JP2024093938A - Stator of electric motor for man-power driven vehicle, electric motor for man-power driven vehicle, and component for man-power driven vehicle - Google Patents

Abstract

To provide a stator of an electric motor for a man-power driven vehicle, an electric motor for a man-power driven vehicle, and a component for a man-power driven vehicle that allow suitable assembly of a plurality of insulation members.SOLUTION: A stator of an electric motor for a man-power driven vehicle comprises a stator core, a plurality of insulation members, and a coil. The stator core includes a plurality of division cores. Each of the plurality of division cores includes a yoke part and at least one of a plurality of teeth. The yoke part includes a first core end surface, and a second core end surface. The first core end surface and the second core end surface are formed so as to be parallel to a central axis of the stator. The plurality of insulation members are arranged side by side in a circumferential direction. Each of the plurality of insulation members includes a first insulation end surface and a second insulation end surface. Each of the first insulation end surface and the second insulation end surface has a non-parallel part. The non-parallel part overlaps the stator core when viewed from a radial direction with respect to the central axis of the stator.SELECTED DRAWING: Figure 3

Description

The present disclosure relates to a stator for an electric motor for a human-powered vehicle, an electric motor for a human-powered vehicle, and a component for a human-powered vehicle.

The electric motor disclosed in Patent Document 1 has multiple insulators arranged in the circumferential direction.

JP 2019-216549 A

One of the objectives of the present disclosure is to provide a stator for an electric motor for a human-powered vehicle, an electric motor for a human-powered vehicle, and a component for a human-powered vehicle that can be suitably assembled with multiple insulating members.

A stator according to a first aspect of the present disclosure is a stator for an electric motor for a human-powered vehicle, the stator comprising: a yoke and a stator core including a plurality of teeth protruding from the yoke; a plurality of insulating members including a first portion covering a portion of the yoke and a second portion covering at least a portion of the plurality of teeth; and a coil wound around the second portion, the stator core including a plurality of split cores arranged in a circumferential direction relative to a central axis of the stator, each of the plurality of split cores including a yoke portion constituting a part of the yoke and at least one of the plurality of teeth provided on the yoke portion, the yoke portion of each of the plurality of split cores being arranged in a circumferential direction relative to the central axis of the stator. the first core end face and the second core end face are formed parallel to the central axis of the stator, the multiple insulating members are arranged side by side in the circumferential direction, and each of the multiple insulating members includes a first insulating end face in the circumferential direction and a second insulating end face opposite the first insulating end face in the circumferential direction, the first insulating end face and the second insulating end face each have non-parallel portions extending in a second direction different from a first direction parallel to the central axis of the stator, and the non-parallel portions overlap the stator core when viewed in a radial direction relative to the central axis of the stator.
According to the stator having the first side surface, the insulating members each include a first insulating end surface and a second insulating end surface each having a non-parallel portion extending in a second direction different from the first direction, so that the insulating members are unlikely to be misaligned in the first direction. Therefore, the insulating members can be suitably assembled into the stator.

In the stator of the second aspect according to the first aspect of the present disclosure, the non-parallel portion is formed by at least one of a protrusion and a recess.
According to the stator having the second side surface, the non-parallel portions of the insulating members are formed by at least one of a convex portion and a concave portion, so that the insulating members are less likely to become misaligned in the first direction.

In the stator of a third aspect according to the second aspect of the present disclosure, a protruding length of the convex portion is equal to or greater than 0.2 and less than 1 when the diameter of the coil is 1.
According to the stator of the third side, the insulating member can suppress displacement of the multiple insulating members in the first direction by the convex portion having a protruding length of 0.2 or more and less than 1 when the diameter of the coil is 1.

In the stator according to the second or third aspect of the present disclosure, a recessed length of the recess is equal to or greater than 0.2 and less than 1 when the diameter of the coil is 1.
According to the stator of the fourth side face, the recess, whose recessed length is 0.2 or more and less than 1 when the diameter of the coil is 1, can suppress displacement of the multiple insulating members in the first direction.

In the stator of a fifth aspect according to any one of the first to fourth aspects of the present disclosure, the non-parallel portion includes an inclined surface inclined with respect to the first direction.
According to the stator having the fifth side surface, the inclined surface can suppress displacement of the multiple insulating members in the first direction.

In the stator of a sixth aspect according to the fifth aspect of the present disclosure, an angle of the inclined surface with respect to the first direction is greater than or equal to 10 degrees and less than 60 degrees.
According to the stator having the sixth side surface, the inclined surface having an angle of 10 degrees or more and less than 60 degrees with respect to the first direction can suppress displacement of the multiple insulating members in the first direction.

In a seventh aspect of the stator according to any one of the first to sixth aspects of the present disclosure, the non-parallel portion includes a curved portion.
According to the stator of the seventh side face, the curved portion can suppress displacement of the multiple insulating members in the first direction.

In a stator of an eighth side according to any one of the first to seventh sides of the present disclosure, the multiple split cores include a first split core and a second split core adjacent to each other in the circumferential direction, the multiple insulating members include a first insulating member provided on the first split core and a second insulating member provided on the second split core, the first core end face of the first split core contacts the second core end face of the second split core, and a first gap is formed between the first insulating end face of the first insulating member and the second insulating end face of the second insulating member.
According to the stator having the eighth side surface, a first gap is formed between the first insulating end surface of the first insulating member and the second insulating end surface of the second insulating member, making it easy to assemble the stator.

In the stator of a ninth aspect according to the eighth aspect of the present disclosure, the size of the first gap is greater than or equal to 0 and less than 1 when the diameter of the coil is 1.
According to the stator of the ninth aspect, the size of the first gap can be set to be greater than or equal to 0 and less than 1 when the diameter of the coil is taken as 1.

In a stator of a tenth side according to any one of the first to ninth sides of the present disclosure, each of the multiple insulating members includes a first end and a second end in the first direction, and includes a first end side portion including the first end, and a second end side portion including the second end formed separately from the first end side portion.
According to the stator of the tenth side, each of the multiple insulating members includes a first end side portion and a second end side portion that includes a second end portion that is formed separately from the first end side portion, making it easy to assemble the stator.

