JP5525069B2 - Coil member and stator - Google Patents

Description

  The present invention relates to a coil member used for a rotary motor, a linear motor, a generator, and the like, and a stator provided with the coil member.

  As a coil member disposed in a motor, a generator, a reactor, a transformer, or the like, a member in which a plurality of coil wires are wound in parallel is known. In particular, recently, a structure has been proposed in which a conducting wire having a rectangular cross section called a flat wire is wound on top and bottom layers.

  By the way, since the lengths of the two conductors wound on the upper and lower layers are different, there is a difference in resistance. If there is a difference in resistance between the two rectangular conductors connected to the common terminal, a voltage difference occurs with respect to the high-frequency current, and a circulating current flows. This circulating current does not contribute to the output of the motor and becomes an invalid current.

  Therefore, Patent Document 1 discloses a technique as a countermeasure. Patent Document 1 discloses a structure of a split stator in which two rectangular conductive wires (coil wires) are wound in an edgewise shape. Here, it is described that a rectangular conductor (inner coil wire) on the inner side of one stator is connected to a rectangular conductor (outer coil wire) on the outer side of the other stator between vertically wound coils that are phase-connected. (See paragraph [0050] of the same document). By connecting in this way, an attempt is made to suppress the unbalance of the electrical resistance of the two coil wires.

Japanese Patent Laid-Open No. 2005-19618

However, in the technique of Patent Document 1, the terminal connection structure between the coil members becomes complicated, and the connection work becomes difficult. In addition, the motor shaft length may increase unnecessarily.
Furthermore, in the structure of Patent Document 1, the number of slots (number of divided stators) must be an even number in order to set the difference in resistivity of coil wires belonging to a common phase to zero.

  An object of the present invention is to provide a coil member that can suppress a circulating current while adopting a structure in which a plurality of layers of coil wires are wound in parallel as the structure of the coil, and a stator including the coil member. .

The coil member of the present invention is a coil member in which a plurality of coil wires are wound in parallel from the inner layer to the outer layer,
At least two layers of coil wires among the plurality of coil wires are exchanged with each other by joining ends cut at intermediate points so that the resistance values of all the coil wires approach a common value. Has been.
A typical example is the case of two-layer winding. In this case, the inner layer coil wire and the outer layer coil wire are converted into the outer layer coil wire and the inner layer coil wire, respectively, in the middle part.
In the case of the three-layer winding, the intermediate layer coil wire is not changed in the middle part and is always the intermediate layer. Then, the inner layer coil wire and the outer layer coil wire are converted into the outer layer coil wire and the inner layer coil wire, respectively, in the middle part.
In the case of four-layer winding, the first layer and the fourth layer are changed in the middle part, and the second layer and the third layer are exchanged in the middle part.
In the case of five-layer winding, the third-layer coil wire is the third layer without changing the layer in the middle. Then, the first layer and the fifth layer are changed to each other at an intermediate position, and the second layer and the fourth layer are changed to each other at an intermediate position.

  Thereby, the resistance values of all the coil wires are close to each other according to the magnitude relationship of the resistance values corresponding to the lengths of the coil wires. Therefore, the difference in resistance value of each coil wire is reduced, the circulating current is reduced with respect to the high-frequency current, and the current utilization efficiency is improved.

  Moreover, as a form in which the layers are exchanged at a midpoint, at least two coil wires are cut at the midpoint and the ends are joined to each other, so that the above-described effects can be obtained with simple processing. it can.

  It is preferable that at least two layers of coil wires are exchanged with each other at the coil end portion. Thereby, the fall of a space factor can be suppressed.

  A stator having the above-described coil member mounted on the core exhibits high convenience as a component such as a motor, a generator, a reactor, or a transformer with a small loss. The stator may be a split stator or an integrated stator.

  According to the coil member or the stator of the present invention, current utilization efficiency can be improved while adopting a structure in which a plurality of coil wires are wound in parallel from the inner layer to the outer layer.

