JP6322665B2 - Slot coil and stator of rotating electric machine - Google Patents

Description

  The present invention relates to a stator of a rotating electrical machine that can be mounted on an electric vehicle, a hybrid vehicle, and the like, and a slot coil that is inserted into a slot provided in a stator core of the stator.

  In recent years, rotating electric machines using segment coils have been proposed as stators for rotating electric machines. For example, in Patent Document 1, a coil loop is formed by caulking and joining a slot coil disposed in a slot of a stator core and a connection coil serving as a transition portion disposed outside the stator core.

JP 2013-027174 A

  In the rotating electrical machine described in Patent Document 1, it is described that a slot coil covered with an insulating material is press-fitted into a slot of a stator core.

  In general, when a slot coil is press-fitted into a slot of a stator core, an insulating material is caught by a convex portion formed on the inner peripheral surface of the slot due to a dimensional error of laminated steel plates, and the insertion of the slot coil is obstructed. It was necessary to increase the load. On the other hand, when the press-fitting load is increased, a part of the insulating material or the end of the steel plate protruding into the slot is damaged during the press-fitting and stays inside, and there is a possibility that it becomes a foreign object during use of the rotating electrical machine.

  The present invention has been made in view of the above-described problems, and an object of the present invention is to provide a slot coil and a stator for a rotating electrical machine that can be easily assembled and can suppress the generation of foreign matter.

In order to achieve the above object, the invention described in claim 1
A slot coil (for example, a slot coil 25 in an embodiment described later) inserted into a slot (for example, a slot 23 in an embodiment described later) provided in a stator core (for example, a stator core 21 in an embodiment described later),
The slot coil is covered with an insulating material (for example, an insulating material 28 in an embodiment described later),
The insulating material is provided with an ear portion (for example, an ear portion 29 in an embodiment described later) on the outer peripheral surface,
The slot coil is fixed by the ear portion being sandwiched between the stator cores.

The invention according to claim 2 is the invention according to claim 1,
The ear portion is sandwiched between the stator cores in a pressed state,
The said ear | edge part is provided in the surface which faces the circumferential direction among the said outer peripheral surfaces.

The invention according to claim 3 is the invention according to claim 2,
The ear portion includes a circumferential contact portion (for example, a circumferential contact portion 29a in an embodiment described later) that contacts the stator core in the circumferential direction, and a radial contact portion (for example, described later) that contacts the radial direction. A radial contact portion 29b) of the embodiment.

The invention according to claim 4 is the invention according to any one of claims 1 to 3,
The ear portion is provided at the center in the longitudinal direction of the slot coil.

The invention described in claim 5
A stator core (for example, a stator core 21 according to an embodiment described later) having a plurality of slots (for example, a slot 23 according to an embodiment described later);
In a stator of a rotating electrical machine (e.g., a stator 10 in an embodiment described later) provided with a coil (e.g., a coil 50 in an embodiment described later) attached to the stator core,
The coil includes a plurality of slot coils (for example, a slot coil 25 according to an embodiment described later) inserted into the slot and a plurality of slots that connect the slot coils on the axially outer side from the axial end surface of the stator core. A connection coil (for example, a connection coil 40 in an embodiment described later), and the slot coil and the connection coil are coupled to each other at a contact portion (for example, contact surfaces P2, P3 in an embodiment described later). And
The stator core includes a first stator core (for example, a first stator core 21A in an embodiment described later) and a second stator core (for example, a second stator core 21B in an embodiment described later),
The slot coil is covered with an insulating material (for example, an insulating material 28 in an embodiment described later),
The insulating material is provided with an ear portion (for example, an ear portion 29 in an embodiment described later) on the outer peripheral surface,
The slot coil is fixed by the ear portion being sandwiched between the first stator core and the second stator core.

The invention according to claim 6 is the invention according to claim 5,
The ear portion is sandwiched between the first stator core and the second stator core in a pressed state,
The said ear | edge part is provided in the surface which faces the circumferential direction among the said outer peripheral surfaces.

The invention according to claim 7 is the invention according to claim 5 or 6,
The stator core is configured by laminating a plurality of steel plates,
The ears are accommodated in steel plates (for example, silicon steel plates 21c and 21d in the embodiments described later) facing each other on the mating surfaces of the first stator core and the second stator core (for example, a mating surface MS in the embodiments described later). The ear | edge part accommodation recessed part (For example, the ear | edge part accommodation recessed part 70 of the below-mentioned embodiment) to be formed is formed.

The invention according to claim 8 is the invention according to claim 7,
The ear portion includes a circumferential contact portion (for example, a circumferential contact portion 29a in an embodiment described later) that contacts the ear housing recess of the stator core in the circumferential direction, and the ear housing recess of the stator core. A radial abutting portion that abuts in the radial direction (for example, a radial abutting portion 29b in an embodiment described later).

The invention according to claim 9 is the invention according to any one of claims 5 to 8,
The ear portion is provided at the center in the longitudinal direction of the slot coil.

  According to the first aspect of the present invention, the ear portion is provided on the outer peripheral surface of the insulating material covering the slot coil, and the slot coil is fixed by the ear portion being sandwiched between the stator cores. It can be fixed to the stator core. In addition, since the slot coil is not press-fitted, it is possible to prevent a part of the insulating material or the end of the steel plate protruding into the slot from being damaged during the press-fitting and staying in the inside, and becoming a foreign object during use of the rotating electric machine. Furthermore, since assembly by general-purpose equipment is possible, the number of assembling steps can be reduced and the influence of dimensional miscalculation can be suppressed.

  According to the invention of claim 2, since the ear portion is sandwiched between the stator core in a pressed state, the slot coil can be stably fixed to the stator core by the frictional force between the ear portion and the stator core. In addition, since a fastening portion for fixing to a housing or the like is generally provided on the outer peripheral portion of the stator core, the ear portion is damaged by providing the ear portion on the surface facing the circumferential direction of the slot coil away from the fastening portion. It is possible to prevent sagging and suppress a decrease in frictional force.