In a stator according to an eleventh aspect of the present disclosure, the non-parallel portion is provided in each of the first end portion and the second end portion.
According to the stator of the eleventh side face, the non-parallel portions are provided at both the first end portion and the second end portion, so that the stator can be easily assembled.

In a stator of a twelfth aspect according to any one of the first to eleventh aspects of the present disclosure, each of the plurality of split cores includes one of the plurality of teeth.
According to the stator of the twelfth aspect, each of the multiple split cores includes one of the multiple teeth, making it easy to wind a coil around each of the multiple teeth.

In a stator according to a thirteenth aspect of the present disclosure, the number of the insulating members is equal to the number of the split cores.
According to the stator of the thirteenth aspect, since the number of the insulating members is equal to the number of the split cores, an insulating member can be provided for each of the split cores.

An electric motor according to a fourteenth aspect of the present disclosure is an electric motor for a human-powered vehicle, comprising a stator according to any one of the first to fourteenth aspects, and a rotor rotatable relative to the stator.
According to the electric motor of the fourteenth aspect, the multiple insulating members of the stator can be suitably assembled, which contributes to the manufacturing efficiency of the electric motor.

In the electric motor of a fifteenth aspect according to the fourteenth aspect of the present disclosure, the yoke is formed in a cylindrical shape, and the rotor is disposed inside the yoke in the radial direction.
According to the electric motor of the fifteenth aspect, it is possible to contribute to the manufacturing efficiency of the electric motor in which the rotor is disposed radially inside the yoke.

A component according to a sixteenth aspect of the present disclosure is a component for a human-powered vehicle, comprising an electric motor according to the fourteenth or fifteenth aspects.
The component of the sixteenth aspect can contribute to the efficiency of manufacturing electric motors, and therefore to the efficiency of manufacturing components.

A component of a seventeenth aspect according to the sixteenth aspect of the present disclosure is a drive unit, wherein the electric motor is configured to provide propulsive force to the human-powered vehicle.
The component of the seventeenth aspect can contribute to the manufacturing efficiency of components that provide propulsive force to a human-powered vehicle by an electric motor.

The stator of the electric motor for a human-powered vehicle, the electric motor for a human-powered vehicle, and the component for a human-powered vehicle disclosed herein can be suitably assembled with multiple insulating members.

1 is a side view of a human-powered vehicle including a stator of an electric motor for a human-powered vehicle according to a first embodiment, an electric motor for a human-powered vehicle, and components for the human-powered vehicle; FIG. 2 is a cross-sectional view of the drive unit of FIG. 1 . FIG. 3 is a perspective view of the stator of FIG. 2 . FIG. 4 is a plan view of the stator of FIG. 3 . FIG. 4 is a first perspective view of the stator core of FIG. 3 . FIG. 4 is a second perspective view of the stator core of FIG. 3 . 4 is a front view of a first divided core and a second divided core of the stator core of FIG. 3. FIG. 4 is a first perspective view of the insulating member of FIG. 3 . FIG. 4 is a second perspective view of the insulating member of FIG. 3 . FIG. 4 is a front view of the insulating member of FIG. 3 . 4 is a front view of the first split core, the second split core, the first insulating member, and the second insulating member of FIG. 3. FIG. 11 is a front view of an insulating member according to a second embodiment. 13 is a front view of a first split core, a second split core, a first insulating member, and a second insulating member of a second embodiment. FIG. FIG. 11 is a front view of an insulating member according to a first modified example. 13 is a front view of a first divided core, a second divided core, a first insulating member, and a second insulating member of a first modified example. FIG.

First Embodiment
With reference to Figs. 1 to 11, a stator 70 of an electric motor 52 for a human-powered vehicle, an electric motor 52 for a human-powered vehicle, and a component 50 for a human-powered vehicle will be described. A human-powered vehicle is a vehicle that has at least one wheel and can be driven at least by human-powered driving force. Human-powered vehicles include various types of bicycles, such as mountain bikes, road bikes, city bikes, cargo bikes, hand bikes, and recumbents. The number of wheels that a human-powered vehicle has is not limited. Human-powered vehicles also include, for example, one-wheeled vehicles and vehicles with two or more wheels. Human-powered vehicles are not limited to vehicles that can be driven only by human-powered driving force. Human-powered vehicles include E-bikes that use not only human-powered driving force but also the driving force of an electric motor for propulsion. E-bikes include electric-assisted bicycles whose propulsion is assisted by an electric motor. In the following, in each embodiment, a human-powered vehicle will be described as a bicycle.

The human-powered vehicle 10 includes, for example, at least one wheel 12 and a vehicle body 14. The at least one wheel 12 includes, for example, a front wheel 12F and a rear wheel 12R. The vehicle body 14 includes, for example, a frame 16. To the frame 16, for example, a saddle is attached.

The human-powered vehicle 10 further includes, for example, a crank 18 to which human-powered driving force is input. The crank 18 includes, for example, a crank shaft 20 that is rotatable relative to the frame 16, and a crank arm 22. The crank arm 22 includes, for example, a first crank arm 22A and a second crank arm 22B. The first crank arm 22A and the second crank arm 22B are provided, for example, at both axial ends of the crank shaft 20, respectively.

For example, pedals 24 are connected to the crank arm 22. The pedals 24 include, for example, a first pedal 24A and a second pedal 24B. For example, the first pedal 24A is connected to the first crank arm 22A. For example, the second pedal 24B is connected to the second crank arm 22B. For example, a front fork 26 is connected to the frame 16. For example, a front wheel 12F is attached to the front fork 26. For example, a handlebar 28 is connected to the front fork 26 via a stem 30. The rear wheel 12R is supported by the frame 16, for example.

