
- 229920000784 Nomex Polymers 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 230000004308 accommodation Effects 0.000 description 1
- 210000000078 claw Anatomy 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000005470 impregnation Methods 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000004763 nomex Substances 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
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- Insulation, Fastening Of Motor, Generator Windings (AREA)
Abstract
A stator for an outer rotor-type multi-pole generator includes a stator core which is comprised of a plurality of salient poles projectingly provided at equal distances around an outer periphery of a ring-shaped core base, a bobbin covering the stator core, and coils wound around the bobbin in sections corresponding to the salient poles. In this stator, an insulating member formed by folding an insulating sheet of paper into an angle shape is inserted between the coil corresponding to particular one of the salient poles and each of the coils corresponding to the salient poles adjacent to the particular salient pole to come into resilient contact with the coils on opposite sides of the insulating member. Thus, the dielectric strength between the adjacent coils can be increased in a simple structure.
Description
' 1 INSULATING STRUCTURE IN STATOR FOR OUTER
ROTOR-TYPE MULTI-POLE GENERATOR
BACKGROUND OF THE INVENTT_ON
1. FT_ELD OF THE INVENTT_ON
The present invention relates to an insulating structure in a stator for an outer rotor-type multi-pole generator including a stator core which is comprised of a plurality of salient poles projectingly provided at equal distances around an outer periphery of a ring-shaped core base, a bobbin covering the stator core, and coils wound around the bobbin in sections corresponding to the salient poles , with an enhanced insulating ability between adjacent coils.
ROTOR-TYPE MULTI-POLE GENERATOR
BACKGROUND OF THE INVENTT_ON
1. FT_ELD OF THE INVENTT_ON
The present invention relates to an insulating structure in a stator for an outer rotor-type multi-pole generator including a stator core which is comprised of a plurality of salient poles projectingly provided at equal distances around an outer periphery of a ring-shaped core base, a bobbin covering the stator core, and coils wound around the bobbin in sections corresponding to the salient poles , with an enhanced insulating ability between adjacent coils.
2. DESCRT_pTT_ON OF THE RELATED ART
Such stators are already known from Japanese Patent Application Laid-open No.9-93849 and the like. In such stator, V-shaped voids opening outwards remain created between the coils corresponding to the salient poles.
When it is desired to increase the dielectric strength between the coils wound around the adjacent salient poles through the bobbin, it is conceived that an insulating member is inserted into the void created between the coils . In this case, if a sheet-shaped insulating member is only inserted between the adjacent coils , the insulating member is fallen out of the void, because the void is of the V-shape opening outwards .
If the stator is sub jected to a vanish impregnating treatment in a state in which the insulating member has been inserted ' 2 between the adjacent coils, the insulating member cannot be fallen down. However, if the insulating member moves in the void during carrying-out of the vanish impregnating treatment, a sufficient dielectric strength may not be obtained.
Accordingly, it is an object of the present invention to provide an insulating structure in a stator for an outer rotor-type multi-pole generator, wherein the dielectric strength between adjacent coils can be increased in a simple structure.
To achieve the above object, according to the present invention, there is provided an insulating structure in a stator for an outer rotor-type multi-pole generator comprising a stator core which is comprised of a plurality of salient poles projectingly provided at equal distances around an outer periphery of a ring-shaped core base, a bobbin covering the stator core, and coils wound around the bobbin in sections corresponding to the salient poles, wherein the insulating structure includes an insulating member formed by folding an insulating sheet of paper into an angle shape and inserted between the coil corresponding to a particular one of the salient poles and each of the coils corresponding to the salient poles adjacent to the particular salient pole to come into resilient contact with the coils on opposite sides of the insulating member.
With such arrangement , the insulating member made of the insulating sheet of paper is inserted between the adjacent coils and hence, the dielectric strength between the adjacent coils can be increased. Moreover, the insulating member is formed by folding the insulating sheet of paper into the angle shape and inserted between the adjacent coils to come into resilient contact with the adjacent coils on the opposite sides of the insulating member. Therefore, the insulating member is reliably retained between the adjacent coils before and during carrying-out of a vanish impregnating treatment and thus , the dielectric strength between the adjacent coils can be reliably increased.
The above and other objects, features and advantages of the invention will become apparent from the following description of the preferred embodiment taken in conjunction with the accompanying drawings.
BRT_EF DESCRT_pTT_ON OF THE DRAWTN
Figs.l to 16 show an embodiment of the present invention, wherein Fig.l is a vertical sectional view of an outer rotor type multi-pole generator, taken along a line 1-1 in Fig.2;
Fig.2 is a plan view of a stator, taken in a direction of an arrow 2-2 in Fig. l;
Fig.3 is a back view of the stator, taken in a direction of an arrow 3-3 in Fig. l;
Fig.4 is an enlarged sectional view taken along a line 4-4 in Fig.2 in a holder-mounted state;
' 4 Fig.5 is a diagram of a coil connection circuit;
Fig.6 is a perspective view of a coil-side terminal, a support plate and a male terminal;
Fig . 7 is a view taken in a direction of an arrow 7 in Fig . 6 ;
Fig . 8 is a view taken in a direction of an arrow 8 in Fig . 7 ;
Fig.9 is a side view of a holder;
Fig.lO is a view taken in a direction of an arrow 10 in Fig.9;
Fig.ll is a side view of the holder with female terminals and external conductors mounted therein;
Fig.l2 is a view taken in a direction of an arrow 12 in Fig.ll;
Fig.l3 is a sectional view taken along a line 13-13 in Fig. l2;
Fig . 14 is a perspective view showing an insulating member which is being mounted;
Fig.l5 is a side view of the insulating member; and Fig.l6 is a view taken in a direction of an arrow 16 in Fig. l5.
DESGRTpTTON OF THE PREFERR n EMBODIMENT
The present invention will now be described by way of an embodiment with reference to Figs . 1 to 16 . Referring first to Fig.l, a stator 21 for an outer rotor-type multi-pole generator is coupled to a sleeve 22 connected to an engine body ( not shown ) by a plurality of, e.g. , four bolts 23. A crankshaft 24 of the engine ( not shown ) is coaxially disposed within the sleeve 22 to extend coaxially through the stator 21, and a bearing 25 and a seal member 26 are mounted between the sleeve 22 and the crankshaft 24. A bowl-shaped rotor yoke 27 is coaxially fastened to an end of the crankshaft 24 to cover the stator 21, and a magnet 29 is secured to an inner periphery of the rotor yoke 27 to coaxially surround the stator 21, so that an small air gap is defined between the magnet 29 and the stator 21. A
cover 30 is secured to the sleeve 22 to cover an opened end of the rotor yoke 27.
The stator 21 includes a stator core 31 which is formed from a plurality of core plates laminated one on another. The stator core 31 comprises a plurality of, e.g. , 27 substantially T-shaped salient poles 33 which are projectingly provided at equal distances around an outer periphery of a core base 32 formed into a ring-shape.
The plurality of core plates forming the stator core 31 are partially covered, over axially opposite ends in a direction of lamination of the plates , with a bobbin 34 made of a synthetic resin, so that the laminated state of the core plates is maintained, thereby constituting the stator core 31. The bobbin 34 is formed to cover the stator 31 over their axially opposite ends, in such a manner that tip ends of the salient poles 33 and an inner peripheral surface of a portion of the core base 32 are exposed.
Referring also to Figs.2 and 3, first, second, third and fourth insertion bores 351, 35z, 353 and 354 are provided at a ~ ~ 6 plurality of , e. g. , four points spaced at equal distances apart from one another in circumferential directions of the core base 32 and the bobbin 34 , and bolts 23 for fastening the sleeve 22 to the stator 21 are inserted through the insertion bores 351 to 354, respectively.