  According to the invention of claim 3, since the ear portion includes the circumferential contact portion that contacts the stator core in the circumferential direction and the radial contact portion that contacts the radial direction, the slot coil includes the axial direction, the circumferential direction, and the diameter. Positioned in the direction.

  According to the invention of claim 4, since the ear portion is provided at the center in the longitudinal direction of the slot coil, it is possible to reduce the influence due to the difference in the linear expansion coefficient between the stator core and the insulating material.

  According to the fifth aspect of the present invention, the ear is provided on the outer peripheral surface of the insulating material covering the slot coil, and the slot coil is fixed by being pinched between the first stator core and the second stator core. The slot coil can be easily fixed to the stator core. In addition, since assembly with general-purpose equipment is possible, the number of assembly steps can be reduced and the influence of dimensional miscalculation can be suppressed.

  According to the invention of claim 6, since the ear portion is sandwiched between the first stator core and the second stator core in a pressed state, the slot coil is stably fixed to the stator core by the frictional force between the ear portion and the stator core. be able to. In addition, since a fastening portion for fixing to a housing or the like is generally provided on the outer peripheral portion of the stator core, the ear portion is damaged by providing the ear portion on the surface facing the circumferential direction of the slot coil away from the fastening portion. It is possible to prevent sagging and suppress a decrease in frictional force.

  According to the seventh aspect of the present invention, the steel plate facing the mating surface of the first stator core and the second stator core is formed with the ear portion accommodating recess for accommodating the ear portion, thereby preventing a gap from being formed on the mating surface. it can.

  According to the eighth aspect of the present invention, the ear portion includes the ear portion receiving recess of the stator core and the circumferential contact portion contacting the circumferential direction, and the radial contact portion contacting the ear portion receiving recess of the stator core in the radial direction. Therefore, the slot coil is positioned in the axial direction, the circumferential direction, and the radial direction.

  According to the invention of claim 9, since the ear portion is provided at the center in the longitudinal direction of the slot coil, it is possible to reduce the influence due to the difference in the linear expansion coefficient between the stator core and the insulating material.

It is a perspective view of the stator of the rotary electric machine of one Embodiment of this invention. It is a disassembled perspective view of the stator shown in FIG. FIG. 3 is an exploded perspective view of one base plate assembly shown in FIG. 2. FIG. 3 is an exploded perspective view of the other base plate assembly shown in FIG. 2. It is a perspective view of a slot coil. It is a disassembled perspective view of a slot coil. It is a longitudinal cross-sectional view which shows a part of stator shown in FIG. FIG. 5 is a front view showing a part of the base plate assembly shown in FIGS. 3 and 4. It is a front view which shows a part of base plate assembly shown in FIG. It is a perspective view of a multi-phase coil. It is a front view of FIG. It is a perspective view which extracts and shows the coil for one phase from the coil of multiple phases shown in FIG. It is an expanded view which shows the connection aspect of the coil of a U phase. It is a schematic diagram which shows the connection aspect of the coil of U phase, V phase, and W phase. It is a perspective view for demonstrating joining with an outer side connection coil extension part and an inner side connection coil extension part. It is a perspective view for demonstrating joining of the inner diameter side edge part of an outer side connection coil, and the level | step-difference part of an outer diameter side slot coil, and joining of the inner diameter side edge part of an inner side connection coil, and the level difference part of inner diameter side slot coil. It is a perspective view of the recessed part formed in the mating surface. It is a top view of the mating surface of the stator core in which the slot coil was inserted. It is a perspective view of the stator core assembly explaining the assembly of the stator core assembly. It is sectional drawing of an ear | edge part vicinity.

  Hereinafter, an embodiment of a stator for a rotating electrical machine according to the present invention will be described with reference to the accompanying drawings. The drawings are viewed in the direction of the reference numerals.

[Stator]
As shown in FIGS. 1 and 2, the stator 10 of the rotating electrical machine of the present embodiment includes a stator core assembly 20 and a pair of base plate assemblies 30L and 30R, and the base plate assemblies 30L and 30R include the stator core assembly. The solid 20 is arranged and assembled on both sides. Between the stator core assembly 20 and the base plate assemblies 30L, 30R, for example, an insulating sheet 65 such as a silicon sheet is disposed to insulate the stator core assembly 20 from the base plate assemblies 30L, 30R.

[1 Stator core assembly]
The stator core assembly 20 includes a stator core 21 and a plurality of (108 in the illustrated embodiment) slot coils 25.

[1-1 Stator core]
The stator core 21 is configured, for example, by assembling a first stator core 21A and a second stator core 21B having substantially the same thickness (a length in the axial direction) on which a plurality of punched silicon steel plates are laminated, at a mating surface MS. A plurality (108 in the illustrated embodiment) of teeth 22 and a plurality of (108 in the illustrated embodiment) slots 23 formed between adjacent teeth 22 are provided on the radially inner side. The slot 23 is formed so as to penetrate in the axial direction of the stator core 21, is formed in a substantially oval shape that is long in the radial direction of the stator core 21 when viewed from the axial direction, and the opening 24 opens to the inner peripheral surface of the stator core 21. Yes. A plurality of fastening portions 15 that fasten the first stator core 21 </ b> A and the second stator core 21 </ b> B are provided on the outer peripheral portion of the stator core 21.

[1-2 Slot coil]
The slot coil 25 inserted into each slot 23 has an outer-diameter side slot coil 26 and an inner-diameter side slot coil 27 which are plate-like conductors having a rectangular cross section with reference to FIG. 5A, FIG. 5B and FIG. The outer peripheral side slot coil 26 and the inner peripheral side slot coil 27 except for both ends in the axial direction are integrally formed by being coated with an insulating material 28 having a rectangular cross section such as injection molded resin. Specifically, the outer diameter side slot coil 26 has a length (L1 + 4 × L2) substantially equal to the sum of the axial width L1 of the stator core 21 and the axial width (4 × L2) of four connecting coils 40 described later. And both end portions in the axial direction are exposed from the insulating material 28 by a length (2 × L2) substantially equal to the axial width of the two connecting coils 40 in the axial direction. Further, one end of the outer diameter side slot coil 26 in the axial direction is notched in a stepped manner in a surface facing one side in the circumferential direction by a length (L2) equal to the axial width of one connection coil 40. The stepped portion 26a is formed by reducing the thickness, and the other axial end of the outer diameter side slot coil 26 is the other in the circumferential direction by a length (L2) equal to the axial width of one connecting coil 40. A stepped portion 26a is formed by cutting the surface facing the step into a step and reducing the plate thickness.

