Rotating electric machine

Slot accommodation portions of single coils forming an armature coil are arranged so as to be stacked in the radial direction in a slot. On the anti-wire-connection side, a one-side extending portion which is a coil end extending from the slot accommodation portion in the first layer, and a one-side extending portion which is a coil end extending from the slot accommodation portion in the second layer, extend in the same direction. No insulation sheet is provided in intervals between coil ends extending in the same direction, such as the extending portions (23b) and (21b) and extending portions (21d) and (22d).

TECHNICAL FIELD

The present invention relates to a rotating electric machine, in particular, to the insulation structure of coil ends of armature windings of the rotating electric machine.

BACKGROUND ART

In recent years, rotating electric machines such as motors and electric generators have been required to have a small size, high output, and high quality. In such a rotating electric machine required to have high output, high voltage is applied and therefore there is a great potential difference between winding bodies forming the armature windings, in particular, at coil ends.

Accordingly, a high-quality and high-output rotating electric machine is proposed in which insulation sheets are provided between the coil ends of the winding bodies to improve a dielectric strength at the coil ends (see, for example, Patent Document 1).

In addition, a high-quality, small-sized, and high-output rotating electric machine is proposed in which the thickness in the radial direction of conductive wires at a coil end parts is designed to be small to increase the thickness of insulators, thereby the dielectric strength is improved (see, for example, Patent Document 1).

CITATION LIST

Patent Document

SUMMARY OF THE INVENTION

Problems to be Solved by the Invention

In a rotating electric machine in which insulation sheets are provided between coil ends of winding bodies as described in Patent Document 1, since insulation sheets are provided among all layers of coil ends, the use amount of insulation sheets increases, thus a problem exists in that the manufacturing cost is increased.

In addition, there is a problem that the number of processes for providing insulation sheets to the coil ends increases and therefore it is difficult to improve the productivity.

In addition, in order to improve the dielectric strength of coil ends in response to requirement for further high output, it is necessary to increase the thickness of insulation sheets, and therefore the thickness in the radial direction of coil ends of the armature winding increases, and a problem exists in that the size of the rotating electric machine is increased.

In addition, in the rotating electric machine in which the thickness in the radial direction of conductive wires at coil end parts is designed to be small as described in Patent Document 1, it is possible to increase the thickness of insulation sheets without increasing the thickness in the radial direction of coil ends, and the dielectric strength of winding bodies can be further improved.

However, this rotating electric machine also has a problem that the manufacturing cost increases because a large amount of insulation sheets is used, and a problem that it is difficult to improve the productivity because the number of processes for providing insulation sheets increases.

In addition, since coil end parts of the winding bodies need to be machined, there is a problem that the number of manufacturing processes greatly increases and therefore it is difficult to improve the productivity.

The present invention has been made to solve the above problems, and an object of the present invention is to obtain a rotating electric machine that achieves improvement in the dielectric strength at coil ends of armature windings (hereinafter, referred to as armature coils), reduction in the use amount of insulation sheets, and decrease in the number of manufacturing processes, and that achieves high quality, size reduction, high output, cost reduction, and high productivity.

Means of Solution to the Problems

A first rotating electric machine according to the present invention includes an armature; and a rotor rotatably arranged on an inner circumferential side of the armature with a gap interposed therebetween. The armature includes an armature core, armature coils mounted to the armature core, and phase to phase insulators for insulating coil end parts of the armature coils. The armature coils are formed such that (4n+2) number of slot accommodation portions of single coils forming the armature coils are arranged so as to be stacked in a radial direction in slots of the armature core, n being a natural number. On an anti-wire-connection side, a coil end extending in a circumferential direction from the slot accommodation portion in a first layer on an innermost side in the radial direction in the slot and a coil end extending in the circumferential direction from the slot accommodation portion in a second layer extend toward the same direction, or a coil end extending in the circumferential direction from the slot accommodation portion in a (4n+1)th layer and a coil end extending in the circumferential direction from the slot accommodation portion in a (4n+2)th layer extend toward the same side. The phase to phase insulators are provided between the coil ends that extend toward directions opposite to each other in the circumferential direction and are adjacent in the radial direction, and the phase to phase insulator is not provided between the coil ends that extend toward the same direction in the circumferential direction and are adjacent in the radial direction.

A second rotating electric machine according to the present invention includes an armature; and a rotor rotatably arranged on an inner circumferential side of the armature with a gap interposed therebetween. The armature includes an armature core, armature coils mounted to the armature core, and phase to phase insulators for insulating coil end parts of the armature coils. The armature coils are formed such that (4n+2) number of slot accommodation portions of single coils forming the armature coils are arranged so as to be stacked in a radial direction in slots of the armature core, n being a natural number. In each single coil, the slot accommodation portions forming the first to (4n+2)th layers are formed by one continuous conductive wire. On an anti-wire-connection side, coil ends extending in a circumferential direction from the slot accommodation portions in the (4n)th layer and the (4n+1)th layer extend toward the same direction as a coil end extending in the circumferential direction from the slot accommodation portion in the first layer, coil ends extending in the circumferential direction from the slot accommodation portions in the second layer, the (4n−1)th layer, and the (4n+2)th layer extend toward a direction opposite to the coil end extending in the circumferential direction from the slot accommodation portion in the first layer. The phase to phase insulators are provided between the coil ends that extend toward directions opposite to each other in the circumferential direction and are adjacent in the radial direction, and the phase to phase insulator is not provided between the coil ends that extend toward the same direction in the circumferential direction and are adjacent in the radial direction.

Effect of the Invention

The first and second rotating electric machines according to the present invention have coil ends that are adjacent in the radial direction and extend toward the same direction in the circumferential direction from the slot accommodation portions. Therefore, the number of insulation sheets which are phase to phase insulators at the coil ends can be decreased, thus high quality, a small size, and high output can be achieved, and cost reduction and productivity can be improved.

EMBODIMENTS FOR CARRYING OUT THE INVENTION

Hereinafter, a rotating electric machine according to the present invention will be described with reference to the drawings.

In the present invention, a circumferential direction, a radial direction, and an axial direction respectively indicate the circumferential direction, the radial direction, and the axial direction of an armature or the rotating electric machine, unless otherwise specified.

FIG. 1is a schematic one-side sectional view of the rotating electric machine according to embodiment 1 of the present invention.

FIG. 2is a schematic perspective view showing a major part of the rotating electric machine according to embodiment 1 of the present invention.

As shown inFIG. 1andFIG. 2, the rotating electric machine100of the present embodiment includes: a housing1having a bottomed cylindrical frame2and an end plate3closing the opening of the frame2; an armature10fixed by being fitted into the cylinder part of the frame2; and a rotor5provided on the inner circumferential side of the armature10with a gap therebetween.

The rotor5is a permanent magnet rotor having a rotor core7fixed to a rotation shaft6inserted at the axis position, and permanent magnets8embedded on the outer circumferential side of the rotor core7. The rotation shaft6is rotatably supported via bearings4by the bottom part of the frame2and the end plate3.

The rotor in the present embodiment is a permanent magnet rotor, but without limitation thereto, a cage rotor or a winding rotor may be used.

FIG. 3is a schematic perspective view of the armature of the rotating electric machine according to embodiment 1 of the present invention.

As shown inFIG. 3, the armature10in the present embodiment includes: an armature core11; armature coils20mounted to the armature core11; phase-to-phase insulators (not shown inFIG. 3) for insulating coil end parts of the armature coils20; and a ground insulator (not shown inFIG. 3) for insulating the armature coils20and the armature core11from each other.

Although described in detail later, the armature coils20are formed by winding conductive wires, and generate magnetic field by being energized. The magnetic flux of the generated magnetic field passes through the armature core11.

The armature core11is formed by arranging core blocks12annularly in the circumferential direction.

FIG. 4is a schematic perspective view of a core block composing the armature core of the armature according to embodiment 1 of the present invention.

As shown inFIG. 4, the core block12has a shape obtained by dividing the annular armature core11in the circumferential direction.

The core block12is formed by stacking a necessary number of core block pieces14stamped in a predetermined shape from electromagnetic steel sheets. The core block12has an arc shape as seen from a direction (hereinafter, referred to as a stacking direction), indicated by arrow A, in which the core block pieces14are stacked, and includes a back yoke formation portion12aserving as a back yoke of the armature core11, and two teeth12bprotruding inward in the radial direction from the inner circumferential surface of the back yoke formation portion12a.

A plurality of core blocks12are annularly arranged with their circumferential-direction side surfaces abutting each other, to form the armature core11.

Slots13are formed between the two teeth12band between the teeth12bof the core blocks12adjacent to each other in the circumferential direction.

Each tooth12bis tapered such that the width thereof in the circumferential direction is gradually narrowed inward in the radial direction. Each slot13has a rectangular shape as seen from the stacking direction indicated by arrow A, and the armature coils20are arranged in the slots13.