In this embodiment, the crank 18 is connected to the rear wheel 12R by the drive mechanism 32. The rear wheel 12R is driven, for example, by the rotation of the crankshaft 20. At least one of the front wheel 12F and the rear wheel 12R may be connected to the crank 18 by the drive mechanism 32. The drive mechanism 32 includes, for example, at least one first rotating body 34 connected to the crankshaft 20. The at least one first rotating body 34 includes, for example, a front sprocket. The at least one first rotating body 34 may include a pulley or a bevel gear. The crankshaft 20 may be connected to the front sprocket via a one-way clutch.

The drive mechanism 32 further includes, for example, at least one second rotating body 36 and a transmission body 38. The transmission body 38 is configured to transmit, for example, the rotational force of the at least one first rotating body 34 to the at least one second rotating body 36. The transmission body 38 includes, for example, a chain. The transmission body 38 may include a belt or a shaft. The at least one second rotating body 36 includes, for example, a rear sprocket. The at least one second rotating body 36 may include a pulley or a bevel gear. The chain is wound around, for example, the front sprocket and the rear sprocket. The at least one second rotating body 36 is connected to, for example, the rear wheel 12R. The rear wheel 12R is configured to rotate, for example, with the rotation of the at least one second rotating body 36.

The at least one second rotating body 36 and the rear wheel 12R may be connected via a first one-way clutch. The first one-way clutch includes, for example, at least one of a roller clutch, a sprag clutch, and a ratchet clutch. When the at least one second rotating body 36 rotates in association with the forward rotation of the at least one first rotating body 34, the first one-way clutch transmits a driving force from the at least one second rotating body 36 to the rear wheel 12R. The first one-way clutch is configured to allow relative rotation between the rear wheel 12R and the at least one second rotating body 36 when the speed at which the rear wheel 12R rotates forward is higher than the speed at which the at least one second rotating body 36 rotates forward.

The human-powered vehicle 10 further includes, for example, a battery 40. The battery 40 includes one or more battery elements. The battery elements include a rechargeable battery. The battery 40 is configured to supply power to, for example, a component 50 for the human-powered vehicle. The battery 40 is connected to, for example, the component 50 so as to be able to communicate with it via wires or wirelessly. The battery 40 can communicate with the component 50 via, for example, power line communication (PLC), a controller area network (CAN), or a universal asynchronous receiver/transmitter (UART).

The component 50 for a human-powered vehicle includes, for example, an electric motor 52. The component 50 is, for example, at least one of a drive unit 54, an electric transmission, an electric adjustable seat post, and an electric suspension. In this embodiment, the component 50 is the drive unit 54. Hereinafter, the component 50 will be described as the drive unit 54.

The drive unit 54 includes, for example, an electric motor 52. The electric motor 52 is configured to provide a propulsive force to the human-powered vehicle 10. The electric motor 52 is configured, for example, to drive the transmission body 38. The electric motor 52 is configured to provide a propulsive force to the human-powered vehicle 10, for example, in response to the human-powered driving force. The electric motor 52 includes, for example, one or more electric motors. The electric motor 52 is, for example, a brushless motor. The electric motor 52 is configured, for example, to transmit a rotational force to at least one member included in the power transmission path of the human-powered driving force from the first pedal 24A and the second pedal 24B to at least one second rotating body 36.

The electric motor 52 of this embodiment is an inner rotor type motor. The electric motor 52 may be an outer rotor type motor. The electric motor 52 for a human-powered vehicle includes, for example, a stator 70 and a rotor 56 that can rotate relative to the stator 70. The rotor 56 is formed of a metal material. The rotor 56 has, for example, a hole 56A that penetrates in a first direction Y1 parallel to the central axis A1 of the stator 70. For example, at least a portion of the rotor 56 is disposed inside the rotor 56. The electric motor 52 of this embodiment is an inner rotor type motor. The electric motor 52 is, for example, a brushless motor.

The electric motor 52 further includes, for example, an output shaft 58. The output shaft 58 is provided, for example, in the hole 56A. The rotation axis of the output shaft 58 coincides with the central axis A1 of the stator 70. The output shaft 58 transmits the rotational force of the electric motor 52 to at least one of the members included in the power transmission path of the human-powered driving force from, for example, the first pedal 24A and the second pedal 24B to at least one second rotating body 36.

In this embodiment, the electric motor 52 is configured to drive the transmission body 38, for example, via at least one first rotating body 34. The electric motor 52 is configured to be provided, for example, on the frame 16 and to transmit rotational force to at least one first rotating body 34. The electric motor 52 may be configured to drive the transmission body 38 via the second rotating body 36. The electric motor 52 may be provided on the hub of the human-powered vehicle 10 and to transmit rotational force to the second rotating body 36.

The drive unit 54 further includes, for example, a housing 60. The housing 60 is attached to the frame 16. The housing 60 rotatably supports the crankshaft 20. The electric motor 52 may be configured to transmit a rotational force to the transmission body 38 without passing through at least one first rotating body 34. When the electric motor 52 is configured to transmit a rotational force to the transmission body 38 without passing through at least one first rotating body 34, for example, a sprocket that engages with the transmission body 38 is provided on the output shaft 58 or a member to which the force of the output shaft 58 is transmitted.

The drive unit 54 further includes, for example, an output section 62. The output section 62 and the crankshaft 20 are, for example, arranged coaxially. The output section 62 is, for example, configured to transmit a manual driving force and the output of the electric motor 52. The output section 62 is, for example, configured to transmit a rotational force of the crankshaft 20 and the output of the electric motor 52. The output section 62 is, for example, formed in a cylindrical shape. The output section 62 is, for example, provided on the outer periphery of the crankshaft 20 around the central axis B1 of rotation of the crankshaft 20. At least one first rotor 34 is, for example, connected to an end 62A of the output section 62 so as to rotate integrally with the output section 62.

The drive unit 54 includes, for example, a reducer 64. The reducer 64 is provided, for example, between the electric motor 52 and the power transmission path of the human-powered driving force. The reducer 64 includes, for example, at least one reduction section. The at least one reduction section includes, for example, a first reduction section 64A, a second reduction section 64B, and a third reduction section 64C. The reducer 64 may include one, two, or four or more reduction sections.