Referring further to Fig.4, four grooves 36 are provided in the inner periphery of the core base 32 of the stator core 31 over axially opposite ends of the core base 32 , so that each of the grooves 36 is located between the adjacent insertion bores 351, 352, 353, 354. First, second, third and fourth recesses 381, 382, 383, 384 are provided in the bobbin 34 at locations corresponding to the grooves 36 between the insertion bores 351, 352, 353, 354 to form a connecting surface 46 facing the cover 30, so that their portions adjacent to the cover and their radially inner portions are opened.
Those portions of the bobbin 34 which correspond to the first, second and fourth recesses 381, 382 and 384 are provided with a plurality of, e. g. , three first fitting bores 391 disposed at equal distances in the circumferential direction of the bobbin 34 at locations equally spaced apart from the center of the bobbin 34, and a plurality of, e.g., four second fitting bores 392 disposed alternately with the first fitting bores 391 in the circumferential direction of the bobbin 34 at locations spaced at larger distances apart from the center of the bobbin 34 than the distances at which the first fitting bores 391 are spaced apart from the center of the bobbin 34 . The fitting bores ~ ' 7 391 and 39z are defined to have a rectangular cross-sectional shape longer in a direction perpendicular to a radial direction of the bobbin 34. One end of each of the fitting bores 391 and 392 opens into the end face of the bobbin 34 which faces the rotor yoke 27, and the other ends of the fitting bores 391 and 39z open into the connecting surface 46 to face the recesses 381, 382, 383 and 384.
Here, the salient pole 33 disposed in basic position PB
established in the vicinity of the first insertion bore 351 is defined as being a first pole, and the salient poles 33, which are second, third, ---, twenty seventh in a counterclockwise direction as viewed in Fig.2 (in a clockwise direction as viewed in Fig.3), are defined as being second, third, ---, twenty seventh poles . In such stator core 31, eight U-phase main coils 40U, eight V-phase main coils 40V and eight W-phase main coils 40W are wound around the first to twenty fourth salient poles 33 respectively with the bobbin 34 interposed therebetween, and a charging coil 41, a subsidiary coil 42 and a DC coil 43 are wound around the twenty fifth to twenty seventh salient poles 33 respectively with the bobbin 34 interposed therebetween.
Each of the U-phase main coils 40U is wound around each of the salient poles 33 disposed at every third places in the circumferential direction of the stator core 31 with the bobbin 34 interposed therebetween.
Referring to Fig.5, one of the eight U-phase main coils 40U connected in series, which is disposed at one end in a direction of arrangement of them, i.e., in the basic position PB, is connected at one end thereof to a second coil-side terminal 452, and one of the eight V-phase main coils 40V
connected in series , which is disposed at one end in a direction of arrangement of them, i.e., second from the basic position PB, is connected at one end thereof to a first coil-side terminal 451. One of the eight W-phase main coils 40W connected in series , which is disposed at one end in a direction of arrangement of them, i.e. , third from the basic position PB, is connected to a second coil-side terminal 452, and the DC coil 43 is connected at its opposite ends to first and second coil-side terminals 451 and 452, respectively.
The first and second coil-side terminals 451 and 452 each of which is connected to one end of each of the main coils 40U, 40V and 40W connected in series in the above manner and the opposite ends of the DC coil 43 respectively are fixed to the bobbin 34 in a section corresponding to the first recess 381 between the first and second insertion bores 351 and 352. Each of the two first coil-side terminals 451 is integrally connected to one end of each of support plates 48 made of a conductive metal and fitted and fixed in the first fitting bores 391 closer to the first insertion bore 351, and each of the three second coil-side terminals 452 is also integrally connected to one end of each of support plates 48 fitted and fixed in the second fitting bores 392 closer to the first insertion bore 351.
The other end of one of the eight U-phase main coils 40U
connected in series , which is disposed at the other end in the direction of arrangement of them, i . a . , twenty second from the basic position PB, the other end of one of the eight V-phase main coils 40V connected in series, which is disposed at the other end in the direction of arrangement of them, i . a . , twenty third from the basic position PB, and the other end of one of the eight W-phase main coils 40W connected in series , which is disposed at the other end in the direction of arrangement of them, i.e., twenty fourth from the basic position PB, are commonly connected as neutral points to the first coil-side terminal 451, and the opposite ends of the charging coil 41 and the opposite ends of the subsidiary coil 42 are connected to first and second coil-side terminals 451 and 45z, respectively.
The first and second coil-side terminals 451 and 452 connected to the neutral points of the main coils 40U, 40V and 40W and the opposite ends of the charging coil 41 and the subsidiary coil 42 in the above manner are fixed to the bobbin 34 in a section corresponding to the fourth recess 384 between the fourth and first insertion bores 354 and 351. Each of the first coil-side terminals 451 is integrally connected to one end of each of the support plates 48 fitted and fixed in the first fitting bores 391, respectively, and each of the second coil-side terminals 452 is integrally connected to one end of each of the support plates 48 fitted and fixed in the second fitting bores 392, respectively.
In this embodiment, the support plates 48 which are integral with the first and second coil-side terminals 451 and 452 are not fitted into all of the first and second fitting bores 391 and 39z disposed in correspondence to the second recess 382 between the third and fourth insertion bores 353 and 354, as well as into some of the first and second fitting bores 391 and 392 disposed in correspondence to the first and fourth recesses 381 and 384. However, the fitting of the support plates 48 into the fitting bores 391 and 392 may be selected properly depending on the type of the generator, and in another type of a generator, the support plates 48 may be fitted into all of the fitting bores 391 and 392 respectively in some cases.
Referring to Figs.6 to 8, the first coil-side terminal 451 is formed from a conductive metal and integrally provided with a flat connecting plate portion 49 connected at one end thereof at a right angle to one end of the support plate 48 fitted and fixed in the fitting bore 391, and a connecting terminal portion 50 connected to the other end of the connecting plate portion 49 . Before assembling of the stator 21, the connecting terminal portion 50 is connected at a right angle to the connecting plate portion 49 in a direction opposite to the support plate 48 , i . a . , in a direction away from the bobbin 34 at the time of fitting of the support plate 48 into the first fitting bore 391, but the connecting terminal portion 50 can be folded, so that it is superposed onto the connecting plate portion 49.
The support plate 48 is formed into a flat plate-shape ~ 11 from a conductive metal so as to be fitted and fixed in the first fitting bore 391. The length of the support plate 48 is set at such a value that when the connecting plate portion 49 is fitted into the fitting bore 391 up to a position where it abuts against the bobbin 34 , as shown in Fig. 4 , the other end protrudes from the connecting surface 46. Moreover, the support plate 48 has claws 51 provided on its opposite sides respectively to bite into inner surfaces of opposite sides of the first fitting bore 391 and to inhibit the detachment of the support plate 48 out of the fitting bore 391.
The connecting plate portion 49 is connected at the right angle to the other end of the support plate 48 in such a manner that when the support plate 48 is fitted into the first fitting bore 391, the connecting plate portion 49 is put into abutment against the end face of the bobbin 34 on the side of the rotor yoke 27 and extends outwards in the radial direction of the stator 21.
The connecting terminal portion 50 is formed into a cylindrical shape by rounding a flat plate. Each of lead wires 52 ( see Figs . 2 and 4 ) extending from each of the coils 40U, 40V, 40W, 41, 42 and 43 can be inserted through the connecting terminal portion 50. Moreover, the lead wire 52 inserted through the connecting terminal portion 50 is connected to the other end, i.e. , the tip end of the connecting terminal portion 50 by fusing. A window 53 is provided in a notched manner in an intermediate portion of the connecting terminal portion 50 to face outwards of the stator 21, and the connecting terminal portion 50 includes a connecting portion 50a formed therein on the side of the tip end, and an introducing portion 50b formed therein on the side of the connecting plate portion 49 for permitting the insertion of the lead wire 52 toward the connecting portion 50a, so that the window 53 is interposed between the connecting portion 50a and the introduction portion 50b.