It is a perspective view which shows the structure of the coil member which concerns on Embodiment 1 of this invention, and a split core. 2 is a cross-sectional view showing a schematic structure of a stator according to Embodiment 1. FIG. 3 is a plan view of a stator of the three-phase AC motor according to Embodiment 1. FIG. 3 is a diagram showing an equivalent circuit of a stator of the three-phase AC motor according to Embodiment 1. FIG. (A), (b) is the perspective view of the coil member in Embodiment 2, and sectional drawing of a division | segmentation stator in order, respectively. FIG. 10 is a cross-sectional view of a divided stator in a third embodiment. FIG. 10 is a cross-sectional view of a divided stator in a fourth embodiment.

(Embodiment 1)
-Structure of coil member and stator-
FIGS. 1A and 1B are perspective views showing a procedure for forming the coil member 20 according to the first embodiment. The coil member 20 of the present embodiment is obtained by winding a multiple coil wire 10 including first and second coil wires 10a and 10b in an edgewise manner. The multiple coil wire 10 is obtained by arranging the long sides of the first coil wire 10a and the second coil wire 10b on the same plane.

  First, as shown to Fig.1 (a), the 1st winding part 20a and the 2nd winding part 20b whose inner layer and an outer layer are mutually reverse are formed. Specifically, if one is right-handed, the other is left-handed. The first winding portion 20a is wound with the first coil wire 10a on the inside and the second coil wire 10b on the outside. The second winding portion 20b is wound with the second coil wire 10b on the inside and the first coil wire 10a on the outside. The 1st winding part 20a and the 2nd winding part 20b are connected by conversion part 10z.

  Next, as shown in FIG.1 (b), the 1st winding part 20a and the 2nd winding part 20b are bent, and coil surfaces are match | combined. At this time, the first coil wire 10a of the first winding part 20a and the second coil wire 10b of the second winding part 20b face each other. Further, the second coil wire 10b of the first winding part 20a and the first coil wire 10a of the second winding part 20b face each other. And in the conversion part 10z, the multiple coil wire 10 is the state twisted.

  In the converter 10z, the first coil wire 10a is converted from the inner layer to the outer layer, and the second coil wire 10b is converted from the outer layer to the inner layer. That is, the layers of the first and second coil wires 10 a and 10 b are converted to each other in the conversion unit 10 z that is an intermediate part of the coil member 20. In the present embodiment, conversion unit 10z is located above the coil end portion. Thereby, the fall of a space factor can be suppressed.

  Each of the coil wires 10a and 10b has a copper wire 12 having a substantially rectangular cross section and a coating film 13 made of an imide-based resin typified by polyimide, polyamideimide, polyesterimide, or the like that covers the copper wire 12. doing. The cross-sectional dimensions of the copper wire 12 are about 0.95 mm for the short side and about 2.40 mm for the long side, and the thickness of the coating film 13 is about 0.03 mm.

  The first coil wire 10a and the second coil wire 10b are electrically connected to each other at the first external terminal 21 and the second external terminal 22 at both ends. That is, the first coil wire 10a and the second coil wire 10b are electrically connected in parallel.

As shown in FIG. 1B, the split core 51 has a yoke portion 51a and a teeth portion 51b protruding from the yoke portion 51a toward the rotor. In this embodiment, although the powder core structure is employ | adopted, you may use a laminated steel plate. In the case of the compacted structure, the broken line portions shown in FIG.
Although not shown in FIG. 1B, the coil member 20 includes a mold resin that molds the entire coil. Then, the coil member 20 is attached to the split core 51 by fitting the mold resin and the tooth portion 51 b of the split core 51. The coil member 20 and the split core 51 constitute a split stator.
At that time, the converter 10z is embedded in the mold resin 40, but the first external terminal 21 and the second external terminal 22 are exposed from the mold resin.

-Motor structure-
FIG. 2 is a cross-sectional view showing a schematic structure of the stator 50 of the motor according to the present embodiment. Also in FIG. 2, the display of the mold resin is omitted. As shown in the figure, the stator 50 is assembled by enclosing a plurality of divided cores 51 in an annular shape and enclosing from the outside using a ring member or the like (not shown). In the present embodiment, a core in which the split cores 51 are assembled is used as the core, but the core may be integrated without being split.

