Source: https://patents.google.com/patent/JP2010200596A/en
Timestamp: 2020-02-19 23:53:55
Document Index: 521763378

Matched Legal Cases: ['art 13', 'arts 16', 'art 25', 'art 25', 'art 32', 'art 13', 'art 33', 'arts 33', 'art 33', 'art 35', 'art 25', 'art 32', 'art 32', 'art 32', 'art 35', 'art 32', 'art 35', 'art 32', 'art 35', 'art 32', 'art 33', 'art 25', 'art 32', 'art 35', 'art 35', 'art 16', 'art 13', 'art 35', 'art 35', 'art 33', 'art 34', 'art 35', 'art 41']

JP2010200596A - Armature for rotating electrical machine and manufacturing method of same - Google Patents
Armature for rotating electrical machine and manufacturing method of same Download PDF
JP2010200596A
JP2010200596A JP2009189463A JP2009189463A JP2010200596A JP 2010200596 A JP2010200596 A JP 2010200596A JP 2009189463 A JP2009189463 A JP 2009189463A JP 2009189463 A JP2009189463 A JP 2009189463A JP 2010200596 A JP2010200596 A JP 2010200596A
JP2009189463A
Keiichi Shinohara
清隆 古賀
新一 大竹
敬一 篠原
2009-01-28 Priority to JP2009016854 priority Critical
2009-08-18 Application filed by Aisin Aw Co Ltd, アイシン・エィ・ダブリュ株式会社 filed Critical Aisin Aw Co Ltd
2009-08-18 Priority to JP2009189463A priority patent/JP2010200596A/en
2010-09-09 Publication of JP2010200596A publication Critical patent/JP2010200596A/en
<P>PROBLEM TO BE SOLVED: To provide an armature for a rotating electrical machine capable of improving a space factor of coils and reducing eddy current loss. <P>SOLUTION: The armature for a rotating electrical machine includes a cylindrical core 11 having a plurality of longitudinally extending slots 12 that are dispersedly arranged circumferentially and coils 21 wound around the slots 12. Each of the slots is formed such that the inner circumferential opening is smaller than the interior of the slot in a circumferential width, and linear conductors forming the coils are each formed to be larger than the inner circumferential opening in the circumferential width. Coil ends 23 on one side of the axial direction among the coils 21 have radial conductors 25, which are bent coil ends 24 formed being bent inside radially. The slot 12 includes narrow-width recesses 32 which are dented relative to the other parts of the radial conductors 25, at the radial positions of the radial conductors 25 corresponding to the inner circumferential opening, such that the circumferential width becomes narrower than that of the inner circumferential opening. <P>COPYRIGHT: (C)2010,JPO&INPIT
The present invention relates to an armature for a rotating electrical machine including a cylindrical core having a plurality of axially extending slots distributed in the circumferential direction, and a coil wound around the slot, and a method for manufacturing the same.
In general, a rotating electrical machine used as a motor (electric motor), a generator (generator) or the like is required to have a smaller physique and a larger output. Therefore, increasing the energy efficiency of the rotating electrical machine is one of important issues. Here, as a technique for increasing the energy efficiency of the rotating electrical machine, for example, a technique for improving the space factor of the coil in the armature of the rotating electrical machine has been conventionally known.
The following Patent Document 1 is given as a document describing improving the space factor of a coil. In the stator as an armature for a rotating electrical machine described in Patent Document 1, the space factor is improved by forming a coil using a rectangular wire conductor having a substantially rectangular cross section, and an ampere turn per unit cross sectional area. The output of the rotating electrical machine is improved by increasing the power.
In the rotating electrical machine described in Patent Document 1, the stator slot is an open slot (the circumferential width of the opening that opens radially inward is equal to or greater than the circumferential width of the portion where the coil is mounted. The coil, which is formed into a predetermined shape by continuous winding, is inserted in the radial direction from the opening of the open slot and wound around the slot while being deformed in the circumferential direction and the axial direction. Thereby, after inserting a coil in a slot, it is possible to reduce the location which should be electrically connected and to improve productivity.
Moreover, the following patent document 2 is mentioned as another literature in which improving the space factor of a coil was described. In the stator as the armature for a rotating electrical machine described in Patent Document 2, a coil having a predetermined shape is formed by laminating thin wires in the circumferential direction and the radial direction. At this time, in order to increase the space factor in the slot, the thin wires are stacked and bundled so as to have a cross-sectional shape corresponding to the cross-sectional shape of the slot.
In the stator of the rotating electrical machine described in Patent Document 2, the slot provided in the stator core is a semi-open slot (the circumferential width of the opening opening radially inward is the circumference of the portion where the coil is mounted). The slot is narrower than the width in the direction). Thus, the output of the rotating electrical machine is also improved by increasing the effective magnetic flux acting between the stator and the rotor as the field. Here, in the stator of this rotating electric machine, as the semi-open slot type core is used, the thin wire is bent radially inward and laminated in the axial direction at the coil end portion on one axial side of the coil. Pre-formed into a different shape. In other words, at the portion where the thin wire constituting the coil extends in the radial direction, the thin wire is not laminated in the circumferential direction so that the circumferential width of the portion is made smaller than the width of the opening on the radially inner side of the slot. The pre-formed coil is inserted in the axial direction from the bent coil end side and wound around the slot of the core.
JP 2008-167567 A Japanese Patent No. 3798968
However, since the rotating electrical machine described in Patent Document 1 is an open slot, the circumferential width of the opening of the slot is large, and the surface area of the flat wire conductor on the rotor side is large. Therefore, when the rotor rotates, the magnetic flux from a permanent magnet or the like reaches the rectangular wire conductor, and an eddy current is generated on the surface on the rotor side. For this reason, there is a problem that eddy current loss increases and the energy efficiency of the rotating electrical machine may decrease instead.
In this respect, in order to reduce the amount of magnetic flux from a permanent magnet or the like reaching a rectangular conductor and reduce eddy current loss, a semi-open slot type core as described in Patent Document 2 may be used. Conceivable. However, when a rotating electrical machine is configured using a semi-open slot core and a coil composed of a rectangular wire conductor, the circumferential width of the rectangular wire conductor itself is wider than the circumferential width of the opening of the slot. Therefore, as described in Patent Document 1, the coil cannot be inserted into the slot from the inside in the radial direction. Further, even if the coil end on one side in the axial direction is bent radially inward, the circumferential width of the rectangular wire conductor itself is wider than the circumferential width of the opening of the slot. It is also not possible to insert the coil axially into the slot as was done.
As described above, since the manufacture itself is difficult, it has not been done so far to configure a rotating electrical machine using a semi-open slot type core and a coil formed of a flat wire conductor. In other words, a technology that enables both improvement of the coil space factor and reduction of eddy current loss has not yet been established.
The present invention has been made in view of the above-described problems, and an object of the present invention is to provide an armature for a rotating electrical machine that can reduce eddy current loss while improving the space factor of a coil.
To achieve this object, a rotating electrical machine comprising a cylindrical core having a plurality of axially extending slots distributed in the circumferential direction according to the present invention, and a coil wound around the slot. A feature of the child is that the slot is formed such that the circumferential width of the inner circumferential opening that opens radially inward is narrower than the circumferential width of the slot located radially outside of the inner circumferential opening. In addition, the circumferential width of the linear conductor constituting the coil is formed wider than the circumferential width of the inner circumferential opening, and the coil is arranged between the coil side portions arranged in different slots. Coil end portions connected at both axial end portions, the coil end portion on one axial side of the slot being a bent coil end portion bent radially inward, and the bent coil end portion is Diameter from coil side A radial conductor portion extending inward and a circumferential conductor portion connecting the pair of radial conductor portions radially inward of the inner circumferential opening, the inner circumferential opening in the radial conductor portion A narrow recess having a shape recessed with respect to another portion of the radial conductor portion so that a circumferential width is narrower than a circumferential width of the inner peripheral opening at a corresponding radial position. It is in.
In the present application, the directions of “axial direction”, “radial direction”, and “circumferential direction” are determined based on a cylindrical core, and “axial direction” is a direction along the central axis of the core. , “Radial direction” represents a direction perpendicular to the direction (axial direction) along the central axis of the core, and “circumferential direction” represents a circumferential direction (or tangential direction) around the central axis of the core. . At this time, each direction about a coil shall prescribe | regulate as a direction in the state by which the coil was wound by the slot.
The “linear conductor” is used as a concept representing a conductor as a single linear member constituting each turn of the coil.
The “rotary electric machine” is used as a concept including a motor (electric motor), a generator (generator), and a motor / generator that performs both functions of the motor and the generator as necessary.
According to the above characteristic configuration, even when the circumferential width of the linear conductor constituting the coil is wider than the circumferential width of the inner circumferential opening of the slot, the narrow recess is formed in the inner circumferential opening of the slot. By letting it pass, the coil can be inserted in the axial direction from the end of the bent coil into the slot of the core.
At this time, since the circumferential width of the linear conductor can be freely set within a range in which the coil can be wound around the slot, the circumferential width of the linear conductor is substantially equal to, for example, the circumferential width inside the slot. By setting, the space factor of the coil can be improved.
In the above configuration, the slot of the core is a so-called semi-open slot in which the circumferential width of the inner circumferential opening is smaller than the circumferential width inside the slot. Therefore, the amount of magnetic flux from a permanent magnet or the like included in the field reaches the surface of the linear conductor constituting the coil can be reduced. Therefore, generation of eddy current can be suppressed and eddy current loss can be reduced.
Therefore, according to said characteristic structure, the armature for rotary electric machines which can reduce an eddy current loss can be provided, aiming at the improvement of the space factor of a coil.
Here, it is preferable that the narrow concave portion is a compression molding portion formed by compressing the radial conductor portion in the circumferential direction and extending in the axial direction.
According to this configuration, a compression-molded portion as a narrow concave portion can be easily formed simply by compressing the radial position of the radial conductor portion at the end of the bending coil corresponding to the inner peripheral opening of the slot in the circumferential direction. can do. When the coil end on one side in the axial direction is bent inward in the radial direction to form a bent coil end, the linear conductor constituting the coil has a circumferential width that is smaller than that before bending. May be larger. Therefore, in order to ensure that the coil can be inserted into the slot in the axial direction while keeping the coil space factor high, before the coil is inserted into the slot, the circumferentially expanded portion of the bent portion is It is preferable to compress in the direction. According to said structure, since a narrow recessed part (compression molding part) can be formed according to compressing the part swelled in the circumferential direction among the bending parts to the circumferential direction, a narrow recessed part (compression molding part) ) Can be formed easily.