The second coil-side terminal 452 which is one end of the support plate 48 fitted in the second fitting bore 392 basically has the same shape as the first coil-side terminal 451, but the length L1 of the connecting plate portion 49 in the first coil-side terminal 451 is set larger than the length L1 of the connecting plate portion 49 in the second coil-side terminal 452. A difference between the length L1 of the connecting plate portion 49 in the first coil-side terminal 451 and the length L1 of the connecting plate portion 49 in the second coil-side terminal 452 is a value equal to a distance L2 ( see Fig . 4 ) between the first and second fitting bores 391 and 392 in the radial direction of the bobbin 34. With such setting as stated above, the connecting terminal portion 50 of the first coil-side terminal 451 with the support plate 48 fitted in the first fitting bore 391 and the connecting terminal portion 50 of the second coil-side terminal 452 with the support plate 48 fitted in the second fitting bore 392 are disposed at locations spaced at equal distances apart from the center of the bobbin 34.
. ' 13 Ribs 56 are integrally, projectingly provided on the bobbin 34 to extend in the radial direction of the bobbin 34 between the fitting bores 391 and 392 for guiding the connecting terminal portions 50 of the first and second coil-side terminals 451 and 452, when these connecting terminal portions 50 are folded.
To assemble the first and second coil-side terminals 451 and 452 to the stator 21 and to connect the lead wires 52 to the first and second coil-side terminals 451 and 452, the support plate 48 may be press-fitted into each of the first and second fitting bores 391 and 392 in a state in which the lead wire 52 has been inserted through the introducing portion 50b and the connecting portion 50a, and the lead wire 52 may be connected to the connecting portion 50a by fusing. Thereafter, the connecting terminal portion 50 may be folded, so that it may be superposed onto the connecting plate portion 49.
Crossover wires 55 for connecting the U-phase main coils 40U to each other, the V-phase main coils 40V to each other as well as the W-phase main coils 40W to each other are disposed, so that they are wound around the bobbin 34 on the side of the rotor yoke 27, as shown in Figs.3 and 4.
The other ends of the support plates 48 fitted and fixed in the fitting bores 391 and 392 protrude from the connecting surface 46 in the first recess 381 between the first and second insertion bores 351 and 352 as well as in the fourth recess 384 between the first and fourth insertion bores 351 and 354, respectively. The protruding ends of the support plates 48 from the connecting surface 46 function as male terminals 58.
Paying attention to Fig.S, female terminals 59 are electrically connected to the male terminals 58, respectively.
Each of the female terminals 59 , each of which is connected to each of the male terminals 58 connected to one end of each of the main coils 40U, 40V and 40W, is coupled to one end of each of first external conductors 601. The female terminals 59, which are connected to the male terminals 58 connected to the opposite ends of the DC coil 43 , are coupled to one ends of second external conductors 602 having a smaller diameter than that of the first external conductors 601, respectively. Each of the female terminals 59 , which are connected to the male terminals 58 connected to the opposite ends of the charging coil 41 and the subsidiary coil 42, is coupled to one end of each of the second external conductors 602, The female terminal 59 , which is connected to the male terminal 58 connected to the neutral point of each of the main coils 40U, 40V and 40W, is coupled to one end of a third external conductor 603.
The five female terminals 59 corresponding to the one ends of each main coils 40U, 40V and 40W and the opposite ends of the DC coil 43 respectively are retained in a holder 611 fitted in the first recess 381 between the first and second insertion bores 351 and 352, and the four female terminals 59 corresponding to the opposite ends of the charging coil 41 and the subsidiary coil 42 and the neutral points of each main coils 40U, 40V and . 15 40W respectively are retained in a holder 612 fitted in the fourth recess 384 between the first and fourth insertion bores 351 and 354.
Referring to Figs.9 and 10, the holders 611 and 612 are formed into the same arcuate shape from a synthetic resin such as a polyamide to be fitted in the recesses 381 and 383. In a state in which the holders 611 and 612 have been fitted in the recesses 381 and 383, the inner surfaces of the holders 611 and 612 are connected substantially flush to the inner peripheral surface of the stator 21.
Four insertion grooves 62 corresponding to the four second fitting bores 392 facing the recesses 381 and 382 are provided in an outer surface of each of the holders 611 and 612, so that opposite ends of the insertion groove 62 open, and three insertion grooves 62 corresponding to the three second fitting bores 391 facing the recesses 381 and 382 are provided in an inner surface of each of the holders 611 and 612, so that opposite ends of the insertion groove 62 open.
In a state in which the holders 611 and 612 have been fitted in the recesses 381 and 383, one end faces 61a thereof are in proximity to and opposed to the connecting surface between the recesses 381 and 383. Seven accommodating recesses 63 are provided in the one end face 61a of each of the holders 611 and 612 to individually lead to the insertion grooves 62 , and steps 64 facing the connecting surface 46 are formed between the accommodating recesses 63 and the insertion grooves 62.
Referring to Figs.ll to 13, the female terminal 59 is formed from a conductive metal and includes a first caulked and coupled portion 59a, a second caulked and coupled portion 59b connected to the first caulked and coupled portion 59a, and a receiving portion 59c connected to the second caulked and coupled portion 59b, so that the male terminal 58 can be fitted therein to enable the electric connection. The first caulked and coupled portion 59a is caulked and coupled to one end of the resinous covering portion in each of the first, second and third external conductors 601, 602 and 603, and the second caulked and coupled portion 59b is caulked and coupled to a core wire pulled out of one end of the resinous covering portion in each of the first, second and third external conductors 601, 602 and 603. The receiving portion 59c is formed to protrude to opposite sides from each of the first, second and third external conductors 601, 602 and 603, and is capable of being accommodated in the accommodating recess 63 in each of the holders 611 and 612.
On the other hand, the insertion groove 62 in each of the holders 611 and 612 is formed, so that each of the first , second and third external conductors 601, 602 and 603 can be inserted through the insertion groove 62 from the inside and outside of each of the holders 611 and 612. The accommodation portion 59c accommodated in the accommodating recess 63 can be put into abutment against the step 64 between the insertion groove 62 and the accommodating recess 63.
The DC coil 43 is wound around one of the plurality of salient poles 33 included in the stator 21 which is twenty seventh from the basic position PB in the counterclockwise direction as viewed in Fig.2, with the bobbin 33 interposed therebetween, so that DC current flows across the DC coil 43, while AC current flow across the U-phase main coil 40U and the subsidiary coil 42 on the opposite sides of the DC coil 43. To enhance the insulating ability between the DC coil 43 and the U-phase main coil 40U and the subsidiary coil 42 adjacent to the DC coil 43 in the circumferential direction of the stator core 31, an insulating member 66 is inserted between the DC coil 43 corresponding to the particular salient pole 33 which is twenty seventh from the basic position PB in the counterclockwise direction as viewed in Fig.2 and each of the U-phase main coil 40U and the subsidiary coil 42 corresponding to the salient poles 33 adjacent to the particular salient pole 33 in the circumferential direction of the stator core 31, as shown in Fig. l4.
Referring also to Figs . 15 and 16 , the insulating member 66 is formed by folding a rectangular insulating sheet of paper known by the trade name of NOMEX of DuPont into an angle shape .
The insulating members 66 are inserted between the DC coil 33 and the U-phase main coil 40U, and between the DC coil 43 and the subsidiary coil 42 , so that the insulating members 66 are in resilient contact with the coils 43 and 40U as well as 43 and 42 on the opposite sides thereof.
1$
The operation of the embodiment will be described below.