A rotor (not shown) provided with permanent magnets is disposed inside the stator 50. In the present embodiment, the split core 51 is formed by compression molding magnetic powder having an insulating coating. However, a large number of silicon steel plates may be laminated with a resin insulating layer interposed therebetween.
The multiple coil wire 10 including the first coil wire 10 a and the second coil wire 10 b is wound around the tooth portion 51 b of the split core 51. Although the resin is not shown, the multiple coil wire 10 is resin-molded.

-Connection structure with bus bar-
FIG. 3 is a plan view of the stator 50 of the present embodiment, which is a stator 50 of a three-phase AC motor. FIG. 4 is a diagram showing an equivalent circuit of the stator 50 of the three-phase AC motor. For ease of viewing, the mold resin 40 is not shown in FIG.
As shown in FIGS. 3 and 4, the coil member 20 of the split core 51 is divided into those supplied with U-phase power, those supplied with V-phase power, and those supplied with W-phase power. Be placed. In each phase, four coil members 20 are arranged in series, and the terminals of each coil member 20 are electrically connected by bus bars 32U, 32V, 32W. The first external terminal 21 of the coil member 20 located at the most central end of each phase is connected to a neutral point (reference point) bus bar 33 in common to each phase. Further, the second external terminal 22 of the coil member 20 located on the outermost side of the series connection is connected to the power supply side connection conductors 31U, 31V, 31W and receives supply of AC power converted from the inverter module or the like.

  In FIG. 3, only the bus bars 32U, 32V, and 32W have a cross-sectional structure. The bus bars 32U, 32V, and 32W are covered with an insulating film except for the terminal portions, but are not necessarily covered with the insulating film.

As shown in FIG. 4, the first coil wire 10a has a resistance value r1 in the inner layer of the first coil wire 10a and a resistance value r2 in the outer layer of the second coil wire 10b. However, r1 <r2. That is, in the outer layer, since the coil wire is longer than the inner layer, the resistance value is large.
On the other hand, the second coil wire 10b has a resistance value r2 in the outer layer of the first coil wire 10a and a resistance value r1 in the inner layer of the second coil wire 10b.
That is, the overall resistance value of both the first coil wire 10a and the second coil wire 10b is r1 + r2. That is, if the variation in the winding diameter at the time of manufacture, the variation in the position of the conversion unit 10z, and the like are ignored, the resistance values of the first and second coil wires 10a and 10b are substantially equal. In this manner, the first and second coil wires 10a and 10b are mutually converted in layers so that the resistance values approach (become equal) in the converter 10z.

-Effects of the embodiment-
According to the coil member 20 or the stator 50 of the present embodiment, the following operational effects are obtained. The coil member 20 has a structure in which the first coil wire 10a and the second coil wire 10b are wound in parallel with an inner layer and an outer layer. The first coil wire 10a and the second coil wire 10b are mutually converted in layers in the converter 10z.

  Thus, the 1st, 2nd coil wire 10a, 10b is wound in parallel, and the layer is mutually converted in the conversion part 10z (in the middle part). As a result, as shown in FIG. 4, the resistance values of the first coil wire 10a and the second coil wire 10b are substantially equal to each other. Therefore, even if a high-frequency current flows, the circulating current is suppressed and the current use efficiency can be increased.

  Further, as in Patent Document 1, when the first coil wire 10a of a certain split stator 51 is connected to the second coil wire 10b of another split stator 51, the simple structure as shown in FIG. That is, the first coil wire 10a and the second coil wire 10b shown in FIG. 4 are divided into two parallel circuits through all the coil members in one phase. Therefore, two bus bars 32U, 32V, and 32W that connect the divided stators 51 are required. Therefore, the connection structure of each terminal 21a, 21b, 22a, 22b and bus bar 32U, 32V, 32W shown in FIG. 3 is complicated, and connection work becomes difficult. Further, when the motor shaft length increases, the motor efficiency may be deteriorated.