Moreover, according to this structure, the cross-sectional area of the surface orthogonal to the energizing direction of the coil can be kept substantially constant over the entire coil. In this case, the electrical resistance value in the compression molded part can be made substantially equal to the electrical resistance value in the part other than the compression molded part. Therefore, it is possible to suppress the occurrence of inconveniences such as locally increasing heat generation in the compression molding portion.
In the above-described characteristic configuration, in a cross section orthogonal to the extending direction of the linear conductor, a direction along the circumferential direction in the slot is a first direction, and a direction orthogonal to the first direction is a second direction. The linear conductor is formed so that the width in the second direction is narrower than the circumferential width of the inner circumferential opening, and the narrow recess corresponds to the inner circumferential opening in the radial conductor. It is preferable that the portion to be formed is a twist forming portion formed by twisting with respect to other portions of the radial conductor portion so that the second direction is substantially parallel to the circumferential direction.
In the present application, the “width in the second direction” represents the width of the linear conductor when viewed from the direction orthogonal to the second direction in the cross section orthogonal to the extending direction of the linear conductor.
According to this configuration, a narrow concave portion is provided by twisting a portion corresponding to the inner peripheral opening in the radial conductor portion with respect to the other portions of the radial conductor portion to form a twisted molded portion. be able to. At this time, since it is not necessary to greatly deform the radial conductor portion locally or to apply a large force locally to the radial conductor portion, the insulating coating covering the linear conductor has a narrow recess. It can suppress that it is damaged by forming.
Further, in order to enjoy the advantage of being a semi-open slot type core as much as possible, the circumferential width of the inner peripheral opening is under the condition that the inner peripheral opening and the linear conductor do not interfere with each other. Although it is desirable to make it as small as possible, according to this configuration, it is possible to avoid the above-mentioned interference only by adopting a linear conductor whose width in the second direction is smaller than the circumferential width of the inner peripheral opening. .
Also in this configuration, since the cross-sectional area of the surface orthogonal to the energization direction of the coil can be kept substantially constant over the entire coil, there is a disadvantage that the amount of heat generation locally increases in the compression molding portion. It can be suppressed from occurring.
In addition, the narrow concave portion compresses the radial conductor portion in the circumferential direction and is a compression-molded portion formed by extending in the axial direction, or the narrow concave portion is formed in the radial conductor portion. In the configuration which is a twist forming portion formed by twisting a portion corresponding to the inner peripheral opening portion with respect to the other portion of the radial conductor portion, the coil is the linear shape constituting the coil side portion. A plurality of conductors are arranged side by side in the radial direction in the slot, the linear conductors constituting the bent coil end portions are arranged in the axial direction, and the narrow concave portions are arranged in the axial direction. This is preferable.
When the narrow concave portions are extended in the axial direction as compression molded portions, by arranging these in parallel in the axial direction, the portions of the compression molded portions extended in the axial direction are in contact with each other in the axial direction. To meet each other. In addition, when the narrow concave portion is configured as the twist forming portion, the axial height of the linear conductor in the twist forming portion is higher than that of other portions of the radial conductor portion adjacent to the twist forming portion. Get higher. Therefore, by arranging the narrow concave portions (twist forming portions) side by side in the axial direction, the portions having the higher axial height contact with each other in the axial direction. As a result, the axial interval between the linear conductors arranged side by side in the axial direction is increased in the portion other than the narrow concave portion at the end of the bending coil. Thereby, when flowing a refrigerant | coolant between linear conductors, since the said refrigerant | coolant flows easily between linear conductors, cooling efficiency improves.
Further, it is preferable that a plurality of coils having different phases are provided, and among the coils of each phase, the linear conductors having different phases constituting the circumferential conductor portion are arranged side by side in the axial direction. .
According to this configuration, even if the linear conductors arranged side by side in the axial direction constitute coils of different phases, it is easy to ensure a certain distance between the coils of different phases, so the insulation structure is simplified. Can be In addition, depending on conditions such as the maximum value of the current flowing through the coil and the maximum value of the voltage applied to both ends of the coil, it is also possible to ensure electrical insulation between the phase coils without providing a special configuration. It becomes. Therefore, the present invention can be effectively applied to the armature for a rotating electrical machine having the above configuration.
In addition, it is preferable that an interphase insulating sheet is disposed between the linear conductors of different phases on the radially inner side of the compression molded portion at the bent coil end.
According to this structure, the electrical insulation between each phase coil can be more appropriately ensured by the interphase insulating sheet. At this time, as described above, since a certain distance is secured by increasing the axial distance between the linear conductors arranged side by side in the axial direction, the insulation performance required for the interphase insulating sheet may be reduced. Manufacturing cost can be reduced. In addition, since the stress applied to the interphase insulating sheet between the linear conductors is reduced, the insulation quality can be stabilized. Therefore, the present invention can be effectively applied to the armature for a rotating electrical machine having the above configuration.
In addition, the core includes protrusions that protrude on both sides in the circumferential direction to form both side walls in the circumferential direction at the radially inner ends of the teeth located between the slots adjacent to each other, Between the slot and the coil side, an in-slot insulating sheet is disposed so as to cover the inner peripheral opening while circling the coil side, and an end of the in-slot insulating sheet in the circumferential direction is It is preferable that the structure is locked to the protruding portion.
According to this structure, the electrical insulation between a core and a coil side part can be appropriately ensured by the in-slot insulating sheet. In addition, the insulating sheet in the slot is arranged so that the end in the direction of circling the coil side is locked to the protruding portion provided in the core and covers the inner peripheral opening of the slot. Without imparting, it is possible to effectively prevent the coil side portion from coming out radially inward. In addition, electrical insulation between the coil side and the field side can be ensured.
A wire comprising a cylindrical core having a plurality of semi-open slot-type slots extending in the axial direction distributed in the circumferential direction and a coil wound around the slot according to the present invention. The circumferential width of the conductor is formed wider than the circumferential width of the inner circumferential opening that opens radially inward of the slot, and the coil is disposed between the coil sides disposed in different slots. A characteristic configuration of a method for manufacturing an armature for a rotating electrical machine having a bent coil end portion that is connected at one end portion in the axial direction and is bent radially inward is a radial direction from the coil side portion at the bent coil end portion. In the radial conductor portion extending to the radial position corresponding to the inner circumferential opening, the circumferential width is narrower than the circumferential width of the inner circumferential opening. Recessed shape The narrow concave portion forming step for forming the narrow concave portion, and the narrow concave portion formed in the narrow concave portion forming step in a state where the narrow concave portion is aligned with the position of the inner peripheral opening, And an insertion step of inserting in the axial direction into the slot from the side.
According to this characteristic configuration, in a coil having a bent coil end on one side in the axial direction, the radial direction corresponding to the inner peripheral opening of the slot (semi-open slot) in the radial conductor portion by the narrow recess forming step A narrow recess is formed at the position having a shape that is recessed with respect to other portions of the radial conductor portion and whose circumferential width is narrower than the circumferential width of the inner circumferential opening. Therefore, even when the circumferential width of the linear conductor constituting the coil is wider than the circumferential width of the inner circumferential opening of the slot, the narrow recess formed in the previous narrow recess forming step in the insertion step Is passed through the inner peripheral opening of the slot, so that the coil can be inserted in the axial direction from the end of the bent coil into the slot of the core.
At this time, since the circumferential width of the linear conductor can be freely set within a range in which the coil can be wound around the slot, the circumferential width of the linear conductor is, for example, substantially equal to the circumferential width inside the slot. By setting, the space factor of the coil can be improved.
In the above configuration, the slot of the core is a semi-open slot, and the circumferential width of the inner circumferential opening is narrower than the circumferential width inside the slot. Therefore, the amount of magnetic flux from a permanent magnet or the like included in the field reaches the surface of the linear conductor constituting the coil can be reduced. Therefore, generation of eddy current can be suppressed and eddy current loss can be reduced.
Therefore, according to said characteristic structure, the armature for rotary electric machines which can reduce an eddy current loss can be manufactured, aiming at the improvement of the space factor of a coil.
Here, it is preferable that the narrow recess forming step is a compression step of compressing a portion corresponding to the inner peripheral opening in the radial conductor portion in the circumferential direction.
According to this structure, a narrow recessed part formation process can be made into the simple process (compression process) of compressing the site | part corresponding to the inner peripheral opening part in a radial direction conductor part to the circumferential direction.
In the above-described characteristic configuration, in a cross section orthogonal to the extending direction of the linear conductor, a direction along the circumferential direction in the slot is a first direction, and a direction orthogonal to the first direction is a second direction. The linear conductor is formed such that a width in the second direction is narrower than a circumferential width of the inner circumferential opening, and the narrow recess forming step includes the inner circumferential opening in the radial conductor. It is preferable that the part corresponding to is a twisting process in which the second direction is twisted with respect to other portions of the radial conductor portion so that the second direction is substantially parallel to the circumferential direction.
According to this configuration, the narrow recessed portion forming step is a simple step (twisting step) in which a portion corresponding to the inner circumferential opening in the radial conductor portion is twisted with respect to the other portions of the radial conductor portion. It can be. At this time, since it is not necessary to greatly deform the radial conductor portion locally or to apply a large force locally to the radial conductor portion, the insulating coating covering the linear conductor has a narrow recess. It can suppress that it is damaged by forming.
Further, in the configuration in which the narrow concave portion forming step is a compression step, in the compressing step, the bent portion of the radial conductor portion constituting the coil is further compressed in the circumferential direction simultaneously with forming the narrow concave portion. It is preferable to adopt a configuration to do so.
When the end of the coil on one side in the axial direction is bent inward in the radial direction to form a bent coil end, the linear conductor constituting the coil has a greater width in the circumferential direction at the bent portion than before bending. There is a case. Therefore, in order to ensure that the coil can be inserted into the slot in the axial direction while keeping the space factor of the coil high, the circumferentially expanded portion of the bent portion is compressed in the circumferential direction before the insertion process. It is preferable to keep it. According to this configuration, the radial conductor portion and the bent portion provided in the vicinity of the same linear conductor can be compressed in the circumferential direction in a single process, so that the manufacturing process is not complicated. The armature for rotating electrical machines according to the invention can be manufactured.
In addition, the core includes protrusions that protrude on both sides in the circumferential direction to form both side walls in the circumferential direction at the radially inner ends of the teeth positioned between the adjacent slots. In the inserting step, the coil is inserted into the slot with the in-slot insulating sheet arranged in the slot extending radially inward from the inner peripheral opening, and the in-slot insulation It is preferable to further include a locking step of locking the end portion extending radially inward of the sheet to the protruding portion after the insertion step.