In the present embodiment, the case where the armature core11has forty-eight teeth12bis shown as an example.

The armature coils20are formed of coil group units each of which is formed of a plurality of single coils and which are arranged so as to be shifted from each other by one slot in the circumferential direction.

In the present embodiment, each coil group unit is formed of three types of single coils.

FIG. 5is a schematic top view (a) and a schematic front view (b) showing the structure of a first single coil forming the coil group unit according to embodiment 1 of the present invention.

As shown inFIG. 5, the first single coil16ahas a first one-side slot accommodation portion21ato be arranged in one slot13, and a first other-side slot accommodation portion21eto be arranged in another slot (hereinafter, referred to as another slot)13positioned counterclockwise in the circumferential direction from the one slot13with, for example, six teeth therebetween.

That is, there are five slots between the slot13in which the first one-side slot accommodation portion21ais arranged and the slot13in which the first other-side slot accommodation portion21eis arranged.

One end side of the first one-side slot accommodation portion21aand one end side of the first other-side slot accommodation portion21eare connected by a first connection portion21has a coil end.

The first connection portion21his formed by: a first one-side extending portion21bextending at a predetermined inclination from the first one-side slot accommodation portion21atoward the first other-side slot accommodation portion21eside; a first other-side extending portion21dextending at a predetermined inclination from the first other-side slot accommodation portion21etoward the first one-side slot accommodation portion21aside; and a first shift portion21cvia which the first other-side extending portion21dis shifted outward in the radial direction by one layer from the first one-side extending portion21b. Thus, at the coil end part, the adjacent coils can be avoided each other.

That is, the first other-side slot accommodation portion21eis shifted outward in the radial direction by one layer from the first one-side slot accommodation portion21a.

The one layer corresponds to the thickness of one conductive wire forming the single coil.

A first one-side terminal portion21fextends from the other end side of the first one-side slot accommodation portion21atoward the first other-side slot accommodation portion21ein the circumferential direction, and a first other-side terminal portion21gextends from the other end side of the first other-side slot accommodation portion21etoward the same direction as the direction to which the first one-side terminal portion21fextends, in the circumferential direction.

FIG. 6is a schematic top view (a) and a schematic front view (b) showing the structure of a second single coil forming the coil group unit according to embodiment 1 of the present invention.

As shown inFIG. 6, the second single coil16bhas a second one-side slot accommodation portion22ato be arranged in one slot13, and a second other-side slot accommodation portion22eto be arranged in another slot13.

One end side of the second one-side slot accommodation portion22aand one end side of the second other-side slot accommodation portion22eare connected by a second connection portion22has a coil end.

The second connection portion22his formed by: a second one-side extending portion22bextending at a predetermined inclination from the second one-side slot accommodation portion22atoward the second other-side slot accommodation portion22eside; a second other-side extending portion22dextending at a predetermined inclination from the second other-side slot accommodation portion22etoward the second one-side slot accommodation portion22aside; and a second shift portion22cvia which the second one-side extending portion22bis shifted outward in the radial direction by one layer from the second other-side extending portion22d. Thus, at the coil end part, the adjacent coils can be avoided each other.

That is, the second one-side slot accommodation portion22ais shifted outward in the radial direction by one layer from the second other-side slot accommodation portion22e.

The one layer corresponds to the thickness of one conductive wire forming the single coil.

A second other-side terminal portion22gextends from the other end side of the second other-side slot accommodation portion22etoward the second one-side slot accommodation portion22ain the circumferential direction, and a second one-side terminal portion22fextends from the other end side of the second one-side slot accommodation portion22atoward the same direction as the direction to which the second other-side terminal portion22gextends, in the circumferential direction.

FIG. 7is a schematic top view (a) and a schematic front view (b) showing the structure of a third single coil forming the coil group unit according to embodiment 1 of the present invention.

As shown inFIG. 7, the third single coil16chas a third one-side slot accommodation portion23ato be arranged in one slot13, and a third other-side slot accommodation portion23eto be arranged in another slot13.

One end side of the third one-side slot accommodation portion23aand one end side of the third other-side slot accommodation portion23eare connected by a third connection portion23has a coil end.

The third connection portion23his formed by: a third one-side extending portion23bextending at a predetermined inclination from the third one-side slot accommodation portion23atoward the third other-side slot accommodation portion23eside; a third other-side extending portion23dextending at a predetermined inclination from the third other-side slot accommodation portion23etoward the third one-side slot accommodation portion23aside; and a third shift portion23cvia which the third other-side extending portion23dis shifted outward in the radial direction by five layers from the third one-side extending portion23b.

That is, the third other-side slot accommodation portion23eis shifted outward in the radial direction by five layers from the third one-side slot accommodation portion23a.

The five layers correspond to the thickness of five conductive wires forming the single coil.

A third one-side terminal portion23fextends from the other end side of the third one-side slot accommodation portion23atoward a direction opposite to the third other-side slot accommodation portion23ein the circumferential direction, and a third other-side terminal portion23gextends from the other end side of the third other-side slot accommodation portion23etoward a direction opposite to the third one-side slot accommodation portion23ain the circumferential direction.

The third one-side terminal portion23fof the third single coil16cis connected to the first one-side terminal portion21fof the first single coil16aby welding or the like.

The first other-side terminal portion21gof the first single coil16ais connected to the second other-side terminal portion22gof the second single coil16bby welding or the like.

The second one-side terminal portion22fof the second single coil16bis connected to the third other-side terminal portion23gof the third single coil16cby welding or the like.

In the present embodiment, the third one-side slot accommodation portion23aof the third single coil16cbecomes the first layer on the radially innermost side in the slot13, and the third other-side slot accommodation portion23eof the third single coil16cbecomes the sixth layer on the radially outermost side in the slot13.

The first one-side slot accommodation portion21aof the first single coil16abecomes the second layer in the slot13, and the first other-side slot accommodation portion21eof the first single coil16abecomes the third layer in the slot13.

The second other-side slot accommodation portion22eof the second single coil16bbecomes the fourth layer in the slot13, and the second one-side slot accommodation portion22aof the second single coil16bbecomes the fifth layer in the slot13.

FIG. 8is a schematic top view illustrating the state in which the slot accommodation portions of a plurality of the coil group units are arranged in the slots, in the armature coils according to embodiment 1 of the present invention.

InFIG. 8, for convenience of description, the teeth12band the slots13annularly arranged in the armature core11are shown in a developed manner in a straight line.

InFIG. 8, for convenience of description, the slots are referred to as a first slot13a, a second slot13b, and then a third slot13c, from the left in the drawing. There are five slots in the circumferential direction in each of the interval between the first slot13aand the second slot13band the interval between the second slot13band the third slot13c.

The slots present between the first slot13aand the second slot13band the slots present between the second slot13band the third slot13care not shown.

As shown inFIG. 8, in each slot13a,13b,13c, the third one-side slot accommodation portion23aof the third single coil16cis located as the first layer, and the third other-side slot accommodation portion23eof the third single coil16cis located as the sixth layer.

In addition, the first one-side slot accommodation portion21aof the first single coil16ais located as the second layer, and the first other-side slot accommodation portion21eof the first single coil16ais located as the third layer.

In addition, the second other-side slot accommodation portion22eof the second single coil16bis located as the fourth layer, and the second one-side slot accommodation portion22aof the second single coil16bis located as the fifth layer.

The slot accommodation portions of the single coils arranged in the slots13a,13b,13care connected via the connection portions and the terminal portions.

With reference toFIG. 8, the state of connection among the slot accommodation portions via the connection portions and the terminal portions will be described.

The state of connection among the slot accommodation portions via the connection portions and the terminal portions will be described focusing on the slot accommodation portions arranged in the second slot13b.

As shown inFIG. 8, the third one-side slot accommodation portion23ain the first layer of the second slot13bis connected to the third other-side slot accommodation portion23ein the sixth layer of the first slot13avia the third connection portion23h. In addition, the third one-side slot accommodation portion23ain the first layer of the second slot13bis connected to the first one-side slot accommodation portion21ain the second layer of the third slot13cvia the third one-side terminal portion23fand the first one-side terminal portion21f.

The first one-side slot accommodation portion21ain the second layer of the second slot13bis connected to the first other-side slot accommodation portion21ein the third layer of the first slot13avia the first connection portion21h. In addition, the first one-side slot accommodation portion21ain the second layer of the second slot13bis connected to the third one-side slot accommodation portion23ain the first layer of the first slot13avia the first one-side terminal portion21fand the third one-side terminal portion23f.

The first other-side slot accommodation portion21ein the third layer of the second slot13bis connected to the first one-side slot accommodation portion21ain the second layer of the third slot13cvia the first connection portion21h. In addition, the first other-side slot accommodation portion21ein the third layer of the second slot13bis connected to the second other-side slot accommodation portion22ein the fourth layer of the first slot13avia the first other-side terminal portion21gand the second other-side terminal portion22g.