  The inner diameter side slot coil 27 is set to a length (L1 + 2 × L2) substantially equal to the sum of the axial width (L1) of the stator core 21 and the axial width (2 × L2) of two connecting coils 40 described later. Both end portions in the axial direction are exposed from the insulating material 28 by a length (L2) substantially equal to the axial width of one connection coil 40. Further, one end of the inner diameter side slot coil 27 in the axial direction is cut into a stepped shape with a surface facing the other in the circumferential direction by a length (L2) equal to the axial width of one connection coil 40. As a result, the step portion 27a is formed, and the other axial end portion of the inner diameter side slot coil 27 faces one side in the circumferential direction by a length (L2) equal to the axial width of one connection coil 40. The stepped portion 27a is formed by cutting the surface into a stepped shape and reducing the plate thickness.

  In other words, the slot coil 25 is exposed from the insulating material 28 on both sides in the axial direction by the length (2 × L2) of the outer diameter side slot coil 26 substantially equal to the axial width of the two connecting coils 40. The inner diameter side slot coil 27 is exposed from the insulating material 28 on both sides in the axial direction by a length (L2) equal to the axial width of one connection coil 40, and the outer diameter side slot coil 26 and the inner diameter side slot coil. Step portions 26a and 27a are formed at both tip portions of 27 so as to face the opposite side in the circumferential direction by a length (L2) equal to the axial width of one connection coil 40, respectively. Further, at one end in the axial direction and the other end in the axial direction, the stepped portions 26a of the outer diameter side slot coil 26 and the stepped portions 27a of the inner diameter side slot coil 27 are formed so as to face each other in the circumferential direction. Yes.

  As shown in FIGS. 5A and 5B, the insulating material 28 is formed with ears 29 extending in the radial direction and the circumferential direction on the surface of the outer peripheral surface facing the one and the other in the circumferential direction. The ear portion 29 is formed at a position corresponding to the mating surface MS of the first stator core 21A and the second stator core 21B described above, at approximately the center in the longitudinal direction (axial direction) of the slot coil 25. Further, as shown in FIG. 16, the end portion 29 has a circumferential end surface forming a circumferential contact portion 29a, and the outer diameter side and inner diameter side radial end surfaces each forming a radial contact portion 29b.

  A plurality of slot coils 25 (108 in the embodiment shown in the figure) consisting of an outer diameter side slot coil 26 and an inner diameter side slot coil 27 have an outer diameter side slot coil 26 radially outward in each slot 23 and an inner diameter side slot. The coil 27 is arranged in the radial direction of the stator core 21 so as to be radially inward. Each slot coil 25 is inserted into a plurality of slots 23 of the stator core 21 and arranged in the circumferential direction of the stator core 21 to constitute the stator core assembly 20.

  The outer-diameter side slot coil 26 has tip portions protruding from both end faces 21a and 21b of the stator core 21 by a length (2 × L2) substantially equal to the axial width of approximately two connecting coils 40, respectively. The inner end side slot coil 27 inserted into the slot 23 protrudes from both end faces 21a and 21b of the stator core 21 by a length (L2) equal to the axial width of approximately one connection coil 40. As shown in FIG.

  Further, an insulating material 28 that covers both the slot coils 26 and 27 is interposed between the outer diameter side slot coil 26 and the inner diameter side slot coil 27 and the slot 23 of the stator core 21 to insulate the stator core 21 from each other. It is secured.

  The insulating material 28 covering the outer diameter side slot coil 26 and the inner diameter side slot coil 27 has an outer peripheral surface other than the ear portion 29 slightly smaller than the slot 23 and substantially the same shape as the slot 23. As the insulating material 28, an epoxy resin, an enamel resin, or the like can be used.

  The mating surface MS of the stator core 21 includes a plurality of (three in this embodiment) silicon steel plates 21c and a plurality of second stator cores 21B (three in this embodiment) of the first stator core 21A facing each other at the mating surface MS. The silicon steel plate 21d is provided with an ear receiving recess 70 so as to be recessed from the mating surface MS on both sides in the circumferential direction of the slot 23. These ear portion accommodating recesses 70 accommodate the ear portions 29 of the insulating material 28 of the slot coil 25 by assembling the first stator core 21A and the second stator core 21B on the mating surface MS. The ear portion 29 is sandwiched from the axial direction in the ear portion pressing surface 71 which is the bottom surface of the ear portion accommodating recess 70. 5A, 5B and 18, the distance T1 between the ear pressing surfaces 71 is smaller than the axial width T2 when the ear 29 is not pressed, and the ear 29 is the ear pressing surface. 71 is accommodated in the ear accommodating recess 70 while being pressed from the axial direction by 71. The silicon steel plates 21c and 21d constituting the ear pressing surface 71 of the ear accommodating recess 70 are set so that the side in contact with the ear 29 becomes the press sag side when being pressed, and the ear 29 is pressed. It is designed not to be damaged by burrs.

  As shown in FIGS. 15 and 16, the ear portion accommodating recess 70 has a circumferential wall portion 72 erected from the circumferential outer end of the ear portion pressing surface 71 toward the mating surface MS in the circumferential direction of the ear portion 29. A radial wall portion 73 that is in contact with the contact portion 29 a and stands from the radially inner end and the radially outer end of the ear pressing surface 71 toward the mating surface MS is a radial contact portion of the ear 29. 29b abuts. Note that a stepped portion 74 is formed at a corner portion with the inner peripheral surface of the slot 23 at the inner end in the circumferential direction of the ear pressing surface 71.

