Abstract:
An axial gap dynamoelectric machine is provided with a stator core in which continuously wound coils ( 10   a,    10   d,    10   g,    10   j ) including a plurality of coils formed of continuously wound insulation-coated conductor wire are disposed in a circumferential direction with the continuously wound coils of the three phases overlapped. With the respective coils being disposed in a radiating shape, the continuously wound coils are configured so that on the inner diameter side of the coils, the insulation-coated conductor wires are continuously wound to adjacent coils via crossover wires ( 15 U 2, 15 U 3, 15 U 4, 15 U 5 ), and the coils are bent in the vertical direction and the continuously wound coils of each phase are made to overlap with each other so that the length (2×L 3 +L 2 ) of the crossover wires can be adjusted regardless of the core layer thickness (L 1 ) of the stator core. This configuration makes it possible to reduce copper loss, achieve a price reduction and improve durability, insulation properties and cooling performance of the axial gap dynamoelectric machine.

Description:
TECHNICAL FIELD 
       [0001]    The present invention relates to an axial gap dynamoelectric machine used as a motor or a dynamo or the like. 
       BACKGROUND ART 
       [0002]    In recent years, as global warming is becoming more and more serious, there is a growing demand for more energy-saving electric apparatuses. Power consumption by motors accounts for approximately 55% of annual power consumption in Japan, and therefore there is currently a high level of attention to highly efficient motors. Designs using rare earth magnets having a high energy product have been adopted so far to attain highly efficient motors. 
         [0003]    However, prices of Nd (neodymium) and Dy (dysprosium) which are raw materials of rare earth magnets are rising in recent years due to the export ceiling control by China which is the world&#39;s largest producer. The export control policy by China is intended to prevent environmental destruction caused by extraction of Nd and Dy, and rising prices of rare earths and supply shortage are likely to continue in the future. 
         [0004]    For this reason, axial gap motors are getting attention as one of means capable of realizing highly efficient motors using only ferrite magnets instead of rare earth magnets. Axial gap motors allow a wider magnet area to be secured than conventional radial gap ones, and can thereby compensate for deterioration in holding power when rare earth magnets are replaced by ferrite magnets and achieve efficiency equivalent to or higher than conventional efficiency. 
         [0005]    An axial gap motor is configured in various combinations such as 1-rotor/2-stator type, 2-rotor/1-stator type and 1-rotor/1-stator type. 
         [0006]    Patent Literature 1 described below shows a configuration in which four coils of the same phase are continuously wound and an axial gap motor (1-rotor/1-stator type) is formed using a Y-connection, and which is intended to reduce the motor price by reducing the number of connection points using the continuous winding. Moreover, by gathering crossover wires for connecting the coils on the inner diameter side of the coils, the coil outside diameter side is used as a free space and cooling performance is improved by causing the coil outside diameter side to contact the motor housing. 
         [0007]      FIG. 9  shows a winding device for manufacturing conventional four continuously wound coils corresponding to one phase. 
         [0008]    In this winding device, four winding bobbins are arranged in a line and mounted in split core back-and-forth adjustment mechanisms  21   a,    21   b,    21   c  and  21   d  that drive these bobbins back and forth.  FIG. 9  describes, as an example, a state after completing winding of up to a third core and immediately before starting winding of a fourth core. 
         [0009]    A nozzle  24   a  that supplies an insulation-coated conductor wire has a mechanism for transfer in three axial directions, can form inter-core crossover wires, and in this example, suppose the nozzle  24   a  is fixed and winding is performed by rotating an entire winding portion including a work. It goes without saying, however, that similar four continuous coils can be formed using a scheme in which the nozzle is rotated. 
         [0010]    After completion of winding of the third core, the split core back-and-forth adjustment mechanism  21   c  is made to retreat as illustrated, the split core back-and-forth adjustment mechanism  21   d  equipped with an empty bobbin is then made to move forward by a distance that a winding path can be secured. At this time, a crossover wire  25 U 4  is fixed by fixing pins  22   e  and  22   f,  but to secure the winding path, the split core back-and-forth adjustment mechanism  21   d  needs to move at a stroke equal to or greater than a core layer thickness L 1  of each core, and therefore the length of the crossover wire  25 U 4  is at least the core layer thickness L 1  or more. 
         [0011]    Once the crossover wire  25 U 4  is fixed by the fixing pins  22   e  and  22   f,  by rotating the entire winding portion around the split core back-and-forth adjustment mechanism  21   d  as a center, it is possible to wind the insulation-coated conductor wire around the bobbin. 