The first reduction gear portion 64A, for example, transmits the rotational torque of the electric motor 52. The first reduction gear portion 64A includes, for example, two gears that mesh with each other. The first reduction gear portion 64A may include a belt and a pulley instead of the gears. The first reduction gear portion 64A may include a sprocket and a chain instead of the gears.

The second reduction gear portion 64B receives the rotational torque of the electric motor 52 via the first reduction gear portion 64A, for example. The second reduction gear portion 64B includes, for example, two gears that mesh with each other. The second reduction gear portion 64B may include a belt and pulley instead of the gears. The second reduction gear portion 64B may include a sprocket and chain instead of the gears.

The third reduction gear portion 64C transmits the rotational torque of the electric motor 52, for example, via the second reduction gear portion 64B. The third reduction gear portion 64C transmits the rotational torque of the electric motor 52 to the output portion 62, for example. The third reduction gear portion 64C includes, for example, two gears that mesh with each other. The third reduction gear portion 64C may include a belt and a pulley instead of the gears. The third reduction gear portion 64C may include a sprocket and a chain instead of the gears.

The drive unit 54 further includes, for example, a second one-way clutch 66. The second one-way clutch 66 is provided, for example, in the power transmission path from the crankshaft 20 to at least one of the first rotors 34. The second one-way clutch 66 is provided, for example, between the crankshaft 20 and the output section 62.

The second one-way clutch 66 rotates at least one first rotating body 34 forward, for example, when the crankshaft 20 rotates forward. The second one-way clutch 66 is configured to allow relative rotation between the crankshaft 20 and at least one first rotating body 34, for example, when the crankshaft 20 rotates backward. The second one-way clutch 66 includes at least one of a roller clutch, a sprag clutch, and a ratchet clutch, for example.

The drive unit 54 further includes, for example, a third one-way clutch 68. The third one-way clutch 68 is provided, for example, in the power transmission path from the electric motor 52 to at least one first rotor 34. The third one-way clutch 68 is provided, for example, in the reducer 64.

The third one-way clutch 68 is configured, for example, to transmit the rotational force of the electric motor 52 to the output section 62. The third one-way clutch 68 is configured, for example, to suppress the transmission of the rotational force of the crankshaft 20 to the electric motor 52 when the crankshaft 20 rotates forward. The third one-way clutch 68 includes, for example, at least one of a roller clutch, a sprag clutch, and a ratchet clutch.

At least a portion of the electric motor 52 is housed, for example, in the internal space of the housing 60. The rotor 56 is rotatably supported, for example, in the housing 60. The rotor 56 may be rotatably supported, for example, via an output shaft 58, in the housing 60. The stator 70 is supported, for example, in the housing 60. The electric motor 52 may include a motor housing formed separately from the housing 60, and may be provided in the housing 60 by attaching the motor housing to the housing 60.

The stator 70 of the electric motor 52 for a human-powered vehicle includes a stator core 72, a plurality of insulating members 74, and a coil 76. The stator core 72 includes a yoke 78 and a plurality of teeth 80 protruding from the yoke 78. The coil 76 includes, for example, at least one winding 76A. The winding 76A is wound around each tooth 80, for example, via a plurality of insulating members 74. The winding 76A is, for example, an insulated wire. The electric motor 52 constitutes an AC motor. In this embodiment, the electric motor 52 constitutes a three-phase AC motor. Each winding 76A wound around each tooth 80 is star-connected (Y-connected) or delta-connected (Δ-connected). The method of connecting the coils 76 in a three-phase AC motor is publicly known, so a description thereof will be omitted.

The yoke 78 is formed, for example, in a cylindrical shape. The rotor 56 is disposed, for example, inside the yoke 78 in a radial direction R1 relative to the central axis A1 of the stator 70. The teeth 80 protrude from the yoke 78, for example, in the radial direction R1. The radial direction R1 is, for example, a direction perpendicular to the central axis A1.

The stator core 72 includes a plurality of split cores 82 arranged in the circumferential direction X1 with respect to the central axis A1 of the stator 70. The plurality of split cores 82 are arranged, for example, in a circular shape centered on the central axis A1. The number of the plurality of split cores 82 is, for example, equal to the number of the plurality of teeth 80. In this embodiment, each of the plurality of split cores 82 has one tooth 80. In this embodiment, the number of the plurality of split cores 82 is 12, and the number of the plurality of teeth 80 is also 12, so that the electric motor 52 is a 12-pole electric motor. The plurality of split cores 82 are formed, for example, from a magnetic metal material. Each of the plurality of split cores 82 is formed, for example, by stacking a plurality of electromagnetic steel sheets in a first direction Y1 parallel to the central axis A1.

Each of the multiple split cores 82 includes a yoke portion 78A that constitutes a part of the yoke 78, and at least one of the multiple teeth 80 provided on the yoke portion 78A. The multiple split cores 82 are arranged in the circumferential direction X1 with respect to the central axis A1 of the stator 70, for example, so that each yoke portion 78A forms a circular ring shape as a whole. By arranging the yoke portions 78A to form a circular ring shape, the yoke 78 is formed into a cylindrical shape.

Each of the multiple split cores 82 includes, for example, one of the multiple teeth 80. One split core 82 includes, for example, a yoke portion 78A and one tooth 80. The yoke portion 78A is, for example, formed integrally with the tooth 80. In each split core 82, the tooth 80 protrudes from the yoke portion 78A, for example, toward the inside in the radial direction R1. The multiple teeth 80 protrude, for example, from the inner wall surface 78B of the yoke portion 78A toward the central axis A1 of the stator 70. The free ends 80A of the multiple teeth 80 in the radial direction R1 each protrude in the circumferential direction X1 relative to the central axis A1 of the stator 70. The shape of the multiple teeth 80 can be determined using known techniques.