According to this configuration, in the inserting step, the coil can be inserted into the slot with the insulating sheet in the slot interposed between the core and the coil, so that the linear conductor constituting the coil is covered. The coil can be inserted into the slot without damaging the insulating coating.
Further, in the locking step after the insertion step, the end portion of the insulating sheet in the slot is locked to the protruding portion, thereby covering the inner peripheral opening of the slot without giving a special configuration, and the coil constituting the coil It is possible to effectively prevent the side portion from coming out radially inward.
Furthermore, the electrical insulation between the core and the coil side and between the coil side and the field side can be appropriately ensured by the in-slot insulating sheet.
It is sectional drawing which shows the whole structure of the rotary electric machine which concerns on 1st embodiment of this invention. It is a perspective view showing the whole stator composition concerning a first embodiment of the present invention. It is a top view which shows the stator which concerns on 1st embodiment of this invention. It is a perspective view which shows the coil of the stator which concerns on 1st embodiment of this invention. It is a top view in the state where the phase insulation sheet of the stator concerning a first embodiment of the present invention is arranged. It is VI-VI sectional drawing in FIG. It is VII-VII sectional drawing in FIG. It is VIII-VIII sectional drawing in FIG. It is explanatory drawing for demonstrating the compression process for manufacturing the stator which concerns on 1st embodiment of this invention. It is a perspective view which shows the one aspect | mode of the insertion process for manufacturing the stator which concerns on 1st embodiment of this invention. It is the elements on larger scale in FIG. It is explanatory drawing for demonstrating the latching process for manufacturing the stator which concerns on 1st embodiment of this invention. It is a top view which shows a part of stator which concerns on 2nd embodiment of this invention. FIG. 6 is a partial cross-sectional view in the axial direction of a stator according to a second embodiment of the present invention. It is an enlarged view of the twist formation part which concerns on 2nd embodiment of this invention. It is XVI-XVI sectional drawing in FIG. It is XVII-XVII sectional drawing in FIG. It is explanatory drawing of the insertion process for manufacturing the stator which concerns on 2nd embodiment of this invention.
1. First Embodiment A first embodiment of an armature for a rotating electrical machine according to the present invention will be described with reference to the drawings. In the present embodiment, the case where the armature for a rotating electrical machine according to the present invention is applied to the stator 2 of the rotating electrical machine 1 will be described as an example. FIG. 1 is a cross-sectional view illustrating the overall configuration of the rotating electrical machine 1 according to the present embodiment, and FIG. 2 is a perspective view illustrating the overall configuration of the stator 2 according to the present embodiment. The stator 2 according to the present embodiment is a combination of the stator core shape and the coil shape so as to reduce the eddy current loss while improving the space factor of the coil 21 in the slot 12 of the stator core 11. It has the characteristics. Hereinafter, the configuration of each part of the rotating electrical machine 1 will be described in detail.
1-1. Overall Configuration of Rotating Electric Machine As shown in FIG. 1, the rotating electric machine 1 includes a stator 2, a rotor 3, and a case 5. The stator 2 includes a coil 21, and a magnetic field can be generated by passing a current through the coil 21. In the present embodiment, the stator 2 corresponds to the “armature for rotating electrical machine” in the present invention. The stator 2 is fixed to the inner peripheral surface of the case 5. The configuration of the stator 2 will be described in detail later. Further, on the radially inner side of the stator 2, a rotor 3 as a field magnet having a permanent magnet (not shown) is disposed so as to be rotatable relative to the stator 2 with the rotor shaft 4 as a rotation axis. Yes. That is, the rotating electrical machine 1 in this embodiment is an inner rotor type rotating electrical machine including a stator 2 as an armature. The case 5 is formed in a cylindrical shape in which an end wall 5a is provided on one side in the axial direction. The case 5 opens to the other side in the axial direction, and a cover 6 is attached to the case 5 so as to close the opening. And the bearing 7 is provided in the radial direction center part of the end wall 5a of the case 5 and the cover 6, and the rotor 3 and the rotor shaft | axis 4 are rotatably supported with respect to the case 5 and the cover 6 via the bearing 7. FIG. ing.
1-2. Configuration of Stator As shown in FIG. 2, the stator 2 includes a stator core 11 and a coil 21. The stator core 11 is formed by laminating a plurality of hollow disc-shaped electromagnetic steel plates, and is formed in a substantially cylindrical shape. On the inner peripheral surface of the stator core 11, a plurality of slots 12 extending in the axial direction L are distributed in the circumferential direction C and provided at predetermined circumferential intervals. In the present embodiment, the stator core 11 corresponds to a “core” in the present invention. Each slot 12 has the same cross-sectional shape, and has a predetermined width and depth. In the present embodiment, the stator core 11 is provided with a total of 48 slots 12 on the entire circumference thereof. Each slot 12 includes an inner peripheral opening 13 that opens to the inside in the radial direction R of the stator core 11.
As shown in FIG. 3A, teeth 15 are provided between the slots 12 adjacent to each other of the stator core 11. At this time, the slot 12 is provided between the teeth 15 adjacent to each other. Protruding portions 16 that protrude in the circumferential direction C are provided on both ends of the teeth 15 in the circumferential direction C at the ends of the teeth 15 on the inner side in the radial direction R. In this example, the projecting portion 16 is formed integrally with the teeth 15 so that the cross-sectional shape orthogonal to the axial direction L is substantially rectangular and is continuous in the axial direction L. And the inner peripheral opening part 13 is formed between the two protrusion parts 16 provided in each of the adjacent two teeth 15 and facing the circumferential direction C. Further, the space outside the inner circumferential opening 13 in the slot 12 in the radial direction R is the slot interior 14.
As described above, the inner peripheral opening 13 is formed between the two protrusions 16 facing each other in the circumferential direction C provided in each of the two adjacent teeth 15. Therefore, the slot 12 included in the stator core 11 in the present embodiment is a semi-open slot in which the circumferential width W1 of the inner circumferential opening 13 that opens inward in the radial direction R is narrower than the circumferential width W3 of the slot interior 14. It has become. A linear conductor 31 constituting the coil 21 is disposed inside the slot 14, and the coil 21 is wound around the slot 12. At this time, as will be described in detail later, an in-slot insulating sheet 42 is disposed between the slot 12 and the coil 21.
The stator 2 includes a plurality of coils 21 having different phases. In the present embodiment, the stator 2 is a stator used in the rotating electrical machine 1 driven by a three-phase alternating current, and includes a three-phase coil 21 of U phase, V phase, and W phase. Here, the coil 21 of each phase is formed using a linear conductor 31. In the present embodiment, the linear conductor 31 is configured by a single rectangular wire having a substantially rectangular cross section. Further, in this example, in order to maximize the space factor of the coil 21 in relation to the size of the slot 12, the circumferential width W5 of the linear conductor 31 is made substantially equal to the circumferential width W3 of the slot interior 14. Is formed. More specifically, the circumferential width W5 of the linear conductor 31 is determined based on the precondition that the coil 21 formed using the linear conductor 31 can be physically inserted into the slot interior 14. 14 is set to a value substantially equal to the circumferential width W3. Thereby, the energy efficiency of the rotary electric machine 1 is improved by improving the space factor of the coil 21. As described above, in the present embodiment, the slot 12 of the stator core 11 is a semi-open slot, and the circumferential width W1 of the inner circumferential opening 13 is narrower than the circumferential width W3 of the slot interior 14. Therefore, the circumferential width W5 of the linear conductor 31 having a circumferential width substantially equal to the circumferential width W3 of the slot interior 14 is formed wider than the circumferential width W1 of the inner circumferential opening 13 of the slot 12. Become. Therefore, in the present embodiment, the radial conductor portion 25 of the bending coil end portion 24 of each coil 21 has a narrow concave portion whose circumferential width W7 is narrower than the circumferential width W1 of the inner circumferential opening 13 of the slot 12. 32 is provided. Details will be described later.
Each phase coil 21 is formed in a predetermined shape. In the present embodiment, the coil 21 is formed in a substantially cylindrical corrugated shape as a whole, as shown in FIG. FIG. 4 shows only the U-phase coil 21u. Each coil 21 includes a coil end portion 23 that connects a coil side portion 22 disposed in the slot 12 and a pair of coil side portions 22 disposed in different slots 12 at both ends in the axial direction L of the stator core 11. And. The coil side portions 22 are linearly formed so as to extend along the axial direction L corresponding to the shape of the slot interior 14. The coil end portion 23 is formed so as to extend along the circumferential direction C by connecting a pair of coil side portions 22 arranged in different slots 12. As shown in FIG. 2, each coil end portion 23 is disposed so as to protrude from both axial end portions of the stator core 11 in the axial direction L of the stator core 11. As shown in FIG. 4, the coil 21 extends in the axial direction L and is sequentially arranged in the plurality of slots 22, and the coil side portions 22 are connected to the coil end 23 on one side in the axial direction L and the axial direction L. The coil ends 23 are alternately connected to the other coil end 23 to form a waveform that circulates in the circumferential direction C of the stator core 11. As described above, the coils 21 of the respective phases are formed in advance so as to have a shape that is wound around the stator core 11 by wave winding in a state in which the coil side portions 22 are respectively disposed in the corresponding slots 12. .
In the present embodiment, the coil 21 is formed as a set of two coil side portions 22 arranged in the same slot 12. The set of two coil side portions 22 is formed by circulating a single continuous linear conductor 31 in the circumferential direction C of the stator core 11. In addition, two sets of two coil side portions 22 constituting the in-phase coil 21 are arranged in parallel in the circumferential direction C so as to be arranged in the slots 12 adjacent to each other. The two sets of coil side portions 22 are connected so as to be continuous at a predetermined position of the coil end portion 23. Therefore, the coil 21 shown in FIG. 4 is formed by circulating a single continuous linear conductor 31 in the circumferential direction C of the stator core 11 four times. In the present embodiment, three sets of coils 21 having substantially the same shape as that shown in FIG. 4 are arranged adjacent to each other in the radial direction R in the same slot 12. Therefore, for each of the two adjacent slots 12, the six coil side portions 22 are arranged in a line in the radial direction R in the slot 12.
4 shows only the U-phase coil 21u, the V-phase coil 21v and the W-phase coil 21w are also configured to have the same shape. Also, three sets of the V-phase coil 21v and the W-phase coil 21w are arranged adjacent to each other in the radial direction R in the same slot 12, and six adjacent coil sides of the same phase are provided for each of the two adjacent slots 12. 22 are aligned in the radial direction R and arranged in a line in the slot 12.