The second other-side slot accommodation portion22ein the fourth layer of the second slot13bis connected to the second one-side slot accommodation portion22ain the fifth layer of the third slot13cvia the second connection portion22h. In addition, the second other-side slot accommodation portion22ein the fourth layer of the second slot13bis connected to the first other-side slot accommodation portion21ein the third layer of the third slot13cvia the second other-side terminal portion22gand the first other-side terminal portion21g.

The second one-side slot accommodation portion22ain the fifth layer of the second slot13bis connected to the second other-side slot accommodation portion22ein the fourth layer of the first slot13avia the second connection portion22h. In addition, the second one-side slot accommodation portion22ain the fifth layer of the second slot13bis connected to the third other-side slot accommodation portion23ein the sixth layer of the third slot13cvia the second one-side terminal portion22fand the third other-side terminal portion23g.

The third other-side slot accommodation portion23ein the sixth layer of the second slot13bis connected to the third one-side slot accommodation portion23ain the first layer of the third slot13cvia the third connection portion23h. In addition, the third other-side slot accommodation portion23ein the sixth layer of the second slot13bis connected to the second one-side slot accommodation portion22ain the fifth layer of the first slot13avia the third other-side terminal portion23gand the second one-side terminal portion22f.

InFIG. 8, connection via the connection portions which are the coil ends of the anti-wire-connection side is indicated by a solid line, and connections by the terminal portions which are the coil ends of the wire-connection side are indicated by broken lines.

Next, on the basis of the arrangement state of the coil accommodation portions of the single coils in the slots and the connection state of the connection portions of the coil accommodation portions shown inFIG. 8, the structure of coil ends of the anti-wire-connection side which is a side on which the connection portions of the single coils are present will be described.

FIG. 9is a schematic front view showing coil ends of the anti-wire-connection side in the armature according to embodiment 1 of the present invention.

As shown inFIG. 9, the third single coil16chaving the third one-side slot accommodation portion23aas the first layer, and the first single coil16ahaving the first one-side slot accommodation portion21aas the second layer, have the connection portions extending in the same direction and have the same phase. Therefore, voltage between the third one-side extending portion23bwhich is a coil end of the third single coil16c, and the first one-side extending portion21bwhich is a coil end of the first single coil16a, is the same as voltage between their respective slot accommodation portions in the first layer and the second layer adjacent to each other in the slot. Therefore, no insulation sheet is provided in a coil end interval24abetween the third one-side extending portion23band the first one-side extending portion21b.

The first single coil16ahaving the first one-side slot accommodation portion21aas the second layer, and another first single coil16ahaving the first other-side slot accommodation portion21eas the third layer, have the connection portions extending in directions opposite to each other and have phases different from each other. Therefore, voltage between the first one-side extending portion21bwhich is a coil end of the first single coil16a, and the first other-side extending portion21dwhich is a coil end of the other first single coil16a, is greater than voltage between their respective slot accommodation portions in the second layer and the third layer adjacent to each other in the slot. Therefore, an insulation sheet41is provided in a coil end interval24bbetween the first one-side extending portion21band the first other-side extending portion21dof the other first single coil16a.

The first single coil16ahaving the first other-side slot accommodation portion21eas the third layer, and the second single coil16bhaving the second other-side slot accommodation portion22eas the fourth layer, have the connection portions extending in the same direction and have the same phase. Therefore, voltage between the first other-side extending portion21dwhich is a coil end of the first single coil16a, and the second other-side extending portion22dwhich is a coil end of the second single coil16bis the same as voltage between their respective slot accommodation portions in the third layer and the fourth layer adjacent to each other in the slot. Therefore, no insulation sheet is provided in a coil end interval24cbetween the first other-side extending portion21dand the second other-side extending portion22d.

The second single coil16bhaving the second other-side slot accommodation portion22eas the fourth layer, and another second single coil16bhaving the second one-side slot accommodation portion22aas the fifth layer, have the connection portions extending in directions opposite to each other and have phases different from each other. Therefore, voltage between the second other-side extending portion22dwhich is a coil end of the second single coil16b, and the second one-side extending portion22bwhich is a coil end of the other second single coil16b, is greater than voltage between their respective slot accommodation portions in the fourth layer and the fifth layer adjacent to each other in the slot. Therefore, an insulation sheet42is provided in a coil end interval24dbetween the second other-side extending portion22dand the second one-side extending portion22b.

The second single coil16bhaving the second one-side slot accommodation portion22aas the fifth layer, and the third single coil16chaving the third other-side slot accommodation portion23eas the sixth layer, have the connection portions extending in directions opposite to each other and have phases different from each other. Therefore, voltage between the second one-side extending portion22bwhich is a coil end of the second single coil16b, and the third other-side extending portion23dwhich is a coil end of the third single coil16c, is greater than voltage between their respective slot accommodation portions in the fifth layer and the sixth layer adjacent to each other in the slot. Therefore, an insulation sheet43is provided in a coil end interval24ebetween the second one-side extending portion22band the third other-side extending portion23d.

Next, on the basis of the arrangement state of the coil accommodation portions of the single coils in the slots and the connection state of the terminal portions of the coil accommodation portions shown inFIG. 8, the structure of coil ends on the wire-connection side which is a side on which the terminal portions of the single coils are present will be described.

FIG. 10is a schematic front view showing coil ends of the wire-connection side in the armature according to embodiment 1 of the present invention.

The third one-side terminal portion23fprotruding clockwise in the circumferential direction in an inclined manner from the third one-side slot accommodation portion23aof the third single coil16c, located as the first layer is electrically connected, by welding or the like, to the first one-side terminal portion21fprotruding counterclockwise in the circumferential direction in an inclined manner from the first one-side slot accommodation portion21aof the first single coil16a, located as the second layer in another slot.

That is, in the same slot, the third single coil16chaving the third one-side slot accommodation portion23aas the first layer, and the first single coil16ahaving the first one-side slot accommodation portion21aas the second layer, have the terminal portions extending in directions opposite to each other and have phases different from each other. Therefore, an insulation sheet45is provided in a coil end interval25abetween the third one-side terminal portion23fand the first one-side terminal portion21f.

The first one-side terminal portion21fprotruding in the circumferential direction in an inclined manner from the first one-side slot accommodation portion21aof the first single coil16a, located as the second layer, and the first other-side terminal portion21gprotruding in the circumferential direction in an inclined manner from the first other-side slot accommodation portion21eof the first single coil16a, located as the third layer in the same slot, extend in the same direction from the same slot, and the first single coil16alocated as the second layer and the first single coil16alocated as the third layer have the same phase. Therefore, no insulation sheet is provided in a coil end interval25bbetween the first one-side terminal portion21fand the first other-side terminal portion21g.

The first other-side terminal portion21gprotruding counterclockwise in the circumferential direction in an inclined manner from the first other-side slot accommodation portion21eof the first single coil16a, located as the third layer is electrically connected, by welding or the like, to the second other-side terminal portion22gprotruding clockwise in the circumferential direction in an inclined manner from the second other-side slot accommodation portion22eof the second single coil16b, located as the fourth layer in another slot.

That is, in the same slot, the first single coil16ahaving the first other-side slot accommodation portion21eas the third layer, and the second single coil16bhaving the second other-side slot accommodation portion22eas the fourth layer, have the terminal portions extending in directions opposite to each other and have phases different from each other. Therefore, an insulation sheet46is provided in a coil end interval25cbetween the first other-side terminal portion21gand the second other-side terminal portion22g.

The second other-side terminal portion22gprotruding in the circumferential direction in an inclined manner from the second other-side slot accommodation portion22eof the second single coil16b, located as the fourth layer, and the second one-side terminal portion22fprotruding in the circumferential direction in an inclined manner from the second one-side slot accommodation portion22aof the second single coil16b, located as the fifth layer, extend in the same direction from the same slot, and the second single coil16blocated as the fourth layer and the second single coil16blocated as the fifth layer have the same phase. Therefore, no insulation sheet is provided in a coil end interval25dbetween the second other-side terminal portion22gand the second one-side terminal portion22f.

The second one-side terminal portion22fprotruding clockwise in the circumferential direction in an inclined manner from the second one-side slot accommodation portion22aof the second single coil16b, located as the fifth layer is electrically connected, by welding or the like, to the third other-side terminal portion23gprotruding counterclockwise in the circumferential direction in an inclined manner from the third other-side slot accommodation portion23eof the third single coil16c, located as the sixth layer in another slot.

That is, in the same slot, the second single coil16bhaving the second one-side slot accommodation portion22aas the fifth layer, and the third single coil16chaving the third other-side slot accommodation portion23eas the sixth layer, have the terminal portions extending in directions opposite to each other and have phases different from each other. Therefore, an insulation sheet47is provided in a coil end interval25ebetween the second one-side terminal portion22fand the third other-side terminal portion23g.