         [0012]    After completion of winding, the wire is cut at an end of the winding, the split core back-and-forth adjustment mechanism  21   d  is made to retreat to its original position and the winding is thereby completed. At this time, the crossover wire  25 U 4  is detached from the fixing pins  22   e  and  22   f  as with the crossover wires  25 U 2  and  25 U 3 , and remains floating. 
       CITATION LIST 
     Patent Literature 
       [0013]    Patent Literature 1: Japanese Patent Laid-Open Publication No. 2008-172859 
       SUMMARY OF INVENTION  
     Technical Problem 
       [0014]    After completion of the winding corresponding to the four cores, when a case of assembling a dynamoelectric machine is assumed as will be described later using  FIG. 4 , if the core layer thickness of the stator core is the length of the crossover wire in the diameter direction is L 3 , and the length in the circumferential direction is L 2 , an ideal length L of the crossover wire is 2×L 3 +L 2 . 
         [0015]    However, as described above, since the length of the crossover wire is inevitably the core layer thickness L 1  or more due to a minimum stroke of the split core back-and-forth adjustment mechanism in the winding device, if this length is greater than 2×L 3 +L 2 , an excess portion is generated, which causes mutual interference, making it difficult to assemble the four continuously wound coils corresponding to three phases. From the standpoint of providing a dynamoelectric machine with high output, when the length L 3  of the crossover wire in the diameter direction and the length L 2  of the crossover wire in the circumferential direction are minimized or the core layer thickness L 1  is increased to increase the lamination factor by applying high-density winding to each coil, there has been a problem that the excess portion of the crossover wire increases significantly, the crossover wires cause interference when continuously wound coils are created and assembled around the shaft, making assembly extremely difficult or causing durability or insulation properties to deteriorate. 
         [0016]    It is therefore an object of the present invention to provide an axial gap dynamoelectric machine capable of simply assembling, in an axial direction, a continuously wound coil densely wound with an insulation-coated conductor wire, reducing copper loss and reducing the price of the dynamoelectric machine by optimizing the length and arrangement of crossover wires, improving durability and insulation properties, and further improving cooling performance. 
       Solution to Problem 
       [0017]    In order to attain the object described above, an axial gap dynamoelectric machine of the present invention is provided with a stator core in which continuously wound coils including a plurality of coils formed of continuously wound insulation-coated conductor wire are disposed in a circumferential direction with the continuously wound coils of three phases overlapped, in which with the respective coils being disposed in a radiating shape, the continuously wound coils are configured so that on the inner diameter side of the coils, the insulation-coated conductor wires are continuously wound to adjacent coils via crossover wires, and the coils are bent in a vertical direction and the continuously wound coils of each phase are made to overlap with each other so that the length of the crossover wires can be adjusted regardless of the core layer thickness of the stator core. 
         [0018]    When each coil is bent in the vertical direction and continuously wound coils of each phase are overlapped with each other, if neutral points which are winding start ends of the insulation-coated conductor wires in each phase are arranged so as to be adjacent to each other in the inner circumference of the stator core, it is possible to integrate connection points into one point and further reduce the price of the motor. 
         [0019]    The length of the crossover wire is adjusted using the fixing pins provided in a winding jig that holds each cons in a radiating shape, and it is thereby possible to construct the crossover wire having an optimum shape and length. 
         [0020]    When bending each coil in the vertical direction and causing the continuously wound coils in each phase to overlap with each other, the crossover wire of the continuously wound coil in the circumferential direction is formed into an arc shape, and it is thereby possible to keep the distance constant in the diameter direction between the rotation shaft of the rotor and the crossover wire and further improve insulation properties. 
         [0021]    Furthermore, when each coil is bent in the vertical direction and the continuously wound coils in each phase are caused to overlap with each other, the crossover wires in each phase are disposed so as not to cause interference, and it is thereby possible to secure the spatial insulation distance. 
       Advantageous Effects of Invention 
       [0022]    As described above, according to the present invention, in order to provide a dynamoelectric machine with higher output, even when the length of the crossover wires in the diameter direction and length in the circumferential direction are minimized or the core layer thickness is maximized, it is possible to adjust the length of the crossover wires regardless of the core layer thickness of the stator core to increase the occupancy by densely winding a wire, and thereby reduce the price of the axial gap dynamoelectric machine, reduce copper loss, improve cooling performance and further increase durability and reliability. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0023]      FIG. 1  is a schematic diagram illustrating an arrangement of crossover wires of coils in each phase of a motor with a 12-slot motor which is an embodiment of the present invention. 