As shown in FIG. 3B, the stator core 11 has two U-phase slots 12u adjacent to each other, two V-phase slots 12v adjacent to each other, and two W-phase slots 12w adjacent to each other sequentially. It is formed repeatedly. Then, the coil side portions 22 of the U-phase coil 21u, the V-phase coil 21v, and the W-phase coil 21w having the shapes shown in FIG. 4 are sequentially shifted by two slots in the circumferential direction C, respectively. Arranged in the V-phase slot 12v and the W-phase slot 12w.
Of the coil ends 23 at both ends in the axial direction L of the stator core 11 of each phase coil 21, the coil end 23 on one side in the axial direction L (upper side in FIG. 2) is bent to the inside in the radial direction R. The end 24 is provided. As shown in FIG. 6, the bent coil end portion 24 is bent inward in the radial direction R at a bent portion 34 at a substantially right angle with respect to the coil side portion 22. As shown in FIG. 3B and FIG. 4, the bent coil end portion 24 is more radial than the radial conductor portion 25 extending in the radial direction R from the coil side portion 22 and the inner peripheral opening portion 13 of the slot 12. And a circumferential conductor portion 26 that connects the pair of radial conductor portions 25 in the circumferential direction C inside the R.
In the present embodiment, the linear conductor 31 constituting the radial conductor portion 25 is formed so as to be bent inward in the radial direction R after extending in the axial direction L of the stator core 11 from the coil side portion 22. Yes. As described above, since the six linear conductors 31 constituting the coil side portion 22 are arranged in a line in the radial direction R in the slot 12, the radial conductor portion 25 has six wires. The conductors 31 are arranged in an aligned manner so as to be bent inward in the radial direction R from a state substantially parallel to the axial direction L and to be in a state substantially parallel to the radial direction R while maintaining the state of being aligned in a line. Thereby, the radial direction conductor part 25 becomes the structure arrange | positioned along with the axial direction L. As shown in FIG. 2 and 3B, the radial conductor portion 25 is at least in the radial outer side of the inner peripheral opening 13 of the slot 12 of the stator core 11 in the radial conductor portion. The portions 25 are arranged without overlapping in the circumferential direction C. Further, the radial conductor portion 25 extends to the inside in the radial direction R at least with respect to the inner peripheral surface of the stator core 11. In the present embodiment, a portion of the linear conductor 31 constituting the bent coil end portion 24 having the same position as the coil side portion 22 and the circumferential direction C is used as the radial conductor portion 25.
The linear conductor 31 constituting the circumferential conductor portion 26 extends while bending in the circumferential direction C from the radial conductor portion 25 corresponding to one slot 12 toward the radial conductor portion 25 corresponding to the other slot 12. After being taken out, it is formed to be bent outward in the radial direction R and connected to the radial conductor portion 25 corresponding to the other slot 12. As described above, since the radial conductor portion 25 extends at least inward in the radial direction R with respect to the inner peripheral surface of the stator core 11, the circumferential conductor portion 26 extends radially inward with respect to the inner peripheral surface of the stator core 11. Placed in. At this time, in the circumferential conductor portion 26, of the six linear conductors 31 arranged in a line in the radial direction R in the slot 12, two linear conductors arranged on the outer peripheral side in the radial direction R. The conductors 31 are arranged side by side in the radial direction R, and a total of four linear conductors 31 are arranged in combination with the two linear conductors 31 arranged on the outer peripheral side of the radial direction R in each of the two adjacent slots 12 of the same phase. The conductors 31 are arranged side by side in the radial direction R. Of the six linear conductors 31 arranged in a line in the radial direction R in the slot 12, the two linear conductors 31 arranged on the inner peripheral side in the radial direction R are arranged in the radial direction R. A total of four linear conductors 31 are arranged in the radial direction R together with the two linear conductors 31 that are arranged side by side and arranged on the inner peripheral side in the radial direction R in each of the two adjacent slots 12 of the same phase. Are arranged side by side. Of the six linear conductors 31 arranged in a line in the radial direction R in the slot 12, the remaining two linear conductors 31 are arranged side by side in the radial direction R so as to be adjacent to each other. A total of four linear conductors 31 are arranged in the radial direction R together with the remaining two linear conductors 31 in each of the two slots 12. The three sets of four linear conductors 31 arranged side by side in the radial direction R are arranged on the one side in the axial direction L as they are continuous from the coil side portion 22 arranged outside the radial direction R in the slot 12. Is arranged.
In addition, in the bending coil end portion 24 of each phase coil 21, the linear conductors 31 constituting the coils 21 of different phases are arranged adjacent to each other in the axial direction L in the circumferential conductor portion 26. In this example, as shown in FIGS. 5 and 6, the linear conductor 31 constituting the U-phase coil 21 u is in the axial direction L with respect to the linear conductor 31 constituting the V-phase coil 21 v and the W-phase coil 21 w. It is arranged adjacent to the side (the right side in FIG. 6). The linear conductor 31 constituting the V-phase coil 21v is disposed adjacent to the one side in the axial direction L with respect to the linear conductor 31 constituting the W-phase coil 21w in an area overlapping with the W-phase coil 21w in the circumferential direction C. Has been. Further, the linear conductor 31 constituting the V-phase coil 21v is adjacent to the other side in the axial direction L with respect to the linear conductor 31 constituting the U-phase coil 21u in a region overlapping with the U-phase coil 21u in the circumferential direction C. Are arranged. The linear conductor 31 constituting the W-phase coil 21w is arranged adjacent to the other side in the axial direction L with respect to the linear conductor 31 constituting the U-phase coil 21u and the V-phase coil 21v.
In order to ensure electrical insulation between the linear conductors 31 constituting the circumferential conductor portions 26 of the coils 21 of different phases adjacent to each other in the axial direction L at the bent coil end portion 24. As shown in FIGS. 5 and 6, an interphase insulating sheet 41 is interposed and arranged. As the interphase insulating sheet 41, for example, a sheet formed of a material having high electrical insulation and heat resistance such as a laminate of aramid fiber and polyethylene terephthalate can be used.
1-3. Configuration of Radial Conductor Portion Next, the configuration of the radial conductor portion 25 of the bending coil end 24 in each coil 21 will be described. As shown in FIG. 3B and FIG. 4, the radial conductor portion 25 includes a narrow recess 32 whose circumferential width W7 is narrower than the circumferential width W1 of the inner circumferential opening 13 of the slot 12. . The narrow concave portion 32 is provided at a radial position corresponding to the inner peripheral opening 13 of the slot 12 in the radial conductor portion 25. Note that the circumferential width of the portion other than the narrow recess 32 in the radial conductor portion 25 is equal to the circumferential width W5 of the linear conductor 31 constituting the coil 21, and therefore the circumferential direction of the inner circumferential opening 13 of the slot 12. It is formed wider than the width W1. That is, in the radial conductor portion 25, a narrow concave portion 32 is formed at a radial position corresponding to the inner peripheral opening portion 13 of the slot 12, and is recessed with respect to a portion other than the radial conductor portion 25. Has been.
The narrow recess 32 is formed so that its outer shape corresponds to the outer shape of the protruding portion 16 provided at the inner end in the radial direction R of the tooth 15 of the stator core 11 when viewed from the axial direction L. Yes. That is, a narrow recess 32 is formed in the radial conductor portion 25 by recessing only the vicinity of the radial position corresponding to the inner peripheral opening 13 of the slot 12. At this time, the circumferential width W 7 of the narrow recess 32 is formed to be narrower than the circumferential width W 1 of the inner circumferential opening 13 of the slot 12. In this way, the narrow concave portion 32 in which the circumferential width W7 is narrower than the circumferential width W1 of the inner circumferential opening 13 only at the radial position corresponding to the inner circumferential opening 13 of the slot 12 in the radial conductor 25. Is formed. In addition, since only the predetermined position of the radial direction conductor part 25 is made into the narrow recessed part 32, the process site | part of the coil 21 becomes only the site | part corresponding to the inner peripheral opening part 13, and a process becomes easy.
As described above, the radial conductor portion 25 includes the narrow concave portion 32 having a shape corresponding to the outer shape of the protruding portion 16 at the radial position corresponding to the inner peripheral opening portion 13 of the slot 12. When viewed from the axial direction L, the protruding portion 16 provided at the inner end in the radial direction R of the tooth 15 and the linear conductor 31 constituting the coil 21 have no overlapping portion. Therefore, as in the present embodiment, a semi-open slot type stator core 11 and a coil 21 constituted by a linear conductor 31 having a circumferential width W5 substantially equal to the circumferential width W3 of the slot inside 14 of the stator core 11 are used. Even when the stator 2 is configured, the coil 21 is connected to the bent coil end portion 24 with respect to the slot 12 by passing the narrow recess 32 through the inner peripheral opening 13 of the slot 12 included in the stator core 11. It can be inserted in the axial direction L from the side.
Here, in the present embodiment, the linear conductor 31 is formed of a single rectangular wire, and the circumferential width W5 of the linear conductor 31 is formed to be substantially equal to the circumferential width W3 of the slot interior 14. Therefore, for example, the space factor of the coil 21 in the slot interior 14 is improved as compared with the case where the coil 21 is configured using an aggregate of thin linear conductors configured by bundling a plurality of thin linear conductors. Can be made.
In this embodiment, the slot 12 of the stator core 11 is a so-called semi-open slot in which the circumferential width W1 of the inner circumferential opening 13 is narrower than the circumferential width W3 of the slot interior 14. Therefore, when the rotor 3 rotates, the amount by which the magnetic flux from the permanent magnet included in the rotor 3 reaches the surface of the linear conductor 31 constituting the coil 21 can be reduced. Therefore, generation | occurrence | production of the eddy current in the surface of the linear conductor 31 can be suppressed, and an eddy current loss can be reduced.
Therefore, according to the configuration of the stator 2 according to the present embodiment, both improvement of the coil space factor and reduction of eddy current loss can be achieved.
Here, in the present embodiment, the narrow concave portion 32 is a compression-molded portion 33 formed by compressing a portion extending in the radial direction R of the radial conductor portion 25 in the circumferential direction C. As shown in FIGS. 4 and 6, the radial conductor portion 25 is compressed in the circumferential direction C and extended in the axial direction L by the compression molding portion 33. The portions of the compression molding portion 33 that extend in the axial direction L are arranged side by side in the axial direction L. In other words, the narrow recesses 32 are arranged in the axial direction L. In the present embodiment, the compression molding portion 33 has a cross-sectional area of the cross section perpendicular to the energizing direction of the coil 21 in the compression molding portion 33 in a portion other than the compression molding portion 33 over the entire radial direction R. It is extended in the axial direction L while being compressed in the circumferential direction C so as to be substantially equal to the cross-sectional area of the cross section. Thereby, since the cross-sectional area of the cross section orthogonal to the energizing direction is kept substantially constant over the entire coil 21, the electric resistance value in the compression molding portion 33 is substantially equal to the electric resistance value in a portion other than the compression molding portion 33. Can be equal. Therefore, it is possible to suppress the occurrence of inconveniences such as locally increasing heat generation in the compression molding section 33.