FIG. 11is a schematic side view showing the state of coils arranged in the slots of the armature core in the rotating electric machine according to embodiment 1 of the present invention.

As shown inFIG. 11, in the axial direction of the armature core11, the coil ends of the anti-wire-connection side protrude from one end side and the coil ends of the wire-connection side protrude from the other end side.

At the coil ends of the anti-wire-connection side, the insulation sheets41,42,43are respectively provided between the first one-side extending portion21band the first other-side extending portion21d, between the second other-side extending portion22dand the second one-side extending portion22b, and between the second one-side extending portion22band the third other-side extending portion23d.

At the coil ends on the wire-connection side, the insulation sheets45,46,47are respectively provided between the third one-side terminal portion23fand the first one-side terminal portion21f, between the first other-side terminal portion21gand the second other-side terminal portion22g, and between the second one-side terminal portion22fand the third other-side terminal portion23g.

The third one-side terminal portion23fand the first one-side terminal portion21fare connected via a welded portion51. The first other-side terminal portion21gand the second other-side terminal portion22gare connected via a welded portion52. The second one-side terminal portion22fand the third other-side terminal portion23gare connected via a welded portion53.

In the rotating electric machine of the present embodiment, among the coil ends, parts required to have high dielectric strength are insulated by insulation sheets, whereby the reliability is improved.

In the armature, the amount of insulation sheets used at the coil ends of the anti-wire-connection side and the coil ends of the wire-connection side can be decreased. Therefore, the cost can be reduced, and the process steps for providing the insulation sheets can be decreased, whereby the productivity can be improved.

The number of locations among layers, in which the insulation sheets are provided at the coil ends, is decreased. Therefore, the size of the armature can be reduced, and even if insulation sheets with a large thickness are used in response to high voltage due to high output, increase in the size of the armature can be avoided.

That is, a small-sized and high-output rotating electric machine can be obtained.

In the present embodiment, insulation sheets are used as the insulators provided in coil end intervals, but insulation films may be used.

In the present embodiment, the number of layers formed by the slot accommodation portions of the single coils arranged in the slot13is six, but, for example, ten layers may be formed.

FIG. 12is a schematic top view illustrating the state in which ten layers of slot accommodation portions are arranged in each slot in the armature coil according to embodiment 1 of the present invention.

Also inFIG. 12, connection via the connection portions which are the coil ends of the anti-wire-connection side is indicated by a solid line, and connection via the terminal portions which are the coil ends of the wire-connection side is indicated by a broken line.

As shown inFIG. 12, the configuration from the first layer to the fifth layer is the same as in the case of six layers shown inFIG. 8.

However, the second one-side slot accommodation portion22aforming the fifth layer is connected via the terminal portions to the first one-side slot accommodation portion21a, of the first single coil16a, which forms the sixth layer. The first one-side slot accommodation portion21aforming the sixth layer is connected via the connection portions to the first other-side slot accommodation portion21eforming the seventh layer. The first other-side slot accommodation portion21eforming the seventh layer is connected via the terminal portions to the second other-side slot accommodation portion22e, of the second single coil16b, which forms the eighth layer. The second other-side slot accommodation portion22eforming the eighth layer is connected via the connection portions to the second one-side slot accommodation portion22aforming the ninth layer. The second one-side slot accommodation portion22aforming the ninth layer is connected via the terminal portions to the third other-side slot accommodation portion23e, of the third single coil, which forms the tenth layer.

The configuration from the sixth layer to the ninth layer formed by the first single coil16aand the second single coil16bis the same as the configuration from the second layer to the fifth layer formed by the first single coil16aand the second single coil16b.

That is, the configurations of the coil ends of the anti-wire-connection side and the wire-connection side extending in the circumferential direction from the slot accommodation portions of the sixth to ninth layers are the same as the configurations of the coil ends of the anti-wire-connection side and the wire-connection side extending in the circumferential direction from the slot accommodation portions of the second to fifth layers. In the sixth to ninth layers, insulation sheets are provided between the coil ends extending in directions opposite to each other from the slot accommodation portions.

In the third single coil, the third one-side slot accommodation portion23aforming the first layer is connected to the third other-side slot accommodation portion23eforming the tenth layer, via the third connection portion23hhaving a shift portion for shifting upward in the radial direction by nine layers.

The armature coil of the present embodiment may have, between the coil accommodation portion in the first layer and the coil accommodation portion in the outermost layer in the radial direction, one or more of the structure in which four layers of slot accommodation portions of the first single coils and the second single coils are stacked from the lowermost layer in the order of the first one-side slot accommodation portion21a, the first other-side slot accommodation portion21e, the second other-side slot accommodation portion22e, and then the second one-side slot accommodation portion22a.

In the present embodiment, a slot in which the one-side slot accommodation portion of each single coil is arranged, and a slot in which the other-side slot accommodation portion of the single coil is arranged, are separated from each other with five slots interposed therebetween in the circumferential direction, but the number of the slots is not limited to five.

In the armature of the present embodiment, as shown inFIG. 8, in the case where the armature coil is configured by six layers of slot accommodation portions corresponding to (4n+2) layers (n is a natural number) at n=1, at the coil ends of the anti-wire-connection side, the connection portions extending from the slot accommodation portions in the second layer and the fifth layer which is the (4n+1)th layer extend toward the same direction in the circumferential direction as the connection portion extending from the slot accommodation portion in the first layer.

In addition, the connection portions extending from the slot accommodation portions in the third layer which is the (4n−1)th layer, the fourth layer which is the (4n)th layer, and the (4n+2)th layer which is the outermost layer, extend toward a direction, in the circumferential direction, opposite to the connection portion extending from the slot accommodation portion in the first layer.

As shown inFIG. 12, in the case where the armature coil is configured by ten layers of slot accommodation portions corresponding to (4n+2) layers at n=2, at the coil ends of the anti-wire-connection side, the connection portions extending from the slot accommodation portions in the second layer, the fifth and ninth layers which are the (4n+1)th layers, and the sixth layer which is the (4n+2)th layer other than the outermost layer, extend toward the same direction in the circumferential direction as the connection portion extending from the slot accommodation portion in the first layer.

In addition, the connection portions extending from the third and seventh layers which are the (4n−1)th layers, the fourth and eighth layers which are the (4n)th layers, and the tenth layer which is the outermost (4n+2)th layer, extend toward a direction, in the circumferential direction, opposite to the connection portion extending from the slot accommodation portion in the first layer.

In the armature of the present embodiment, in the armature coil, insulation sheets are provided between connection portions that are adjacent in the radial direction and extend toward directions different from each other in the circumferential direction, and no insulation sheet is provided between connection portions that are adjacent in the radial direction and extend toward the same direction in the circumferential direction.

A rotating electric machine in the present embodiment is the same as the rotating electric machine100in embodiment 1 except that the armature coil is configured by using a coil group unit composed of: a first single coil17a(FIG. 23) having terminal portions extending toward a direction, in the circumferential direction, opposite to the terminal portions of the first single coil16ain embodiment 1; a second single coil17b(FIG. 24) having terminal portions extending toward a direction, in the circumferential direction, opposite to the terminal portions of the second single coil16bin embodiment 1; and a third single coil17c(FIG. 13) having a third shift portion33cdifferent from the third shift portion23cin embodiment 1.

FIG. 23is a schematic front view showing the structure of the first single coil forming the coil group unit according to embodiment 2 of the present invention.

As shown inFIG. 23, the first single coil17ahas a first one-side slot accommodation portion31ato be arranged in one slot13, and a first other-side slot accommodation portion31eto be arranged in another slot13positioned counterclockwise in the circumferential direction from the one slot13with, for example, six teeth interposed therebetween.

That is, there are five slots between the slot13in which the first one-side slot accommodation portion31ais arranged and the slot13in which the first other-side slot accommodation portion31eis arranged.

One end side of the first one-side slot accommodation portion31aand one end side of the first other-side slot accommodation portion31eare connected by a first connection portion31has a coil end.

The first connection portion31his formed by: a first one-side extending portion31bextending at a predetermined inclination from the first one-side slot accommodation portion31atoward the first other-side slot accommodation portion31eside; a first other-side extending portion31dextending at a predetermined inclination from the first other-side slot accommodation portion31etoward the first one-side slot accommodation portion31aside; and a first shift portion31cvia which the first other-side extending portion31dis shifted outward in the radial direction by one layer from the first one-side extending portion31b. Thus, at the coil end part, the adjacent coils can be avoided.

That is, the first other-side slot accommodation portion31eis shifted outward in the radial direction by one layer from the first one-side slot accommodation portion31a.

The one layer corresponds to the thickness of one conductive wire forming the single coil.

A first other-side terminal portion31gextends from the other end side of the first other-side slot accommodation portion31etoward the first one-side slot accommodation portion31ain the circumferential direction, and a first one-side terminal portion31fextends from the other end side of the first one-side slot accommodation portion31atoward the same direction as the direction to which the first other-side terminal portion31gextends, in the circumferential direction.