  In the stator core assembly 20 configured as described above, for example, the slot coil 25 is disposed in each slot 23 of the first stator core 21A, and the phase of the slot 23 is matched so that the first stator core 21A and the second stator core 21B are aligned at the mating surface MS. The stator core assembly 20 is assembled by being assembled and fastened through the fastening portion 15. At this time, the ear portion 29 is axially directed to the ear portion pressing surface 71 in the ear portion accommodating recess 70 formed by the silicon steel plate 21c of the first stator core 21A and the silicon steel plate 21d of the second stator core 21B facing each other at the mating surface MS. It is accommodated in a pressed state. Further, the circumferential contact portion 29a of the ear portion 29 contacts the circumferential wall portion 72, and the radial contact portion 29b contacts the radial wall portion 73, so that the slot coil 25 is added in the axial direction. , Positioned circumferentially and radially.

[2 Base plate assembly]
The base plate assemblies 30L and 30R respectively disposed on both sides of the stator core assembly 20 include base plates 31L and 31R and a plurality of connection coils 40 as shown in FIGS.

[2-1 Base plate]
The base plates 31 </ b> L and 31 </ b> R are substantially annular members that are formed of an insulating resin (nonmagnetic material) or the like and have inner and outer diameters substantially equal to the stator core 21.

  On the inner diameter side of the base plate 31R, as shown in FIG. 3, a plurality (see FIG. 3) corresponding to the outer diameter side slot coil 26 and the inner diameter side slot coil 27 of each slot coil 25 inserted into the slot 23 of the stator core 21, respectively. 108 in the embodiment shown) and a plurality (108 in the embodiment shown in the drawing) of the inner diameter side through holes 33 penetrate the base plate 31R at equal intervals, respectively, It is formed so as to communicate with the side surface 36. By assembling the base plate assembly 30R to the stator core assembly 20, the outer diameter side slot coil 26 inserted into the slot 23 of the stator core 21 and protruding from the end faces 21a, 21b of the stator core 21 into the outer diameter side through hole 32 of the base plate 31R. The distal end portion of the inner diameter side slot coil 27 that is inserted into the slot 23 of the stator core 21 and protrudes from the end faces 21a and 21b of the stator core 21 is disposed in the inner diameter side through hole 33 of the base plate 31R. As for the outer diameter side through hole 32, the opening portion of the inner side surface 36 is smaller than the opening portion of the outer surface 35, and only the portion through which the tip end portion of the outer diameter side slot coil 26 passes through the base plate 31R. Yes.

  On the outer diameter side of the base plate 31R, a plurality of (108 in the embodiment shown in the figure) outer peripheral side holes 34 are formed so as to penetrate the base plate 31R at equal intervals so as to communicate the outer side surface 35 and the inner side surface 36. Has been. As shown in FIG. 7A, the outer side surface 35 and the inner side surface 36 of the base plate 31R have a plurality of substantially U-shaped cross-sections that open to the outer side surface 35 and the inner side surface 36, respectively. , 108) outer surface grooves 37 and inner surface grooves 38 are formed adjacent to each other in the circumferential direction along the involute curve.

  The base plate 31L also basically has the same structure as the base plate 31R. On the inner diameter side, the outer diameter side slot coil 26 and the inner diameter side slot coil 27 of each slot coil 25 inserted into the slot 23 of the stator core 21 are provided. Correspondingly, a plurality (108 in the embodiment shown) of the outer diameter side through-holes 32 and a plurality (108 in the embodiment shown in the drawings) of the inner diameter-side through holes 33 respectively form the base plate 31L at equal intervals. The outer side surface 35 and the inner side surface 36 are formed so as to penetrate therethrough.

  On the other hand, on the outer diameter side of the base plate 31L, a deployment portion 31a extending in a fan shape radially outward is provided in the upper portion in the drawing, and a plurality of outer peripheral side holes 34 are equally spaced apart from the deployment portion 31a. The outer side surface 35 and the inner side surface 36 are communicated with each other through the base plate 31L. In the expanded portion 31a, two U, V, and W phases are combined as a set so that the outer peripheral hole 34a having an opening area slightly larger than the other outer peripheral holes 34 sandwiches the six outer peripheral holes 34. Two sets are formed, and input terminal cutouts 34c are formed at equal intervals for each phase. Input terminal portions 43 of three inner connecting coils 42b, which will be described later, in which the input terminal portion 43 is integrally formed are disposed in the input terminal cutout portion 34c.

  On the inner diameter side of the developed portion 31a of the base plate 31L, there are eight outer diameter side through holes 32a in which a pair of notches for a bus bar (not shown) are formed on the inner peripheral side with two phases as a set. The inner diameter side through hole 33a formed with the side through hole 32 sandwiched therebetween, and further provided with a notch portion (not shown) for a midpoint bus bar for each phase on the inner peripheral side is replaced with eleven inner diameter side through holes 33. It is formed between. In the bus bar notch part, bus bar 61U, 61V, 61W bus bar connecting parts for connecting in-phase coils are arranged, and in the middle point bus bar notch part, U, V, W phase coils are connected to each other. A midpoint busbar connection portion of the point busbar 62 is disposed.

  In the outer peripheral side holes 34 and 34a of the base plates 31L and 31R, an outer diameter side end 112 of the outer connection coil 41 and an outer diameter side end 123 of the inner connection coil 42 which will be described later are arranged. The outer diameter side through holes 32 and 32a, the inner diameter side through holes 33 and 33a, and the outer peripheral side holes 34 and 34a have a rectangular shape when viewed from the axial direction, and have a larger space than the coil members disposed inside them. doing.