Each yoke portion 78A of the multiple split cores 82 includes a first core end face 82A in the circumferential direction X1 and a second core end face 82B on the opposite side of the first core end face 82A in the circumferential direction X1. The first core end face 82A and the second core end face 82B are formed parallel to the central axis A1 of the stator 70. For example, the first core end face 82A of one of the yoke portions 78A contacts the second core end face 82B of another of the yoke portions 78A in the circumferential direction X1.

The multiple split cores 82 include, for example, a first split core 84 and a second split core 86 that are adjacent to each other in the circumferential direction X1. The first core end surface 82A of the first split core 84 contacts, for example, the second core end surface 82B of the second split core 86.

The insulating members 74 are arranged side by side in the circumferential direction X1. The insulating members 74 electrically insulate the split cores 82 from the coil 76, for example. The insulating members 74 include, for example, a resin material. The insulating members 74 are attached to the teeth 80, for example. One insulating member 74 is attached to one tooth 80, for example. The number of insulating members 74 is equal to the number of split cores 82, for example. The insulating members 74 include, for example, 12 insulating members 74.

Each of the insulating members 74 includes, for example, a first end 74A and a second end 74B in the first direction Y1. Each of the insulating members 74 includes, for example, a first end portion 74C including the first end 74A and a second end portion 74D including a second end portion 74B formed separately from the first end portion 74C. The end of the first end portion 74C on the second end portion 74D side has, for example, a shape corresponding to the end of the first end portion 74C of the second end portion 74D. The first end portion 74C and the second end portion 74D have, for example, the same shape. The first end portion 74C and the second end portion 74D may have different shapes. The first end portion 74C and the second end portion 74D are arranged to face opposite each other in the first direction Y1, for example. The first end portion 74C and the second end portion 74D are arranged, for example, so as not to contact each other. The gap between the first end portion 74C and the second end portion 74D in the first direction Y1 is equal to or smaller than the diameter of the winding 76A. The first end portion 74C and the second end portion 74D may be arranged so that at least a portion of them are in contact with each other.

The insulating members 74 include a first portion 74E that covers a portion of the yoke 78, and a second portion 74F that covers at least a portion of the teeth 80. The coil 76 is wound around the second portion 74F, for example. The first portion 74E extends in the circumferential direction X1 and the first direction Y1, for example. The second portion 74F has, for example, a cylindrical portion 74K that extends in the radial direction R1 from the first portion 74E, and a flange portion 74N that extends in the circumferential direction X1 and the first direction Y1 from the insulating member free end portion 74M of the cylindrical portion 74K. The flange portion 74N is formed to surround the tooth free end portion 80A in the radial direction R1 of the teeth 80. The flange portion 74N prevents the winding 76A wound around the cylindrical portion 74K from moving inward in the radial direction R1. The cylindrical portion 74K is formed, for example, in a rectangular cylindrical shape. At least one notch 74P is formed in the corners of the outer peripheral surface of the cylindrical portion 74K to suppress misalignment of the winding 76A wound around the cylindrical portion 74K. At least one notch 74P is formed at equal intervals in the radial direction R1 in each corner of the outer peripheral surface of the cylindrical portion 74K. The multiple insulating members 74 are provided on each split core 82 so that the free end faces 80B of the multiple teeth 80 in the radial direction R1 are exposed.

The first portion 74E covers, for example, at least a part of the inner wall surface 78B of the yoke portion 78A. The second portion 74F covers, for example, both end faces of the teeth 80 in the first direction Y1 and both end faces of the teeth 80 in the circumferential direction X1. The first end portion 74C includes, for example, at least a part of the first portion 74E and at least a part of the second portion 74F. The second end portion 74D includes, for example, at least a part of the first portion 74E and at least a part of the second portion 74F. The first end portion 74C covers, for example, one end face of the teeth 80 in the first direction Y1 and at least a part of the inner wall surface 78B. The second end portion 74D covers, for example, the other end face of the teeth 80 in the first direction Y1 and at least a part of the inner wall surface 78B.

Each of the insulating members 74 includes a first insulating end surface 74G in the circumferential direction X1 and a second insulating end surface 74H opposite the first insulating end surface 74G in the circumferential direction X1. The first insulating end surface 74G is provided at one end of the first portion 74E in the circumferential direction X1, and the second insulating end surface 74H is provided at the other end of the first portion 74E in the circumferential direction X1. The insulating members 74 are arranged such that, for example, the first insulating end surface 74G and the second insulating end surface 74H adjacent to each other in the circumferential direction X1 do not contact each other. The insulating members 74 may be arranged such that, for example, at least a portion of the first insulating end surface 74G and the second insulating end surface 74H adjacent to each other in the circumferential direction X1 contact each other.

The first insulating end face 74G and the second insulating end face 74H each have a non-parallel portion 88 extending in a second direction Y2 different from the first direction Y1 parallel to the central axis A1 of the stator 70. The non-parallel portion 88 overlaps the stator core 72 when viewed from the radial direction R1 relative to the central axis A1 of the stator 70. By providing the non-parallel portion 88 on the first insulating end face 74G, at least a portion of the first insulating end face 74G extends in a direction different from the first direction Y1. The non-parallel portion 88 is provided, for example, on at least a portion of the first insulating end face 74G. The non-parallel portion 88 may be provided on the entire first insulating end face 74G, or may be provided only on a portion of the first insulating end face 74G. By providing the non-parallel portion 88 on the second insulating end face 74H, at least a portion of the second insulating end face 74H extends in a direction different from the first direction Y1. The non-parallel portion 88 is provided, for example, on at least a portion of the second insulating end surface 74H. The non-parallel portion 88 may be provided on the entire second insulating end surface 74H, or may be provided on only a portion of the second insulating end surface 74H.

In this embodiment, the non-parallel portion 88 of the first insulating end surface 74G is provided on a portion of the first insulating end surface 74G. The portion of the first insulating end surface 74G different from the non-parallel portion 88 extends substantially parallel to the first direction Y1. In this embodiment, the non-parallel portion 88 of the second insulating end surface 74H is provided on a portion of the second insulating end surface 74H. The portion of the second insulating end surface 74H different from the non-parallel portion 88 extends substantially parallel to the first direction Y1.