FIG. 24is a schematic front view showing the structure of the second single coil forming the coil group unit according to embodiment 2 of the present invention.

As shown inFIG. 24, the second single coil17bhas a second one-side slot accommodation portion32ato be arranged in one slot13, and a second other-side slot accommodation portion32eto be arranged in another slot13.

One end side of the second one-side slot accommodation portion32aand one end side of the second other-side slot accommodation portion32eare connected by a second connection portion32has a coil end.

The second connection portion32his formed by: a second one-side extending portion32bextending at a predetermined inclination from the second one-side slot accommodation portion32atoward the second other-side slot accommodation portion32eside; a second other-side extending portion32dextending at a predetermined inclination from the second other-side slot accommodation portion32etoward the second one-side slot accommodation portion32aside; and a second shift portion32cvia which the second one-side extending portion32bis shifted outward in the radial direction by one layer from the second other-side extending portion32d. Thus, at the coil end part, the adjacent coils can be avoided.

That is, the second one-side slot accommodation portion32ais shifted outward in the radial direction by one layer from the second other-side slot accommodation portion32e.

The one layer corresponds to the thickness of one conductive wire forming the single coil.

A second one-side terminal portion32fextends from the other end side of the second one-side slot accommodation portion32atoward the second other-side slot accommodation portion32ein the circumferential direction, and a second other-side terminal portion32gextends from the other end side of the second other-side slot accommodation portion32etoward the same direction as the direction to which the second one-side terminal portion32fextends, in the circumferential direction.

FIG. 13is a schematic top view (a) and a schematic front view (b) showing the structure of the third single coil forming the coil group unit in the rotating electric machine according to embodiment 2 of the present invention.

As shown inFIG. 13, in the third single coil17cof the present embodiment, a third one-side slot accommodation portion33ato be arranged in one slot13is shifted outward in the radial direction by five layers from a third other-side slot accommodation portion33eto be arranged in another slot13, by a third shift portion33cof a third connection portion33has a coil end.

A third one-side extending portion33bextends from one end side of the third one-side slot accommodation portion33a, and a third other-side extending portion33dextends from one end side of the third other-side slot accommodation portion33e.

A third one-side terminal portion33fextends from the other end side of the third one-side slot accommodation portion33a, and a third other-side terminal portion33gextends from the other end side of the third other-side slot accommodation portion33e.

The directions to which the extending portions and the terminal portions of the third single coil17cextend in the circumferential direction are the same as in the third single coil16cin embodiment 1.

FIG. 14is a schematic front view showing coil ends of the anti-wire-connection side in the armature according to embodiment 2 of the present invention.

As shown inFIG. 14, the third single coil17chaving the third other-side slot accommodation portion33eas the first layer, and the first single coil17ahaving the first one-side slot accommodation portion31aas the second layer, have the connection portions extending in directions opposite to each other and have phases different from each other. Therefore, voltage between the third other-side extending portion33dwhich is the coil end of the third single coil17c, and the first one-side extending portion31bwhich is the coil end of the first single coil17a, is greater than voltage between their respective slot accommodation portions in the first layer and the second layer adjacent to each other in the slot. Therefore, an insulation sheet81is provided in a coil end interval34abetween the third other-side extending portion33dand the first one-side extending portion31b.

The directions of the extending portions extending from the second-layer slot accommodation portion of the first single coil17a, the third-layer slot accommodation portion of the first single coil17a, the fourth-layer slot accommodation portion of the second single coil17b, and the fifth-layer slot accommodation portion of the second single coil17bare the same as those in embodiment 1. Therefore, an insulation sheet82is provided in a coil end interval34bbetween the first one-side extending portion31band the first other-side extending portion31d, no insulation sheet is provided in a coil end interval34cbetween the first other-side extending portion31dand the second other-side extending portion32d, and an insulation sheet83is provided in a coil end interval34dbetween the second other-side extending portion32dand the second one-side extending portion32b.

The second single coil17bhaving the second one-side slot accommodation portion32aas the fifth layer, and the third single coil17chaving the third one-side slot accommodation portion33aas the sixth layer, have the connection portions extending in the same direction and have the same phase. Therefore, voltage between the second one-side extending portion32bwhich is the coil end of the second single coil17b, and the third one-side extending portion33bwhich is the coil end of the third single coil17c, is the same as voltage between the slot accommodation portions in the fifth layer and the sixth layer adjacent to each other in the slot. Therefore, no insulation sheet is provided in a coil end interval34ebetween the second one-side extending portion32band the third one-side extending portion33b.

Also in the rotating electric machine using the first single coil17a, the second single coil17b, and the third single coil17cin the present embodiment, it is not necessary to provide insulation sheets in all the coil end intervals on the anti-wire-connection side and the wire-connection side (not shown). Therefore, the same effect as in the rotating electric machine in embodiment 1 can be obtained.

In the present embodiment, no insulation sheet is provided in the coil end interval on the radially outermost side, and an insulation sheet is provided in the coil end interval on the radially innermost side. Thus, the amount of insulation sheets needed around the circumference decreases, and the material cost can be reduced.

Also in the present embodiment, insulation sheets are used as the insulators provided in coil end intervals, but insulation films may be used.

In the armature of the present embodiment, as shown inFIG. 14, in the case where the armature coil is configured by six layers of slot accommodation portions corresponding to (4n+2) layers (n is a natural number) at n=1, at the coil ends on the anti-wire-connection side, the connection portions extending from the slot accommodation portions in the second layer, the fifth layer which is the (4n+1)th layer, and the sixth layer which is the (4n+2)th layer, extend toward a direction, in the circumferential direction, opposite to the connection portion extending from the slot accommodation portion in the first layer.

In addition, the connection portions extending from the slot accommodation portions in the third layer which is the (4n−1)th layer and the fourth layer which is the (4n)th layer extend toward the same direction in the circumferential direction as the connection portion extending from the slot accommodation portion in the first layer.

In the armature of the present embodiment, in the armature coil, insulation sheets are provided between connection portions that are adjacent in the radial direction and extend toward directions different from each other in the circumferential direction, and no insulation sheet is provided between connection portions that are adjacent in the radial direction and extend toward the same direction in the circumferential direction.

A rotating electric machine in the present embodiment is the same as the rotating electric machine100in embodiment 1 except that a plurality of single coils60respectively formed by one conductive wire are arranged so as to be shifted from each other in the circumferential direction, to form an armature coil.

FIG. 15is a schematic top view (a) and a schematic front view (b) of the single coil forming the armature coil in the rotating electric machine according to embodiment 3 of the present invention.

FIG. 16is a schematic perspective view of the single coil forming the armature coil in the rotating electric machine according to embodiment 3 of the present invention.

As shown inFIG. 15andFIG. 16, in the single coil60of the present embodiment, slot accommodation portions to form respective layers from the first layer to the sixth layer arranged in the slot13are formed by one conductive wire.

As shown inFIG. 15, in the single coil60, a first slot accommodation portion61aand a fifth slot accommodation portion61bare located at one end in the circumferential direction, a third slot accommodation portion63ais located at the other end in the circumferential direction, and a second slot accommodation portion62a, a fourth slot accommodation portion62b, and a sixth slot accommodation portion62care located at the center in the circumferential direction.

The slot accommodation portions at one end in the circumferential direction are separated from the slot accommodation portions at the center in the circumferential direction with a predetermined number of slots interposed therebetween, and the slot accommodation portion at the other end in the circumferential direction is also separated from the slot accommodation portions at the center in the circumferential direction with a predetermined number of slots interposed therebetween.

A first terminal portion66aextends toward one side in the circumferential direction from one end of the first slot accommodation portion61a, and a second terminal portion66bextends toward the other side in the circumferential direction from one end of the sixth slot accommodation portion62c.

InFIG. 15(b)andFIG. 16, the upper side in the drawings in which the first terminal portion66aand the second terminal portion66bare present is a coil end of the wire-connection side, and the lower side in the drawing is a coil end of the anti-wire-connection side. The first terminal portion66ais connected, by welding or the like, to the second terminal portion66bof another single coil60on one side in the circumferential direction, and the second terminal portion66bis connected, by welding or the like, to the first terminal portion66aof another single coil60on the other side in the circumferential direction.

In the single coil60, the first slot accommodation portion61abecomes the first layer, the second slot accommodation portion62abecomes the second layer, the third slot accommodation portion63abecomes the third layer, the fourth slot accommodation portion62bbecomes the fourth layer, the fifth slot accommodation portion61bbecomes the fifth layer, and the sixth slot accommodation portion62cbecomes the sixth layer.

The other end of the first slot accommodation portion61aand the other end of the second slot accommodation portion62aare connected by a first connection portion64a. The first connection portion64ahas a first shift portion65aby which the second slot accommodation portion62ais shifted outward in the radial direction by one layer from the first slot accommodation portion61a.