In a state in which the lead wire 52 from each of the coils 40U, 40V, 40W, 41, 42 and 43 has been inserted through that connecting terminal portion 50 of each of the first and second coil-side terminals 451 and 452 which are integral with the support plates 48 fitted and fixed in the fitting bores 391 and 392 in the bobbin 34 , which has been connected at the right angle to the connecting plate portion 49, the lead wire 52 is connected by fusing to the connecting portion 50a laying at a location relatively spaced apart from the bobbin 34. Therefore, even if each of the coils 40U, 40V, 40W, 41, 42 and 43 is formed of a magnet wire, it is possible to easily achieve the connection of the coils 40U, 40V, 40W, 41, 42 and 43 to the coil-side terminals 451 and 452 without peeling-off operation of an insulating film, leading to a facilitated connecting operation and to a decreased number of operating steps.
In addition, since the connecting terminal portion 50 can be folded so that it is superposed onto the connecting plate portion 49 after connection of the lead wore 52 , it is possible to avoid the protrusion of the connecting terminal portion 50 from the stator 21, and to reduce the spaces for arrangement of the coil-side terminals 451 and 452.
Moreover, the first and second coil-side terminals 451 and 452 adjacent one another in the circumferential direction of the bobbin 34 are fixed to the bobbin 34 at the locations alternately shifted in the radial direction of the bobbin 34.
Thus, the plurality of coil-side terminals 451 and 452 can be fixed in a compact arranged manner to the bobbin 34, leading to a reduction in size of the stator 21. In addition, the first and second coil-side terminals 451 and 452 are fixed to the bobbin 34 at the locations spaced at different distances apart from the center of the bobbin 34, so that the connecting terminal portions 50 of the first and second coil-side terminals 451 and 452 are disposed at the same distance from the center of the bobbin 34 in the state in which they have been connected at the right angle to the connecting plate portions 49. Therefore, to fold the each of the connecting terminal portions 50 after connection of the lead wire 52 to the connecting terminal portion 50, an urging force in a folding direction may be applied to the connecting terminal portions 50 at the locations spaced at the same distance from the center of the bobbin 34. Therefore, an urging means for applying the urging force to each of the connecting terminal portions 50 in the folding direction need not be moved in the radial direction of the bobbin 34 , but may be moved sequentially in the circumferential direction of the bobbin 34 and hence, a mechanism for moving the urging means can be simplified.
Since the connecting portion 50a for connecting the lead wire 52 by fusing and the introduction portion 50b for permitting the insertion of the lead wire 52 are formed in the connecting terminal portion 50, with the window 53 facing outwards of the stator 21 being interposed therebetween.
' 20 Therefore, when the connecting terminal portion 50 is to be folded, the introduction portion 50b is pushed, and a stress generated during folding is prevented from being applied to the connecting portion 50a with the lead wire 52 connected thereto .
Thus , the connection of the connecting terminal portion 50 and the lead wire 52 to each other can be maintained reliably, regardless of the folding of the connecting terminal portion 50.
The plurality of ribs 56 are projectingly provided on the bobbin 34 and disposed between the fitting bores 391 and 392 to extend in the radial direction of the bobbin 34. The ribs 56 function as guides, when the connecting terminal portions 50 of the coil-side terminals 451 and 452 with the support plates 48 fitted in the fitting bores 391 and 392 are folded, and hence, it is possible to reliably avoid that the coil-side terminals 451 and 452 adjacent one another in the circumferential direction of the bobbin 34 are brought into contact with one another. Therefore, it is unnecessary to space the coil-side terminals 451 and 452 at large distances apart from one another, and it is possible to prevent the stator from being increased in size due to the arrangement of the coil-side terminals 451 and 452.
The male terminals 58 connected to the coils 40U, 40V, 40W, 41, 42 and 43 respectively are fixed to the bobbin 34 to protrude from the connecting surface 46, and the female terminals 59 capable of being fitted into and electrically connected to the male terminals 58 are coupled to the external conductors 601, 602 and 603, but the female terminals 59 coupled to the external conductors 601, 602 and 603 are retained in the holders 611 and 612.
The insertion grooves 62 capable of permitting the insertion of the external conductors 601, 602 and 603 from the sideways direction are provided, with their opposite ends opened, in the inner and outer surfaces of the holders 611 and 612 made of the synthetic resin. The accommodating recesses 63 individually leading to the insertion grooves 62 are provided in those one end faces 61a of the holders 611 and 612 which are opposed to the connecting surface 46 of the bobbin 34 , and the steps 64 facing the connecting surface 46 of the bobbin 34 are formed between the accommodating recesses 63 and the insertion grooves 62, respectively. Moreover, the female terminal 59 has the receiving portion 59c into which the male terminal 58 can be fitted for electrical connection, and the receiving portion 59c is accommodated in the accommodating recess 63 capable of being put into abutment against the step 64.
Therefore, when the external conductors 601, 602 and 603 are inserted into the insertion grooves 62 from the inside and outside of the bobbin 34 and a pulling force is applied to the external conductors 601, 602 and 603, the receiving portions 59c of the female terminals 59 are accommodated in the accommodating recesses 63 in such a manner that they are received on the steps 64. Thus, the female terminals 59 coupled to the external conductors 601, 602 and 603 can be easily mounted in the holders 611 and 612, irrespective of the length of the external conductors 601, 602 and 603.
When a force is applied to the holders 611 and 612 in a direction to permit the one-end faces 61a of the holders 611 and 612 to come close to the connecting surface 46 of the bobbin 34 in a state in which the female terminals 59 have been mounted in the holders 611 and 612, a force is applied simultaneously to the receiving portions 59c of the female terminals 59 in a direction to fit the male terminals 58 into the receiving portion 59c, whereby the external conductors 601, 602 and 603 are connected simultaneously to the plurality of male terminals 58, leading to a facilitated connecting operation. Moreover, the holders 611 and 612 are only pushed one time toward the stator 21 and hence, an operator is less tired.
The holders 611 and 612 may be of such a simple configuration that the plurality of insertion grooves 62 and the plurality of accommodating recesses 63 connected the insertion grooves 62 through the steps 64 are only defined therein, and thus, the structure of a mold for forming the holders 611 and 612 is also simplified.
The holders 611 and 612 are only fitted in the recesses 381 and 382 of the bobbin 34 and not fixed to the bobbin 34, but the state of holders 611 and 612 fitted in the recesses 381 and 382 is maintained by a friction force provided between the holders 611 and 612 and the bobbin 34 by the fitting of the holders 611 and 612 in the recesses 381 and 382. Even if the holders 611 and 612 are to be moved away from the recesses 381 and 382 due to a weak friction force , the movement of the holders 611 and 612 in a direction away from the recesses 381 and 382 is inhibited by the cover 30 , because the holders 611 and 612 are fixedly disposed so that they are opposed to the stator 21 on the disposed side.
Moreover, since the insulating members 66 made of the insulating sheet of paper are inserted between the DC coil 43 and the U-phase main coil 40U and between the DC coil 43 and the subsidiary coil 42, respectively, the dielectric strength between the adjacent coils 43 and 40U as well as 43 and 42 can be increased. Moreover, since the insulating member 66 is formed by folding the insulating sheet of paper into the angle shape, and inserted between the adjacent coils 43 and 40U as well as 43 and 42 on the opposite sides thereof to come into resilient contact with such adjacent coils 43 and 40U as well as 43 and 42, the insulating members 66 are reliably retained between the adjacent coils 43 and 40U as well as 43 and 42 before and during execution of the impregnation with a vanish.
Therefore, the dielectric strength between the adjacent coils 43 and 40U as well as 43 and 42 can be reliably increased in a simple structure in which the insulating members 66 made of the insulating sheet of paper are only inserted between the adjacent coils 43 and 40U as well as 43 and 42.
Although the embodiment of the present invention has been ' 24 described in detail, it will be understood that the present invention is not limited to the above-described embodiment , and various modifications may be made without departing from the spirit and scope of the invention defined in claims.
Such stators are already known from Japanese Patent Application Laid-open No.9-93849 and the like. In such stator, V-shaped voids opening outwards remain created between the coils corresponding to the salient poles.