The non-parallel portion 88 of the first insulating end surface 74G and the non-parallel portion 88 of the second insulating end surface 74H are, for example, located at substantially the same position in the first direction Y1. The non-parallel portion 88 of the first insulating end surface 74G and the non-parallel portion 88 of the second insulating end surface 74H have, for example, corresponding shapes.

The first insulating end surface 74G and the second insulating end surface 74H are provided, for example, on the first end side portion 74C and the second end side portion 74D, respectively. The non-parallel portion 88 is provided, for example, on the first end side portion 74C and the second end side portion 74D, respectively. The non-parallel portion 88 may be provided only on the first end side portion 74C, or may be provided only on the second end side portion 74D.

The non-parallel portion 88 is formed by, for example, at least one of a convex portion 88A and a concave portion 88B. When the convex portion 88A is provided on the first insulating end surface 74G, the convex portion 88A protrudes, for example, toward the second insulating end surface 74H adjacent to the first insulating end surface 74G. When the convex portion 88A is provided on the second insulating end surface 74H, the convex portion 88A protrudes, for example, toward the first insulating end surface 74G adjacent to the second insulating end surface 74H. When the concave portion 88B is provided on the first insulating end surface 74G, the concave portion 88B is recessed, for example, toward the opposite side of the second insulating end surface 74H adjacent to the first insulating end surface 74G. When the concave portion 88B is provided on the second insulating end surface 74H, the concave portion 88B is recessed, for example, toward the opposite side of the first insulating end surface 74G adjacent to the second insulating end surface 74H.

The non-parallel portion 88 includes, for example, both a convex portion 88A and a concave portion 88B. For example, one of the first insulating end surface 74G and the second insulating end surface 74H includes a convex portion 88A, and the other of the first insulating end surface 74G and the second insulating end surface 74H includes a concave portion 88B. At least one of the convex portion 88A and the concave portion 88B is provided, for example, on at least one of the first end side portion 74C and the second end side portion 74D. At least one of the convex portion 88A and the concave portion 88B is provided, for example, on both the first end side portion 74C and the second end side portion 74D.

When the diameter of the coil 76 is 1, the length L1 of the protruding portion 88A is, for example, 0.2 or more and less than 1. When the diameter of the coil 76 is 1, the length L2 of the recessed portion 88B is, for example, 0.2 or more and less than 1. The length L1 of the protruding portion 88A is, for example, equal to the length L2 of the recessed portion 88B. For example, at least the step portion of the protruding portion 88A and the recessed portion 88B extends in the second direction Y2. The length of the protruding portion 88A in the first direction Y1 is, for example, 1/3 or more and less than 2/3 of the length of the stator in the first direction Y1. The length of the recessed portion 88B in the first direction Y1 is, for example, 1/3 or more and less than 2/3 of the length of the stator in the first direction Y1. In this embodiment, the length of the protruding portion 88A in the first direction Y1 is equal to the length of the recessed portion 88B in the first direction Y1.

The multiple insulating members 74 include, for example, a first insulating member 90 provided on the first split core 84 and a second insulating member 92 provided on the second split core 86. The first split core 84 and the second split core 86 are, for example, any two split cores 82 adjacent to each other in the circumferential direction X1 among the multiple split cores 82. The first insulating member 90 and the second insulating member 92 are, for example, any two insulating members 74 adjacent to each other in the circumferential direction X1 among the multiple insulating members 74. The first insulating end surface 74G of the first insulating member 90 and the second insulating end surface 74H of the second insulating member 92 have, for example, complementary shapes.

A first gap 94 is formed between the first insulating end surface 74G of the first insulating member 90 and the second insulating end surface 74H of the second insulating member 92. The first gap 94 is also formed, for example, between the first insulating member 90 and the insulating member 74 other than the second insulating member 92 among the multiple insulating members 74. The first gap 94 is also provided in a portion corresponding to the non-parallel portion 88. The size L3 of the first gap 94 is, for example, within a predetermined range in any portion of the first direction Y1. The size L3 of the first gap 94 when the diameter of the coil 76 is 1 is, for example, 0 or more and less than 1. The size L3 of the first gap 94 when the diameter of the coil 76 is 1 is, for example, 0.2 or more and less than 0.8. The size L3 of the first gap 94 is, for example, equal to or less than the diameter of the winding 76A. The size L3 of the first gap 94 is, for example, a size suitable for the dimensional tolerance of the insulating member 74 when assembling the stator 70. The first gap 94 does not extend in a linear direction due to at least one of the protrusion 88A and the recess 88B.

The assembly process of the stator 70 includes, for example, a first step, a second step, and a third step. The assembly process of the stator 70 is performed in the order of the first step, the second step, and the third step.

The first step is a step of attaching one of the insulating members 74 to each of the multiple split cores 82. The multiple insulating members 74 are formed in advance by, for example, resin molding such as injection molding. In the first step, the first end side portion 74C is attached to each of the multiple split cores 82 so as to cover one end face of the multiple teeth 80 in the first direction Y1. In the first step, the second insulating end face 74H is attached to each of the multiple split cores 82 so as to cover the other end face of the multiple teeth 80 in the first direction Y1. When the first step is completed, the multiple split cores 82 have at least a part of the inner wall surface 78B of the yoke portion 78A covered by the first portion 74E, and at least a part of the multiple teeth 80 covered by the second portion 74F.

The second step is a step of forming the coil 76 by winding the winding 76A around each of the multiple teeth 80. One winding 76A is wound around each tooth 80. Two lead wires are drawn out from one end and the other end of each winding 76A. In the second step, the winding 76A is wound around the multiple teeth 80 by a winding machine via the second portions 74F of the multiple insulating members 74. The winding machine is, for example, a flyer-type winding machine. The winding machine may also be a nozzle-type winding machine.