           [0024]      FIG. 2  is a connection wiring diagram of coils in each phase of a 12-slot motor which is an embodiment of the present invention. 
           [0025]      FIG. 3  is a schematic diagram illustrating an arrangement of four continuously wound coils of a U phase which is the embodiment of the present invention. 
           [0026]      FIG. 4  is a perspective view illustrating an arrangement of the four continuously wound coils of a U phase which is the embodiment of the present invention. 
           [0027]      FIG. 5  is a perspective view illustrating an arrangement of the four continuously wound coils of a U phase which is the embodiment of the present invention when the core layer thickness is greater than the length of the crossover wires. 
           [0028]      FIG. 6  is a perspective view illustrating a configuration of a winding device for manufacturing four continuously wound coils corresponding to one phase, which is the embodiment of the present invention, also applicable to a case where a core layer thickness is greater than the length of the crossover wire. 
           [0029]      FIG. 7  is a diagram illustrating each coil of the four continuously wound coils corresponding to one phase, which is the embodiment of the present invention, with each coil turned back by 90° vertically within the vertical plane in the diameter direction using the crossover wire as a reference. 
           [0030]      FIG. 8  is a cross-sectional view of a first coil at the start of winding illustrating crossover wires of the continuously wound coils corresponding to two phases, which is the embodiment of the present invention, tilted in advance at different angles in the axial direction and the four continuously wound coils corresponding to three phases assembled in the axial direction. 
           [0031]      FIG. 9  is a perspective view illustrating a conventional winding device for manufacturing four continuously wound coils corresponding to one phase. 
       
    
    
     DESCRIPTION OF EMBODIMENTS 
       [0032]    Hereinafter, an embodiment will be described with reference to the accompanying drawings. 
       Embodiment 
       [0033]      FIG. 1  schematically illustrates an arrangement of crossover wires of coils of each phase of a 12-slot motor, which is an embodiment of the present invention. The “crossover wire” referred to here is defined as a name of an insulation-coated conductor wire portion that connects neighboring coils of continuously wound coils ( FIG. 1  shows four continuously wound coils). 
         [0034]    An axial gap motor  100  is provided with a stator core  1  as a stator configured by arranging in a ring shape, four coils with insulation-coated conductor wires continuously wound around an iron core  3 , in which a rotor  2  is disposed above and/or below the stator core  1 . The rotor  2  is connected to a rotation shaft (not shown) disposed at a center and is disposed at a certain distance from the stator core  1 . Though not shown, magnets are disposed in the circumferential direction with the N pole and S pole placed alternately on the stator core side of the rotor  2 . Note that the axial gap motor  100 , which will be described below, is an example, and it goes without saying that the number of coils in each phase, that is, the number of slots can be changed as appropriate. 
         [0035]    In the embodiment in  FIG. 1 , four U-phase coils  10   a,    10   d,    10   g  and  10   j  are continuously wound by a winding device, which will be described later using  FIG. 6 , via crossover wires. Note that the winding direction of the coils is the same for all the coils and all the crossover wires are integrated on the inner diameter side of the coils. 
         [0036]    The four V-phase coils  10   b,    10   e,    10   h  and  10   k  and the four W-phase coils  10   c,    10   f,    10   i  and  10   l  also have the same winding direction of continuously wound wires and the same arrangement of crossover wires. 
         [0037]    By arranging terminal wires which are wiring starting ends of the four U-phase continuously wound coils, four V-phase continuously wound coils and four W-phase continuously wound coils in mutually neighboring positions and connecting these three phase terminal wires via connection terminals or by welding, it is possible to cause the connected part to function as a neutral point  5 . 
         [0038]    As a result, it is possible to reduce the number of connection points to one point and thereby reduce the motor price. 
         [0039]    By integrating all the crossover wires on the coil inner diameter side, the coil outside diameter side becomes a free space, and it is possible to improve cooling performance of the motor, for example, by making the coil outside diameter side contact the motor housing. Furthermore, since respective input wires  4  of the four U-phase continuously wound coils, four V-phase continuously wound coils and four W-phase continuously wound coils can be necessarily arranged at neighboring positions, it is possible to guide these input wires so as not to contact the rotor  2  and lead them out of a motor case and thereby cause the stator core  1  to function as a stator. 