Moreover, while the compression molding part 33 is extended and formed in the axial direction L, the part extended in the axial direction L among the compression molding parts 33 is arranged side by side in the axial direction L, as shown in FIG. The portions of the compression-molded portion 33 extended in the axial direction L are in contact with each other in the axial direction L. As a result, as can be understood with reference to FIGS. 7 to 9, the linear conductor 31 adjacent to the axial direction L is provided at a portion other than the compression molding portion of the bending coil end portion 24 without particularly providing a spacer or the like. The axial distance D between them increases. Thereby, for example, when a refrigerant is caused to flow between the linear conductors 31 in order to cool the bent coil end portion 24, the refrigerant easily flows between the linear conductors 31 and heat exchange efficiency is increased. improves.
As described above, the interphase insulating sheet 41 is interposed between the linear conductors 31 constituting the coils 21 of different phases that are adjacent to each other in the axial direction L at the bending coil end 24. Yes. As shown in FIGS. 5 and 6, the interphase insulating sheet 41 is disposed on the inner side in the radial direction R with respect to the compression molding portion 33 formed in the radial conductor portion 25. At this time, as described above, the compression molding portion 33 is formed to extend in the axial direction L, and the portions of the compression molding portion 33 that extend in the axial direction L are arranged side by side in the axial direction L, so that the axial direction L Since the axial distance D between the adjacent linear conductors 31 is increased, the insulation performance required for the interphase insulating sheet 41 can be reduced, and the manufacturing cost can be reduced. In addition, since the stress applied to the interphase insulating sheet 41 between the linear conductors 31 in the axial direction L can be reduced, the insulation quality can be stabilized.
1-4. Next, a method for manufacturing the stator 2 according to this embodiment will be described. The stator 2 according to the present embodiment includes a core formation process, a coil preliminary formation process, a compression process, an insertion process, and a locking process, and can be manufactured through these processes. Below, these each process is demonstrated in detail.
The core forming step is a step of forming the stator core 11. In the core forming process, first, a plurality of thin electromagnetic steel sheets are formed into a hollow disk-like predetermined shape (the semi-open slot type shape described above). At this time, each electromagnetic steel plate is formed in the same shape. A plurality of electromagnetic steel plates having the same shape are stacked in the axial direction L, and held and fixed by a cylindrical core holder (not shown). In this way, the stator core 11 is formed.
The coil preliminary forming step is a step of forming the coils 21 of the respective phases in advance. In the coil pre-formation step, each phase of a predetermined shape (the above-described wave winding shape) is obtained by using a single linear conductor 31 composed of rectangular wires and using a predetermined coil forming jig (not shown). The coil 21 is formed. In the coil 21 of each phase formed in this coil pre-forming step, the coil side portion 22 extending in the axial direction L is bent inward in the radial direction R to form the radial conductor portion 25 or outside in the radial direction R. When the radial conductor portion 25 extending in the axial direction is bent in the axial direction L to form the coil side portion 22, the bent portion 34 connecting the coil side portion 22 and the radial conductor portion 25 of the bent coil end portion 24 is There may be a bulging portion protruding in the direction C. In this case, the circumferential width of the bulging portion may be larger than the circumferential width W5 of the linear conductor 31 constituting the coil 21. In particular, as in the present embodiment, in order to increase the space factor of the coil 21 in the slot interior 14, the coil 21 is used by using a linear conductor 31 having a circumferential width W 5 formed substantially equal to the circumferential width W 3 of the slot interior 14. Such a situation is likely to occur.
The compression step is a step of compressing and forming the linear conductors 31 constituting the coils 21 of the respective phases formed in advance in the coil preliminary forming step into a predetermined shape. In the present embodiment, the radial width of the radial conductor portion 25 extending in the radial direction from the coil side portion 22 in the bent coil end portion 24 is a radial position corresponding to the inner peripheral opening portion 13, and the circumferential width of the inner peripheral opening portion 13. The narrow recess forming step for forming the narrow recess 32 having a shape recessed with respect to the other portion of the radial conductor portion 25 is performed by this compression step so as to be narrower than the circumferential width W1. In the compression step, the bulging portion generated in the bent portion 34 of the coil 21 of each phase is compressed in the circumferential direction C, and is shaped so that the circumferential width is substantially equal to the circumferential width W5 of the linear conductor 31. . Further, in the compression step, the radial direction R position corresponding to the inner circumferential opening 13 of the slot 12 of the stator core 11 in the radial conductor portion 25 is compressed in the circumferential direction C, and the circumferential width W7 thereof is the inner circumferential opening. 13 is formed to be narrower than the circumferential width W1. In other words, in the compression step, the portion corresponding to the inner peripheral opening 13 in the radial conductor portion 25 is compressed in the circumferential direction C. Here, “the portion corresponding to the inner peripheral opening 13 in the radial conductor portion 25” means “the portion of the radial conductor 25 where the inner peripheral opening 13 corresponds to the radial position”. means. In this way, the compression molding portion 33 as the narrow recess 32 is formed.
Here, the bent portion 34 is located at a portion where the coil side portion 22 and the radial conductor portion 25 are connected, and as is apparent from FIGS. 4 and 9, the inner peripheral opening in the radial conductor portion 25. The radial R position corresponding to 13 and the bent portion 34 are located close to each other on the same linear conductor 31. These parts are both compressed and molded in the circumferential direction C. Therefore, in the present embodiment, the bulging portion generated in the bent portion 34 in this compression step is compressed in the circumferential direction C, and at the same time, corresponds to the inner peripheral opening 13 in the radial conductor portion 25. The compression molding part 33 is formed by compressing the radial direction R position in the circumferential direction C as well. In other words, the radial direction R position corresponding to the inner circumferential opening 13 in the radial conductor portion 25 is compressed in the circumferential direction C to form the compression molded portion 33, and at the same time, it is generated in the bent portion 34. The bulging portion is also compressed in the circumferential direction C. In this way, the radial conductor portion 25 and the bent portion 34 provided close to each other on the same linear conductor 31 can be compressed together in the circumferential direction C in a single work process. The stator 2 can be manufactured without an increase.
When the radial conductor portion 25 and the bent portion 34 are compressed in the circumferential direction C and formed, for example, the protrusions 16 provided on the teeth 15 of the stator core 11 are arranged on the planes facing each other in parallel. A pair of molds (not shown) provided with protrusions corresponding to the cross-sectional shape can be used. That is, by pressing the mold against the linear conductor 31 constituting the radial conductor portion 25 and the bent portion 34 from both sides in the circumferential direction C, the compression molded portion 33 is formed and the bent portion 34 is formed. The circumferential width of can be adjusted.
The insertion step is a step of inserting the coils 21 of the respective phases formed into a predetermined shape through the compression step into the slots 12 included in the stator core 11 in the axial direction L. In other words, in the insertion step, the coil 21 is axially moved into the slot 12 from the bent coil end 24 side in a state where the narrow concave portion formed in the narrow concave portion forming step is aligned with the position of the inner peripheral opening 13. It is a process of inserting into L. Here, at the stage where the compression process is completed, the compression molding portion 33 is provided in the radial conductor portion 25 and the circumferential width of the bent portion 34 is adjusted to be substantially equal to the circumferential width W5 of the linear conductor 31. Therefore, when viewed from the axial direction L, the stator core 11 and the linear conductor 31 constituting the coil 21 of each phase are configured so as not to overlap. In this insertion step, as shown in FIGS. 10 and 11, the compression molding portion 33 as the narrow concave portion 32 in the radial conductor portion 25 and the inner peripheral opening portion 13 of the slot 12 included in the stator core 11 are made to correspond to each other. In the state, the coil 21 is inserted into the slot 12 in the axial direction L from the bent coil end 24 side.
As described above, in the present embodiment, the coils 21 of each phase are formed in advance so that each coil side portion 22 has a wave shape that can be disposed in the corresponding slot 12. Thus, by forming the coils 21 of the respective phases in a predetermined shape in advance, the coils 21 can be easily inserted into the slots 12 in the axial direction L. Therefore, it is possible to reduce the work load when the coils 21 of the respective phases are assembled to the stator core 11.
At this time, in the present embodiment, as shown in FIG. 10, the U-phase, V-phase, and W-phase coils 21 are combined to form one unit, and each coil side portion 22 corresponds to the corresponding slot 12. The unit is integrally inserted into the slot 12 in a state of being aligned so as to be disposed in the slot 12. It is to be noted that three subunits are formed by combining the U-phase, V-phase, and W-phase coils 21 having the shape shown in FIG. 4 and arranged at the same position in the radial direction R in the slot 12. And the coil side portions 22 may be sequentially inserted integrally into the slots 12 in such a state that the coil side portions 22 are positioned so as to be arranged in the corresponding slots 12 respectively. In this case, the subunits are sequentially inserted from the subunits arranged outside the radial direction R in the slot 12. Alternatively, each coil 21 having the shape shown in FIG. 4 may be sequentially inserted into the slot 12 such that each coil side portion 22 is disposed in the corresponding slot 12. In this case, the coil side portion 22 is disposed outside the radial direction R in the slot 12, and the circumferential conductor portion 26 of the bending coil end portion 24 is sequentially inserted from the coil 21 disposed on one side in the axial direction L. .
In the present embodiment, as shown in FIGS. 11 and 12, the in-slot insulating sheet 42 disposed in the slot 12 extends to the inside in the radial direction R from the inner peripheral opening 13 of the slot 12 and opens. In this state, the coil 21 is inserted into the slot 12. That is, the in-slot insulating sheet 42 is arranged so that the inside of the slot 12 makes a round along the inner surface of the slot 12 and both end portions 42e thereof protrude inward in the radial direction R from the inner peripheral opening 13. . As the inter-slot insulating sheet 42, for example, a sheet formed of a material having high electrical insulation and heat resistance such as a laminate of aramid fiber and polyethylene terephthalate is used for the in-slot insulating sheet 42. it can. In this state, the coil 21 is inserted on the inner peripheral side of the in-slot insulating sheet 42 that makes a round along the inner surface of the slot 12. In this way, since the coil 21 is inserted into the slot 12 with the in-slot insulating sheet 42 interposed between the stator core 11 and the coil 21 in the insertion step, the linear conductor constituting the coil 21 The coil 21 can be inserted into the slot 12 without damaging the insulating coating covering 31.