The third step is a step of assembling the multiple split cores 82 into an annular shape. In the third step, for example, the 12 split cores 82 are arranged in the circumferential direction X1 so that the yoke portion 78A of each of the split cores 82 is annular. In the third step, the multiple teeth 80 are arranged, for example, so as to protrude from the inner wall surface 78B of the yoke portion 78A in the radial direction R1. In the third step, the multiple insulating members 74 are also arranged so as to be aligned in the circumferential direction X1, so that a first gap 94 is formed between two adjacent insulating members 74 among the multiple insulating members 74.

In the first step, the non-parallel portion 88 of one insulating member 74 comes into contact in the first direction Y1 with the non-parallel portion 88 of another insulating member 74 adjacent thereto in the circumferential direction X1, thereby suppressing misalignment in the first direction Y1 between one insulating member 74 and the other insulating member 74 adjacent thereto in the circumferential direction X1.

After the third step, for example, the two lead wires drawn from each tooth 80 are connected to at least one of the other lead wires directly or via a bus bar or the like. The part of the winding 76A that is connected to the lead wire can move relative to the tooth 80 from after the second step until the lead wire is connected. The lead wire is connected to the other lead wire, for example, in a state in which the part of the winding 76A that is connected to the lead wire is appropriately stretched. Since the insulating member 74 includes at least one of the protrusions 88A and the recesses 88B, it is difficult to form a state in which the part of the winding 76A that is connected to the lead wire moves to the first gap 94 after the third step and the third step. Therefore, it is easy to form a state in which the part of the winding 76A that is connected to the lead wire is appropriately stretched, improving the manufacturing efficiency of the stator 70.

Second Embodiment
A stator 70 of an electric motor 52 for a human-powered vehicle according to a second embodiment will be described with reference to Figures 12 and 13. Components of the stator 70 of an electric motor 52 for a human-powered vehicle according to the second embodiment that are common to the first embodiment are given the same reference numerals as in the first embodiment, and duplicated descriptions will be omitted.

The non-parallel portion 88 of the second embodiment includes an inclined surface 96 that is inclined with respect to the first direction Y1. The angle D of the inclined surface 96 with respect to the first direction Y1 is, for example, 10 degrees or more and less than 60 degrees. The angle D of the inclined surface 96 with respect to the first direction Y1 is, for example, 30 degrees or more and less than 60 degrees. The first end side portion 74C and the second end side portion 74D of the second embodiment include, for example, the same shape. In the second embodiment, the second direction Y2 corresponds to the inclination direction of the inclined surface 96.

The inclined surface 96 includes, for example, a first inclined surface 96A provided on the first insulating end surface 74G of the first end side portion 74C, and a second inclined surface 96B provided on the second insulating end surface 74H of the first end side portion 74C. The first inclined surface 96A is, for example, substantially parallel to the second inclined surface 96B. The angle D1 of each of the first inclined surface 96A and the second inclined surface 96B with respect to the first direction Y1 is, for example, 10 degrees or more and less than 60 degrees. The angle D1 of each of the first inclined surface 96A and the second inclined surface 96B with respect to the first direction Y1 is, for example, 30 degrees or more and less than 60 degrees.

The inclined surface 96 includes, for example, a third inclined surface 96C provided on the first insulating end surface 74G of the second end side portion 74D, and a fourth inclined surface 96D provided on the second insulating end surface 74H of the second end side portion 74D. The third inclined surface 96C is, for example, substantially parallel to the fourth inclined surface 96D. The angle D2 of each of the third inclined surface 96C and the fourth inclined surface 96D with respect to the first direction Y1 is, for example, 10 degrees or more and less than 60 degrees. The angle D2 of each of the third inclined surface 96C and the fourth inclined surface 96D with respect to the first direction Y1 is, for example, 30 degrees or more and less than 60 degrees.

Angle D1 is, for example, equal to angle D2. The first inclined surface 96A and the second inclined surface 96B are, for example, inclined in the opposite direction to the third inclined surface 96C and the fourth inclined surface 96D with respect to the first direction Y1. Therefore, the first gap 94 does not extend in a linear direction.

Each of the first inclined surface 96A and the second inclined surface 96B includes, for example, an end portion of the first end portion 74C on the second end portion 74D side in the first direction Y1. Each of the third inclined surface 96C and the fourth inclined surface 96D includes, for example, an end portion of the second end portion 74D on the first end portion 74C side in the first direction Y1. The position of the end portion of the first inclined surface 96A on the second end portion 74D side in the circumferential direction X1 is different, for example, from the position of the end portion of the third inclined surface 96C on the first end portion 74C side in the circumferential direction X1. The position of the end portion of the second inclined surface 96B on the second end portion 74D side in the circumferential direction X1 is different, for example, from the position of the end portion of the fourth inclined surface 96D on the first end portion 74C side in the circumferential direction X1.

The first inclined surface 96A and the third inclined surface 96C are inclined in the opposite direction to the second inclined surface 96B and the fourth inclined surface 96D with respect to the first direction Y1, for example, so that the portion of the winding 76A that is continuous with the outlet wire is unlikely to move to the first gap 94 after the third step and the third step. Therefore, the portion of the winding 76A that is continuous with the outlet wire is likely to be appropriately stretched, improving the manufacturing efficiency of the stator 70.

<Example of change>
The explanations of each embodiment are examples of forms that the stator of an electric motor for a human-powered vehicle, the electric motor for a human-powered vehicle, and the components for a human-powered vehicle according to the present disclosure may take, and are not intended to limit the forms. The stator of an electric motor for a human-powered vehicle, the electric motor for a human-powered vehicle, and the components for a human-powered vehicle according to the present disclosure may take forms, for example, modified examples of each embodiment shown below, or a combination of at least two modified examples that are not mutually contradictory. In the modified examples below, parts that are common to each embodiment are given the same reference numerals as each embodiment, and their explanations are omitted.