  Further, the outer surface 35 and the inner surface 36 of the base plate 31L also have a plurality of substantially U-shaped cross-sections that open to the outer surface 35 and the inner surface 36, respectively (in the embodiment shown in the figure, 102 inner surfaces are provided on the outer surface 35). 102 outer surface grooves 37 and inner surface grooves 38 are formed adjacent to each other in the circumferential direction along the involute curve. The developed portion 31a of the base plate 31L has twelve outer surface grooves 37a formed on the outer surface 35 slightly longer than the other outer surface grooves 37, a total of four each phase, and is formed on the inner surface 36. A total of fifteen inner side grooves 38a formed slightly longer than the other inner side grooves 38 are formed for each phase. The number of outer side grooves 37 and 37a is six less than the number of outer side grooves 37 formed on the base plate 31R, two for each phase, and the number of inner side grooves 38 and 38a is formed on the base plate 31R. The inner side grooves 38 are less than the inner side groove 38 by one for each phase. Instead, the coils of the same phase are connected by the bus bars 61U, 61V, 61W and the coils of the different phases are connected by the midpoint bus bar 62. Are to be connected. In these base plates 31L and 31R, as shown in FIG. 6, the space between the outer surface grooves 37 and 37a adjacent to each other and the space between the inner surface grooves 38 and 38a are separated by a wall 31b standing from the base plate 31L. Further, the outer surface grooves 37 and 37a and the inner surface grooves 38 and 38a facing each other in the axial direction are separated by a partition wall 31c and are electrically insulated from each other.

  The base plates 31L and 31R have the innermost diameter portion 39 in which the inner diameter side through-hole 33 is formed set to a length (L2) equal to the axial width of one connection coil 40, and the outer diameter side. The region other than the innermost diameter portion 39 in which the through hole 32 and the outer peripheral side hole 34 are formed is the sum of the axial width (2 × L2) of the two connecting coils 40 and the thickness (L3) of the partition wall 31c. The axial width is set to be approximately equal (2 × L2 + L3).

  In the base plate assemblies 30L and 30R, as shown in FIG. 7A, the outer surface grooves 37 of the base plates 31L and 31R have an outer peripheral side hole 34 and a predetermined angle in the counterclockwise direction from the outer peripheral side hole 34 in a front view. It is curved along an involute curve so as to connect the spaced outer diameter side through holes 32. However, as shown in FIG. 7B, of the plurality of outer surface grooves 37 of the base plate 31L, the twelve outer surface grooves 37a extending toward the development portion 31a are separated from the outer peripheral side hole 34a and the outer peripheral side hole 34a. It is curved along an involute curve so as to connect the outer diameter side through hole 32 spaced slightly beyond the predetermined angle in the clockwise direction. 7A and 7B show a state in which an outer connection coil 41 and an inner connection coil 42 described later are accommodated in the outer surface groove 37 and the inner surface groove 38, respectively.

  Further, each of the inner side surface grooves 38 of the base plates 31L and 31R is separated from the outer peripheral side hole 34 by a predetermined angle from the outer peripheral side hole 34 in the counterclockwise direction (clockwise as viewed from the side in FIG. 7A). The inner diameter side through hole 33 is formed so as to be bent while avoiding the outer diameter side through hole 32. However, as shown in FIG. 7B, among the plurality of inner side surface grooves 38 of the base plate 31L, the twelve inner side surface grooves 38a extending toward the developed portion 31a of the base plate 31L include the outer peripheral side holes 34a and the outer peripheral side holes. It is curved along an involute curve so as to connect the inner diameter side through hole 33 spaced slightly beyond the predetermined angle in the counterclockwise direction from 34a. Of the fifteen inner surface grooves 38a, the remaining three inner surface grooves 38a communicate with the input terminal cutout 34c.

  That is, as shown in FIGS. 7A and 7B, the outer diameter side through hole 32 and the inner diameter side through hole 33 are the outer peripheral side hole 34 or the outer side surface groove 37a in which the outer surface groove 37 and the inner surface groove 38 are continuously connected in common. And the inner side surface groove | channel 38a is connected through the outer peripheral side hole 34a which continues in common.

[2-2 Connection coil]
The connection coil 40 is formed in a plate shape using a conductive material such as copper, and is inserted into the outer connection coil 41 (41a, 41b) inserted into the outer surface grooves 37 and 37a and the inner surface groove 38, respectively. It can be divided into inner connection coils 42 (42a, 42b). The outer connection coil 41 referred to here is the connection coil 40 that is on the outer side in the axial direction of the stator 10 when the stator core assembly 20 and the base plate assemblies 30L and 30R are assembled. Is the connecting coil 40 which is the axially inner side of the stator 10.

  The outer connection coil 41a is a plate-like conductor having a uniform thickness and a rectangular cross section, and the inner diameter side end portion 111 extends from the outer connection coil main body 110 formed along the involute curve having the same shape as the outer surface groove 37. While being bent in the radial direction, the outer diameter side end portion 112 is also bent in the radial direction from the outer connecting coil body 110. An outer connecting coil extending portion 113 is formed at the outer diameter side end portion 112 of the outer connecting coil 41a so as to extend inward in the axial direction. The axial width (L2) of the outer connecting coil body 110 and the inner diameter side end portion 111 is equal to the groove depth of the outer surface groove 37, and the axial width (L4) of the outer connecting coil extending portion 113 is outer. The axial width (2 × L2 + L3) is set equal to the sum of the groove depths of the side surface groove 37 and the inner side surface groove 38 and the thickness (L3) of the partition wall 31c. Further, the twelve outer connecting coils 41b have the same configuration as the outer connecting coil 41a except that the outer connecting coil body 110 is curved in the same shape as the outer surface groove 37a.

  The inner connection coil 42a is a plate-like conductor having a uniform thickness and a rectangular cross section, and the outer diameter side through hole 32 extends from the inner connection coil body 120 formed along the involute curve having the same shape as the inner surface groove 38. The inner diameter side end portion 122 is bent in the radial direction via the bypass portion 121 formed so as to bypass the inner diameter, and the outer diameter side end portion 123 is also bent in the radial direction from the inner connection coil body 120. An inner connection coil extending portion 124 is formed at the outer diameter side end portion 123 of the inner connection coil 42a so as to extend outward in the axial direction. The axial width (L2) of the inner connecting coil main body 120 and the inner diameter side end portion 122 is equal to the groove depth of the inner side surface groove 38, and the axial width (L4) of the inner connecting coil extending portion 124 is the outer width. The axial width (2 × L2 + L3) is set equal to the sum of the groove depths of the side groove 37 and the inner side groove 38 and the thickness of the partition wall 31c. The fifteen inner connecting coils 42b inserted into the inner groove 38a are basically the same as the inner connecting coil 42a except that the inner connecting coil main body 120 is curved in the same shape as the inner groove 38a. Of the 15 inner connecting coils 42b, the three inner connecting coils 42b arranged at positions corresponding to the input terminal cutouts 34c are connected to an external device or the like. The input terminal portion 43 is integrally formed with the outer diameter side end portion 123 so as to fit into the input terminal cutout portion 34c.