One end of the second slot accommodation portion62aand one end of the third slot accommodation portion63aare connected by a second connection portion64b. The second connection portion64bhas a second shift portion65bby which the third slot accommodation portion63ais shifted outward in the radial direction by one layer from the second slot accommodation portion62a.

The other end of the third slot accommodation portion63aand the other end of the fourth slot accommodation portion62bare connected by a third connection portion64c. The third connection portion64chas a third shift portion65cby which the fourth slot accommodation portion62bis shifted outward in the radial direction by one layer from the third slot accommodation portion63a.

One end of the fourth slot accommodation portion62band one end of the fifth slot accommodation portion61bare connected by a fourth connection portion64d. The fourth connection portion64dhas a fourth shift portion65dby which the fifth slot accommodation portion61bis shifted outward in the radial direction by one layer from the fourth slot accommodation portion62b.

The other end of the fifth slot accommodation portion61band the other end of the sixth slot accommodation portion62care connected by a fifth connection portion64e. The fifth connection portion64ehas a fifth shift portion65eby which the sixth slot accommodation portion62cis shifted outward in the radial direction by one layer from the fifth slot accommodation portion61b.

In the present embodiment, the connection portions and the terminal portions on one end side of the slot accommodation portions are coil ends on the wire-connection side, and the connection portions on the other end side of the slot accommodation portions are coil ends on the anti-wire-connection side.

In each single coil60, the first slot accommodation portion61aof the other single coil60positioned on the other side in the circumferential direction is located radially inward with respect to the second slot accommodation portion62a, and the fifth slot accommodation portion61bof the other single coil60positioned on the other side in the circumferential direction is located between the fourth slot accommodation portion62band the sixth slot accommodation portion62c.

The third slot accommodation portion63aof another single coil60positioned on one side in the circumferential direction is located between the second slot accommodation portion62aand the fourth slot accommodation portion62b.

In the present embodiment, the second connection portion64band the fourth connection portion64dare coil ends on the wire-connection side, and the first connection portion64a, the third connection portion64c, and the fifth connection portion64eare coil ends on the anti-wire-connection side.

That is, on the anti-wire-connection side, in the same slot13, the connection portion extending in the circumferential direction from the second slot accommodation portion62aand the connection portion extending in the circumferential direction from the third slot accommodation portion63aextend toward a direction opposite to the connection portion extending in the circumferential direction from the first slot accommodation portion61a. And the connection portion extending in the circumferential direction from the fourth slot accommodation portion62band the connection portion extending in the circumferential direction from the fifth slot accommodation portion61bextend toward the same direction as the connection portion extending in the circumferential direction from the first slot accommodation portion61a. Further the connection portion extending in the circumferential direction from the sixth slot accommodation portion62cextends toward a direction opposite to the connection portion extending in the circumferential direction from the first slot accommodation portion61a.

On the wire-connection side, the connection portion extending in the circumferential direction from the second slot accommodation portion62aextends toward a direction opposite to the terminal portion extending in the circumferential direction from the first slot accommodation portion61a, the connection portion extending in the circumferential direction from the third slot accommodation portion63aand the connection portion extending in the circumferential direction from the fourth slot accommodation portion62bextend toward the same direction as the terminal portion extending in the circumferential direction from the first slot accommodation portion61a, and the connection portion extending in the circumferential direction from the fifth slot accommodation portion61band the terminal portion extending in the circumferential direction from the sixth slot accommodation portion62cextend toward a direction opposite to the terminal portion extending in the circumferential direction from the first slot accommodation portion61a.

FIG. 17is a schematic side view showing the state of coils arranged in the slots of the armature in the rotating electric machine according to embodiment 3 of the present invention.

As shown inFIG. 17, at the coil ends on the anti-wire-connection side at the right on the drawing, in the single coil60, the connection portion extending from the first layer and the connection portion extending from the second layer extend toward directions opposite to each other in the circumferential direction and have phases different from each other. And the connection portion extending from the third layer and the connection portion extending from the fourth layer extend toward directions opposite to each other in the circumferential direction and have phases different from each other. Further the connection portion extending from the fifth layer and the connection portion extending from the sixth layer extend toward directions opposite to each other in the circumferential direction and have phases different from each other. Therefore, insulation sheets75,76,77are provided in the coil end intervals between these pairs of connection portions, and no insulation sheet is provided in the coil end intervals between the other pairs of layers.

At the coil ends on the wire-connection side, in the single coil60, the terminal portion extending from the first layer and the connection portion extending from the second layer extend toward directions opposite to each other in the circumferential direction and have phases different from each other. And the connection portion extending from the second layer and the connection portion extending from the third layer extend toward directions opposite to each other in the circumferential direction and have phases different from each other. Further the connection portion extending from the fourth layer and the connection portion extending from the fifth layer extend toward directions opposite to each other in the circumferential direction and have phases different from each other. Therefore, insulation sheets71,72,73are provided in the coil end intervals between these pairs of connection portions, and no insulation sheet is provided in the coil end intervals between the other pairs of layers.

Also in the rotating electric machine of the present embodiment, the number of insulation sheets for insulating the coil ends of the armature from each other can be decreased, and thus the same effect as in the rotating electric machine of embodiment 1 can be obtained.

In addition, since the armature coil is formed by arranging single coils respectively, formed by one conductive wire, the number of components and the number of welding locations can be decreased. Thus, also in this point, the productivity can be improved.

The direction to which the first terminal portion66aextends and the direction to which the second terminal portion66bextends may be reversed in the circumferential direction. In this case, at the coil ends on the wire-connection side, an insulation sheet is provided between the connection portion extending from the fifth layer and the terminal portion extending from the sixth layer, and it is not necessary to provide an insulation sheet between the terminal portion extending from the first layer and the connection portion extending from the second layer.

In the present embodiment, the slot in which the slot accommodation portion on one side in the circumferential direction of the single coil is arranged and the slot in which the slot accommodation portion at the center of the single coil is arranged are separated from each other with five slots interposed therebetween in the circumferential direction, and the slot in which the slot accommodation portion on the other side in the circumferential direction of the single coil is arranged and the slot in which the slot accommodation portion at the center of the single coil is arranged are separated from each other with five slots interposed therebetween in the circumferential direction. However, the number of the slots is not limited to five.

Also in the present embodiment, insulation sheets are used as the insulators provided in coil end intervals, but insulation films may be used.

The single coil60in the present embodiment has six slot accommodation portions from the first slot accommodation portion to the sixth slot accommodation portion, and six layers of slot accommodation portions are provided in each slot. However, the single coil may have ten slot accommodation portions from the first slot accommodation portion to the tenth slot accommodation portion so that ten layers of slot accommodation portions are provided in each slot.

The single coil may have more than ten slot accommodation portions as long as the single coil have (4n+2) number (n is a natural number) of slot accommodation portions in the same manner in which the single coil has six slot accommodation portions and the single coil has ten slot accommodation portions.

FIG. 18is schematic top views illustrating the state (a) in which six layers of slot accommodation portions are arranged in each slot and the state (b) in which ten layers of slot accommodation portions are arranged in each slot, in the armature coil according to embodiment 3 of the present invention.

InFIG. 18, for convenience of description, the teeth12band the slots13annularly arranged in the armature core11are shown in a developed manner in a straight line.

InFIG. 18, the slots are referred to as a first slot13a, a second slot13b, and then a third slot13c, from the left in the drawing.

InFIG. 18, the connection portions which are the coil ends on the anti-wire-connection side are indicated by solid lines, and connections by the terminal portions which are the coil ends on the wire-connection side are indicated by broken lines.

As shown inFIG. 18, the single coil having ten slot accommodation portions is formed by connecting, to the wire-connection-side end of the sixth slot accommodation portion62cof the single coil60excluding the second terminal portion66b, the same structure as that from the wire-connection-side end of the second slot accommodation portion62ato the wire-connection-side end of the sixth slot accommodation portion62cso that a seventh slot accommodation portion63b, an eighth slot accommodation portion62d, a ninth slot accommodation portion61cand a tenth slot accommodation portion62eare formed. Then the second terminal portion66bis provided at the wire-connection-side end of the tenth slot accommodation portion62e.

In addition, a single coil having more slot accommodation portions is obtained by further adding the same structure as that from the wire-connection-side end of the second slot accommodation portion62ato the wire-connection-side end of the sixth slot accommodation portion62c.

The armature coil of the armature in the present embodiment is configured by using single coils each having (4n+2) number of slot accommodation portions.

At n=1, in the case of using the single coils60having six slot accommodation portions, at the coil ends of the anti-wire-connection side, the connection portions extending from the slot accommodation portion in the fourth layer which is the (4n)th layer and the slot accommodation portion in the fifth layer which is the (4n+1)th layer, extend toward the same direction in the circumferential direction as the connection portion extending from the slot accommodation portion in the first layer.