When it is desired to increase the dielectric strength between the coils wound around the adjacent salient poles through the bobbin, it is conceived that an insulating member is inserted into the void created between the coils . In this case, if a sheet-shaped insulating member is only inserted between the adjacent coils , the insulating member is fallen out of the void, because the void is of the V-shape opening outwards .
If the stator is sub jected to a vanish impregnating treatment in a state in which the insulating member has been inserted ' 2 between the adjacent coils, the insulating member cannot be fallen down. However, if the insulating member moves in the void during carrying-out of the vanish impregnating treatment, a sufficient dielectric strength may not be obtained.
Accordingly, it is an object of the present invention to provide an insulating structure in a stator for an outer rotor-type multi-pole generator, wherein the dielectric strength between adjacent coils can be increased in a simple structure.
To achieve the above object, according to the present invention, there is provided an insulating structure in a stator for an outer rotor-type multi-pole generator comprising a stator core which is comprised of a plurality of salient poles projectingly provided at equal distances around an outer periphery of a ring-shaped core base, a bobbin covering the stator core, and coils wound around the bobbin in sections corresponding to the salient poles, wherein the insulating structure includes an insulating member formed by folding an insulating sheet of paper into an angle shape and inserted between the coil corresponding to a particular one of the salient poles and each of the coils corresponding to the salient poles adjacent to the particular salient pole to come into resilient contact with the coils on opposite sides of the insulating member.
With such arrangement , the insulating member made of the insulating sheet of paper is inserted between the adjacent coils and hence, the dielectric strength between the adjacent coils can be increased. Moreover, the insulating member is formed by folding the insulating sheet of paper into the angle shape and inserted between the adjacent coils to come into resilient contact with the adjacent coils on the opposite sides of the insulating member. Therefore, the insulating member is reliably retained between the adjacent coils before and during carrying-out of a vanish impregnating treatment and thus , the dielectric strength between the adjacent coils can be reliably increased.
The above and other objects, features and advantages of the invention will become apparent from the following description of the preferred embodiment taken in conjunction with the accompanying drawings.
BRT_EF DESCRT_pTT_ON OF THE DRAWTN
Figs.l to 16 show an embodiment of the present invention, wherein Fig.l is a vertical sectional view of an outer rotor type multi-pole generator, taken along a line 1-1 in Fig.2;
Fig.2 is a plan view of a stator, taken in a direction of an arrow 2-2 in Fig. l;
Fig.3 is a back view of the stator, taken in a direction of an arrow 3-3 in Fig. l;
Fig.4 is an enlarged sectional view taken along a line 4-4 in Fig.2 in a holder-mounted state;
' 4 Fig.5 is a diagram of a coil connection circuit;
Fig.6 is a perspective view of a coil-side terminal, a support plate and a male terminal;
Fig . 7 is a view taken in a direction of an arrow 7 in Fig . 6 ;
Fig . 8 is a view taken in a direction of an arrow 8 in Fig . 7 ;
Fig.9 is a side view of a holder;
Fig.lO is a view taken in a direction of an arrow 10 in Fig.9;
Fig.ll is a side view of the holder with female terminals and external conductors mounted therein;
Fig.l2 is a view taken in a direction of an arrow 12 in Fig.ll;
Fig.l3 is a sectional view taken along a line 13-13 in Fig. l2;
Fig . 14 is a perspective view showing an insulating member which is being mounted;
Fig.l5 is a side view of the insulating member; and Fig.l6 is a view taken in a direction of an arrow 16 in Fig. l5.
DESGRTpTTON OF THE PREFERR n EMBODIMENT
The present invention will now be described by way of an embodiment with reference to Figs . 1 to 16 . Referring first to Fig.l, a stator 21 for an outer rotor-type multi-pole generator is coupled to a sleeve 22 connected to an engine body ( not shown ) by a plurality of, e.g. , four bolts 23. A crankshaft 24 of the engine ( not shown ) is coaxially disposed within the sleeve 22 to extend coaxially through the stator 21, and a bearing 25 and a seal member 26 are mounted between the sleeve 22 and the crankshaft 24. A bowl-shaped rotor yoke 27 is coaxially fastened to an end of the crankshaft 24 to cover the stator 21, and a magnet 29 is secured to an inner periphery of the rotor yoke 27 to coaxially surround the stator 21, so that an small air gap is defined between the magnet 29 and the stator 21. A
cover 30 is secured to the sleeve 22 to cover an opened end of the rotor yoke 27.
The stator 21 includes a stator core 31 which is formed from a plurality of core plates laminated one on another. The stator core 31 comprises a plurality of, e.g. , 27 substantially T-shaped salient poles 33 which are projectingly provided at equal distances around an outer periphery of a core base 32 formed into a ring-shape.
The plurality of core plates forming the stator core 31 are partially covered, over axially opposite ends in a direction of lamination of the plates , with a bobbin 34 made of a synthetic resin, so that the laminated state of the core plates is maintained, thereby constituting the stator core 31. The bobbin 34 is formed to cover the stator 31 over their axially opposite ends, in such a manner that tip ends of the salient poles 33 and an inner peripheral surface of a portion of the core base 32 are exposed.
Referring also to Figs.2 and 3, first, second, third and fourth insertion bores 351, 35z, 353 and 354 are provided at a ~ ~ 6 plurality of , e. g. , four points spaced at equal distances apart from one another in circumferential directions of the core base 32 and the bobbin 34 , and bolts 23 for fastening the sleeve 22 to the stator 21 are inserted through the insertion bores 351 to 354, respectively.
Referring further to Fig.4, four grooves 36 are provided in the inner periphery of the core base 32 of the stator core 31 over axially opposite ends of the core base 32 , so that each of the grooves 36 is located between the adjacent insertion bores 351, 352, 353, 354. First, second, third and fourth recesses 381, 382, 383, 384 are provided in the bobbin 34 at locations corresponding to the grooves 36 between the insertion bores 351, 352, 353, 354 to form a connecting surface 46 facing the cover 30, so that their portions adjacent to the cover and their radially inner portions are opened.
Those portions of the bobbin 34 which correspond to the first, second and fourth recesses 381, 382 and 384 are provided with a plurality of, e. g. , three first fitting bores 391 disposed at equal distances in the circumferential direction of the bobbin 34 at locations equally spaced apart from the center of the bobbin 34, and a plurality of, e.g., four second fitting bores 392 disposed alternately with the first fitting bores 391 in the circumferential direction of the bobbin 34 at locations spaced at larger distances apart from the center of the bobbin 34 than the distances at which the first fitting bores 391 are spaced apart from the center of the bobbin 34 . The fitting bores ~ ' 7 391 and 39z are defined to have a rectangular cross-sectional shape longer in a direction perpendicular to a radial direction of the bobbin 34. One end of each of the fitting bores 391 and 392 opens into the end face of the bobbin 34 which faces the rotor yoke 27, and the other ends of the fitting bores 391 and 39z open into the connecting surface 46 to face the recesses 381, 382, 383 and 384.
Here, the salient pole 33 disposed in basic position PB
established in the vicinity of the first insertion bore 351 is defined as being a first pole, and the salient poles 33, which are second, third, ---, twenty seventh in a counterclockwise direction as viewed in Fig.2 (in a clockwise direction as viewed in Fig.3), are defined as being second, third, ---, twenty seventh poles . In such stator core 31, eight U-phase main coils 40U, eight V-phase main coils 40V and eight W-phase main coils 40W are wound around the first to twenty fourth salient poles 33 respectively with the bobbin 34 interposed therebetween, and a charging coil 41, a subsidiary coil 42 and a DC coil 43 are wound around the twenty fifth to twenty seventh salient poles 33 respectively with the bobbin 34 interposed therebetween.