         [0040]      FIG. 2  illustrates a wire connection diagram of the stator core  1  in the axial gap motor  100  of the present embodiment. 
         [0041]    A U-phase coil  10 U is configured by connecting an input wire  15 U 1 , coil  10   a,  crossover wire  15 U 2 , coil  10   d,  crossover wire  15 U 3 , coil  10   g,  crossover wire  15 U 4 , coil  10   j  and terminal wire  15 U 5 . The coil winding direction is the same for all the coils. The configuration as well as the coil winding direction is also the same for the V-phase coil  10 V and W-phase coil  10 W. 
         [0042]    That is, the axial gap motor  100  of the present embodiment is made up of a four-series Y-connection using three sets of four continuously wound coils. As described above, the stator core functions as a stator by connecting a central point (N) of the U-phase coil  10 U, V-phase coil  10 V and W-phase coil  10 W as a neutral point. 
         [0043]    In order to illustrate the structure and arrangement of each four continuously wound coil,  FIG. 3  shows a schematic diagram and  FIG. 4  shows a perspective view using the coil U phase as an example. It goes without saying that the V-phase coil  10 V and the W-phase coil  10 W also have the same structure and arrangement. 
         [0044]    Here, when a core layer thickness of the stator core  1  is L 1 , a length in a diameter direction of the crossover wire is L 3 , and a length in a circumferential direction thereof is L 2 , and the circumferential direction of the crossover wire is assumed to be disposed along the outer circumference of the rotation shaft of the dynamoelectric machine located at the center, an ideal length L of the crossover wire is 2×L 3 +L 2  as is obvious from  FIG. 4 . 
         [0045]    By forming, in advance, the circumferential direction of the crossover wire in an arc shape, it is possible to bend the four continuously wound coils corresponding to three phases in the vertical direction and assemble them in the axial direction centered on the rotation shaft. 
         [0046]    Furthermore, as shown in  FIG. 1 , in areas where crossover wires cross each other between neighboring U phase and V phase, between neighboring V phase and W phase and between neighboring W phase and U phase, by setting the crossover wires  15 U 2 ,  15 V 2  and  15 W 2  to different angles with respect to the axial direction of the rotation shaft ( 15 U 2  is set to be horizontal,  15 V 2  is set at angle φ 1  and  15 W 2  is set at angle φ 2  in  FIG. 8 ) as shown in the example in  FIG. 8 , it is possible to prevent interference of wires in the intersection of crossover wires, prevent the wires from contacting each other and reliably prevent short circuits of the wires. 
         [0047]      FIG. 6  shows an example of a winding device for realizing an ideal length of the crossover wire when creating four continuously wound coils corresponding to one phase. 
         [0048]    Four winding bobbins are arranged at intervals of approximately 90° in the circumferential direction with respect to a winding jig  31 . Suppose the central axis of rotation of winding is substantially perpendicular to the axis of rotation of the winding jig  31 . 
         [0049]    Note that the number of winding bobbins is not limited to four, but can be changed depending on the number of coils of each phase and the angle interval in the circumferential direction may be set so as to adapt to the change. 
         [0050]    Here, as in the case of  FIG. 9 , a case will be described as an example where winding of up to a third core is completed and winding of a fourth core is started. In this example, a nozzle  24   b  that supplies an insulation-coated conductor wire has a mechanism for transfer in three axial directions, so that it can form a crossover wire in any given direction when starting winding onto the next bobbin. 
         [0051]    After completion of winding of the third core, the winding jig  31  is made to rotate by 90° around the vertical axis and an empty bobbin is caused to protrude on the axis of rotation of a winding support section  36 . At this time, a crossover wire  35 U 4  is fixed by fixing pins  32   e  and  32   f  with a transfer of the nozzle  24   b,  and wiring of the fourth core is made possible by causing the whole wiring section to rotate around a split core  30   j.  After completion of the wiring, the winding end wire is cut and the wiring is thereby completed. At this time, the crossover wires  35 U 2 ,  35 U 3  and  35 U 4  are not detached from the fixing pins and can maintain their desired shapes. 