In the locking step, the end portion 42e of the in-slot insulating sheet 42 extending inward in the radial direction R from the inner peripheral opening 13 of the slot 12 is locked to the protruding portion 16 provided in the tooth 15 of the stator core 11. It is a process. In the present embodiment, as described above, the protruding portion 16 having a substantially rectangular cross section is formed integrally with the tooth 15. The projecting portion 16 includes a circumferential wall portion 16c facing the inner circumferential opening 13 of the slot 12, and an outer-diameter side wall portion 16r facing the slot interior 14 located on the outer side in the radial direction R when viewed from the projecting portion 16. It has. In the locking step, as shown in FIG. 12, the end portions 42 e on both sides of the in-slot insulating sheet 42 are sequentially folded and locked to the outer diameter side wall portion 16 r of the protruding portion 16. At this time, the end portion 42e on one side in the circumferential direction C is locked to the outer diameter side wall portion 16r of the protruding portion 16 provided on the tooth 15 on the other side in the circumferential direction C. Further, the other end portion 42e on the other side in the circumferential direction C is locked to the outer diameter side wall portion 16r of the protruding portion 16 provided on the tooth 15 on the one side in the circumferential direction C through the in-slot insulating sheet 42. In addition, in order to improve workability when the end portion 42e is folded, it is preferable to crease the in-slot insulating sheet 42 in advance along the axial direction L at a predetermined position.
Thus, in-slot insulation is provided between the slot 12 and the coil side 22 disposed in the slot 12 of the coil 21 so as to cover the inner peripheral opening 13 of the slot 12 while circling the coil side 22. The sheet 42 is disposed. Therefore, the insulating sheet 42 in the slot appropriately ensures electrical insulation between the stator core 11 and the coil side 22 constituting the coil 21 and between the coil side 22 and the rotor 3 as a field. be able to.
Further, the end portions 42e on both sides of the in-slot insulating sheet 42 are locked to the outer diameter side wall portions 16r of the protrusions 16 provided on the adjacent teeth 5, and the inner peripheral opening 13 of the slot 12 is covered. Further, it is possible to effectively prevent the coil side 22 constituting the coil 21 from coming out inward in the radial direction R. Therefore, it is not necessary to separately provide a member (such as a wedge) that is normally installed to close the inner peripheral opening 13 of the slot 12, and the manufacturing cost can be reduced and the manufacturing process can be simplified. .
Then, the stator 2 according to the present embodiment is completed by connecting the coils 21 of the respective phases at predetermined positions by welding or the like.
2. Second Embodiment Next, a second embodiment of the armature for a rotating electrical machine according to the present invention will be described. FIG. 13 is a plan view showing a part of the stator 2 according to the present embodiment. The stator core 11 included in the stator 2 has the same configuration as that of the first embodiment, but the configuration of the coil 21 included in the stator 2, specifically, the configuration of the narrow recess 32 included in the coil 21. However, this is different from the first embodiment. Below, the structure of the armature for rotary electric machines which concerns on this embodiment is demonstrated centering around difference with said 1st embodiment, referring FIGS. 13-18 suitably. Note that points not particularly described are the same as those in the first embodiment. Of the drawings referred to in the following description, FIGS. 13, 14, and 18 are drawings corresponding to FIGS. 3B, 6, and 11 referred to in the first embodiment, respectively. .
2-1. Configuration of Radial Conductor Part As shown in FIG. 13, in this embodiment, the linear conductor 31 forming the coil 21 is formed by a single rectangular wire having a substantially rectangular cross section, as in the first embodiment. The circumferential width of the linear conductor 31 is formed to be substantially equal to the circumferential width W3 of the slot interior 14 (see FIG. 3A). Here, the “circumferential width of the linear conductor” is a direction along the circumferential direction C in the slot 12 (first direction shown in FIGS. 16 and 17) in a cross section orthogonal to the extending direction of the linear conductor 31. It means the width W8 of the linear conductor 31 of D1). The width W8 in the first direction of the linear conductor 31 (hereinafter simply referred to as “first direction width W8”) allows the coil 21 formed using the linear conductor 31 to be physically inserted into the slot interior 14. Is set to a value substantially equal to the circumferential width W3 of the slot interior 14. Therefore, the first direction width W8 of the linear conductor 31 is formed wider than the circumferential direction width W1 of the inner peripheral opening 13 of the slot 12.
On the other hand, in the cross section orthogonal to the extending direction of the linear conductor 31, the width W9 of the linear conductor 31 in the direction intersecting the first direction D1 in the slot 12 (second direction D2 shown in FIGS. 16 and 17) ( Hereinafter, the “second direction width W9” is simply narrower than the circumferential width W1 of the inner circumferential opening 13 (see FIG. 3A). As is clear from FIGS. 16 and 17, in the present embodiment, the second direction D2 is a direction orthogonal to the first direction D1.
Similar to the first embodiment, the linear conductor 31 constituting the radial conductor portion 25 extends from the coil side portion 22 in the axial direction L of the stator core 11 as shown in FIG. It is formed to be bent inward in the radial direction R. Therefore, the portion extending in the radial direction R of the radial conductor portion 25 excluding the portion where the narrow recess 32 is formed has a width in the circumferential direction C equal to the first direction width W8 of the linear conductor 31 and the width in the axial direction L. Becomes equal to the second direction width W9 of the linear conductor 31 (see FIG. 17).
In the present embodiment, the narrow recess 32 provided in the radial conductor portion 25 is a portion corresponding to the inner peripheral opening 13 in the radial conductor portion 25, and the second direction D2 is substantially parallel to the circumferential direction C. Thus, it is set as the twist shaping | molding part 35 formed by twisting with respect to the other part of the radial direction conductor part 25. As shown in FIG. Specifically, as shown in FIG. 15, the narrow recess 32 is formed by extending the portion of the radial conductor portion 25 corresponding to the inner peripheral opening 13 of the linear conductor 31 constituting the radial conductor portion 25. The twist forming portion 35 is formed by twisting a predetermined angle with the direction as an axis. As described above, in the present embodiment, since the second direction D2 is a direction orthogonal to the first direction D1, the predetermined angle is 90 degrees. Further, “the portion corresponding to the inner circumferential opening 13 in the radial conductor portion 25” means “the portion of the radial conductor portion 25 corresponding to the inner circumferential opening 13 and the radial position”. To do. By forming the narrow concave portion 32 in this manner as the twist forming portion 35, the circumferential width W 7 of the narrow concave portion 32 (strictly, the minimum value of the circumferential width of the narrow concave portion 32) is the same as that of the linear conductor 31. It becomes equal to the second direction width W9.
Here, as described above, the second direction width W9 of the linear conductor 31 is formed to be narrower than the circumferential direction width W1 of the inner peripheral opening 13 of the slot 12. Accordingly, as shown in FIG. 13, when viewed from the axial direction L, the outer shape of the narrow concave portion 32 (twist forming portion 35) is provided at the inner end in the radial direction R of the teeth 15 of the stator core 11. It is formed so as to correspond to the outer shape of the protruding portion 16. In other words, when viewed from the axial direction L, the protruding portion 16 and the linear conductor 31 constituting the radial conductor portion 25 are configured so as not to overlap. In this example, the twist forming portion 35 is formed so that the portion in which the circumferential width of the twist forming portion 35 is the narrowest and the circumferential wall portion 16c of the inner peripheral opening 13 overlap in the radial direction R. Has been. Therefore, the coil 21 is inserted into the slot 12 in the axial direction L from the side of the bent coil end 24 while avoiding interference between the radial conductor portion 25 and the inner peripheral opening 13 of the slot 12. Can do.
In the present embodiment, the narrow recess 32 corresponds to the inner peripheral opening 13 in the radial conductor portion 25, and the second conductor D of the radial conductor portion 25 is substantially parallel to the circumferential direction C. Since it is formed by twisting with respect to other portions, the axial height of the narrow concave portion 32 (strictly speaking, the maximum value of the axial height of the narrow concave portion 32) is the first of the linear conductors 31. It becomes equal to the unidirectional width W8 (see FIG. 16). On the other hand, the axial height of the portion extending in the radial direction R of the radial conductor portion 25 excluding the portion where the narrow recess 32 is formed becomes equal to the second direction width W9 of the linear conductor 31 (see FIG. 17). That is, the axial height of the linear conductor 31 in the narrow recess 32 is higher than the axial height of the linear conductor 31 in the other part of the radial conductor 25 adjacent to the narrow recess 32. . And as shown in FIG. 14, since the narrow recessed part 32 is arranged in the axial direction L, the parts where the axial direction height of the narrow recessed part 32 is high contact | abuts to the axial direction L. Mutually win each other. As a result, as can be understood from FIGS. 14, 16, and 17, in the portions other than the twist forming portion 35 of the bending coil end portion 24, a spacer or the like is not particularly provided as in the first embodiment. In addition, the axial distance D between the linear conductors 31 adjacent to each other in the axial direction L increases.
Moreover, in this embodiment, since the narrow recessed part 32 is the twist formation part 35, naturally the narrow recessed part 32 is the said over the radial direction R like the said 1st embodiment. The cross-sectional area of the cross section perpendicular to the energizing direction of the coil 21 in the narrow concave portion 32 is substantially equal to the cross-sectional area of the cross section in the portion other than the narrow concave portion 32.
By the way, in order to enjoy as much as possible the advantage that the stator core 11 is a semi-open slot type core, the inner circumferential opening 13 and the linear conductor 31 interfere with the circumferential width W1 of the inner circumferential opening 13. However, in the present embodiment, by adopting the linear conductor 31 having a width in the second direction D2 smaller than the circumferential width W1 of the inner circumferential opening 13, The above interference can be avoided.
2-2. Method for Manufacturing Stator The method for manufacturing the stator 2 according to the present embodiment is basically the same as that of the first embodiment described above, but includes the “twisting step” instead of the “compression step”. It differs from one embodiment. That is, in this embodiment, the narrow recess forming process is performed by a twisting process.