Each of the U-phase main coils 40U is wound around each of the salient poles 33 disposed at every third places in the circumferential direction of the stator core 31 with the bobbin 34 interposed therebetween.
Referring to Fig.5, one of the eight U-phase main coils 40U connected in series, which is disposed at one end in a direction of arrangement of them, i.e., in the basic position PB, is connected at one end thereof to a second coil-side terminal 452, and one of the eight V-phase main coils 40V
connected in series , which is disposed at one end in a direction of arrangement of them, i.e., second from the basic position PB, is connected at one end thereof to a first coil-side terminal 451. One of the eight W-phase main coils 40W connected in series , which is disposed at one end in a direction of arrangement of them, i.e. , third from the basic position PB, is connected to a second coil-side terminal 452, and the DC coil 43 is connected at its opposite ends to first and second coil-side terminals 451 and 452, respectively.
The first and second coil-side terminals 451 and 452 each of which is connected to one end of each of the main coils 40U, 40V and 40W connected in series in the above manner and the opposite ends of the DC coil 43 respectively are fixed to the bobbin 34 in a section corresponding to the first recess 381 between the first and second insertion bores 351 and 352. Each of the two first coil-side terminals 451 is integrally connected to one end of each of support plates 48 made of a conductive metal and fitted and fixed in the first fitting bores 391 closer to the first insertion bore 351, and each of the three second coil-side terminals 452 is also integrally connected to one end of each of support plates 48 fitted and fixed in the second fitting bores 392 closer to the first insertion bore 351.
The other end of one of the eight U-phase main coils 40U
connected in series , which is disposed at the other end in the direction of arrangement of them, i . a . , twenty second from the basic position PB, the other end of one of the eight V-phase main coils 40V connected in series, which is disposed at the other end in the direction of arrangement of them, i . a . , twenty third from the basic position PB, and the other end of one of the eight W-phase main coils 40W connected in series , which is disposed at the other end in the direction of arrangement of them, i.e., twenty fourth from the basic position PB, are commonly connected as neutral points to the first coil-side terminal 451, and the opposite ends of the charging coil 41 and the opposite ends of the subsidiary coil 42 are connected to first and second coil-side terminals 451 and 45z, respectively.
The first and second coil-side terminals 451 and 452 connected to the neutral points of the main coils 40U, 40V and 40W and the opposite ends of the charging coil 41 and the subsidiary coil 42 in the above manner are fixed to the bobbin 34 in a section corresponding to the fourth recess 384 between the fourth and first insertion bores 354 and 351. Each of the first coil-side terminals 451 is integrally connected to one end of each of the support plates 48 fitted and fixed in the first fitting bores 391, respectively, and each of the second coil-side terminals 452 is integrally connected to one end of each of the support plates 48 fitted and fixed in the second fitting bores 392, respectively.
In this embodiment, the support plates 48 which are integral with the first and second coil-side terminals 451 and 452 are not fitted into all of the first and second fitting bores 391 and 39z disposed in correspondence to the second recess 382 between the third and fourth insertion bores 353 and 354, as well as into some of the first and second fitting bores 391 and 392 disposed in correspondence to the first and fourth recesses 381 and 384. However, the fitting of the support plates 48 into the fitting bores 391 and 392 may be selected properly depending on the type of the generator, and in another type of a generator, the support plates 48 may be fitted into all of the fitting bores 391 and 392 respectively in some cases.
Referring to Figs.6 to 8, the first coil-side terminal 451 is formed from a conductive metal and integrally provided with a flat connecting plate portion 49 connected at one end thereof at a right angle to one end of the support plate 48 fitted and fixed in the fitting bore 391, and a connecting terminal portion 50 connected to the other end of the connecting plate portion 49 . Before assembling of the stator 21, the connecting terminal portion 50 is connected at a right angle to the connecting plate portion 49 in a direction opposite to the support plate 48 , i . a . , in a direction away from the bobbin 34 at the time of fitting of the support plate 48 into the first fitting bore 391, but the connecting terminal portion 50 can be folded, so that it is superposed onto the connecting plate portion 49.
The support plate 48 is formed into a flat plate-shape ~ 11 from a conductive metal so as to be fitted and fixed in the first fitting bore 391. The length of the support plate 48 is set at such a value that when the connecting plate portion 49 is fitted into the fitting bore 391 up to a position where it abuts against the bobbin 34 , as shown in Fig. 4 , the other end protrudes from the connecting surface 46. Moreover, the support plate 48 has claws 51 provided on its opposite sides respectively to bite into inner surfaces of opposite sides of the first fitting bore 391 and to inhibit the detachment of the support plate 48 out of the fitting bore 391.
The connecting plate portion 49 is connected at the right angle to the other end of the support plate 48 in such a manner that when the support plate 48 is fitted into the first fitting bore 391, the connecting plate portion 49 is put into abutment against the end face of the bobbin 34 on the side of the rotor yoke 27 and extends outwards in the radial direction of the stator 21.
The connecting terminal portion 50 is formed into a cylindrical shape by rounding a flat plate. Each of lead wires 52 ( see Figs . 2 and 4 ) extending from each of the coils 40U, 40V, 40W, 41, 42 and 43 can be inserted through the connecting terminal portion 50. Moreover, the lead wire 52 inserted through the connecting terminal portion 50 is connected to the other end, i.e. , the tip end of the connecting terminal portion 50 by fusing. A window 53 is provided in a notched manner in an intermediate portion of the connecting terminal portion 50 to face outwards of the stator 21, and the connecting terminal portion 50 includes a connecting portion 50a formed therein on the side of the tip end, and an introducing portion 50b formed therein on the side of the connecting plate portion 49 for permitting the insertion of the lead wire 52 toward the connecting portion 50a, so that the window 53 is interposed between the connecting portion 50a and the introduction portion 50b.
The second coil-side terminal 452 which is one end of the support plate 48 fitted in the second fitting bore 392 basically has the same shape as the first coil-side terminal 451, but the length L1 of the connecting plate portion 49 in the first coil-side terminal 451 is set larger than the length L1 of the connecting plate portion 49 in the second coil-side terminal 452. A difference between the length L1 of the connecting plate portion 49 in the first coil-side terminal 451 and the length L1 of the connecting plate portion 49 in the second coil-side terminal 452 is a value equal to a distance L2 ( see Fig . 4 ) between the first and second fitting bores 391 and 392 in the radial direction of the bobbin 34. With such setting as stated above, the connecting terminal portion 50 of the first coil-side terminal 451 with the support plate 48 fitted in the first fitting bore 391 and the connecting terminal portion 50 of the second coil-side terminal 452 with the support plate 48 fitted in the second fitting bore 392 are disposed at locations spaced at equal distances apart from the center of the bobbin 34.
. ' 13 Ribs 56 are integrally, projectingly provided on the bobbin 34 to extend in the radial direction of the bobbin 34 between the fitting bores 391 and 392 for guiding the connecting terminal portions 50 of the first and second coil-side terminals 451 and 452, when these connecting terminal portions 50 are folded.
To assemble the first and second coil-side terminals 451 and 452 to the stator 21 and to connect the lead wires 52 to the first and second coil-side terminals 451 and 452, the support plate 48 may be press-fitted into each of the first and second fitting bores 391 and 392 in a state in which the lead wire 52 has been inserted through the introducing portion 50b and the connecting portion 50a, and the lead wire 52 may be connected to the connecting portion 50a by fusing. Thereafter, the connecting terminal portion 50 may be folded, so that it may be superposed onto the connecting plate portion 49.
Crossover wires 55 for connecting the U-phase main coils 40U to each other, the V-phase main coils 40V to each other as well as the W-phase main coils 40W to each other are disposed, so that they are wound around the bobbin 34 on the side of the rotor yoke 27, as shown in Figs.3 and 4.