  On the other hand, in the present embodiment, the first coil wire 10 a and the second coil wire 10 b are electrically connected to each other through the external terminals 21 and 22 in each coil member 20. Therefore, the coil member 20 is connected in series (see FIG. 4). Therefore, only one bus bar is required to electrically connect the divided cores 51, and the bus bar structure is simple. Specifically, the terminals 21 and 22 and the converter 10z shown in FIG. 3 can be embedded in the mold resin 40. Excluding the neutral point (reference point) bus bar 33, only one bus bar 32U, 32V, 32W connecting the coil members 20 of the divided cores 51 is required. Therefore, the connection work between the bus bar and the terminal is also easy.

Further, in the structure of Patent Document 1, in order to make the resistivity difference between two series of coil wires belonging to a common phase zero, the number of coil members 20 (divided stators 51) belonging to a common phase must be an even number. I must.
In contrast, in the present embodiment, regardless of the number of coil members 20, the difference in resistance value between the first and second coil wires 10a and 10b in the coil member 20 is substantially zero. Therefore, it is possible to design the optimum number of slots according to the type and structure of the motor and the like. In other words, the one having the structure of the split stator can be designed to have an optimal number of split stators (number of coil members).

(Embodiment 2)
FIGS. 5A to 5B are perspective views showing a procedure for forming the coil member 20 in the second embodiment. 5 (a) to 5 (b), the same members as those in the first embodiment are denoted by the same reference numerals and description thereof is omitted.
First, as shown in FIG. 5A, a first winding portion 20a is prepared in which the first coil wire 10a is an inner layer and the second coil wire 10b is an outer layer. In addition, a second winding portion 20b is prepared in which the first coil wire 10a is an outer layer and the second coil wire 10b is an inner layer. However, at this stage, the first coil wire 10a and the second coil wire 10b have the same structure.

  Next, as shown in FIG.5 (b), the 1st winding part 20a and the 2nd winding part 20b are integrated. Then, the cut portions of the coils 20a and 20b are aligned.

  Then, as shown in FIG. 5B, the first coil wires 10a are connected to each other at the first converter 10z1. Further, the second coil wires 10b are joined to each other by TIG welding or the like in the second conversion portion 10z2. That is, the inner and outer layers of the first and second coil wires 10a and 10b are converted in the converter 10z including the first and second converters 10z1 and 10z2.

  In the second embodiment, the conversion portion 10z is formed by welding such as TIG welding, but can be joined by other methods such as brazing.

  Also in the present embodiment, the schematic structure of the stator 50 of the motor is as shown in FIG. The planar structure and equivalent circuit of the stator 50 are as shown in FIGS.

  Also in the present embodiment, as in the first embodiment, the resistance values of the first coil wire 10a and the second coil wire 10b are substantially equal. Therefore, the same effect as Embodiment 1 can be exhibited. In addition, the present embodiment has an advantage that the first winding part 20a and the second winding part 20b can have the same structure.

(Embodiment 3)
FIG. 6 is a cross-sectional view of the split stator in the third embodiment. In the figure, illustration of the mold resin is omitted. In FIG. 6, the same members as those in the first embodiment are denoted by the same reference numerals, and the description thereof is omitted.
In the present embodiment, the first coil wire 10a and the second coil wire 10b are wound in a flatwise shape.
In FIG. 6, for easy understanding, a conversion unit 10 z that does not exist in this cross section is displayed.

Also in the present embodiment, the first coil wire 10a is converted from the inner layer to the outer layer in the converter 10z. The second coil wire 10b is converted from the outer layer to the inner layer in the converter 10z. That is, in the conversion unit 10z, the first and second coil wires 10a and 10b are exchanged with each other.
Although not shown, the coil wires 10a and 10b are electrically connected to each other at the external terminals (21 and 22) at both ends.
Also in the present embodiment, the schematic structure of the stator 50 of the motor is as shown in FIG. The planar structure and equivalent circuit of the stator 50 are as shown in FIGS.

  Also in the present embodiment, as in the first embodiment, the resistance values of the first coil wire 10a and the second coil wire 10b are substantially equal. Therefore, the same effect as Embodiment 1 can be exhibited. In addition, in this embodiment, the stress required for deformation at the time of winding can be reduced by winding in a flatwise shape. That is, the coil member 20 can be easily formed.

(Embodiment 4)
FIG. 7 is a cross-sectional view of the divided stator in the third embodiment. In the figure, illustration of the mold resin is omitted. In FIG. 7, the same members as those of the first embodiment are denoted by the same reference numerals and description thereof is omitted.