In the twisting process, the portion corresponding to the inner circumferential opening 13 in the radial conductor portion 25 is set to the other portion of the radial conductor portion 25 so that the second direction D2 is substantially parallel to the circumferential direction C. It is a process of twisting. Here, “the portion corresponding to the inner peripheral opening 13 in the radial conductor portion 25” means “the portion of the radial conductor 25 where the inner peripheral opening 13 corresponds to the radial position”. means. And the twist formation part 35 as the narrow recessed part 32 is formed by this twist process. Thus, by making the narrow recess forming step a twisting step, there is no need to locally deform the radial conductor portion 25 or to apply a large force locally to the radial conductor portion 25. For this reason, it is possible to prevent the insulating coating (for example, enamel) covering the linear conductor 31 from being damaged by forming the narrow recess 32.
The twisting process includes, for example, a holding mechanism that holds a portion adjacent to both sides in the extending direction of the linear conductor 31 with respect to a portion where the twist forming portion 35 is formed, and a portion where the twist forming portion 35 is formed. And a rotation mechanism that grips the vicinity of the central portion in the extending direction of the wire and rotates the gripped portion by a predetermined angle (90 degrees in this example) with the extending direction of the linear conductor 31 as an axis. The twist forming part 35 as shown in FIG. 15 can be formed by the mechanism. Also, such a twisting process may be performed on the linear conductor 31 constituting the coil 21 of each phase formed in advance in the coil pre-forming process, similarly to the compression process in the first embodiment. It is good also as a structure performed with respect to the linear conductor 31 before performing a coil preliminary | backup formation process.
In the present embodiment, in the present embodiment, as shown in FIG. 18, the coil 21 is bent coil end portion 24 in a state where the twist forming portion 35 formed in the twisting step is aligned with the position of the inner peripheral opening 13. This is a step of inserting in the slot 12 from the side in the axial direction L.
(1) In said 1st embodiment, the case where the narrow recessed part 32 was used as the compression molding part 33 formed by compressing the radial direction conductor part 25 in the circumferential direction C was demonstrated as an example. Moreover, in said 2nd embodiment, the case where the narrow recessed part 32 was used as the twist formation part 35 was demonstrated as an example. However, embodiments of the present invention are not limited to these. That is, the narrow recess 32 only needs to be formed so that the circumferential width W7 thereof is narrower than the circumferential width W1 of the inner peripheral opening 13 of the slot 12, for example, as a narrow groove formed by cutting or the like. Constructing the narrow recess 32 is one of the preferred embodiments of the present invention.
(2) In the first embodiment, the narrow recess 32 is formed so that the cross-sectional area of the cross section perpendicular to the energizing direction of the coil 21 is substantially equal to the cross-sectional area of the cross section in the portion other than the compression molding portion 33. The case where the compression molded portion 33 is formed by being expanded in the axial direction L while being compressed in the circumferential direction C has been described as an example. However, the embodiment of the present invention is not limited to this. That is, for example, it is also one preferred embodiment of the present invention that the narrow concave portion 32 is configured as the compression-molded portion 33 that is compressed only in the circumferential direction C and not extended in the axial direction L. In addition, when the compression molded portion 33 is formed by being expanded in the axial direction L while being compressed in the circumferential direction C, the cross-sectional area of the cross section orthogonal to the energizing direction of the coil 21 is a cross-sectional breakage at a portion other than the compression molded portion 33. One of the preferred embodiments of the present invention is to form the narrow concave portion 32 as the compression molding portion 33 formed to have a different area.
(3) In the first embodiment, the linear conductor 31 is configured by a single rectangular wire having a substantially rectangular cross section, and its circumferential width W5 is the circumferential width of the slot interior 14. The case where it is formed to be substantially equal to W3 has been described as an example. However, the embodiment of the present invention is not limited to this. That is, the circumferential width W5 of the linear conductor 31 only needs to be larger than the circumferential width W1 of the inner circumferential opening 13 of the slot 12, and the circumferential width of the slot inner 14 from the circumferential width W1 of the inner circumferential opening 13 is sufficient. It can be arbitrarily set up to W3. Further, the cross-sectional shape of the linear conductor 31 is not particularly limited, and various shapes such as a round shape and a polygonal shape can be adopted. Further, if the circumferential width W5 is formed wider than the circumferential width W1 of the inner circumferential opening 13, the linear conductor 31 is as if a plurality of conductors are a single conductor. It is also possible to use a conductor made of an aggregate that is configured by being assembled. For example, it is also possible to use a wire conductor or the like in which a plurality of conductors are gathered and formed integrally.
(4) In the second embodiment described above, the linear conductor 31 is configured by a single rectangular wire having a substantially rectangular cross section, and the first direction width W8 is the circumferential direction of the slot interior 14. The case where it is formed to be substantially equal to the width W3 has been described as an example. However, the embodiment of the present invention is not limited to this. That is, the first direction width W8 of the linear conductor 31 only needs to be wider than the circumferential width W1 of the inner circumferential opening 13 of the slot 12, and the circumferential direction of the slot interior 14 from the circumferential width W1 of the inner circumferential opening 13 is sufficient. It can be arbitrarily set up to the width W3. Further, the linear conductor 31 is not limited to one having a substantially rectangular cross-sectional shape. That is, the first direction width W8 is wider than the circumferential width W1 of the inner circumferential opening 13 of the slot 12, and the second direction width W9 is smaller than the circumferential width W1 of the inner circumferential opening 13 of the slot 12. For example, a linear conductor 31 having various shapes of cross sections such as an elliptical shape and a polygonal shape can be employed. In this case, the second direction D2 may not be orthogonal to the first direction D1. For example, it is preferable that the second direction D2 is a direction intersecting the first direction D1 and the second direction width W9 is the minimum. Further, as the linear conductor 31, a conductor made of an aggregate configured by assembling a plurality of conductors as if they were one conductor can also be used. For example, it is also possible to use a wire conductor or the like in which a plurality of conductors are gathered and formed integrally.
(5) In the second embodiment, the linear conductor 31 has a substantially rectangular cross section having a long side and a short side, the first direction D1 is a direction along the long side, and the second direction The case where D2 is the direction along the short side and the second direction D2 is a direction orthogonal to the first direction D1 has been described as an example. However, the embodiment of the present invention is not limited to this. That is, when viewed from the axial direction L, it overlaps between the protruding portion 16 provided at the inner end in the radial direction R of the tooth 15 of the stator core 11 and the linear conductor 31 constituting the radial conductor portion 25. If the configuration can be configured such that there is no portion, the second direction D2 that is substantially parallel to the circumferential direction C in the twist forming portion 35 can be configured to be a direction that does not follow the short side of the substantially rectangular cross section. . For example, the second direction D2 can be a direction that intersects the first direction D1 at a predetermined angle that is not 90 degrees (for example, 70 degrees or 80 degrees). In this case, the narrow concave portion 32 has the portion corresponding to the inner peripheral opening 13 in the radial conductor portion 25 at the predetermined angle with the extending direction of the linear conductor 31 constituting the radial conductor portion 25 as an axis. The twist forming portion 35 is formed by twisting only.
(6) In said 2nd embodiment, the part where the circumferential direction width | variety of the twist formation part 35 is the narrowest, and the circumferential direction wall part 16c of the inner peripheral opening part 13 overlap with radial direction R. The case where the twist forming part 35 is formed as described above has been described as an example. However, the embodiment of the present invention is not limited to this. That is, when viewed from the axial direction L, it overlaps between the protruding portion 16 provided at the inner end in the radial direction R of the tooth 15 of the stator core 11 and the linear conductor 31 constituting the radial conductor portion 25. If the configuration can be made such that there is no portion, the portion other than the portion where the circumferential width of the twist forming portion 35 is the narrowest and the circumferential wall portion 16c of the inner circumferential opening 13 overlap in the radial direction R. Thus, a configuration in which the twist forming part 35 is formed may be employed.
(7) In the second embodiment, the case where the manufacturing method of the stator 2 includes the “twisting step” instead of the “compression step”, that is, the case where the “compression step” is not provided will be described as an example. did. However, the embodiment of the present invention is not limited to this. That is, the manufacturing method of the stator 2 compresses the bent portion 34 in the coil 21 of each phase in the circumferential direction C in addition to the twisting process, and the circumferential width thereof becomes the first direction width W8 of the linear conductor 31. It is one of the preferred embodiments of the present invention to further comprise a compression step for forming to be substantially equal. This embodiment can be suitably implemented when a bulging portion that protrudes in the circumferential direction C is formed in the bent portion 34 that connects the coil side portion 22 and the radial conductor portion 25 of the bent coil end portion 24.
(8) In the first embodiment and the second embodiment described above, the case where the stator 2 is a stator used in the rotating electrical machine 1 driven by three-phase alternating current has been described as an example. However, embodiments of the present invention are not limited to these. That is, it is one of the preferred embodiments of the present invention that the stator 2 is used in the rotating electrical machine 1 driven by single-phase alternating current. Alternatively, a configuration used for the rotating electrical machine 1 driven by a two-phase or four-phase or more AC power supply is also one of the preferred embodiments of the present invention.
(9) In the first embodiment and the second embodiment described above, three sets of the coils 21 having the shape as shown in FIG. 4 are arranged adjacent to each other in the radial direction R in the same slot 12. The case where the six coil side portions 22 per slot are arranged in a line in the radial direction R and arranged in the slot 12 has been described as an example. However, embodiments of the present invention are not limited to these. That is, the number of coil sides 22 per slot arranged in a line in the radial direction R can be changed as appropriate. Moreover, the shape of the coil 21 preliminarily formed shown in FIG. 4 is merely an example, and various shapes can be adopted.
(10) In the first embodiment and the second embodiment described above, between the linear conductors 31 constituting the coils 21 of different phases adjacent to each other in the axial direction L at the bending coil end 24, The case where the interphase insulating sheet 41 is interposed and disposed has been described as an example. However, embodiments of the present invention are not limited to these. That is, it is one of the preferred embodiments of the present invention that the interphase insulating sheet 41 is not provided depending on the use conditions. As described above, in the first embodiment and the second embodiment described above, the axial distance D between the linear conductors 31 adjacent to each other in the axial direction L at the bending coil end portion 24 is large. Therefore, depending on conditions such as the maximum value of the current flowing through the coil 21 and the maximum value of the voltage applied to both ends of the coil 21, the surface of the linear conductor 31 is covered without interposing the interphase insulating sheet 41. This is because it is possible to ensure electrical insulation between the phase coils 21 with only the insulating coating.
(11) In the first embodiment and the second embodiment described above, an example in which the projecting portion 16 includes the circumferential wall portion 16c and the outer diameter side wall portion 16r, and the cross-sectional shape thereof is a substantially rectangular shape. As explained. However, embodiments of the present invention are not limited to these. That is, various shapes can be adopted as the protrusions 16, for example, two protrusions that do not include the circumferential wall 16 c and protrude so as to face each other in the circumferential direction C in the adjacent teeth 15. One of the preferred embodiments of the present invention is a configuration in which the circumferential width between the sixteen is widened from the inner circumferential opening 13 toward the outer side in the radial direction R. One.