         [0052]    Thus, since the winding bobbins are arranged in a radiating shape, any winding bobbin does not interfere with other winding bobbins during the winding and high-density winding is thereby made possible, and it is also possible to form crossover wires between the roots of the neighboring winding bobbins, and reduce the length L of the crossover wires regardless of the core layer thickness L 1  of the stator core unlike the prior art in which the length L of the crossover wires inevitably become the core layer thickness L 1  or more. 
         [0053]    That is, by adjusting the pin shape and arrangement positions of the fixing pins  32   e  and  32   f,  it is possible to set the length L of the crossover wires to an ideal length of the crossover wires of 2×L 3 +L 2  as shown in  FIG. 4  and further form the crossover wires into an arc shape by arranging a plurality of fixing pins on the circumference. It goes without saying that it is possible to use a winding device with the pin shape and arrangement changed for each U phase, V phase and W phase and to adjust the length and shape of the respective crossover wires to appropriate ones. 
         [0054]    When arc crossover wires are adopted, it is possible to further improve insulation properties by keeping the distance constant in the diameter direction between the rotation shaft of the rotor  2  and the crossover wires. 
         [0055]    When the winding of the four continuous coils is completed in this way, the four continuous coils are removed from the winding jig, the four continuous coils are then bent by 90° so that each coil is oriented toward the vertical direction within the vertical plane in the diameter direction of each coil with reference to the crossover wires  35 U 2 ,  35 U 3  and  35 U 4  as shown in  FIG. 7 , and it is thereby possible to form four continuous coils that can be assembled in the axial direction as shown in  FIG. 5  by setting the length L of the crossover wire to, for example, 2×L 3 +L 2 , while maintaining the crossover wire in a desired shape regardless of the core layer thickness L 1 ′ which may be large. 
         [0056]    Lastly, as shown in  FIG. 8 , by forming, in advance, the crossover wires  15 V 2  and  15 W 2  of the V-phase coil  10 V and W-phase coil  10 W so as to tilt at different angles φ 1  and φ 2  in the axial direction with respect to the U-phase coil  10 U, it is possible to assemble the four continuously wound coils corresponding to three phases in the axial direction. Here, a minimum value of φ 1  is defined by a spatial insulation distance between the U-phase reference coil  10 U and the V-phase coil  10 V, and a minimum value of φ 2  is likewise defined by a spatial insulation distance between the V-phase coil  10 V and the W-phase coil  10 W. 
         [0057]    Instead of this, when the winding end positions of the U-phase coil  10 U, V-phase coil  10 V and W-phase coil  10 W are made to differ from each other and the coils are bent back by 90° so that all the coils are oriented toward the vertical direction, the respective crossover wires may be made to have different heights. 
       REFERENCE SIGNS LIST 
       [0058]      1  Stator 
         [0059]      2  Rotor 
         [0060]      3  Iron core 
         [0061]      4  Input wire 
         [0062]      5  Neutral point 
         [0063]      10   a  to  10   l  Coil 
         [0064]      10 U U-phase coil 
         [0065]      10 V V-phase coil 
         [0066]      10 W W-phase coil 
         [0067]      15 U 1  Input wire 
         [0068]      15 U 2 ,  15 U 3 ,  15 U 4  Crossover wire 
         [0069]      15 U 5  Terminal wire 
         [0070]      15 V 1  Input wire 
         [0071]      15 V 2 ,  15 V 3 ,  15 V 4  Crossover wire 
         [0072]      15 V 5  Terminal wire 
         [0073]      15 W 1  Input wire 
         [0074]      15 W 2 ,  15 W 3 ,  15 W 4  Crossover wire 
         [0075]      15 W 5  Terminal wire 
         [0076]      20   a,    20   d,    20   g,    20   j  Split core 
         [0077]      21   a  to  21   d  Split core back-and-forth adjustment mechanism 
         [0078]      22   a  to  22   f  Fixing pin 
         [0079]      23   a  to  23   d  Winding bobbin fixing section 
         [0080]      24   a  Nozzle 
         [0081]      25 U 2 ,  25 U 3 ,  25 U 4  Crossover wire 
         [0082]      30   a,    30   d,    30   g,    30   j  Split core 
         [0083]      31  Winding jig 
         [0084]      32   a  to  32   f  Fixing pin 
         [0085]      33   c  to  33   d  Winding bobbin fixing section 
         [0086]      34  Winding Support section 
         [0087]      36  Winding Support section 
         [0088]      24   b  Nozzle 
         [0089]      35 U 2 ,  35 U 3 ,  35 U 4  Crossover wire 
         [0090]      100  Axial gap motor