In addition, the connection portions extending from the slot accommodation portions in the second layer, the third layer which is the (4n−1)th layer, and the sixth layer which is the (4n+2)th layer, extend toward a direction, in the circumferential direction, opposite to the connection portion extending from the slot accommodation portion in the first layer.

At n=2, in the case of using the single coils having ten slot accommodation portions, at the coil ends of the anti-wire-connection side, the connection portions extending from the slot accommodation portions in the fourth and eighth layers which are the (4n)th layers and the slot accommodation portions in the fifth and ninth layers which are the (4n+1)th layers, extend toward the same direction in the circumferential direction as the connection portion extending from the slot accommodation portion in the first layer.

In addition, the connection portions extending from the slot accommodation portion in the second layer, the slot accommodation portions in the third and seventh layers which are the (4n−1)th layers, and the slot accommodation portions in the sixth and tenth layers which are the (4n+2)th layers, extend toward a direction, in the circumferential direction, opposite to the connection portion extending from the slot accommodation portion in the first layer.

Also at n=3 or greater, in the case of using the single coils having (4n+2) number of slot accommodation portions, the connection portions extending from the first layer, the second layer, the (4n−1)th layer, the (4n)th layer, the (4n+1)th layer, and the (4n+2)th layer extend in the same manner in the circumferential direction as in the case of using the single coils having six or ten slot accommodation portions.

In the armature of the present embodiment, in the armature coil, insulation sheets are provided between connection portions that are adjacent in the radial direction and extend toward directions different from each other in the circumferential direction, and no insulation sheet is provided between connection portions that are adjacent in the radial direction and extend toward the same direction in the circumferential direction.

A rotating electric machine in the present embodiment is the same as the rotating electric machine100in embodiment 1 except that a plurality of single coils90respectively formed by one conductive wire are arranged so as to be shifted from each other in the circumferential direction, to form an armature coil.

FIG. 19is a schematic top view of a single coil forming an armature coil in the rotating electric machine according to embodiment 4 of the present invention.

FIG. 20is a schematic front view of the single coil forming the armature coil in the rotating electric machine according to embodiment 4 of the present invention.

FIG. 21is a schematic perspective view of the single coil forming the armature coil of the rotating electric machine according to embodiment 4 of the present invention.

As shown inFIG. 19,FIG. 20, andFIG. 21, in the single coil90of the present embodiment, slot accommodation portions to form respective layers from the first layer to the tenth layer arranged in the slot13are formed by one conductive wire.

As shown inFIG. 19,FIG. 20, andFIG. 21, in the single coil90, a first slot accommodation portion92a, a third slot accommodation portion92b, a fifth slot accommodation portion92c, a seventh slot accommodation portion92d, and a ninth slot accommodation portion92eare located at the center in the circumferential direction.

In addition, a fourth slot accommodation portion91aand an eighth slot accommodation portion91bare located at one end in the circumferential direction, and a second slot accommodation portion93a, a sixth slot accommodation portion93b, and a tenth slot accommodation portion93care located at the other end in the circumferential direction.

The slot accommodation portions at one end in the circumferential direction are separated from the slot accommodation portions at the center in the circumferential direction with a predetermined number of slots interposed therebetween, and the slot accommodation portions at the other end in the circumferential direction are also separated from the slot accommodation portions at the center in the circumferential direction with a predetermined number of slots interposed therebetween.

A first terminal portion96aextends toward one side in the circumferential direction from one end of the first slot accommodation portion92a, and a second terminal portion96bextends toward the other side in the circumferential direction from one end of the tenth slot accommodation portion93c.

InFIG. 20andFIG. 21, the upper side in the drawings in which the first terminal portion96aand the second terminal portion96bare present is a coil end of the wire-connection side, and the lower side in the drawings is a coil end of the anti-wire-connection side. The first terminal portion96ais connected, by welding or the like, to the second terminal portion96bof another single coil90on one side in the circumferential direction, and the second terminal portion96bis connected, by welding or the like, to the first terminal portion96aof another single coil90on the other side in the circumferential direction.

In the single coil90, the first slot accommodation portion92abecomes the first layer, the second slot accommodation portion93abecomes the second layer, the third slot accommodation portion92bbecomes the third layer, the fourth slot accommodation portion91abecomes the fourth layer, the fifth slot accommodation portion92cbecomes the fifth layer, the sixth slot accommodation portion93bbecomes the sixth layer, the seventh slot accommodation portion92dbecomes the seventh layer, the eighth slot accommodation portion91bbecomes the eighth layer, the ninth slot accommodation portion92ebecomes the ninth layer, and the tenth slot accommodation portion93cbecomes the tenth layer.

The other end of the first slot accommodation portion92aand the other end of the second slot accommodation portion93aare connected by a first connection portion94a. The first connection portion94ahas a first shift portion95aby which the second slot accommodation portion93ais shifted outward in the radial direction by one layer from the first slot accommodation portion92a.

One end of the second slot accommodation portion93aand one end of the third slot accommodation portion92bare connected by a second connection portion94b. The second connection portion94bhas a second shift portion95bby which the third slot accommodation portion92bis shifted outward in the radial direction by one layer from the second slot accommodation portion93a.

The other end of the third slot accommodation portion92band the other end of the fourth slot accommodation portion91aare connected by a third connection portion94c. The third connection portion94chas a third shift portion95cby which the fourth slot accommodation portion91ais shifted outward in the radial direction by one layer from the third slot accommodation portion92b.

One end of the fourth slot accommodation portion91aand one end of the fifth slot accommodation portion92care connected by a fourth connection portion94d. The fourth connection portion94dhas a fourth shift portion95dby which the fifth slot accommodation portion92cis shifted outward in the radial direction by one layer from the fourth slot accommodation portion91a.

The other end of the fifth slot accommodation portion92cand the other end of the sixth slot accommodation portion93bare connected by a fifth connection portion94e. The fifth connection portion94ehas a fifth shift portion95eby which the sixth slot accommodation portion93bis shifted outward in the radial direction by one layer from the fifth slot accommodation portion92c.

One end of the sixth slot accommodation portion93band one end of the seventh slot accommodation portion92dare connected by a sixth connection portion94f. The sixth connection portion94fhas a sixth shift portion95fby which the seventh slot accommodation portion92dis shifted outward in the radial direction by one layer from the sixth slot accommodation portion93b.

The other end of the seventh slot accommodation portion92dand the other end of the eighth slot accommodation portion91bare connected by a seventh connection portion94g. The seventh connection portion94ghas a seventh shift portion95gby which the eighth slot accommodation portion91bis shifted outward in the radial direction by one layer from the seventh slot accommodation portion92d.

One end of the eighth slot accommodation portion91band one end of the ninth slot accommodation portion92eare connected by an eighth connection portion94h. The eighth connection portion94hhas an eighth shift portion95hby which the ninth slot accommodation portion92eis shifted outward in the radial direction by one layer from the eighth slot accommodation portion91b.

The other end of the ninth slot accommodation portion92eand the other end of the tenth slot accommodation portion93care connected by a ninth connection portion94i. The ninth connection portion94ihas a ninth shift portion95iby which the tenth slot accommodation portion93cis shifted outward in the radial direction by one layer from the ninth slot accommodation portion92e.

In the present embodiment, the connection portions and the terminal portions on one end side of the slot accommodation portions are coil ends on the wire-connection side, and the connection portions on the other end side of the slot accommodation portions are coil ends on the anti-wire-connection side.

In each single coil90, the second slot accommodation portion93aof the other single coil90positioned on one side in the circumferential direction is located between the first slot accommodation portion92aand the third slot accommodation portion92b, and the sixth slot accommodation portion93bof the other single coil90positioned on one side in the circumferential direction is located between the fifth slot accommodation portion92cand the seventh slot accommodation portion92d.

In addition, the fourth slot accommodation portion91aof another single coil90positioned on the other side in the circumferential direction is located between the third slot accommodation portion92band the fifth slot accommodation portion92c, and the eighth slot accommodation portion91bof another single coil90positioned on the other side in the circumferential direction is located between the seventh slot accommodation portion92dand the ninth slot accommodation portion92e.

In addition, the tenth slot accommodation portion93cof the other single coil90positioned on one side in the circumferential direction is located radially outward with respect to the ninth slot accommodation portion92e.

In the present embodiment, the second connection portion94b, the fourth connection portion94d, the sixth connection portion94f, and the eighth connection portion94hare coil ends on the wire-connection side, and the first connection portion94a, the third connection portion94c, the fifth connection portion94e, the seventh connection portion94g, and the ninth connection portion94iare coil ends on the anti-wire-connection side.

FIG. 22is a schematic top view illustrating the state in which ten layers of slot accommodation portions are arranged in each slot, in the armature coil according to embodiment 4 of the present invention.