(12) In the first and second embodiments described above, the slot 42 is formed by sequentially folding the end portions 42e on both sides of the in-slot insulating sheet 42 and engaging with the outer-diameter side wall portion 16r of the protruding portion 16. The case where the inner peripheral opening 13 of the coil 12 is covered and the coil side 22 constituting the coil 21 is prevented from slipping out inward in the radial direction R has been described as an example. However, embodiments of the present invention are not limited to these. That is, the end portions 42e on both sides of the in-slot insulating sheet 42 are not locked to the outer-diameter side wall portion 16r of the protruding portion 16, or after being locked, a blocking member such as a wedge is provided. A configuration in which the inner peripheral opening 13 of the slot 12 is closed is also one preferred embodiment of the present invention.
(13) In the first embodiment, in the compression step, the bent portion 34 is adapted to compress the radial R position corresponding to the inner circumferential opening 13 in the radial conductor portion 25 in the circumferential direction C. Also, the case where compression is performed in the circumferential direction C has been described as an example. However, the embodiment of the present invention is not limited to this. That is, the bending step 34 in the coil 21 of each phase is compressed in the circumferential direction C, and the circumferential step width is substantially equal to the circumferential width W5 of the linear conductor 31, and the radial conductor portion 25, the radial R position corresponding to the inner circumferential opening 13 of the slot 12 of the stator core 11 is compressed in the circumferential direction C, and the circumferential width W7 is narrower than the circumferential width W1 of the inner circumferential opening 13. It is also one of the preferred embodiments of the present invention to have a configuration in which the forming process is performed separately. At this time, it is also preferable that the latter work process is performed on the linear conductor 31 before the coil preliminary forming process.
(14) In the first embodiment and the second embodiment described above, the in-slot insulating sheet 42 disposed in the slot 12 is radially inward from the inner peripheral opening 13 of the slot 12 in the insertion step. As an example, the case where the coil 21 is inserted into the slot 12 in a state where the coil 21 extends and opens is described. However, embodiments of the present invention are not limited to these. That is, for example, a configuration in which the coil 21 is inserted into the slot 12 in a state in which the in-slot insulating sheet 42 is preliminarily wound around the coil side portion 22 is also a preferred embodiment of the present invention.
(15) In the first embodiment and the second embodiment described above, the armature for a rotating electrical machine according to the present invention is applied to a stator 2 as a stator of the rotating electrical machine 1, and the rotating electrical machine 1 is The case where the inner rotor type rotating electrical machine including the stator 2 is used as an example has been described. However, embodiments of the present invention are not limited to these. That is, for example, the armature for a rotating electrical machine according to the present invention is applied to the rotor of the rotating electrical machine 1, and the rotating electrical machine 1 can be an outer rotor type rotating electrical machine having a rotor as an armature. This is one of the preferred embodiments.
INDUSTRIAL APPLICABILITY The present invention can be suitably used for an armature for a rotating electrical machine including a cylindrical core in which a plurality of axially extending slots are distributed in the circumferential direction and a coil wound around the slot. it can.
1 Rotating electrical machine 2 Stator (armature)
11 Stator core (core)
12 Slot 13 Inner peripheral opening 14 Inside slot 15 Teeth 16 Protruding portion 16c Circumferential wall portion 21 Coil 22 Coil side portion 23 Coil end portion 24 Bending coil end portion 25 Radial conductor portion 26 Circumferential conductor portion 31 Linear conductor 32 Narrow recessed part 33 Compression molding part 34 Bending part 35 Twist molding part 41 Interphase insulation sheet 42 Insulation sheet L in slot Axial direction R Radial direction C Circumferential direction D1 First direction D2 Second direction
A rotary electric machine armature comprising: a cylindrical core in which a plurality of slots extending in the axial direction are distributed in the circumferential direction; and a coil wound around the slot,
The slot is formed such that a circumferential width of an inner circumferential opening that opens radially inward is narrower than a circumferential width of a slot located radially outside the inner circumferential opening, and the coil The circumferential width of the linear conductor to be formed is formed wider than the circumferential width of the inner circumferential opening,
The coil includes a coil end portion that connects between coil side portions disposed in different slots at both axial end portions of the core, and the coil end portion on one axial side of the slot is radially inward. It is a bent coil end formed by bending,
The bending coil end portion includes a radial conductor portion extending in a radial direction from the coil side portion, and a circumferential conductor portion connecting a pair of the radial conductor portions radially inward of the inner peripheral opening. Prepared,
With respect to other portions of the radial conductor portion so that the circumferential width is narrower than the circumferential width of the inner circumferential opening at a radial position corresponding to the inner circumferential opening in the radial conductor portion. An armature for a rotating electrical machine having a narrow recess with a hollow shape.
2. The armature for a rotating electrical machine according to claim 1, wherein the narrow concave portion is a compression-molded portion formed by compressing the radial conductor portion in the circumferential direction and extending in the axial direction.
In the cross section orthogonal to the extending direction of the linear conductor, the direction along the circumferential direction in the slot is the first direction, and the direction orthogonal to the first direction is the second direction,
The linear conductor is formed such that the width in the second direction is narrower than the circumferential width of the inner peripheral opening,
The narrow concave portion has a portion corresponding to the inner circumferential opening in the radial conductor portion with respect to other portions of the radial conductor portion so that the second direction is substantially parallel to the circumferential direction. The armature for a rotating electrical machine according to claim 1, wherein the armature is a twist formed part formed by twisting.
In the coil, a plurality of the linear conductors constituting the coil side portions are arranged in the radial direction in the slot, and the linear conductors constituting the bent coil end portions are arranged in the axial direction. ,
The armature for rotary electric machines according to claim 2 or 3, wherein the narrow recesses are arranged side by side in the axial direction.
Comprising a plurality of coils of different phases,
5. The armature for a rotating electrical machine according to claim 4, wherein among the coils of each phase, the linear conductors of different phases constituting the circumferential conductor portion are arranged side by side in the axial direction.
The armature for a rotating electrical machine according to claim 5, wherein an interphase insulating sheet is disposed between the linear conductors of different phases on the radially inner side of the compression-molded portion at the bent coil end.
The core includes projecting portions that project on both sides in the circumferential direction to form both side walls in the circumferential direction at the radially inner end of the teeth located between the slots adjacent to each other,
Between the slot and the coil side, an in-slot insulating sheet is disposed so as to cover the inner peripheral opening while circling the coil side,
The armature for a rotating electrical machine according to any one of claims 1 to 6, wherein an end portion of the in-slot insulating sheet in a circumferential direction is locked to the projecting portion.
A cylindrical core in which a plurality of semi-open slot type slots extending in the axial direction are distributed in the circumferential direction, and a coil wound around the slot,
The circumferential width of the linear conductor constituting the coil is formed wider than the circumferential width of the inner circumferential opening that opens radially inward of the slot,
Manufacture of an armature for a rotating electrical machine, wherein the coil is connected between coil side portions arranged in different slots at one end in the axial direction of the core and has a bent coil end bent inward in the radial direction A method,
The radial width of the radial conductor portion extending in the radial direction from the coil side portion at the bent coil end portion is narrower than the circumferential width of the inner peripheral opening portion at a radial position corresponding to the inner peripheral opening portion. A narrow recess forming step for forming a narrow recess having a shape recessed with respect to the other portion of the radial conductor portion,
An insertion step of axially inserting the coil into the slot from the bent coil end side in a state where the narrow concave portion formed in the narrow concave portion forming step is aligned with the position of the inner peripheral opening; The manufacturing method of the armature for rotary electric machines which has these.
The method of manufacturing an armature for a rotating electrical machine according to claim 8, wherein the narrow recess forming step is a compression step of compressing a portion corresponding to the inner peripheral opening in the radial conductor portion in the circumferential direction.
In the narrow recess forming step, the portion corresponding to the inner peripheral opening in the radial conductor portion is placed on another portion of the radial conductor portion so that the second direction is substantially parallel to the circumferential direction. The method for manufacturing an armature for a rotating electrical machine according to claim 8, which is a twisting process for twisting the armature.
The method for manufacturing an armature for a rotating electrical machine according to claim 9, wherein, in the compression step, the bent portion of the radial conductor portion constituting the coil is further compressed in the circumferential direction simultaneously with forming the narrow recess. .
The core includes protrusions that protrude on both sides in the circumferential direction to form both side walls in the circumferential direction at the radially inner end of the teeth located between the slots adjacent to each other,
In the inserting step, the coil is inserted into the slot in a state in which an in-slot insulating sheet disposed in the slot extends and opens radially inward from the inner peripheral opening,
The rotating electrical machine according to any one of claims 8 to 11, further comprising a locking step of locking an end portion extending radially inward of the in-slot insulating sheet to the protruding portion after the inserting step. Method for manufacturing armature.
JP2009189463A 2009-01-28 2009-08-18 Armature for rotating electrical machine and manufacturing method of same Pending JP2010200596A (en)
JP2009016854 2009-01-28
JP2009189463A JP2010200596A (en) 2009-01-28 2009-08-18 Armature for rotating electrical machine and manufacturing method of same
DE200911002227 DE112009002227T5 (en) 2009-01-28 2009-12-11 Anchor for a rotating electrical machine and its manufacturing process
PCT/JP2009/070762 WO2010087078A1 (en) 2009-01-28 2009-12-11 Armature for dynamo electric machine and method of manufacturing same
CN2009801372583A CN102160266A (en) 2009-01-28 2009-12-11 Armature for electric rotating machine and method of manufacturing same
US12/654,964 US8164229B2 (en) 2009-01-28 2010-01-11 Armature for rotating electrical machine and manufacturing method thereof
JP2010200596A true JP2010200596A (en) 2010-09-09
ID=42353600
JP2009189463A Pending JP2010200596A (en) 2009-01-28 2009-08-18 Armature for rotating electrical machine and manufacturing method of same
US (1) US8164229B2 (en)
JP (1) JP2010200596A (en)
CN (1) CN102160266A (en)
DE (1) DE112009002227T5 (en)
WO (1) WO2010087078A1 (en)
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2009-12-11 DE DE200911002227 patent/DE112009002227T5/en not_active Withdrawn
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2009-12-11 CN CN2009801372583A patent/CN102160266A/en not_active Application Discontinuation
2010-01-11 US US12/654,964 patent/US8164229B2/en not_active Expired - Fee Related
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2012-07-06 A02 Decision of refusal