  The outer connection coil 41 and the inner connection coil 42 have the same plate thickness, and the outer connection coil 41 and the inner connection coil 42 have the same plate thickness as the outer diameter side slot coil 26 and the inner diameter side slot. The same plate thickness as that of the coil 27 is set. The plate thickness of the outer connection coil 41 and the inner connection coil 42 is smaller than the axial width (L2) of the outer connection coil 41 and the inner connection coil 42 (the outer connection coil body 110 and the inner connection coil body 120). Note that “the axial width of x (x = 1, 2, 4) of the connection coils 40” described above means the axial width of the outer connection coil body 110 and the inner connection coil body 120. Further, “substantially equal” is an expression including an error corresponding to the partition wall 31c. The thickness of the insulating sheet 65 was not considered.

  The outer connection coil 41, the inner connection coil 42, and the slot coil 25 are processed by press punching or the like from a metal plate (for example, a copper plate) having a predetermined plate thickness, so that a desired axial width and a desired planar shape are obtained. Can be formed. Further, for the outer connection coil 41, an outer connection coil body 110 formed along an involute curve having the same shape as the outer surface grooves 37 and 37a by bending a punched plate-shaped conductor, and the outer connection coil An inner diameter side end portion 111 and an outer diameter side end portion 112 connected so as to be bent from the main body 110 can be formed. Similarly, for the inner connection coil 42, the inner connection coil main body 120 formed along the involute curve having the same shape as the inner surface grooves 38, 38a by bending the punched plate-like conductor, and the inner connection coil An inner diameter end 122 and an outer diameter end 123 connected to be bent from the coil body 120 can be formed.

  The outer connection coils 41a and 41b are inserted into the outer surface grooves 37 and 37a of the base plates 31L and 31R. The inner diameter side end portion 111 of the outer connection coil 41 is disposed in the outer diameter side through hole 32. As shown in FIG. 14, when the stator core assembly 20 and the base plate assemblies 30L and 30R are assembled, the slots of the stator core 21 are similarly formed. 23 is in contact with the stepped portion 26a of the outer diameter side slot coil 26 inserted into the outer diameter side through hole 32.

  The inner connection coils 42a and 42b are inserted into the inner side grooves 38 and 38a of the base plates 31L and 31R. The inner diameter side end portions 122 of the inner connection coils 42a and 42b are disposed in the inner diameter side through hole 33. As shown in FIG. 14, the stator core 21 and the base plate assemblies 30L and 30R are similarly assembled with the stator core 21. It is inserted into the slot 23 and comes into contact with the stepped portion 27 a of the inner diameter side slot coil 27 disposed in the inner diameter side through hole 33.

  As shown in FIG. 13, the outer diameter side end portion 112 of the outer connection coils 41a, 41b and the outer diameter side end portion 123 of the inner connection coils 42a, 42b are both disposed in the outer peripheral side hole 34, and the outer connection coil A side surface 113a facing one side in the circumferential direction of the extending portion 113 and a side surface 124a facing the other circumferential direction of the inner connecting coil extending portion 124 are in contact with each other over the entire radial direction and axial direction.

[3 Joining]
The inner diameter side end 111 of the outer connection coil 41 and the stepped portion 26a of the outer diameter side slot coil 26, the inner diameter side end 122 of the inner connection coil 42 and the stepped portion 27a of the inner diameter side slot coil 27, which are in contact with each other, and the outer side The outer connecting coil extending portion 113 of the connecting coil 41 and the inner connecting coil extending portion 124 of the inner connecting coil 42 are both welded, preferably laser welded, with planar plate surfaces intersecting the plate thickness direction. Are joined together. In the following description, the case of joining by laser welding will be described as an example.

  As shown in FIG. 13, the outer connection coil extension portion 113 and the inner connection coil extension portion 124 are both planar plate surfaces that intersect with the plate thickness direction and extend along the axial direction. The side surfaces 113a facing the circumferential direction of the extending portion 113 and the side surfaces 124a facing the other circumferential direction of the inner connecting coil extending portion 124 are brought into contact with each other so that the respective plate surfaces are in the entire radial and axial directions. Surface contact is made. In a state where both side surfaces 113a and 124a are in surface contact, laser welding is performed along the contact surface P1 extending in the radial direction from the outer side in the axial direction of the outer peripheral side hole 34 to join at the contact surface P1. Thereby, the outer diameter side end portion 112 of the outer connection coil 41 and the outer diameter side end portion 123 of the inner connection coil 42 located in the same outer peripheral side hole 34 are electrically connected, and the base plate assemblies 30L and 30R are configured. Is done. In FIG. 13, the base plates 31L and 31R are omitted. The same applies to FIG.

  As shown in FIG. 14, in the assembly of the stator core assembly 20 and the base plate assemblies 30L and 30R, the outer connection is achieved by assembling the insulating sheet 65 in the axial direction with the relative positions in the circumferential direction aligned. The inner diameter side end portion 111 of the coil 41 and the stepped portion 26a of the outer diameter side slot coil 26 come into contact with each other, and the inner diameter side end portion 122 of the inner connection coil 42 and the stepped portion 27a of the inner diameter side slot coil 27 come into contact with each other. Both are positioned.

  The inner diameter side end portion 111 of the outer connection coil 41 that contacts the stepped portion 26a of the outer diameter side slot coil 26 has a side surface 111a facing the other circumferential direction which is a flat plate surface over the entire side surface 26b of the stepped portion 26a. At the same time, the bottom surface 111b contacts the entire bottom surface 26c of the stepped portion 26a. Along the contact surface P2 that extends in the radial direction from the outer side in the axial direction of the outer diameter side through-hole 32 in a state where the planar side surfaces 111a and 26b that intersect the axial direction and cross the plate thickness direction are in surface contact. It joins in contact surface P2 by laser welding.