- In the first and second embodiments, one, two, or three of the first insulating end face 74G of the first end portion 74C, the second insulating end face 74H of the first end portion 74C, the first insulating end face 74G of the second end portion 74D, and the second insulating end face 74H of the first end portion 74C may not include the non-parallel portion 88. The surfaces that do not include the non-parallel portion 88 of the first insulating end face 74G of the first end portion 74C, the second insulating end face 74H of the first end portion 74C, the first insulating end face 74G of the second end portion 74D, and the second insulating end face 74H of the first end portion 74C are, for example, parallel to the first direction Y1.

- In the second embodiment, the inclination direction of at least one of the first inclined surface 96A, the second inclined surface 96B, the third inclined surface 96C, and the fourth inclined surface 96D may be changed. At least one of the first inclined surface 96A and the second inclined surface 96B, for example, inclines in the same direction as at least one of the third inclined surface 96C and the fourth inclined surface 96D with respect to the first direction Y1. The first inclined surface 96A, for example, inclines in a different direction from the second inclined surface 96B with respect to the first direction Y1. The third inclined surface 96C, for example, inclines in a different direction from the fourth inclined surface 96D with respect to the first direction Y1.

- As shown in Figs. 14 and 15, the non-parallel portion 88 may include a curved portion 88C. In Figs. 14 and 15, the second direction Y2 includes a direction along the curved portion 88C. The first insulating end face 74G of the first end portion 74C, the second insulating end face 74H of the first end portion 74C, the first insulating end face 74G of the second end portion 74D, and the second insulating end face 74H of the first end portion 74C each include, for example, a curved portion 88C. The curved portion 88C is formed, for example, in a wavy shape. The curved portion 88C may include one convex portion or one concave portion.

- As long as the non-parallel portion 88 extends in a second direction Y2 different from the first direction Y1 parallel to the central axis A1 of the stator 70, the shape of the non-parallel portion 88 can be changed as appropriate.

The term "at least one" as used herein means "one or more" of the desired options. As an example, the term "at least one" as used herein means "only one option" or "both of two options" if the number of options is two. As another example, the term "at least one" as used herein means "only one option" or "any combination of two or more options" if the number of options is three or more.

10...human-powered vehicle, 50...component, 52...electric motor, 54...drive unit, 56...rotor, 70...stator, 72...stator core, 74...insulating member, 74A...first end, 74B...second end, 74C...first end side portion, 74D...second end side portion, 74E...first portion, 74F...second portion, 74G...first insulating end surface, 74H...second insulating end surface, 76...coil, 78...yoke, 78A...yoke portion, 80...teeth, 82...split core, 82A...first core end surface, 82B...second core end surface, 84...first split core, 86...second split core, 88...non-parallel portion, 88A...convex portion, 88B...concave portion, 88C...curved portion, 90...first insulating member, 92...second insulating member, 94...first gap, 96...inclined surface.

Claims (17)

A stator for an electric motor for a human-powered vehicle, comprising:
a stator core including a yoke and a plurality of teeth protruding from the yoke;
a plurality of insulating members including a first portion covering a portion of the yoke and a second portion covering at least a portion of the plurality of teeth;
a coil wound around the second portion;
the stator core includes a plurality of split cores arranged in a circumferential direction about a central axis of the stator,
Each of the plurality of split cores is
A yoke portion constituting a part of the yoke;
at least one of the plurality of teeth provided in the yoke portion;
the yoke portions of each of the plurality of split cores include a first core end surface in the circumferential direction and a second core end surface opposite to the first core end surface in the circumferential direction,
the first core end surface and the second core end surface are formed parallel to the central axis of the stator,
The insulating members are arranged side by side in the circumferential direction,
Each of the insulating members includes a first insulating end surface in the circumferential direction and a second insulating end surface opposite to the first insulating end surface in the circumferential direction,
the first insulating end surface and the second insulating end surface each have a non-parallel portion extending in a second direction different from a first direction parallel to the central axis of the stator,
A stator, wherein the non-parallel portion overlaps the stator core when viewed in a radial direction relative to the central axis of the stator. The stator of claim 1, wherein the non-parallel portion is formed by at least one of a protrusion and a recess. The stator according to claim 2, wherein the length of the protrusion is greater than or equal to 0.2 and less than 1 when the diameter of the coil is 1. The stator according to claim 2, wherein the recessed length is 0.2 or more and less than 1 when the diameter of the coil is 1. The stator of claim 1, wherein the non-parallel portion includes an inclined surface that is inclined with respect to the first direction. The stator of claim 5, wherein the angle of the inclined surface with respect to the first direction is greater than or equal to 10 degrees and less than 60 degrees. The stator of claim 1, wherein the non-parallel portion includes a curved portion. The plurality of divided cores include a first divided core and a second divided core adjacent to each other in the circumferential direction,
the plurality of insulating members include a first insulating member provided on the first split core and a second insulating member provided on the second split core,
the first core end surface of the first split core is in contact with the second core end surface of the second split core,
The stator according to claim 1 , wherein a first gap is formed between the first insulating end surface of the first insulating member and the second insulating end surface of the second insulating member. The stator of claim 8, wherein the size of the first gap is greater than or equal to 0 and less than 1 when the diameter of the coil is 1. Each of the plurality of insulating members is
a first end and a second end in the first direction;
The stator according to claim 1 , comprising: a first end side portion including the first end; and a second end side portion including the second end formed separately from the first end side portion. The stator according to claim 10, wherein the non-parallel portion is provided on each of the first end portion and the second end portion. The stator of claim 1, wherein each of the plurality of split cores includes one of the plurality of teeth. The stator of claim 12, wherein the number of the insulating members is equal to the number of the split cores. 1. An electric motor for a human-powered vehicle, comprising:
A stator according to any one of claims 1 to 13;
a rotor rotatable relative to the stator. The yoke is formed in a cylindrical shape,
The electric motor of claim 14 , wherein the rotor is disposed radially inward of the yoke. A component for a human-powered vehicle, comprising:
A component comprising an electric motor according to claim 14. A drive unit,
The component of claim 16 , wherein the electric motor is configured to provide propulsive force to the human powered vehicle.

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