In the present embodiment, there is a third coil wire 10c in addition to the first coil wire 10a and the second coil wire 10b. That is, the three coil wires 10a, 10c, and 10b are overlapped in order from the inside and wound in an edgewise manner. The first coil wire 10a is converted from the inner layer to the outer layer in the converter 10z. The second coil wire 10b is converted from the outer layer to the inner layer in the converter 10z. On the other hand, the third coil wire 10c remains as an intermediate layer. That is, in the conversion unit 10z, the first and second coil wires 10a and 10b have their layers exchanged, and the third coil wire 10c has not been converted in layer.
In addition, although not shown in figure, each coil wire 10a-10c is mutually connected in the external terminal (21, 22) of both ends.

  Also in the present embodiment, the schematic structure of the stator 50 of the motor is as shown in FIG. The planar structure and equivalent circuit of the stator 50 are as shown in FIGS. However, in the structure shown in the partially enlarged view of FIG. 4, the three coil wires 10a to 10c are connected in parallel.

In the present embodiment, the resistance values of the coil wires in the inner layer, the intermediate layer, and the outer layer from the conversion unit 10z to the end are r1, r3, and r2. At this time, r1 <r3 <r2. Then, the resistance value in the coil member 20 of the 1st, 2nd, 3rd coil wire 10a, 10b, 10c is as follows.
Resistance value of the first coil wire 10a: r1 + r2
Resistance value of second coil wire 10b: r1 + r2
Resistance value of third coil wire 10c: 2 × r3

  The resistance values of the first coil wire 10a and the second coil wire 10b are substantially equal. On the other hand, r3 is an intermediate value between r1 and r2. Therefore, the resistance values of the first and second coil wires 10a and 10b and the third coil wire 10c are not exactly equal, but are approximately equal.

  According to the present embodiment, the resistance values of the first to third coil wires 10a to 10c in the coil member 20 are approximately equal. Therefore, even in a structure in which three or more layers of coil wires are wound, the same effect as in the first embodiment can be exhibited.

(Other embodiments)
In each of the above-described embodiments, a structure in which the core 50 is divided into a large number of divided cores 51 is employed, but a plurality of divided cores 51 may be integrated.

  In each of the above embodiments, the cross-sectional shape of each of the coil wires 10a to 10c is substantially rectangular, but it may be circular or other shapes.

  In each of the above embodiments, a cassette coil structure molded with a resin is employed as the coil member 20, but the present invention is not limited to the above embodiment. However, by adopting a cassette coil structure, it is possible to use a modularized member for convenience of assembly and commercialization.

  The structure of the embodiment of the present invention disclosed above is merely an example, and the scope of the present invention is not limited to the scope of these descriptions. The scope of the present invention is indicated by the description of the scope of claims, and further includes meanings equivalent to the description of the scope of claims and all modifications within the scope.

  The coil member and the stator of the present invention can be used for motors (including linear motors), generators, reactors, transformers, and the like disposed in industrial motors, hybrid vehicles, electric vehicles, fuel cell vehicles, robots, and the like. .

DESCRIPTION OF SYMBOLS 10 Multiple coil wire 10a 2nd coil wire 10b 1st coil wire 10c 3rd coil wire 10z Conversion part 12 Copper wire 13 Coating film 20 Coil member 20a 1st winding part 20b 2nd winding part 21 1st external terminal 22 2nd external terminal 31U, 31V, 31W Power supply side connection conductor 32U, 32V, 32W Bus bar 33 Bus bar for neutral point 50 Stator 51 Divided core 51a Yoke part 51b Teeth part

Claims (3)

A plurality of coil wires are coil members wound in parallel from the inner layer to the outer layer,
At least two layers of coil wires among the plurality of coil wires are exchanged with each other by joining ends cut at intermediate points so that the resistance values of all the coil wires approach a common value. A coil member.   The coil member according to claim 1, wherein the layers of the at least two layers of coil wires are exchanged at a coil end portion. The coil member according to claim 1 or 2,
A core on which the coil member is mounted;
Stator with.

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