  The inner diameter side end 122 of the inner connection coil 42 that abuts the stepped portion 27a of the inner diameter side slot coil 27 has a side surface 122a facing one side in the circumferential direction, which is a flat plate surface, over the entire side surface 27b of the stepped portion 27a. The bottom surface 122b contacts the entire bottom surface 27c of the stepped portion 27a. The laser is along the contact surface P3 extending in the radial direction from the outer side in the axial direction of the inner diameter side through hole 33 in a state where the planar both side surfaces 122a, 27b intersecting the plate thickness direction and in the axial direction are in surface contact. It joins in contact surface P3 by welding.

  Similarly, the step portion 26a of the outer diameter side slot coil 26 disposed in the outer diameter side through hole 32a in which the bus bar notch portion is formed and the bus bar connecting portion of the bus bars 61U, 61V, 61W disposed in the bus bar notch portion. And the step portion 27a of the inner diameter side slot coil 27 disposed in the inner diameter side through hole 33a in which the notch portion for the midpoint bus bar is formed and the midpoint bus bar connecting portion of the midpoint bus bar 62 are laser welded. Thus, the bus bars 61U, 61V, 61W and the midpoint bus bar 62 are joined to the outer diameter side slot coil 26 and the inner diameter side slot coil 27, respectively.

  The outer diameter side through holes 32 and 32a, the inner diameter side through holes 33 and 33a, and the outer peripheral side hole 34 have a rectangular shape when viewed from the axial direction, and have a larger space than the coil members disposed inside them. In other words, a gap is provided between the irradiated portion of the laser beam and the base plates 31L and 31R, so that damage to the base plates 31L and 31R due to the laser beam can be prevented.

  By joining in this way, the outer diameter side slot coil 26 and the inner diameter side slot coil 27 inserted into the slot 23 of the stator core 21 are electrically connected via the outer connection coil 41 and the inner connection coil 42. In this state, the base plate assemblies 30L and 30R are assembled to the stator core assembly 20. The outer connection coil 41 and the inner connection coil 42 connect the slot coils 25 of the same phase (for example, U phase) to form a transition portion of the coil 50.

  Therefore, for example, as shown in FIG. 10, the outer diameter side slot coil 26 and the inner diameter side slot coil 27 arranged in the same slot 23 are connected to one end side (the front side in the figure) of the outer diameter side slot coil 26. The outer connection coil 41 is connected to the inner connection coil 42 that extends radially outward and in the clockwise direction, and is connected to the other end side (the rear side in the drawing) of the outer diameter side slot coil 26. The coil 41 extends radially outward and counterclockwise and is connected to the in-phase inner connection coil 42. Further, the inner connection coil 42 connected on one end side (the front side in the drawing) of the inner diameter side slot coil 27 extends radially outward and counterclockwise and is connected to the outer connection coil 41 of the same phase. The inner connection coil 42 connected on the other end side (the rear side in the figure) of the slot coil 27 extends radially outward and clockwise and is connected to the outer connection coil 41 having the same phase.

  Thus, the stator 10 is configured by assembling a pair of base plate assemblies 30L and 30R on both sides of the stator core assembly 20, and the segmented coils 50 have six coil loops each having the same structure. (U-phase coil 50U, V-phase coil 50V, and W-phase coil 50W) are formed. Each of the six coil loops (U-phase coil 50U, V-phase coil 50V, and W-phase coil 50W) has three sets of U-phase coils 50U, three sets of V-phase coils 50V, And three sets of W-phase coils 50W are wound in this order in the counterclockwise direction (see FIG. 11). 8 is a perspective view of a multi-phase coil extracted from the stator 10 for easy understanding, and FIG. 9 is a front view of FIG. 8, and FIG. FIG. 11 is a developed view showing a connection aspect of a U-phase coil, and FIG. 12 is a U-phase, V-phase, and W-phase coil. It is a schematic diagram which shows the connection aspect of.

Referring to FIG. 11, the U-phase coil as an example will be described in detail with reference to FIG. 11. The six coil loops constituting the U-phase coil have three coil loops (U-loops) continuously in the clockwise direction. The three coil loops ( U loop) are continuously wound in the counterclockwise direction, and the U loop and the U loop are connected in series by the bus bar 61U. The outer-diameter side slot coil 26 and the inner-diameter side slot coil 27 which are disposed in one slot 23 and are covered with an insulating material 28 are composed of a coil constituting a U loop and a coil constituting a U loop. The current flow direction is the same direction.

  For example, focusing on one U loop, as shown in FIG. 11, from the axial end of the outer diameter side slot coil 26 arranged in the U-phase slot 23 (right hand side in the figure), the outer connection coil 41, the inner The connecting coils 42 are connected in this order and connected to the inner diameter side slot coil 27 in the next U-phase slot 23. Thereafter, the inner connection coil 42 and the outer connection coil 41 are connected in this order from the other axial end of the inner diameter side slot coil 27 (the left hand side in the figure), and the outer diameter side slot coil in the next U-phase slot 23 is further connected. 26. Thereafter, the U loop is formed by repeating this connection configuration.

Similarly, the other two phases, i.e., also six coil loops that constitute the V-phase coil (W-phase coil), three V loops are wave winding in the opposite direction (W loops) and three V loops (W Loop ) Are connected in series by a bus bar 61U (bus bar 61W), and an outer diameter side slot coil 26 and an inner diameter side slot coil 27 arranged in one slot 23 constitute a V loop (W loop) and a V loop. ( W loop) and the current flow direction is the same direction. These U-phase coil 50U, V-phase coil 50V, and W-phase coil 50W are star-connected by a midpoint bus bar 62 as shown in FIG.

  In the stator 10, the outer connection coil 41 and the inner connection coil 42 are disposed in a region where the stator core 21 is projected in the axial direction, and are disposed at different positions in the axial direction. Further, the outer surfaces of the plurality of outer connection coils 41a and 41b arranged on the outer side in the axial direction of the stator 10 are flush with the end surfaces of the base plates 31L and 31R.