InFIG. 22, for convenience of description, the teeth12band the slots13annularly arranged in the armature core11are shown in a developed manner in a straight line.

InFIG. 22, the slots are referred to as a first slot13a, a second slot13b, and then a third slot13c, from the left in the drawing.

InFIG. 22, connections by the connection portions which are the coil ends on the anti-wire-connection side are indicated by solid lines, and connections by the terminal portions which are the coil ends on the wire-connection side are indicated by broken lines.

As shown inFIG. 22, on the anti-wire-connection side, in the same slot13, the connection portions extending in the circumferential direction from the second slot accommodation portion93a, the third slot accommodation portion92b, the sixth slot accommodation portion93b, the seventh slot accommodation portion92d, and the tenth slot accommodation portion93cextend toward a direction opposite to the connection portion extending in the circumferential direction from the first slot accommodation portion92a.

In addition, the connection portions extending in the circumferential direction from the fourth slot accommodation portion91a, the fifth slot accommodation portion92c, the eighth slot accommodation portion91b, and the ninth slot accommodation portion92eextend toward the same direction as the connection portion extending in the circumferential direction from the first slot accommodation portion92a.

On the wire-connection side, in the same slot13, the connection portions extending in the circumferential direction from the third slot accommodation portion92b, the fourth slot accommodation portion91a, the seventh slot accommodation portion92d, and the eighth slot accommodation portion91b, and the second terminal portion96bextending in the circumferential direction from the tenth slot accommodation portion93c, extend toward a direction opposite to the first terminal portion96aextending in the circumferential direction from the first slot accommodation portion92a.

In addition, the connection portions extending in the circumferential direction from the second slot accommodation portion93a, the fifth slot accommodation portion92c, the sixth slot accommodation portion93b, and the ninth slot accommodation portion92eextend toward the same direction as the first terminal portion96aextending in the circumferential direction from the first slot accommodation portion92a.

That is, at the coil ends on the anti-wire-connection side, in the single coil90, the connection portion extending from the first layer and the connection portion extending from the second layer extend toward directions different from each other in the circumferential direction and have phases different from each other, the connection portion extending from the third layer and the connection portion extending from the fourth layer extend toward directions different from each other in the circumferential direction and have phases different from each other, the connection portion extending from the fifth layer and the connection portion extending from the sixth layer extend toward directions different from each other in the circumferential direction and have phases different from each other, the connection portion extending from the seventh layer and the connection portion extending from the eighth layer extend toward directions different from each other in the circumferential direction and have phases different from each other, and the connection portion extending from the ninth layer and the connection portion extending from the tenth layer extend toward directions different from each other in the circumferential direction and have phases different from each other. Therefore, insulation sheets are provided in the coil end intervals between these pairs of connection portions, and no insulation sheet is provided in the coil end intervals between the other pairs of layers.

At the coil ends on the wire-connection side, in the single coil90, the connection portion extending from the second layer and the connection portion extending from the third layer extend toward directions different from each other in the circumferential direction and have phases different from each other, the connection portion extending from the fourth layer and the connection portion extending from the fifth layer extend toward directions different from each other in the circumferential direction and have phases different from each other, the connection portion extending from the sixth layer and the connection portion extending from the seventh layer extend toward directions different from each other in the circumferential direction and have phases different from each other, the connection portion extending from the eighth layer and the connection portion extending from the ninth layer extend toward directions different from each other in the circumferential direction and have phases different from each other, and the connection portion extending from the ninth layer and the terminal portion extending from the tenth layer extend toward directions different from each other in the circumferential direction and have phases different from each other. Therefore, insulation sheets are provided in the coil end intervals between these pairs of connection portions and between the connection portion and the terminal portion. And no insulation sheet is provided in the coil end intervals between the other pairs of layers.

Also in the rotating electric machine of the present embodiment, the number of insulation sheets for insulating the coil ends of the armature from each other can be decreased, and thus the same effect as in the rotating electric machine of embodiment 1 can be obtained.

In addition, since the armature coil is formed by arranging single coils respectively formed by one conductive wire, the number of components and the number of welding locations can be decreased. Thus, also in this point, the productivity can be improved.

In the present embodiment, the slot in which the slot accommodation portion on one side in the circumferential direction of the single coil is arranged and the slot in which the slot accommodation portion at the center in the circumferential direction of the single coil is arranged are separated from each other with five slots interposed therebetween in the circumferential direction, and the slot in which the slot accommodation portion on the other side in the circumferential direction of the single coil is arranged and the slot in which the slot accommodation portion in the circumferential direction at the center of the single coil is arranged are separated from each other with five slots interposed therebetween in the circumferential direction. However, the number of the slots is not limited to five.

Also in the present embodiment, insulation sheets are used as the insulators provided in coil end intervals, but insulation films may be used.

The single coil90in the present embodiment has ten slot accommodation portions from the first slot accommodation portion to the tenth slot accommodation portion, and ten layers of slot accommodation portions are provided in each slot. However, the single coil may have six slot accommodation portions from the first slot accommodation portion to the sixth slot accommodation portion so that six layers of slot accommodation portions are provided in each slot.

Alternatively, the single coil may have fourteen slot accommodation portions from the first slot accommodation portion to the fourteenth slot accommodation portion so that fourteen layers of slot accommodation portions are provided in each slot.

That is, the single coil may have (4n+2) number (n is a natural number) of slot accommodation portions.

As is obvious fromFIG. 22, the single coil having six slot accommodation portions can be formed by, in the single coil90having ten slot accommodation portions shown inFIG. 19toFIG. 21, eliminating the structure subsequent to the sixth slot accommodation portion and providing the second terminal portion96bat the wire-connection-side end of the sixth slot accommodation portion.

As is obvious fromFIG. 19toFIG. 22, the structure from the wire-connection-side end of the sixth slot accommodation portion to the wire-connection-side end of the tenth slot accommodation portion is the same as the structure from the wire-connection-side end of the second slot accommodation portion to the wire-connection-side end of the sixth slot accommodation portion.

That is, the single coil90having ten slot accommodation portions is formed by connecting, to the wire-connection-side end of the sixth slot accommodation portion of the single coil having six slot accommodation portions excluding the second terminal portion, the same structure as that from the wire-connection-side end of the second slot accommodation portion to the wire-connection-side end of the sixth slot accommodation portion so that seventh to tenth slot accommodation portions are formed. Then the second terminal portion96bis provided at the wire-connection-side end of the tenth slot accommodation portion.

In addition, the single coil having fourteen slot accommodation portions can be formed by connecting, to the wire-connection-side end of the tenth slot accommodation portion of the single coil90having ten slot accommodation portions excluding the second terminal portion96b, the same structure as that from the wire-connection-side end of the second slot accommodation portion to the wire-connection-side end of the sixth slot accommodation portion so that eleventh to fourteenth slot accommodation portions are formed. Then the second terminal portion96bis provided at the wire-connection-side end of the fourteenth slot accommodation portion.

That is, the armature in which more layers of slot accommodation portions are arranged in each slot can be obtained by repeatedly providing the structure from the wire-connection-side end of the second slot accommodation portion to the wire-connection-side end of the sixth slot accommodation portion.

The armature coil of the armature in the present embodiment is configured by using single coils each having (4n+2) number of slot accommodation portions.

As shown inFIG. 22, at n=2, in the case of using the single coils90having ten slot accommodation portions, at the coil ends of the anti-wire-connection side, the connection portions extending from the slot accommodation portions in the fourth and eighth layers which are the (4n)th layers and the slot accommodation portions in the fifth and ninth layers which are the (4n+1)th layers, extend toward the same direction in the circumferential direction as the connection portion extending from the slot accommodation portion in the first layer.

In addition, the connection portions extending from the slot accommodation portion in the second layer, the slot accommodation portions in the third and seventh layers which are the (4n−1)th layers, and the slot accommodation portions in the sixth and tenth layers which are the (4n+2)th layers, extend toward a direction, in the circumferential direction, opposite to the connection portion extending from the slot accommodation portion in the first layer.

Also at n=1 or n=3 or greater, in the case of using the single coil having (4n+2) number of slot accommodation portions, the connection portions extending from the first layer, the second layer, the (4n−1)th layer, the (4n)th layer, the (4n+1)th layer, and the (4n+2)th layer extend in the same manner in the circumferential direction as in the case of using the single coil90having ten slot accommodation portions.

In the armature of the present embodiment, in the armature coil, insulation sheets are provided between connection portions that are adjacent in the radial direction and extend toward directions different from each other in the circumferential direction, and no insulation sheet is provided between connection portions that are adjacent in the radial direction and extend toward the same direction in the circumferential direction.

It is noted that, within the scope of the present invention, the above embodiments may be freely combined with each other, or each of the above embodiments may be modified or eliminated appropriately.

INDUSTRIAL APPLICABILITY

The rotating electric machine of the present invention is applicable to industrial devices required to have high productivity and low cost.