The other ends of the support plates 48 fitted and fixed in the fitting bores 391 and 392 protrude from the connecting surface 46 in the first recess 381 between the first and second insertion bores 351 and 352 as well as in the fourth recess 384 between the first and fourth insertion bores 351 and 354, respectively. The protruding ends of the support plates 48 from the connecting surface 46 function as male terminals 58.
Paying attention to Fig.S, female terminals 59 are electrically connected to the male terminals 58, respectively.
Each of the female terminals 59 , each of which is connected to each of the male terminals 58 connected to one end of each of the main coils 40U, 40V and 40W, is coupled to one end of each of first external conductors 601. The female terminals 59, which are connected to the male terminals 58 connected to the opposite ends of the DC coil 43 , are coupled to one ends of second external conductors 602 having a smaller diameter than that of the first external conductors 601, respectively. Each of the female terminals 59 , which are connected to the male terminals 58 connected to the opposite ends of the charging coil 41 and the subsidiary coil 42, is coupled to one end of each of the second external conductors 602, The female terminal 59 , which is connected to the male terminal 58 connected to the neutral point of each of the main coils 40U, 40V and 40W, is coupled to one end of a third external conductor 603.
The five female terminals 59 corresponding to the one ends of each main coils 40U, 40V and 40W and the opposite ends of the DC coil 43 respectively are retained in a holder 611 fitted in the first recess 381 between the first and second insertion bores 351 and 352, and the four female terminals 59 corresponding to the opposite ends of the charging coil 41 and the subsidiary coil 42 and the neutral points of each main coils 40U, 40V and . 15 40W respectively are retained in a holder 612 fitted in the fourth recess 384 between the first and fourth insertion bores 351 and 354.
Referring to Figs.9 and 10, the holders 611 and 612 are formed into the same arcuate shape from a synthetic resin such as a polyamide to be fitted in the recesses 381 and 383. In a state in which the holders 611 and 612 have been fitted in the recesses 381 and 383, the inner surfaces of the holders 611 and 612 are connected substantially flush to the inner peripheral surface of the stator 21.
Four insertion grooves 62 corresponding to the four second fitting bores 392 facing the recesses 381 and 382 are provided in an outer surface of each of the holders 611 and 612, so that opposite ends of the insertion groove 62 open, and three insertion grooves 62 corresponding to the three second fitting bores 391 facing the recesses 381 and 382 are provided in an inner surface of each of the holders 611 and 612, so that opposite ends of the insertion groove 62 open.
In a state in which the holders 611 and 612 have been fitted in the recesses 381 and 383, one end faces 61a thereof are in proximity to and opposed to the connecting surface between the recesses 381 and 383. Seven accommodating recesses 63 are provided in the one end face 61a of each of the holders 611 and 612 to individually lead to the insertion grooves 62 , and steps 64 facing the connecting surface 46 are formed between the accommodating recesses 63 and the insertion grooves 62.
Referring to Figs.ll to 13, the female terminal 59 is formed from a conductive metal and includes a first caulked and coupled portion 59a, a second caulked and coupled portion 59b connected to the first caulked and coupled portion 59a, and a receiving portion 59c connected to the second caulked and coupled portion 59b, so that the male terminal 58 can be fitted therein to enable the electric connection. The first caulked and coupled portion 59a is caulked and coupled to one end of the resinous covering portion in each of the first, second and third external conductors 601, 602 and 603, and the second caulked and coupled portion 59b is caulked and coupled to a core wire pulled out of one end of the resinous covering portion in each of the first, second and third external conductors 601, 602 and 603. The receiving portion 59c is formed to protrude to opposite sides from each of the first, second and third external conductors 601, 602 and 603, and is capable of being accommodated in the accommodating recess 63 in each of the holders 611 and 612.
On the other hand, the insertion groove 62 in each of the holders 611 and 612 is formed, so that each of the first , second and third external conductors 601, 602 and 603 can be inserted through the insertion groove 62 from the inside and outside of each of the holders 611 and 612. The accommodation portion 59c accommodated in the accommodating recess 63 can be put into abutment against the step 64 between the insertion groove 62 and the accommodating recess 63.
The DC coil 43 is wound around one of the plurality of salient poles 33 included in the stator 21 which is twenty seventh from the basic position PB in the counterclockwise direction as viewed in Fig.2, with the bobbin 33 interposed therebetween, so that DC current flows across the DC coil 43, while AC current flow across the U-phase main coil 40U and the subsidiary coil 42 on the opposite sides of the DC coil 43. To enhance the insulating ability between the DC coil 43 and the U-phase main coil 40U and the subsidiary coil 42 adjacent to the DC coil 43 in the circumferential direction of the stator core 31, an insulating member 66 is inserted between the DC coil 43 corresponding to the particular salient pole 33 which is twenty seventh from the basic position PB in the counterclockwise direction as viewed in Fig.2 and each of the U-phase main coil 40U and the subsidiary coil 42 corresponding to the salient poles 33 adjacent to the particular salient pole 33 in the circumferential direction of the stator core 31, as shown in Fig. l4.
Referring also to Figs . 15 and 16 , the insulating member 66 is formed by folding a rectangular insulating sheet of paper known by the trade name of NOMEX of DuPont into an angle shape .
The insulating members 66 are inserted between the DC coil 33 and the U-phase main coil 40U, and between the DC coil 43 and the subsidiary coil 42 , so that the insulating members 66 are in resilient contact with the coils 43 and 40U as well as 43 and 42 on the opposite sides thereof.
1$
The operation of the embodiment will be described below.
In a state in which the lead wire 52 from each of the coils 40U, 40V, 40W, 41, 42 and 43 has been inserted through that connecting terminal portion 50 of each of the first and second coil-side terminals 451 and 452 which are integral with the support plates 48 fitted and fixed in the fitting bores 391 and 392 in the bobbin 34 , which has been connected at the right angle to the connecting plate portion 49, the lead wire 52 is connected by fusing to the connecting portion 50a laying at a location relatively spaced apart from the bobbin 34. Therefore, even if each of the coils 40U, 40V, 40W, 41, 42 and 43 is formed of a magnet wire, it is possible to easily achieve the connection of the coils 40U, 40V, 40W, 41, 42 and 43 to the coil-side terminals 451 and 452 without peeling-off operation of an insulating film, leading to a facilitated connecting operation and to a decreased number of operating steps.
In addition, since the connecting terminal portion 50 can be folded so that it is superposed onto the connecting plate portion 49 after connection of the lead wore 52 , it is possible to avoid the protrusion of the connecting terminal portion 50 from the stator 21, and to reduce the spaces for arrangement of the coil-side terminals 451 and 452.
Moreover, the first and second coil-side terminals 451 and 452 adjacent one another in the circumferential direction of the bobbin 34 are fixed to the bobbin 34 at the locations alternately shifted in the radial direction of the bobbin 34.
Thus, the plurality of coil-side terminals 451 and 452 can be fixed in a compact arranged manner to the bobbin 34, leading to a reduction in size of the stator 21. In addition, the first and second coil-side terminals 451 and 452 are fixed to the bobbin 34 at the locations spaced at different distances apart from the center of the bobbin 34, so that the connecting terminal portions 50 of the first and second coil-side terminals 451 and 452 are disposed at the same distance from the center of the bobbin 34 in the state in which they have been connected at the right angle to the connecting plate portions 49. Therefore, to fold the each of the connecting terminal portions 50 after connection of the lead wire 52 to the connecting terminal portion 50, an urging force in a folding direction may be applied to the connecting terminal portions 50 at the locations spaced at the same distance from the center of the bobbin 34. Therefore, an urging means for applying the urging force to each of the connecting terminal portions 50 in the folding direction need not be moved in the radial direction of the bobbin 34 , but may be moved sequentially in the circumferential direction of the bobbin 34 and hence, a mechanism for moving the urging means can be simplified.