  As described above, according to the stator 10 of the rotating electrical machine of the present embodiment, the ear portion 29 is provided on the outer peripheral surface of the insulating material 28 that covers the slot coil 25, and the ear portion 29 of the slot coil 25 has the stator core. 21 (first stator core 21 </ b> A, second stator core 21 </ b> B) is fixed by being sandwiched between them, so that the slot coil 25 can be easily fixed to the stator core 21. Further, since the slot coil 25 is not press-fitted, a part of the insulating material 28 or the end of the silicon steel plate protruding into the slot 23 is damaged during the press-fitting and stays in the inside, and becomes a foreign object during use of the rotating electric machine. Can be prevented. Furthermore, since assembly by general-purpose equipment is possible, the number of assembling steps can be reduced and the influence of dimensional error can be suppressed.

  Further, since the ear portion 29 is sandwiched between the stator core 21 in a pressed state, the slot coil 25 can be stably fixed to the stator core 21 by the frictional force between the ear portion 29 and the stator core 21. In addition, since the fastening portion 15 for fixing to the housing or the like is provided on the outer peripheral portion of the stator core 21, the ear portion 29 is provided on the surface facing the circumferential direction of the slot coil 25 away from the fastening portion 15. 29 can be prevented from being damaged and sag, and a decrease in frictional force can be suppressed.

  Further, since the ear portion 29 includes a circumferential contact portion 29a that contacts the stator core 21 in the circumferential direction and a radial contact portion 29b that contacts in the radial direction, the slot coil 25 is provided in the axial direction, the circumferential direction, and the radial direction. Positioned.

  Further, since the ear portion 29 is provided at the center in the longitudinal direction of the slot coil 25, the influence due to the difference in the linear expansion coefficient between the stator core 21 and the insulating material 28 can be reduced.

  Moreover, since the ear | edge part accommodation recessed part 70 which accommodates the ear | edge part 29 is formed in the silicon steel plates 21c and 21d which oppose in the mating face MS of the 1st stator core 21A and the 2nd stator core 21B, a clearance gap is made in the mating face MS. Can be prevented.

In addition, this invention is not limited to embodiment mentioned above, A deformation | transformation, improvement, etc. are possible suitably.
For example, in the above-described embodiment, the triple slot type stator in which the coils of the same phase are arranged for every three slots adjacent in the circumferential direction is exemplified. A single slot type in which phase coils are arranged, or a double slot type stator in which in-phase coils are arranged in every two slots adjacent in the circumferential direction may be used.
Moreover, about the coil connection, not only the said embodiment but arbitrary specifications can be selected, and a serial connection and a parallel connection can also be selected suitably.
The slot coil 25 is not limited to a plate-like conductor having a rectangular cross section, and may be a cylindrical conductor having a circular cross section or a columnar conductor having a polygonal cross section. The coupling between the slot coil 25 and the connection coil 40 is performed by welding. It is not limited to joining by, but includes fastening by caulking. However, when the slot coil is a plate-like conductor, a slot coil in which a slit is formed at a desired position by pressing or the like can be easily manufactured.
Further, an insulating cover may be disposed outside the pair of base plate assemblies 30L and 30R in the axial direction, or may be covered with a resin or the like.

DESCRIPTION OF SYMBOLS 10 Stator 21 of rotating electrical machine Stator core 21A 1st stator core 21B 2nd stator core 21c, 21d
23 Slot 25 Slot coil 28 Insulating material 29 Ear portion 29a Circumferential contact portion 29b Radial contact portion 40 Connection coil 50 Coil 70 Ear portion receiving recess MS Matching surfaces P2, P3 Contact surface (contact portion)

Claims (9)

A slot coil inserted into a slot provided in the stator core,
The slot coil is covered with an insulating material,
The insulating material is provided with ears on the outer peripheral surface,
The slot coil is a slot coil that is fixed by the ear portion being sandwiched between the stator cores. The slot coil according to claim 1,
The ear portion is sandwiched between the stator cores in a pressed state,
The said ear | edge part is a slot coil provided in the surface which faces the circumferential direction among the said outer peripheral surfaces. The slot coil according to claim 2, wherein
The said ear | edge part is a slot coil provided with the circumferential direction contact part which contact | abuts the said stator core in the circumferential direction, and the radial direction contact part which contact | abuts radially. The slot coil according to any one of claims 1 to 3,
The ear coil is a slot coil provided at the center in the longitudinal direction of the slot coil. A stator core having a plurality of slots;
In a stator of a rotating electrical machine comprising a coil attached to the stator core,
The coil includes a plurality of slot coils inserted into the slots, and a plurality of connection coils that connect the slot coils on the axially outer side than the axial end surface of the stator core, and the slot coils; The connecting coil is coupled at the contact portion,
The stator core includes a first stator core and a second stator core,
The slot coil is covered with an insulating material,
The insulating material is provided with ears on the outer peripheral surface,
The slot coil is a stator of a rotating electrical machine in which the ear portion is fixed by being sandwiched between the first stator core and the second stator core. A stator for a rotating electrical machine according to claim 5,
The ear portion is sandwiched between the first stator core and the second stator core in a pressed state,
The said ear | edge part is a stator of a rotary electric machine provided in the surface which faces the circumferential direction among the said outer peripheral surfaces. A stator for a rotating electrical machine according to claim 5 or 6,
The stator core is configured by laminating a plurality of steel plates,
A stator for a rotating electrical machine, wherein a steel plate facing the mating surface of the first stator core and the second stator core is formed with an ear portion accommodating recess for accommodating the ear portion. A stator for a rotating electrical machine according to claim 7,
The ear portion includes a circumferential contact portion that makes contact with the ear housing recess of the stator core in a circumferential direction, and a radial contact portion that makes contact with the ear housing recess of the stator core in a radial direction. A stator for rotating electrical machines. A stator for a rotating electrical machine according to any one of claims 5 to 8,
The ear is a stator of a rotating electrical machine provided at the center in the longitudinal direction of the slot coil.

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