Since the connecting portion 50a for connecting the lead wire 52 by fusing and the introduction portion 50b for permitting the insertion of the lead wire 52 are formed in the connecting terminal portion 50, with the window 53 facing outwards of the stator 21 being interposed therebetween.
' 20 Therefore, when the connecting terminal portion 50 is to be folded, the introduction portion 50b is pushed, and a stress generated during folding is prevented from being applied to the connecting portion 50a with the lead wire 52 connected thereto .
Thus , the connection of the connecting terminal portion 50 and the lead wire 52 to each other can be maintained reliably, regardless of the folding of the connecting terminal portion 50.
The plurality of ribs 56 are projectingly provided on the bobbin 34 and disposed between the fitting bores 391 and 392 to extend in the radial direction of the bobbin 34. The ribs 56 function as guides, when the connecting terminal portions 50 of the coil-side terminals 451 and 452 with the support plates 48 fitted in the fitting bores 391 and 392 are folded, and hence, it is possible to reliably avoid that the coil-side terminals 451 and 452 adjacent one another in the circumferential direction of the bobbin 34 are brought into contact with one another. Therefore, it is unnecessary to space the coil-side terminals 451 and 452 at large distances apart from one another, and it is possible to prevent the stator from being increased in size due to the arrangement of the coil-side terminals 451 and 452.
The male terminals 58 connected to the coils 40U, 40V, 40W, 41, 42 and 43 respectively are fixed to the bobbin 34 to protrude from the connecting surface 46, and the female terminals 59 capable of being fitted into and electrically connected to the male terminals 58 are coupled to the external conductors 601, 602 and 603, but the female terminals 59 coupled to the external conductors 601, 602 and 603 are retained in the holders 611 and 612.
The insertion grooves 62 capable of permitting the insertion of the external conductors 601, 602 and 603 from the sideways direction are provided, with their opposite ends opened, in the inner and outer surfaces of the holders 611 and 612 made of the synthetic resin. The accommodating recesses 63 individually leading to the insertion grooves 62 are provided in those one end faces 61a of the holders 611 and 612 which are opposed to the connecting surface 46 of the bobbin 34 , and the steps 64 facing the connecting surface 46 of the bobbin 34 are formed between the accommodating recesses 63 and the insertion grooves 62, respectively. Moreover, the female terminal 59 has the receiving portion 59c into which the male terminal 58 can be fitted for electrical connection, and the receiving portion 59c is accommodated in the accommodating recess 63 capable of being put into abutment against the step 64.
Therefore, when the external conductors 601, 602 and 603 are inserted into the insertion grooves 62 from the inside and outside of the bobbin 34 and a pulling force is applied to the external conductors 601, 602 and 603, the receiving portions 59c of the female terminals 59 are accommodated in the accommodating recesses 63 in such a manner that they are received on the steps 64. Thus, the female terminals 59 coupled to the external conductors 601, 602 and 603 can be easily mounted in the holders 611 and 612, irrespective of the length of the external conductors 601, 602 and 603.
When a force is applied to the holders 611 and 612 in a direction to permit the one-end faces 61a of the holders 611 and 612 to come close to the connecting surface 46 of the bobbin 34 in a state in which the female terminals 59 have been mounted in the holders 611 and 612, a force is applied simultaneously to the receiving portions 59c of the female terminals 59 in a direction to fit the male terminals 58 into the receiving portion 59c, whereby the external conductors 601, 602 and 603 are connected simultaneously to the plurality of male terminals 58, leading to a facilitated connecting operation. Moreover, the holders 611 and 612 are only pushed one time toward the stator 21 and hence, an operator is less tired.
The holders 611 and 612 may be of such a simple configuration that the plurality of insertion grooves 62 and the plurality of accommodating recesses 63 connected the insertion grooves 62 through the steps 64 are only defined therein, and thus, the structure of a mold for forming the holders 611 and 612 is also simplified.
The holders 611 and 612 are only fitted in the recesses 381 and 382 of the bobbin 34 and not fixed to the bobbin 34, but the state of holders 611 and 612 fitted in the recesses 381 and 382 is maintained by a friction force provided between the holders 611 and 612 and the bobbin 34 by the fitting of the holders 611 and 612 in the recesses 381 and 382. Even if the holders 611 and 612 are to be moved away from the recesses 381 and 382 due to a weak friction force , the movement of the holders 611 and 612 in a direction away from the recesses 381 and 382 is inhibited by the cover 30 , because the holders 611 and 612 are fixedly disposed so that they are opposed to the stator 21 on the disposed side.
Moreover, since the insulating members 66 made of the insulating sheet of paper are inserted between the DC coil 43 and the U-phase main coil 40U and between the DC coil 43 and the subsidiary coil 42, respectively, the dielectric strength between the adjacent coils 43 and 40U as well as 43 and 42 can be increased. Moreover, since the insulating member 66 is formed by folding the insulating sheet of paper into the angle shape, and inserted between the adjacent coils 43 and 40U as well as 43 and 42 on the opposite sides thereof to come into resilient contact with such adjacent coils 43 and 40U as well as 43 and 42, the insulating members 66 are reliably retained between the adjacent coils 43 and 40U as well as 43 and 42 before and during execution of the impregnation with a vanish.
Therefore, the dielectric strength between the adjacent coils 43 and 40U as well as 43 and 42 can be reliably increased in a simple structure in which the insulating members 66 made of the insulating sheet of paper are only inserted between the adjacent coils 43 and 40U as well as 43 and 42.
Although the embodiment of the present invention has been ' 24 described in detail, it will be understood that the present invention is not limited to the above-described embodiment , and various modifications may be made without departing from the spirit and scope of the invention defined in claims.
Claims
1. An insulating structure in a stator for an outer rotor-type mufti-pole generator comprising a stator core (31) which is comprised of a plurality of salient poles (33) projectingly provided at equal distances around an outer periphery of a ring-shaped core base (32), a bobbin (34) covering said stator core (31), and coils (40U, 40V, 40W, 41, 42 and 43) wound around said bobbin (34) in sections corresponding to said salient poles (33), wherein said insulating structure includes an insulating member (66) formed by folding an insulating sheet of paper alternately in opposite directions to have angle portions and inserted between said coil (43) corresponding to a particular one (33) of said salient poles (33) and each of said coils (40U
and 42) corresponding to said salient poles (33) adjacent to said particular salient pole (33) to come into resilient contact at the respective angles with either of said coils (43 and 40U as well as 43 and 42) on opposite sides of said insulating member (66).
and 42) corresponding to said salient poles (33) adjacent to said particular salient pole (33) to come into resilient contact at the respective angles with either of said coils (43 and 40U as well as 43 and 42) on opposite sides of said insulating member (66).
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP11-25389 | 1999-02-02 | ||
| JP02538999A JP4015314B2 (en) | 1999-02-02 | 1999-02-02 | Insulation structure in stator for outer rotor type multipolar generator |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2297534A1 CA2297534A1 (en) | 2000-08-02 |
| CA2297534C true CA2297534C (en) | 2004-05-11 |
Family
ID=12164534
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2297534 Expired - Fee Related CA2297534C (en) | 1999-02-02 | 2000-02-01 | Insulating structure in stator for outer rotor-type multi-pole generator |
Country Status (2)
| Country | Link |
|---|---|
| JP (1) | JP4015314B2 (en) |
| CA (1) | CA2297534C (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP7038827B2 (en) * | 2018-07-27 | 2022-03-18 | 三菱電機株式会社 | Stator, motor, compressor and air conditioner |
-
1999
- 1999-02-02 JP JP02538999A patent/JP4015314B2/en not_active Expired - Fee Related
-
2000
- 2000-02-01 CA CA 2297534 patent/CA2297534C/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| JP4015314B2 (en) | 2007-11-28 |
| JP2000224793A (en) | 2000-08-11 |
| CA2297534A1 (en) | 2000-08-02 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| MKLA | Lapsed |
Effective date: 20160201 |